Low Cost, Multilayer Capacitors Based on Novel Nanocomposite Dielectric

Multi-point initiators used in modern explosive projectiles rely on high voltage capacitors which can deliver high power in a low inductance configuration. Current capacitors meeting the required performance specifications are based on dielectric ceramics in multi-layer configurations. These capacitors cost as much as as $100 and have a volume of over 400 mm3. Consequently, the use of multi-point initiators for many munition applications is limited by size and cost of these capacitors. In response to this need, TPL proposes continued development of a revolutionary capacitor technology based on high energy density polymer-nanoparticle dielectrics. Phase I development was successful in defining a materials and designs which offer over a factor of two increase in capacitor energy density. The Phase II was successful in demonstrating capabilities for incorporating these materials and designs into production processes which allow for low cost manufacturing. A transition path and partner has been defined for producing significantly smaller capacitors for multi-point initiators at a fraction of the cost, <$5.00 per unit in high volume. While all production processes have been defined and demonstrated, the proposed sequential Phase II will focus on completing the design and manufacturing optimization and transition to full-scale production. Specific focus will be directed at addressing identified voltage limitations, establishing statistically reliable performance and ensuring production cost targets are met. A series of capacitor design, fabrication and evaluation iterations are planned and will culminate in a production demonstration with deliverables