PolyCharge Increases the Energy Density and Operating Temp. of DC-Link Capacitors

June 24, 2019 by Scott McMahan

PolyCharge has developed NanoLam™ technology for producing high-energy density capacitors with high-temperature handling capabilities. NanoLam capacitors employ super-thin polymer dielectric layers that form with the metal electrode deposition process. This fabrication technique results in a self-supported, large area, capacitor composite, which is segmented into individual self-healing capacitors. All of this occurs in one machine, eliminating the need for film metallization, extruded films, and capacitor winding.

PolyCharge has addresses capacitor size and thermal limitations of metalized polypropylene (PP) dc-link capacitors, used in electric vehicle inverters and renewable energy inverters, as well as medical, aerospace, and industrial mobility applications.

The company developed solid-state, high energy density capacitors, comprised of 1000s of nano-thick, cross-linked polymer dielectric layers. PolyCharge NanoLam capacitors are suitable for higher voltage applications where space, weight, and high-temperature tolerance are required.

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PolyCharge contends that its NanoLam capacitors represent a transformational and potentially disruptive process for making polymer capacitors. In a single process step, a large-area nanolaminate composite is fabricated, which is segmented and processed into individual capacitors that have low ESL and ESR.

The unique capacitors can operate at temperatures >125°C. They boast high current carrying capacity, excellent self-healing properties, and the company claims they have energy density at least double that of existing PP capacitors.

PolyCharge was formed by Sigma Technologies in September 2017 to develop and commercialize its NanoLam technology.

"PolyCharge is well-positioned to lead in the development of next-generation capacitor products for vehicle electrification and other applications where reductions in weight and volume, as well as performance in harsh operating environments, are required," said Dr. Angelo Yializis, CEO of PolyCharge.

The company plans to disclose more details about its process technology and the capacitor's it can produce in a paper titled, "A Disruptive Nano-laminate Polymer Capacitor Technology for Electric Drive Applications," presented by Dr. Yializis during the international PCNS Passive Conference Networking Symposium September 10-13, 2019 in Bucharest, Romania.