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Aluminum Electrolytic Capacitors

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Aluminum Electrolytic Capacitors Aluminum Electrolytic Capacitors Design and Characteristics Technology 10KV 1KV Film 100V Ceramic VOLTAGE Aluminum 10V Tantalum Electrolytic Ta Polymer EDLC 1V 1 pF 100 pF 10 nF 1 uF 100 uF 10 mF 1 F CAPACITANCE Aluminum Element 13 Al ALUMINUM 26.9815923 Aluminum: Chemical Symbol: Al Atomic Number: 13 Atomic Mass: 26.9815923 Discovered in 1825 © 2019 KEMET Corporation Aluminum Properties Useful properties of Al: • Most abundant element to be found in earth’s crust (8.1%, after O & Si) ✓ Light weight; ✓ Good electrical conductivity • Reasonable corrosion resistance due to the ✓ Good thermal conductivity formation of air-formed Aluminum oxide in nature ✓ Non-toxic • Thicker Aluminum oxide using electrochemical ✓ Non-magnetic method (anodizing) ✓ No reaction with alcohol & other organic solvent • Aluminum oxide is a good dielectric substance ✓ High reflectivity of light ✓ Environmentally friendly © 2019 KEMET Corporation Aluminum Electrolytic Manufacturing Process Slitting Winding Deck Welding Testing Impregnation Sealing Aging Standard Measurements © 2018 KEMET Corporation Aluminum Electrolytic Can Construction Cathode Foil Anode Foil Separator Paper Foil Tabs Safety Vent © 2019 KEMET Corporation Anode Foil Etching Super pure plain aluminum foil (70 – 125 µm thick) undergoes electrochemical reactions to dissolve the metal substrate of the foil in the form of a dense network of microscopic channels, in order to increase the overall surface area providing a maximum capacitance for a given electrode surface size. • Electrochemical tunnel “Etching” of 99.99% aluminum • Tunnel initiation strongly influenced by impurities • Tunnel diameter 1um - 2um across • Tunnel length 15um - 50um long • Density 10 - 25 million tunnels per cm2 The disadvantage of Surface “Etching” is the • Foil gains 50 to 100 (actual area / plain surface area) reduction of the capacitors ability to withstand HIGH DC currents. © 2019 KEMET Corporation Anode Foil Formed Cross-Section Surface of foil Dark area in the 3500 times middle is solid core (Al) magnification © 2019 KEMET Corporation Foil Technology Evolution Al Anode Foil Capacitance Evolution Foil Capacitance Evolution (550 VF) ~ Foil for 400V Capacitor ~ Historic Current & Year (µF/cm2) Prediction (µF/cm2) 1993 0.57 1994 0.63 2001 0.65 2003 0.68 2008 0.71 2011 0.74 2015 0.77 2018 0.79 2019 0.83 © 2019 KEMET Corporation Aluminum Electrolytic Basic Model Aluminium Oxide Dielectric Electrolyte Aluminium Oxide Dielectric Aluminum Foil Aluminum Foil Anode Plate Cathode Plate 0 Separator • By etching the anode foil, we increase the capacitance by increasing the surface area • Thicker dielectric reduces maximum capacitance potential • Dielectric thickness determines voltage rating © 2019 KEMET Corporation Electrolyte Composition • High conductivity, neutral pH – Acid + Base -> Salt • Wide operational temperature range – Stay conductive across range • Provides ability to reform oxide – Controlled level of water • Compatibility with paper and deck material – Hydrogen gas absorber • Low flammability, low toxicity © 2019 KEMET Corporation Traditional Aluminum Electrolytic The Electrolyte Allows for the Dielectric to Reform (or “Heal”) ➢ Forward bias is same as formation bias. ➢ If dielectric gets thin enough, the forward bias voltage will form new dielectric ➢ Thinner than original because VFormation > VRating > Vapplication Reform Aluminum -2 O Wet Anode O-2 Dielectric Reduction Electrolyte Plate Reformed dielectric region © 2019 KEMET Corporation Separator Papers • Materials (pulp) – Kraft, manila, esparto, hemp – Combinations of pulp are often used • Properties – Thickness 12µm to 90µm – Density 0.3 to 0.8 g/cm3, uniform density, minimum pinholes – Simplex – single type of paper – Triplex – three papers joined together • Usage – 1 to 3 papers used between anode and cathode – Up to 5-6 actual layers when triplex paper used © 2019 KEMET Corporation Construction • Can – Diameter and Length – Vent – Mounting • Common Termination styles – Screw Terminals – 2-5 pin Solder Pin, Pin Tag, Snap-In – Axial, Radial – SMD – Press-Fit • Sleeve – PVC – PET; UL recognized – Polyolefin © 2019 KEMET Corporation New Press-Fit Termination ➢ Capacitor is pressed into the PCB, not soldered ➢ Specific poke yoke terminations ➢ Eliminates the problems of soldering on thick PCB copper tracks ➢ Eliminates fractured solder joints ➢ Quick exchange of components Press-Fit Pin Material Material: Copper Nickel Silicon Alloy CuNiSi R580 (C19010) Plating: • Ni 1.5-3μ all over • Sn 100% mat 0.4-1.1μ on press-fit area • Sn 100% mat 3-6μ on the remaining area © 2019 KEMET Corporation Press-Fit Solution for Multiple Issues 1 Soldering Problems • Heavy copper tracking on the PCB acts as a heat sink which makes soldering difficult • This can cause cold spots, voids, splatter, cracks etc 2 Washing Issues • More aggressive washing of pcb after reflow soldering can force water under insulating sleeves of electrolytics • Avoiding reflow / washing means expensive and additional processes such as hand soldering, automated selective soldering, or hand washing of components 3 Field work • Preventive maintenance of soldered components often means replacing the entire (and costly) PCB 16 © 2019 KEMET Corporation Characteristics © 2019 KEMET Corporation Electrolytic Parameters • Capacitance • Equivalent Series Resistance, ESR • DC Leakage • Shelf Life & Reforming • Operational Lifetime • End of Life © 2019 KEMET Corporation Terms and Definitions © 2019 KEMET Corporation Basics The basic principle of the capacitor is to store electrical charge (Q in coulombs). The potential charge it can hold is determined by the capacitance (C in Farads) and voltage (V in volts) An electric equivalent schema of an electrolytic capacitor can be described as an equivalent series resistance (ESR), equivalent series inductance (ESL), the capacitance (C) and a parallel resistance for the leakage current (Rleak). 푸 = 푪 × 푽 Rleak depends on the quality of the dielectric. Rleak ESL ESR C © 2019 KEMET Corporation Electrolytic Parameters Capacitance (RC-Ladder) The RC-Ladder is an effect of the tunnel created to increase the area of the foil. The capacitive elements are distributed along the walls to the bottom of the tunnel, connected to a cathode extension created by the electrolyte As frequency increases more capacitive elements will ‘drop out’, eventually getting to point where only those elements near the surface of the foil The electrolyte (or cathode) contact has a resistance that is extremely dependent on temperature. As the temperature decreases, the mobility of the ions in the electrolyte slow down. Because of this the capacitance drop occurs at lower frequencies for lower temperatures. © 2019 KEMET Corporation Electrolytic Parameters Capacitance Change - Frequency and Temperature Effect of Frequency Change: 1 퐶 = (2휋푓푍) ➢ Effective capacitance reduces as frequency increases Effect of Temperature Change: 1 (Al O ) = f r 2 3 T 1 r 0 A A (Al O ) C = contacted 2 3 1 d = f T ➢ Effective capacitance reduces as temperature decreases (Capacitance change with temperature is greater for lower rated voltages) © 2019 KEMET Corporation Capacitance and Capacitance Variation Total Capacitance of the Capacitor By design, a non-solid aluminum electrolytic capacitor has a second aluminum foil, the so-called cathode foil, for contacting the electrolyte. This structure of an aluminum electrolytic capacitor results in a characteristic result because the second aluminum (cathode) foil is also covered with an insulatin oxide layer naturally formed by air. Therefore, the construction of the electrolytic capacitor consists of two single series-connected capacitors with capacitance CA of the anode and capacitance CK of the cathode. The total capacitance of the capacitor Ce-cap is thus obtained from the formula of the series connection of two capacitors: 푪 푪 푪 = 푨 × 푲 풆 − 풄풂풑 푪푨 + 푪푲 ퟏ ퟏ ퟏ = + CK is much higher than CA 푪풕풐풕풂풍 푪풂풏풐풅풆 푪풄풂풕풉풐풅풆 © 2019 KEMET Corporation Capacitance and Capacitance Variation Temperature Dependencies ➢ The temperature has a considerable effect on the capacitance. With decreasing temperature, the viscosity of the electrolyte increases, thus reducing its conductivity. ➢ The resulting typical behavior is shown in the figure. © 2019 KEMET Corporation Capacitance and Capacitance Variation Frequency Dependencies Frequency Dependence of the Capacitance The AC capacitance depends not only on the temperature but also on the measuring frequency. The figure below shows the typical behavior. Typical values of the effective capacitance can be derived from the impedance curve, as long as the impedance is still in the range where the capacitive component is dominant. C - Capacitance [F] ퟏ 풇 - Frequency [Hz] 푪 = Z - Impedance [Ω] ퟐ흅풇풁 Standardized measuring conditions for electrolytic capacitors are an AC measurement with 0.5V at a typically frequency of 100Hz or 120Hz and a temperature of 20°C. © 2019 KEMET Corporation Electrolytic Parameters Capacitance Change - Frequency 4700uF/400V, 85°C Screw Terminal 10,000 Freq 20C 50C 85C 20.00 4278.11 4378.17 4504.13 25.00 4271.29 4370.10 4492.97 35.00 4261.24 4356.87 4477.68 1,000 50.00 4250.85 4343.88 4461.13 60.00 4245.75 4337.37 4452.97 70.00 4241.73 4331.77 4445.95 80.00 4238.24 4327.49 4440.40 100.00 4232.13 4319.64 4429.39 200.00 4215.23 4296.63 4400.46 400.00 4199.96 4278.80 4375.35 Characteristics1000. 00of41 00Wet.00 4125 .00 4200.00 100 2000.00 3650.00 3725.00 3800.00 20C 4000.00 3000.00 3070.00 3400.00 Technology10000.00
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