High Energy Density, Low-Cost, High Temperature Capacitors for Hybrid Vehicles

Hybrid Electric Vehicles (HEVs) and plug-in Hybrid Vehicles (PHEVs) require advanced technology capacitors, which must have low cost and the ability to operate at 150oC. However, current 150oC film capacitor solutions are expensive and have lower energy density compared to materials that operate at lower temperatures. Polypropylene Film Capacitors represent a potentially cost effective solution due to their energy storage properties at 150oC, but the inability to achieve reliable operation above 125oC has prevented dielectric viability for the vechicle application. This project will develop highly optimized, low-cost, annular ring capacitor structures, using environmentally-friendly metallized polymeric insulating films, to replace electrolytic capacitors in hybrid-vehicle, DC-bus filtering applications. The goal is to increase the upper operating temperature 30% and to raise the useful capacitance density for this application by up to 500%, compared to conventional polymer film capacitors and electrolytic solutions. Commercial Applications and other Benefits as described by the awardee: The new high-performance capacitors, which will use existing manufacturing infrastructure and commercially available materials, should be able to satisfy the price-sensitive auto industry. Then, the probability of its application in niche-market, less price-sensitive areas should be greatly improved.