High Energy Density Radiation Hardened Capacitors Enabled by Next-Generation Manufacturing Methods

The advancement of manufacturing techniques and materials for electronic components and systems capable of enduring harsh radiation environments is essential for Air Force and Space Force Missions, where components face ionizing radiation (gamma rays, protons, cosmic rays) that can lead to functional degradation.  Among essential passive electronic components, capacitors are used in virtually every electronic circuit. More specifically, metallized polymer film capacitors are almost exclusively used in power generation and energy storage systems applications that combine high voltage, high capacitance, low weight, and high energy density. In high-radiation environments, polymer film capacitors exhibit significant vulnerabilities, including loss of capacitance, increased leakage, lower breakdown strength and degraded equivalent series resistance (ESR).  When considering hypersonic applications, exposure to thermal radiation imposes additional limitations to most polymer film capacitors. To address these limitations, this Phase II SBIR project proposes the use and evaluation of a disruptive solid-state metallized polymer NanoLam™ capacitor technology that is developed by PolyCharge America Inc (PolyCharge), specifically to address high voltage, high capacitance and high energy density applications, combined with self-healing and high temperature properties. The disruptive nature of NanoLam™ capacitors arises from their unique dielectric materials, innovative manufacturing process, and a redefined capacitor supply chain. Traditional wound film capacitor production relies on a limited number of non-U.S. OEMs to manufacture thin-gauge polymer films, which are subsequently distributed to all capacitor manufacturers worldwide, allowing virtually no opportunity for innovation. By contrast, PolyCharge’s approach produces a solid-state nanolaminate capacitor material through a one-step manufacturing process that replaces the film OEM, the metallizing OEM and the capacitor winding operation, using US manufactured organic monomers and aluminum wire. This approach enables complete control over capacitor properties, including nanothick dielectrics that have superior breakdown strength, high temperature polymers with excellent self-healing properties and a unique prismatic construction that can be configured to meet a wide range of application requirements. The primary objective of the proposed Phase II effort is to modify the polymer dielectric formulation to maximize radiation hardening.  PolyCharge has already identified monomer modifications that can further enhance radiation hardening. The proposed chemical structure changes are also expected to increase the operating temperature, maintain high energy density, and further improve capacitor reliability in extreme operating environments.