Technologies to Products on the Leading Edge

News Releases

TPL, Inc.'s Capacitance Technologies Wins DoD Army SBIR Phase II

December 2009

TPL has been selected for an DoD Army Phase II entitled "High Temperature Nano-Composite Film Capacitors For Hybrid Electric Vehicles". Future Army ground vehicles are envisioned to use hybrid electric technology. At present, the propulsion systems for these vehicles require power components which are relatively large and inefficient; limiting widespread integration of the technology. DC filter capacitors used in the high frequency power converters consume a substantial portion of the volume in present system designs. Capacitors that provide efficient filtering at high frequencies (up to 100 kHz) with reduced size and increased temperature tolerance are considered essential to advancing hybrid electric technology for the Army.

In response to this need, TPL has developed a novel capacitor film technology that meets the need for DC filter capacitors with reduced size and improved operational capability. The Phase I program was successful in defining a nanocomposite dielectric that can provide the necessary specific capacitance (> 0.9 degF/cm3) and operating temperature capability (> 150degC).

The proposed Phase II effort will be directed at scaled manufacturing and prototype capacitor fabrication. Continuous film fabrication, metallization, winding capabilities will support the planned capacitor development. A unique capacitor design that includes the fault-tolerant nanocomposite film will be pursued and validated relative to operational conditions, efficiency and reliability. The success of this development program will enable the miniaturization of power converters for future Army hybrid electric vehicles. Similar benefits can also be realized in commercial hybrid electric vehicle applications, where reduction in size and increased efficiency will offer lower fuel consumption and lighter total weight in vehicles. An additional application for high temperature, compact filter capacitors will be in the utility industry for high power converters, where operating temperature and size are also key concerns. Commercial vehicles are expected to experience the most significant impact overall. The sales of light-duty hybrid electric vehicles are projected to be more than 400,000 units in 2009, advancing to more than 2,000,000 in 2015. In addition, heavy-duty truck fleets are systematically being upgraded to hybrid electric drives. Each of these commercial hybrid units will benefit for more compact, higher performance DC filter capacitors.

For more information this project please contact Lew Bragg at 505.344.6744 or via email.


TPL, Inc.'s Defense Systems Wins DoD USMC SBIR Phase I

September 2009

TPL, Inc.’s Defense Systems was selected for a DoD US Marine Corp SBIR Phase I entitled Explosively Clad Liners for Extended Barrel Life. Gun barrel life is limited by erosion, heat and wear. Barrel steels and failure mechanisms have changed little since the end of World War II. Performance requirements of modern gun systems continue toward higher velocities, greater rates of fire and longer projectile ranges result in greater in-bore pressures, heat and erosion. A critical need exists to increase barrel life, and therefore, sustainability.

Coatings are of limited use for over-heating problems. Thicker liners have been tried, but are problematic when they are not bonded to the barrel. Using a proprietary explosive, TPL developed a unique explosive cladding process to metallurgically bond high-temperature, corrosion-resistant liners to steel or lighter weight barrel materials. TPL has demonstrated that solid liners, thicker than coatings and metallurgically bonded to the barrel, extend barrel life by 5-7 times. TPL will adapt this technology to small caliber machine gun barrels.

Phase I Objectives include developing bonding parameters, verifying the metallurgical bond and producing test pieces. Barrel blanks will be clad and tested. Option tasks include cladding, machining and test firing a prototype.

Commercial support is lined up to help develop and market this technology. TPL has experience in barrel cladding and a site to perform the explosive work. Commercial applications include all non-military law enforcement agencies. Lighter, longer-lasting, heat-resistant barrels could also be sold to civilian markets for high end hunting and target rifles in any number of calibers, where allowed by law. The primary consumer would be gun manufacturers, with a secondary market in aftermarket parts for upgrades and replacements. Applications could exist in other Federal or state agencies, such as homeland defense and Border Patrol. Other applications for explosive cladding include lining strut assemblies for longer wear (aerospace) and pipe cladding for corrosion-resistance (oil, gas and chemical industry). For more information on this project please contact Dr. Douglas Taylor at 505.342.4428 or via email.

TPL, Inc.'s Capacitance Technologies Wins DoD Army SBIR Phase II

December 2009

TPL has been selected for an DoD Army Phase II entitled "High Temperature Nano-Composite Film Capacitors For Hybrid Electric Vehicles". Future Army ground vehicles are envisioned to use hybrid electric technology. At present, the propulsion systems for these vehicles require power components which are relatively large and inefficient; limiting widespread integration of the technology. DC filter capacitors used in the high frequency power converters consume a substantial portion of the volume in present system designs. Capacitors that provide efficient filtering at high frequencies (up to 100 kHz) with reduced size and increased temperature tolerance are considered essential to advancing hybrid electric technology for the Army.

In response to this need, TPL has developed a novel capacitor film technology that meets the need for DC filter capacitors with reduced size and improved operational capability. The Phase I program was successful in defining a nanocomposite dielectric that can provide the necessary specific capacitance (> 0.9 degF/cm3) and operating temperature capability (> 150degC).

The proposed Phase II effort will be directed at scaled manufacturing and prototype capacitor fabrication. Continuous film fabrication, metallization, winding capabilities will support the planned capacitor development. A unique capacitor design that includes the fault-tolerant nanocomposite film will be pursued and validated relative to operational conditions, efficiency and reliability. The success of this development program will enable the miniaturization of power converters for future Army hybrid electric vehicles. Similar benefits can also be realized in commercial hybrid electric vehicle applications, where reduction in size and increased efficiency will offer lower fuel consumption and lighter total weight in vehicles. An additional application for high temperature, compact filter capacitors will be in the utility industry for high power converters, where operating temperature and size are also key concerns. Commercial vehicles are expected to experience the most significant impact overall. The sales of light-duty hybrid electric vehicles are projected to be more than 400,000 units in 2009, advancing to more than 2,000,000 in 2015. In addition, heavy-duty truck fleets are systematically being upgraded to hybrid electric drives. Each of these commercial hybrid units will benefit for more compact, higher performance DC filter capacitors. For more information this project please contact Lew Bragg at 505.342.4440 or via email.

TPL, Inc.'s Defense Systems Wins DoD USMC SBIR Phase I

September 2009

TPL, Inc.’s Defense Systems was selected for a DoD US Marine Corp SBIR Phase I entitled Explosively Clad Liners for Extended Barrel Life. Gun barrel life is limited by erosion, heat and wear. Barrel steels and failure mechanisms have changed little since the end of World War II. Performance requirements of modern gun systems continue toward higher velocities, greater rates of fire and longer projectile ranges result in greater in-bore pressures, heat and erosion. A critical need exists to increase barrel life, and therefore, sustainability.

Coatings are of limited use for over-heating problems. Thicker liners have been tried, but are problematic when they are not bonded to the barrel. Using a proprietary explosive, TPL developed a unique explosive cladding process to metallurgically bond high-temperature, corrosion-resistant liners to steel or lighter weight barrel materials. TPL has demonstrated that solid liners, thicker than coatings and metallurgically bonded to the barrel, extend barrel life by 5-7 times. TPL will adapt this technology to small caliber machine gun barrels.

Phase I Objectives include developing bonding parameters, verifying the metallurgical bond and producing test pieces. Barrel blanks will be clad and tested. Option tasks include cladding, machining and test firing a prototype.

Commercial support is lined up to help develop and market this technology. TPL has experience in barrel cladding and a site to perform the explosive work. Commercial applications include all non-military law enforcement agencies. Lighter, longer-lasting, heat-resistant barrels could also be sold to civilian markets for high end hunting and target rifles in any number of calibers, where allowed by law. The primary consumer would be gun manufacturers, with a secondary market in aftermarket parts for upgrades and replacements. Applications could exist in other Federal or state agencies, such as homeland defense and Border Patrol. Other applications for explosive cladding include lining strut assemblies for longer wear (aerospace) and pipe cladding for corrosion-resistance (oil, gas and chemical industry). For more information on this project please contact Dr. Douglas Taylor at 505.342.4428 or via email.

TPL, Inc.'s Capacitance Technologies Wins DOE SBIR Phase I

June 2009

TPL, Inc.’s Capacitance Technologies was selected for a DoE SBIR Phase I High energy density, high voltage capacitors using ceramic composite dielectric.

The project will focus on the potential to reduce the size of energy storage devices used in high power electronics. Successful results could benefit applications in the defense, energy, and power electronics industries.

High energy density capacitors for pulsed power modulators have been under development for several years. While moderate success has been achieved in large scale (50 kJ +) devices (>1.0 J/cc) for applications like electromagnetic launch, devices storing energy at high voltage (100 kV +) have been limited to energy densities less than 0.2 J/cc. High voltage, high energy density capacitors that provide high power will be of great utility in applications such as solid-state pulsed power modulators. TPL proposes to construct and demonstrate a novel 20 nF, 100 kV capacitor using an advanced nanocomposite dielectric to achieve an energy density up to 1.0 J/cc in a low inductance design suitable for duty in future solid state pulse power systems.

Successful completion of this program will also result in size reductions for capacitors used in commercial applications such as radar, and military applications such as directed energy systems.

For more information on TPL, Inc. please contact Trista Mosman at 505.342.4439 or via email.

Current News Releases
2008 Press Release Archives
2007 Press Release Archives
2006 Press Release Archives
2005 Press Release Archives
2004 Press Release Archives
2003 Press Release Archives
2002 Press Release Archives