A Manufacturing Technology for High Energy Density Diamond-Like Carbon Capacitors

Diamond-Like arbon (DLC) possesses the unique properties of high dielectric strength, high resistivity, high decomposition temperature, chemical inertness, great hardness and good thermal conductivity. In Phase I we demonstrated that DLC films an be deposited directly onto smooth aluminum surfaces with good adhesion, and that DLC Films are highly flexible, making them suitable for the production of wound capacitors. The Phase II research will demonstrate an economical manufacturing technique using a dual ion-gun system with a continuous rolling mechanism for the mass production of rolled capacitors, and will also demonstrate a packaged DLC capacitor of high energy density, smaller size, and lower weight as compared to current film capacitors.The main objective of Phase II will involve the assembly and demonstration of a manufacturing operation which combines the DLC deposition system, the capacitor rolling operation and the capacitor encapsulation processes into a single modular system housed within a 100 square foot area. The whole operation will be assembled within a cleanroom enclosure of no more than 375 square feet. This basic modular fabrication system could then be duplicated for the mass production of capacitors in the Phase III effort.