STTR Phase I: Low Temperature Cofired Multilayer Ceramic Power Transformers Incorporating Base Metallization Materials

STTR 第一阶段：采用基础金属化材料的低温共烧多层陶瓷电力变压器

• 批准号: 1448918
• 负责人: Safakcan Tuncdemir
• 金额: $ 22.5万
• 依托单位: Solid State Ceramics, Inc.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2015
• 资助国家: 美国
• 起止时间: 2015-01-01 至 2015-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1448918&HistoricalAwards=false
• 关键词: STTR; Phase; Low; Temperature; Cofired

The broader impact/commercial potential of this project is to a wide range of electronics as to include power supplies, inverters point-of-load (POL) power devices, voltage isolators and voltage sensors. The high thermal operation that is EMI/RFI immune and very rad hard enables completely new electronics design solutions for medical, space, defense, and energy exploration. This new technology proposed will be ideal for distributed POL solutions for commercial solar energy, high performance adaptors and converters for mobile/portable electronics, robotic integrated subcompact power supplies. The success will also open up new capabilities for agencies such as NASA, and commercial space companies to integrate a new subcompact solution for converting mains bus power to all of the subsystems that is far more radiation and high temperature tolerant than anything ever previously available. This is of particular interest to the SmallSat/CubeSat (miniaturized satellite) community. There will also be spin-off benefits to manufacturing of higher performance actuators and transducer devices that will see significant decreased costs through use of significantly less expensive copper materials.This Small Business Technology Transfer Research (STTR) Phase I project will address the challenge of enabling high power/high performance ceramic transformers that replaces conventional magnetics. Many electronics applications can benefit from replacing magnetic transformer with ceramics. Advantages include large increase in safe operating temperatures, drastically reducing the electromagnetic/radio frequency interference (EMI/RFI) issues, and reducing the size/weight. At present, no such transformers exist. Any solution will require multilayer construction; however, for transformers this introduces several difficult and unsolved challenges in electronics process engineering that are not issues for multilayer ceramic capacitors, piezoelectric actuators and piezoelectric sensors manufacture. These new challenges include that the multilayer construction must now enable individual poling of each layer; because transformer devices must operate at resonance they now generate much greater levels of thermal energy requiring drastically improved thermal management (electrode electrical/thermal conduction); also requires replacing soft ceramic with low loss hard ceramic. Copper introduces very superior properties in electrical/thermal conduction but requires significantly lower process temperatures that will be challenging to achieve for sintered hard ceramic but offers enormous pay-off with success. The research will investigate the promising approach of a new low temperature process that uses new doping chemistries and advantageous copper electroding.

该项目的更广泛的影响/商业潜力是广泛的电子产品，包括电源，逆变器负载点（POL）电源设备，电压隔离器和电压传感器。 EMI/RFI免疫和非常硬的高热量操作可实现全新的电子设计解决方案，用于医疗，空间，防御和能源探索。 提出的这项新技术将是用于商业太阳能，高性能适配器和移动/便携式电子设备的转换器的分布式POL解决方案，机器人集成的子紧张电源。 成功还将为NASA等机构和商业太空公司提供新的功能，以整合新的亚型解决方案，以将Mains Bus Power转换为所有辐射和高温耐受性的子系统，远比以前可用的任何东西。 这是Smallsat/Cubesat（微型卫星）社区特别感兴趣的。 制造高性能执行器和换能器设备还将带来衍生的好处，这些设备将通过使用明显较便宜的铜材料来大幅降低成本。这本小型企业技术转移研究（STTR）I阶段项目将应对实现高功率/高性能陶瓷变压器的挑战，以取代传统的磁力。 许多电子应用可以从用陶瓷代替磁变压器中受益。优点包括大幅度升高安全的工作温度，大大降低电磁/射频干扰（EMI/RFI）问题，并降低了大小/重量。目前，没有这样的变压器。 任何解决方案都需要多层结构；但是，对于变压器，这引入了电子工艺工程中的几个困难且未解决的挑战，这些挑战不是多层陶瓷电容器，压电电执行器和压电传感器制造的问题。 这些新的挑战包括多层结构现在必须实现每一层的单独策略。由于变压器设备必须在共振时运行，因此它们现在产生的热能水平更高，需要大幅改进热管理（电极电气/热传导）；还需要用低损失硬陶瓷代替软陶瓷。铜引入了电气/热传导中的非常出色的特性，但需要明显较低的工艺温度，这对于烧结的硬陶瓷才能达到挑战，但成功地提供了巨大的回报。该研究将调查使用新的低温工艺的有前途的方法，该过程使用新的掺杂化学和有利的铜电极。