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Development of Advanced Ceramic Film Capacitors for Power Electronics in Electric Drive Vehicles
Keywords: PLZT, dielectric films, power inverters
Future availability of high-temperature power inverters will advance the market share for hybrid vehicles that are highly fuel efficient and environmentally friendly. Advanced power inverters require capacitors that operate at high voltage and under-hood conditions and yet have minimal footprint. This need can be realized by embedding high-k dielectrics within the layers of a printed wire board (PWB). The “film-on-foil” approach, where the passive component is deposited on base-metal foil, is the most viable fabrication method for embedding the components within a PWB. Technology development in this area would free up surface space, reduce the number of solder joints on the PWB, and therefore, lead to increased device reliability and minimization of electromagnetic interference and inductance loss. We have deposited high-permittivity lead lanthanum zirconate titanate (PLZT) ceramic dielectric films on Ni foils by a chemical solution deposition technique. These prefabricated “film-on-foil” dielectric sheets can be embedded into PWBs. For PLZT films deposited on Ni foils, the measured dielectric constants varied with temperature: from ≈700 at -50ºC to ≈2200 at 250ºC. The dielectric loss remained fairly constant at ≈0.05-0.08. For 300 V bias, we measured a dielectric constant of ≈110 and loss ≈0.004 at room temperature, and a dielectric constant of ≈185 and loss ≈0.008 at 200°C. Leakage current densities of 6.6 x 10-9 A/cm2 at 25°C and 1.4 x 10-8 A/cm2 at 150°C were also measured. The breakdown field strength of PLZT films deposited on LNO-buffered nickel foils was 2.6 MV/cm. Hysteresis loop analysis showed an energy density of ≈85 J/cm3. These results suggest that Argonne’s film-on-foil capacitors have the potential to operate at high voltage in an under-hood temperature environment and yet have minimal footprint. The fabrication procedures and dielectric properties of film-on-foil PLZT samples will be presented in this talk.
U. (Balu) Balachandran, Senior Scientist, Section Leader
Argonne National Laboratory
Argonne, IL
USA


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