Multilayered Film Capacitors for Advanced Power Electronics and Electric Motors for Electric Traction Drives
- PolymerPlus LLC, Valley View, OH (United States)
- Case Western Reserve Univ., Cleveland, OH (United States)
- SBE Inc., Barre, VT (United States)
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Biaxially oriented polypropylene (BOPP) film capacitors are the most suitable technology for high voltage, high temperature, and high ripple current power electronic systems in high performance electric vehicles (EVs). These capacitors, however, occupy 1/4th to 1/3rd of the power electronic unit and have a 50% voltage derating above 85 °C due to their drastically deteriorated breakdown strength and lifetime at high temperature. Development of a new dielectric material system for capacitors to increase temperature use and reduce size is critical in many EV related applications. Multilayer dielectric film developed by PolymerPlus and team has demonstrated improved dielectric constant and breakdown strength as compared to BOPP films. In this program, several film formulations were developed and investigated for dielectric performance and further down-selected for production scale up. Because this technology uses commercial polymers, fabrication of film rolls to demonstrate scalability for initial capacitor fabrication trials was successfully achieved. The film production feasibility, metallization and capacitor prototype fabrication was successfully demonstrated in Year 1 of the program. In Year 2 of the program, film production scale-up leading to significantly large film quantities for metallization and capacitor fabrication led to 600 µF size capacitors. Capacitor characterization was also completed during this year.
- Research Organization:
- PolymerPlus LLC, Valley View, OH (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- Contributing Organization:
- PolymerPlus LLC, Oak Ridge National Laboratory, Case Western Reserve University, SBE Inc.
- DOE Contract Number:
- EE0007211
- OSTI ID:
- 1492686
- Report Number(s):
- 9
- Country of Publication:
- United States
- Language:
- English
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