A case study of high-temperature polyetherimide film capacitor fabrication

Daniel Q. Tan*, Xudong Wu

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

Abstract

Capacitors, as the basic building block of power electronics and electrical systems, are the major constraint of the increasingly integrated power systems that require new capable polymer dielectric films operating at higher temperatures >125 ºC. Despite tremendous research efforts on the lab scale, there remains a considerable barrier and knowledge basis for converting polymeric films to functioning capacitors desired in actual applications. The authors tackled the polyetherimide (PEI) film scaleup issues and developed various engineering processes for film de-wrinkling, optimal metallization, static elimination, and capacitor fabrication improvement. The authors discovered various fabrication challenges such as the electrostatic charge, metallization scheme, winding tension, and end electrode disconnects. To fabricate a high yield of PEI capacitor bobbins, it is necessary to utilize static eliminators (radioactive ionizers), moderately thick Al metallization (15-30 Ω/sq), and winding tension (60-100 g). It is also effective to evaluate capacitance, dielectric loss, ESR, and thermal cycling stability of capacitors. This work sheds some light on converting PEI films and other polymeric films to capacitors on a scaleup fabrication effort. The practical learning from film handling to capacitor fabrication in this work provided the necessary knowledge for manufacturing high-temperature polar film capacitors.
Original languageEnglish
JournalMaterials Today Energy
DOIs
StateE-pub ahead of print - 6 Oct 2022

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