STTR Phase I: Electrode Materials and Processes for Atmospheric Pressure, Continuous Manufacturing of Multi-Layer Capacitors

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The broader impact of this Small Business Technology Transfer (STTR) Phase I project is to improve capacitor technology in power conversion equipment used to electrify our transportation systems. Capacitors are critical components to the systems needed to accelerate the energy transition from petroleum to other fuels. This project will develop new electrical materials and production processes for capacitors. The new electrical materials are formulated to be less hazardous to humans and the environmental while also being compatible with more efficient manufacturing processes. Benefits of the proposed technology include faster charging rates of electric vehicles and reduced sizes of on-board batteries, which lowers the cost and environmental impact of electric vehicle manufacturing. Reduced costs will allow a broader population access to electric vehicles. Through development of these new electrode materials and processes, manufacturing of capacitors in the United States will be available to serve the growing US electric vehicle industry.This goal of the proposed work is to develop electrode materials and roll-to-roll processes compatible with an integrated, continuous manufacturing process for multilayer capacitor products. By combining additive manufacturing process in a roll-to-roll system, sequential deposition, drying, and curing of alternating layers of dielectrics and electrodes will enable production of multilayer capacitors in a single system at atmospheric pressure. Electrode inks and printing processes used in flexible/hybrid electronics do not meet the specifications to replace vacuum-based evaporation or sputtering of thin electrode layers for capacitor applications. The primary approach will be based on adapting the layer coating and alignment techniques developed for dielectrics to conductive materials. These electrode materials will improve upon state-of-the-art conductive inks with poor interfaces between particles to produce dense layers with uniform thickness and low surface roughness. This project seeks to provide prototyping of multilayer capacitors produced in discrete processing steps for verification of electrical performance.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.