K Systems Corporation

K Systems has developed a new manufacturing technology for producing high energy density Diamond-Like Carbon Capacitors under an Air Force SBIR Phase II Program. K Systems unique Patented process (5,844,770, December 1, 1998) produced extremely high quality Diamond-Like Carbon thin films on both sides of capacitor grade aluminum foil with high dielectric strength, high resistivity, high decomposition temperature, chemical inertness, great hardness and good thermal conductivity. Moreover, Diamond-Like Carbon films are optically smooth, flexible, pinhole free and can be rolled into a tubular form. The compact designed Diamond-Like Carbon Capacitors offer at least 50% decrease in size, weight and volume, a greater than 50% increase in temperature capability, and a 2-4 times increase in energy storage density over equal value capacitors built with existing technologies. The tubular form lends itself easily to large-scale, low-cost manufacturing technology.

The compact, high temperature and high energy density Diamond-Like Carbon Capacitors with high reliability have a myriad of uses in both commercial and military applications. These include applications such as in domestic utilities and appliances, oil well drilling equipment, power supplies, aircraft, trains, automobiles and medical devices. The high energy density capabilities of these will enable electrically driven aircraft accessories, such as engine mounted actuators, sensors and mounted flight control for the Air Force's more electronic aircraft. High energy density capacitors are also greatly needed for Air Force, Army and Navy pulse power applications, and for NASA filter applications. 

Through K Systems AF Phase III Program supported by AF, Army and Navy, K Systems has been successfully transferring this innovative technology to Morgan Advanced Ceramics Inc. to deposit long lengths of DLC films on both sides of the capacitor grade metal foils and double metallized polymer films. The long lengths of DLC films has been supplied to Dearborn Electronics Inc. to make prototype commercial packaged DLC capacitors with and without oil impregnation. The yield of the production is 100% by rolling a pair of 0.5 µm DLC coated on double metallized polymer films by K Systems Patent Process. These dry and oil-impregnated DLC capacitors passed the initial thermal cycling from -55 ⁰C to +125 ⁰C for 100 cycles, and thermal aging at 105 ⁰C and 50 V for 500 hours. The scale-up production systems is currently under design. Please contact Dr. Wu at rlwu@aol.com for further information in acquiring the DLC films for testing.  

Contact:

Dr. Richard L.C. Wu, Vice President
K Systems Corporation

1522 Marsetta Drive
Beavercreek, Ohio
45432-2733

Tel: (937) 429-5151
Fax: (937) 429-1122
E-mail: rlwu@aol.com