Santa Ana, CA, United States
Santa Ana, CA, United States

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Grant
Agency: Department of Defense | Branch: Air Force | Program: STTR | Phase: Phase I | Award Amount: 100.00K | Year: 2013

This proposed project is to develop a novel class of high-temperature, high-energy-product permanent magnets with minimized rare-earth element based on a two-phase (Sm2Fe17N3)1-x(Co35Fe65)x (0


Patent
Aegis Technology Inc. | Date: 2014-05-13

Objects of the present invention include creating cathode materials that have high energy density and are cost-effective, environmentally benign, and are able to be charged and discharged at high rates for a large number of cycles over a period of years. One embodiment is a battery material comprised of a doped nanocomposite. The doped nanocomposite may be comprised of LiCoPO4; C; and at least one X, where said X is a metal for substituting or doping into LiCoPO4. In certain embodiments, the doped nanocomposite may be LiCoMnPO4/C. Another embodiment of the present invention is a method of creating a battery material comprising the steps of high energy ball milling particles to create complex particles, and sintering said complex particles to create a nanocomposite. The high energy ball milling may dope and composite the particles to create the complex particles.


Grant
Agency: Department of Defense | Branch: Army | Program: SBIR | Phase: Phase I | Award Amount: 100.00K | Year: 2015

High-energy-density multilayer ceramic capacitors (MLCCs) are receiving more attention because of their strong potential in both military and commercial pulsed power applications. Current commercially available power capacitors, however, suffers from low energy density, low voltage rating, poor stability in a wide temperature range, and high costs. This SBIR project will be devoted into the development of a novel class of high energy density, high voltage MLCCs based on an innovatively designed nanocomposite dielectric material. In addition, the proposed dielectric and capacitors can be processed through scalable and cost-effective methods that exhibit good compatibility with the existing industry technologies, thereby providing for an attractive scalability and potentially low costs suitable for mass productions. In Phase I, the feasibility of the proposed technology will be demonstrated through material design, processing, MLCC prototyping, and characterization. In Phase II, both material design and processing will be further optimized. Based on the results, process scaling-up will be carried out, and MLCCs with the targeted properties will be prototyped. Promising performance of the developed MLCC will be demonstrated through more extensive tests with a focus on high energy density, high voltage rating, enhanced temperature stability, and reduced costs.


Grant
Agency: Department of Defense | Branch: Army | Program: SBIR | Phase: Phase II | Award Amount: 375.00K | Year: 2013

To realize the full potential of Li-ion batteries, the development of more advanced cathode materials are highly desirable, which is critical to enable high-energy-density Li-ion batteries to meet silent watch or other demanding requirements of military vehicles. In this project, Aegis Technology Inc. proposes to develop a novel class of cathode based on layered-spinel lithium-manganese-nickel-oxide (LS-LMNO) nanomaterials that is combined with novel doping and surface coating. This class of cathode material is expected to provide significantly enhanced energy density (>850 Wh/kg vs. 500-600Wh/kg of commercial products), excellent rate capability, and long service/cycle life, which will help to increase technical vehicle silent watch time by 15% or more. In addition, a cost-effective, scalable processing method will also be established to enable the potential mass production with commercial viability. In the accomplished Phase I, technical feasibility of the proposed cathode has been demonstrated successfully with high specific capacity (>250 mAh/g) and promising rate capability and cycling performance. In Phase II, further optimization on material composition and processing will be conducted. Using the developed cathode along with suitable electrolyte and anode material that enable the implementation of this cathode material, Li-ion cell prototypes (e.g., punch cell and 18650/26650 type) and the sub-scale battery packs will be fabricated and tested (>1000 cycles) in order to demonstrate the benefits of the developed cathode at the system level. In addition, preliminary processing scale-up and cost analysis will be conducted, which will pave the way for subsequent commercialization of the developed cathode materials and the resultant Li-ion batteries. As a potentially targeted application, a 6T battery (24V, 100 Ah) based on the high-performance Li-ion cells developed will be designed and demonstrated.


Grant
Agency: Department of Energy | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 150.00K | Year: 2013

Opportunities exists to use high moment magnetic nanoparticles CoxFe100-x to replace annealing-stabilized high induction -FeCo phase as the primary phase in the currently used soft magnetic materials (e.g. HITPERM). The key to this development is to design advanced nanocomposites containing high moment nanoparticles for small, lightweight passive inductors, by using an innovative cost-effective chemical approach to obtain high moment, high temperature soft magnetic materials that have low magnetostrictive coefficients and eddy current, and high induction and operating temperature over conventional HITPERM. The proposed project will (1) develop high permeability, large saturation, and induction, low-loss (hysteretic/eddy current) soft magnetic materials including CoFe and CoFe-based ferromagnetic system capable of operating at high temperatures; and (b) improve mechanical properties and corrosion resistance of these materials with weight reduction and performance enhancement at higher operating temperatures by tuning CoFe nanoparticles and enhancing exchange coupling. In this Phase I study, Aegis Technology will develop an inovative class of advanced nanocomposites containing high moment CoFe nanoparticles, and demonstrate an innovative cost-effective approach to produce high permeability, large saturation, and induction, low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials with high operating temperatures. The Phase I research will cover material design, processing development, chracterization and protoyping, with an aim to identify the underlying technical issues that govern the fabrication and performance of this novel class of soft magnetic nanocomposites. The successful development of the high permeability, high induction soft magnetic nanocompsoite materials with low-loss (hysteretic/eddy current) and high operating temperatures will enable the production of high-efficiency small/lightweight passive inductor. This proposed soft magnetic nanocomposite will lay the foundation for next- generation small/lightweight passive inductors that would have much improved magnetic performance in both induction and application temperatures. Applications for these new magnets are expected to include electric power generation and distribution for use in electric drive vehicles, aircraft, space vehicles, and weapons power systems. Higher operating temperature soft magnetic materials would enable simpler, more efficient designs for many military and commercial applications.


Grant
Agency: Department of Defense | Branch: Defense Advanced Research Projects Agency | Program: SBIR | Phase: Phase I | Award Amount: 100.00K | Year: 2014

The development of high energy density at high temperature capacitors will provide a key enabling technology for applications of power conditioning, power inverters/converters, and pulsed power system at an elevated working temperature. Currently available power capacitors, however, suffers from low energy density at room temperature and even lower density at higher temperature, limiting their applications in a wide temperature range. This SBIR project will be devoted into the development of a novel class of high energy density, high temperature ceramic capacitors based on a new nanocomposite dielectric material with an aim of replacing the currently used dielectrics featured with low energy densities and poor high temperature performance. The proposed dielectric nanocomposite and the resultant capacitors can also be processed through a cost-effective and scalable fabrication technique. The technique will exhibit good compatibilities with the existing standard technologies, allowing for an attractive potentially low costs and high scalability. Phase I research will focus on the feasibility demonstration of the proposed capacitor technology, through material design, processing, prototyping, and characterization. In future Phase II, optimization will be carried out on both material design and processing. In addition, process scale-up will be conducted, and full-scale power capacitors with the targeted performance will be prototyped and tested. Promising properties of the developed capacitor system will be demonstrated to achieve high energy densities, wide temperature stability, low loss, and good reliability under harsh environments.


Grant
Agency: Department of Defense | Branch: Army | Program: SBIR | Phase: Phase II | Award Amount: 749.99K | Year: 2012

Presently U.S. Army is intersted in developing metal nano-coated graphite (carbon) micro/nanofibers that can be used for infrared threat sensor countermeasures and other military applications, because they are excellent attenuators in the infrared region of the electromagnetic spectrum. The metal nano-coatings around carbon micro/nanofibers are desired to have high electrical conductivity, be with the thickness less than 100 nm, and simultaneously can be produced at a low cost. However, there is not a cost-effective processing method available that is capable of depositing a metal nano-coating meeting the above characteristics. In this SBIR project, Aegis Technology proposes to develop a cost-effective, scalable coating process capable of producing highly conductive metal nano-coating for carbon micro/nanofibers. In the accomplished Phase I, Aegis has successfully demonstrated the feasibility of the proposed approach, identified the direction for further improvement and optimization. Based upon the findings and success of the Phase I, in this the Phase II project, Aegis will: (1) fully develop and demonstrate a novel metal nano-coating technology and the resultant highly conductive metal-coated carbon micro/nanofibers including carbon nanotubes; (2) further identify the underlying technical issues that govern the fabrication and performance of the metal nano-coated carbon micro/nanofibers and address the technical issues related with process optimizations and scaling up; (3) use this knowledge to produce metal nano-coated carbon micro/nanofibers with excellent extinction coefficient in infrared frequencies as required by Army; and (4) implement technology transfer for potential mass production. In addition, we will also address the issues related with dispersion, packing and dissemination of metal nano-coated carbon micro/nanofibers, which are essential to transfer this technology into potential field tests and subsequent military applications.


Grant
Agency: Department of Defense | Branch: Army | Program: SBIR | Phase: Phase II | Award Amount: 730.00K | Year: 2011

In this SBIR project, Aegis Technology proposes to develop a high-temperature, electrically-insulating coating (HTEIC) for magnet wires used in the magnetic devices of electro-mechanical and power conversion systems. With such a ceramic coating, the insulation properties, thermal stability and mechanical strength of magnet wires can be substantially enhanced as compared with the-state-of-art product, making the magnet wires can work reliably at high temperatures far exceeding than 300 C. The development of HTEIC-based wires will enable the resultant magnetic devices to operate at high temperatures, high power densities and high frequencies, offering the advantages such as high efficiency, small size and light weight. In the Phase I recently accomplished, we have demonstrated a novel magnet wire insulation concept based on a ceramic coating which can be cost-effectively processed by a polymer-based precursor. Based upon the findings and success of Phase I, the proposed Phase II research will focus on technical issues in optimizing the design/processing, characterization and the system integrations. In addition, the benefits of using this HTEIC-based magnet wires will be addressed systematically.


Grant
Agency: Department of Energy | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 150.00K | Year: 2014

Opportunities exist to use high pressure gas atomization (HPGA) to replace current melt-spinning for making soft magnetic nanocomposite alloy powders containing high moment -CoFe phase. The key to this development is to design advanced soft nanocomposite materials for small, lightweight vehicle power electronics, by using an innovative low cost HPGA approach to obtain high induction, high temperature soft magnetic nanocomposite materials that have low magnetostrictive coefficients and eddy current, and high operating temperatures over conventional ones. The proposed project will (1) develop high permeability, large induction, low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials containing high moment -CoFe, which are capable of operating at high temperatures; and (2) improve mechanical properties and corrosion resistance of these materials with weight reduction and magnetic performance enhancement at higher operating temperatures as a result of reduction in powder size, which can be achieved by lowering the annealing temperature for the crystallization process, because mixtures of amorphous and nanocrystalline powders can be directly obtained by HPGA compared to conventional melt-spinning, which forms amorphous ribbons. In this Phase I study, Aegis Technology will team with Prof. Anderson of Ames National Laboratory, to develop an innovative class of advanced soft CoFe-based nanocomposite materials. We will further demonstrate an innovative low cost approach (25-30% reduction compared to melt-spinning) in order to produce high permeability, large induction, and low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials with high operating temperatures. The Phase I research will cover material design, processing development, chracterization and prototyping, with an aim to identify the underlying technical issues involved with the fabrication and performance of this novel class of soft magnetic nanocomposites. Commercial Applications and Other Benefits: The successful development of the high permeability, high induction soft magnetic nanocomposite materials with low-loss (hysteretic/eddy current) and high operating temperatures will enable the production of high-efficiency small/lightweight inductors. This proposed soft magnetic nanocomposites will lay the foundation for the next- generation of small/lightweight inductors that would have much improved magnetic performance in both permeability and application temperatures with low current losses. Applications for these new magnets are expected for use in electric drive vehicles, aircraft, space vehicles, and weapons power systems. Higher operating temperature soft magnetic nanocomposite materials will enable simpler, lightweight, and more efficient designs for many commercial and military applications.


Grant
Agency: Department of Energy | Branch: | Program: SBIR | Phase: Phase II | Award Amount: 1.00M | Year: 2015

Opportunities exists to use high pressure gas atomization (HPGA) to replace currently used, expensive melt-spinning for making soft magnetic nanocomposite alloy powders containing high moment -CoFe phase. The key to this development is to design advanced soft nanocomposite materials for small, lightweight vehicle power electronics, by using an innovative low cost HPGA approach to obtain high induction, high temperature soft magnetic nanocomposite materials that have low magnetostrictive coefficients and eddy current, and high operating temperature over conventional ones. The proposed project will (1) develop high permeability, large induction, low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials containing high moment -CoFe, which are capable of operating at high temperatures and high frequencies; and (b) improve mechanical properties and corrosion resistance of these materials with weight reduction and magnetic performance enhancement at higher operating temperatures as a result of reduction in powder size, which can be achieved by lowing annealing temperature for crystallization process, because mixtures of amorphous and nanocrystalline powders can be directly obtained by HPGA as compared to the conventional melt-spinning process that forms amorphous ribbons. In this Phase I study, Aegis Technology has demosnttrated a novel class of CoFe-based nanocomposite soft magnetic materials, and developed an innovative cost-effective approach to produce this class of high permeability, large saturation, and induction, low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials with high operating temperatures. The Phase I research covered material design, processing development, chracterization and protoyping, with an aim to identify the underlying technical issues that govern the fabrication and performance of this novel class of soft magnetic nanocomposites. In Phase II more detailed research toward product development will be carried out. The composition design and processing parameters will be further optimized to meet targeted magnetic performance at both room and elevated temperatures. A cost-effective fabrication process for the production of nanocomposite cores established in Phase I will be scaled up. Some typical prototypes of inductors will be designed, built and tested, which will pave the way for potential commercialization of proposed soft materials. The successful development of the high permeability, high induction soft magnetic nanocompsoite materials with low-loss (hysteretic/eddy current) and high operating temperatures/frequencies will enable the production of high-efficiency small/lightweight passive inductor. This proposed soft magnetic nanocomposite will lay the foundation for next-generation small/lightweight passive inductors that would have much improved magnetic performance in both induction and application temperatures. Applications for these new magnets are expected to include electric power generation and distribution for use in electric drive vehicles, aircraft, space vehicles, and weapons power systems. Soft magnetic materials with the capabilities of high temperature and high frequency operation would enable simpler, more efficient designs for many military and commercial applications.

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