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CERAMIC-POLYMER FILM CAPACITORS FOR HIGH TEMPERATURE POWER CONVERTERS
Keywords: fluorenone polyester, nanocomposite, capacitor
Emerging power electronics in a broad range of military, aerospace, hybrid vehicle, renewable energy and down-hole drilling applications rely on advances in dielectric materials for capacitors. Compact capacitors possessing low dielectric loss and high operating temperature capability are needed for power conditioning in advanced converter and inverter designs for these applications. Established wound film capacitors represent the preferred technology but are severely limited by the use of conventional polymer dielectrics. The intrinsic material properties of these dielectrics limit the capacitor volumetric efficiency to less than 1.0 μF/cc and operating temperature to less than 150°C. TPL is developing processes and manufacturing techniques for fabrication of advanced capacitor films comprised of high temperature polymers modified with ceramic nanoparticles. The selected polymers enable high temperature operation and the ceramic nanoparticles enhance volumetric efficiency by increasing the dielectric constant. The fabricated films are directly adaptable to conventional wound film capacitor construction methodologies. TPL has defined a composite dielectric system comprised of fluorenone polyester polymer and titanate nanoparticles that shows significant promise for compact, high temperature capacitors. This paper reports on the progress toward development of power conditioning capacitors capable of operating at 250°C and providing a volumetric efficiency greater than 1.0 µF/cc. Material processing, film production and capacitor manufacturing are detailed. Test results on high temperature operation in a first generation of subscale capacitors (10 µF) are summarized. Finally, remaining capacitor development issues and transition plans for scaled manufacturing are discussed.
Kirk Slenes, Vice President of Capacitance Products
TPL Inc.
Albuquerque, NM
USA


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