High Voltage category

Materials that will bring better Aluminium batteries

Giant Strides have been moving towards research and production of aluminum batteries. Different teams are working hard to ensure the production of sustainable Aluminium batteries. Recently, Standford University scientists released the first high-performance aluminum battery that can last for a long period, charges very fast and is not expensive. The battery makes use of graphite electrodes. However, life is dynamic, and a team of Switzerland scientists who work at the Swiss Federal Institute of Technology in Zurich has identified two major materials that can be used in Aluminium ion batteries. The first is Titanium Nitride also know as Tinite, corrosion-resistant material and the second is an electrically conducting polymer called polyprene.


Tinite (TiN) is a tough ceramic material used for coating substances like Titanium alloys, Steel, Carbide, and Aluminium to improve their surface properties. It also has high corrosive resistance. Titanium Nitride is needed in the production of Aluminium batteries because the electrolyte needs to make an aluminum battery is exceptionally corrosive, it is dangerous to steel and other materials that can be found in the battery. Since Titanium Nitride can coat aluminum components, it was tested alongside other materials and was discovered to be the only material with the capability to survive prolonged contact with the electrolyte.

Another advantage of Titanium Nitride is that it can be produced anytime without glitches or complaints about lack of materials for production as the elements; Titanium and Nitrogen which are needed to produce it are easily accessible.


Another aspect the team took into consideration during their research was energy storage. They knew safety they should be their number one priority and they dealt with that by coating the super corrosive electrolyte with Titanium Nitride. However, the team knew that people not only wanted but also needed long-lasting batteries, so they decided to search for new electrodes. The result of their research was polyprene; an electrically conducting polymer formed from pyrene.

Polyprene can be used to replace graphite as the positive electrode because it has higher energy storage capabilities. Also, the space in polyprene’s molecular chains allows the large ions of the electrolyte to pass through the electrode material easily. Another feature of polyprene that places it above graphite is the ability to control the material’s porosity which can be optimized for specific applications.

Titanium Nitride and Polyprene will increase the production of low cost but high-performance batteries and also ensure the creation of better aluminum batteries.

High Voltage Capacitor Charger for Photo-Flash Using LT3751

The project is built for professional photo flash systems. Circuit generates high voltage from low voltage battery to operate a photo-flash tube. The project can also be used in other applications like high voltage capacitor charger, emergency strobe, high voltage power supply, security, detonators etc. LT3751 is the heart of the project.

The LT3751 is a high voltage input flyback controller designed to rapidly charge a large capacitor to a user-adjustable high target voltage set by the transformer turns ratio and three external resistors. Optionally, a feedback pin can be used to provide a low noise high voltage regulated output. The LT3751 has an integrated rail-to-rail MOSFET gate driver that allows for efficient operation down to 4.75V.

High Voltage Capacitor Charger for Photo-Flash Using LT3751 – [Link]

USB powered – PCB TeslaCoil

Daniel Eindhoven build a usb powered Teslacoil able to produce small sparks. The coil of the device is printed on the board!

A new and improved PCB spiral Teslacoil. This Teslacoil has etched windings on a print circuit board. It has a USB interface which also powers the coil. The resonance frequency is about 4MHz. It has a turns ratio of 1:160 with 6mil tracks for the secondary. The total trace length of the secondary is 25m.

USB powered – PCB TeslaCoil – [Link]

Making of a New Nixie Tube

Dalibor Farny shows us how he hand make new Nixie tubes on this interesting video!

The nixie tube is a vintage display device which had been used until 70s when it was replaced with LED displays. The complex knowledge of manufacture of nixie tubes literally died with tube factory’s engineers, glassblowers and machine operators. I discovered nixie tubes in 2011 and since then, I’ve devoted all my time to studies of nixie tubes and its manufacturing processes. After years of intensive work, with help of many people, I eventually succeeded and have revived the knowledge and equipment for production of nixie tubes.

Making of a New Nixie Tube – [Link]

High Voltage-Current Half Bridge Driver Using IR2153 & IGBT

IGBT based half bridge board has been designed for multiple applications, like induction heater driver, tesla coil driver, DC-DC converters, SMPS etc. High current and high voltage IGBTs are used to serve high power requirements.

IGBT NGTB40N120FL2WG from ON semi and IR2153 from Infineon semiconductor are important parts of the circuit, IR2153 is a gate driver IC including inbuilt oscillator, 40A/1200V IGBT can handle large current. Gate driver circuit works with 15V DC and load supply 60V DC to 400V DC.

High Voltage-Current Half Bridge Driver Using IR2153 & IGBT – [Link]

400V – 5A Power Supply For Brushless Motor Drivers

Although the power supply design is specific to the Brushless Servo Drivers mainly for IPM Modules, the concepts and circuit design may be used for any power supply requires high voltage output up to 400V DC and 5 Amps. The power supply is an unregulated design with an option to allow connection to either 120V or 230V mains and also it can work with lower voltage for audio amplifiers by increasing capacitor value. The design uses fully integrated bridge rectifier, and multiple bus capacitors for low ripple, noise suppression, and provides high current reservoirs. Additionally the dc supply line have bleeder resistor R2 and R3 to drain the large reservoir capacitors PCB, mounted fuse holder provided  for short circuit and over current protections, low ohm NTC used for inrush current at power start up,  C1, C12, TX protects  against turn on/off spikes and EMI noise reduction. This power supply can be used to drive Tesla Coils, Induction heaters, DC Motor drivers, Brushless DC motor driver.

400V – 5A Power Supply For Brushless Motor Drivers – [Link]

A Cost-efficient Super-Cascode SiC Switch

Coping with rapid technological advances and finding efficient energy solutions are the keys for development of power electronics of the future. A new research had been done in North Carolina State University about increasing the efficiency of high-power switches.

Silicon Carbide is a compound of silicon and carbon with chemical formula SiC. It is a wide bandgap (WBG) semiconductor, that allows devices to operate at much higher voltages, frequencies and temperatures than conventional semiconductor materials.

Researchers came up with a high voltage and high frequency silicon carbide (SiC) power switch that could cost much less than similarly rated SiC power switches. This research may guide to new applications in power converters like medium voltage drives, solid state transformers and high voltage transmissions and circuit breakers.

Semiconductor devices like the 15kV SiC MOSFET can lead to great potential applications in high voltage and high frequency power converters. However, these devices are not commercially available and their high cost displaces them from industry competition with other alternatives like the standard IGBT (Insulated-gate Bipolar Transistors) that are widely used, but in the same time they dissipate a lot of energy while switching on and off.

Loss Comparison between Silicon IGBT and SiC MOSFETs
Loss Comparison between Silicon IGBT and SiC MOSFETs

The new SiC power switch, called FREEDM Super-Cascode Switch, contains a series of 1.2kV SiC power devices to produce a 15 kV and 40 mA output that can transcend the 15 kV SiC MOSFET in ease of adoption and cost – since it costs only one third of the estimated high voltage SiC MOSFETs. In addition, this new switch is capable of operating in a wide range of temperatures and frequencies due to its proficiency in heat dissipation, which is considered an advantage in power devices.

FREEDM Super-Cascode SiC Switch
FREEDM Super-Cascode SiC Switch

Since there is no high voltage SiC device commercially available at voltage higher than 1.7 kV, as Alex Huang said – Progress Energy Distinguished Professor, he assures that this solution paves the way for power switches to be developed in large quantities with breakdown voltages from 2.4 kV to 15 kV.

The research took place in North Carolina State’s FREEDM Systems Center which is funded by National Science Foundation. This center’s mission is to modernize the electric grid and mold the generation of leaders by providing all the needed software and hardware tools, funds, and partnerships with Industries. This project had also participated in IEEE Energy Conversion Conference & Expo on September 2016 and it was presented by Xiaoqing Song, a Ph.D. candidate at the FREEDM Systems Center under Huang’s supervision.

More research projects in the same field can be reached at the FREEDM Systems Center website and further details can be found at the university website.

Via: ScienceDaily

9V to 1kV DC/DC converter


Bob tipped us with his latest project, it’s a 9V to 1kV DC-DC converter using CD4011 IC to produce a square wave and a IRF530 transistor to drive the transformer.

Finally, I have made a new high voltage supply based on an inverter transformer and voltage doubler. It seems to be ok for this job, but it can be used in various other applications so I’m presenting it in a separate entry.

Warning! the device produces high voltage that can be lethal, if you want to build it, please take cautions.

9V to 1kV DC/DC converter – [Link]

Isolated Circuit Digitally Indicates 120-/220-V Line Voltage


Edward K. Miguel @ electronicdesign.com has published a circuit that has output high when the votlage in input is 220V and output low when the voltage is 110V. This is often useful on motor control and power supply systems.

The circuit illustrated in the figure monitors the ac line and provides a basic output indicating whether it is at 120 V or 220 V, with the output at the transistor collector going low for 120-V and high for 220-V inputs.

Isolated Circuit Digitally Indicates 120-/220-V Line Voltage – [Link]

DIY Arduino Battery Spot Welder


KaeptnBalu @ instructables.com has build a DIY spot welder based on Arduino board. It is powered from a 12V car battery with enough current capability to solder nickel strips on battery packs. The board generates two short pulses with the first one to be 1/8 of the time of the second one. Pulse time of second pulse is adjustable by the potentiometer and displayed on the screen in mS.

DIY Arduino Battery Spot Welder – [Link]