N142-123 TITLE: High Speed and High Voltage Capacitors for Naval HPRF Directed Energy Applications

TECHNOLOGY AREAS: Materials/Processes, Electronics, Weapons

ACQUISITION PROGRAM: NAVAIR PMA-242 (Direct and Time Sensitive Strike)

RESTRICTION ON PERFORMANCE BY FOREIGN NATIONALS: This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120-130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign nationals may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign national who is not in one of the above two categories, the proposal may be rejected.

OBJECTIVE: To develop compact high precision high voltage capacitors for use in Naval directed energy weapons systems.

DESCRIPTION: Capacitors currently available have a breakdown voltage more than an order of magnitude too low for applications that require small size, weight and power (SWaP), temperature stable dielectrics, low equivalent series resistance and the ability to repetitively charge and discharge in less than 400ns. With lower voltage capacitors, very large banks with the devices connected in series and parallel must be assembled frequently requiring hundreds of capacitors. Capacitors that can store high energies are an integral part of pulse power systems used for high power radio frequency (HPRF) applications. This innovation is seeking to develop compact capacitors with breakdown voltages of at least 80kV with a 5nF capacitance, a volume less than 100 cm3 (which corresponds to an energy density of .16 J/cm3 or better), an equivalent series resistance less than .5 ohm at 1MHz, a type C0G (NPO) dielectric, a rated voltage reversal of at least 80%, and be able to handle the mechanical and thermal stress of repetitively charging and discharging in less than 400ns. It is completely acceptable that this could be realized by stacking several smaller capacitors, with lower individual voltages, such as ceramic chips for greater flexibility as long as the overall specifications including the overall volume of the entire stack are still met.

PHASE I: Define and develop a concept for a capacitor that can meet the performance constraints listed in the description through the use of novel materials and/or manufacturing methods. Perform a technology review of existing capacitor technologies to determine the design feasibility and potential implementations as necessary. Research efforts should also be made to determine the current limitations of capacitor technology with these electrical specifications for the volume specified. The completion of Phase I will include the development of novel capacitor designs to meet the outlined requirements. The conceptual designs, along with the design implementation and capacitor performance models should be included as well as a cost analysis and material development.

PHASE II: Phase II will involve the design refinement, procurement, integration, assembly, and testing of a proof of concept prototype(s) leveraging the Phase I effort. The Phase II prototype will meet all specifications as described in the description except for voltage and volume which must be at least 40KV and less than 0.5 m^3. Noting of course that individual capacitance, voltage and volume may be less if a stacked approached is being pursued. In this case scalability would have to be demonstrated. The prototype(s) must demonstrate a clear path forward to a full scale prototype based on the selected technology. Prototypes will be made available to the government for independent testing in their own facilities at their option. Data packages on all critical components will be submitted throughout the prototype development cycle and test results will be provided for regular review of progress and will include expected lifecycle data.

PHASE III: The capability of future Directed Energy (DE) systems will be affected significantly by the emergence of new technologies. Future DE systems will benefit from advances in power generation, power conversion, energy storage, microwave and laser source development, advanced IED detection/location/tracking systems, and by more sophisticated and capable robotic platforms. Knowledge of these new technologies will be important because advanced threat systems will employ different topologies, materials, and miniaturization. The performer will apply the knowledge gained during Phase I and II to build and demonstrate a full scale final demonstration capacitor device capable of meeting the full electrical specifications, and compact size less than 100cm^3 to include all related packaging requirements. Data packages will be submitted throughout the development cycle and test results will be submitted for regular review of progress. The final demonstration capacitor will represent a complete solution and should be ruggedized for, at a minimum, testing in a shipboard or airborne environment across a temperature range of -20 °C to > 70 °C, MIL-STD shock and vibration, and be environmentally enclosed. The small business will support the Navy with certifying and qualifying the capacitors for Navy use. When appropriate the small business will focus on scaling up manufacturing capabilities and commercialization plans.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Potential commercial applications include a variety of communications, sensor and medical applications using high power RF systems requiring compact, high speed and high voltage capacitors. Capacitors are common across a variety of electronic applications from current blocking, signal filtering, voltage stabilization, frequency tuning, to active power control. As systems get smaller, higher voltage and faster acting capacitors would be an enabler for commercial RF generation related systems. The commercial potential for new and more dynamic system applications would be enabled by lower cost, more reliable, better protected compact high voltage capacitors.

REFERENCES:
1. M. Prevallet, S. Bagdy, J. Prymak, and M. Randall, "High Voltage Considerations with MLCs," IEEE International Power Modulator Symposium and High Voltage Workshop, San Francisco, 2004.

2. K.A. Markowski, S.-E Park, S. Yoshikawa, and L.E. Cross, "Effect of Compositional Variations in the Lead Lanthanum Zirconate Stannate Titanate System on Electrical Properties," J. Am. Ceram. Soc., 79 [12] 3297-304 (1996).

3. S.-E Park, K.A. Markowski, S. Yoshikawa, and L.E. Cross, "Effect on Electrical Properties of Barium and Strontium Additions in the Lead Lanthanum Zirconate Stannate Titanate System," J. Am. Ceram. Soc., 80 [2] 407-12 (1997).

4. Ho, J.; Jow, T.R., Boggs, S., "Historical Introduction to Capacitor Technology," Electrical Insulation Magazine, IEEE , vol. 26, no. 1, pp. 20, 25, January-February 2010.

5. Slenes, K.M., Winsor, P., Scholz, T., Hudis, M., "Pulse Power Capability of High Energy Density Capacitors Based on a New Dielectric Material," Magnetics, IEEE Transactions, vol. 37, no. 1, pp. 324, 327, Jan 2001.

6. Korovin, S.D., Rostov, V.V., Polevin, S.D., PEGEL, I.V., Schamiloglu, E., Fuks, M.I., Barker, R.J., "Pulsed Power-Driven High-Power Microwave Sources," Proceedings of the IEEE , vol. 92, no. 7, pp. 1082, 1095, July 2004.

KEYWORDS: Capacitors; High Voltage Capacitors; Precision Capacitors, Dielectrics, Multi-Layer Ceramic

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