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Electrolyte
(Real Cathode)
Anode aluminum
electrode
Oxide film
Cathode Aluminum
electrode
(Apparent Cathode)
Electrolytic paper
containing electrolyte
Fig. 1 - 1
Table 1-1 Dielectric constants and minimum thickness of dielectrics used in various types of capacitors
Type of Capacitor
Dielectric
Aluminum Oxide
Dielectric Constant
7~10
(0.0013~0.0015/ V)
Tantalum Oxide
24
(0.001~0.0015/ V)
Polyester Film
3.2
0.5~2
Barium Titanate
500~20,000
2~3
Titanium Oxide
15~250
2~3
NICHICON CORPORATION
Section
Surface
Photo 1-1 Surface and section photo of etched aluminum foil for low voltage capacitors.
Section (Replica)
Surface
Photo 1-2 Surface and section photo of etched aluminum foil for middle / high voltage capacitors.
NICHICON CORPORATION
0.0013~0.0015 (m)/ V.
Expanded photography of a dielectric (aluminum oxide
layer) on the foil that has not been etched (plain foil) is
shown in photo 1-3.
The fabrication reaction of the dielectric can be
expressed as follows:
+3e - (Electron)
2Al+3H2O a Al2O3+3H2 (Gas)
dielectric
dielectric
dielectric
20V Formed
100V Formed
250V Formed
Photo 1-3 Enlarged photo of oxide layer formed on a non-etched plain aluminum foil.
1-4 Electrolyte
Anode foil and a cathode foil facing each other are
interleaved with electrolytic paper and wound into a
cylindrical shape. This is called a "capacitor element." At
this stage, it has configuration of a capacitor when
considers electrolytic paper and the aluminum oxide layer
to be dielectric, however, the unit has few capacitance.
When this capacitor element is impregnated with liquid
electrolyte, the anode foil and cathode foil are electrically
connected. With the aluminum oxide layer formed on the
anode foil acting as the sole dielectric, a capacitor with a
high value of capacitance is now attainable. That is to say
that the electrolyte is now functioning as a cathode. The
basic characteristics required of an electrolyte are listed
below:
NICHICON CORPORATION
Main Materials
Contents
Chloride
Pure water
Forming
Etched foil
(Formation of
the Dielectric)
Borate, etc.
Slitting
Pure water
Anode foil
Cathode foil
Electrolytic paper
Leade
Lead
Winding aftixing
material
Element
Foil
Electrolytic
paper
Fig. 1 - 2
NICHICON CORPORATION
Prosess
Element
Impregnation
Electrolyte
Main Materials
Contents
Elements
Electrolyte
Assembly
&
Finishing
Terminal
Lead wire
Aluminum rivet
Curled section
Aluminum lead tab
Rubber packing
Rubber-bakelite
Curled section
Aluminum washer
Aluminum lead tab
Element
Sleeving
Aluminum case
Aluminum
case
Sleeving
Element
Bottom plate
Fig. 1 - 3
Fig. 1 - 4
Assembled products
Aging
Plastic platform
Processing
Taping material
Accessories
(Capacitor mounting braket,
terminal screws , etc.)
Fig. 1 - 5
Inspection
Packaging
Packaging materials
Shipping
TECHNICAL NOTES CAT.8101E-1
NICHICON CORPORATION
1-6 Characteristics
1-6-1 Capacitance
The capacitance of the dielectric portion of the anode
aluminum foil can be calculated with the following formula
(discussed in 1-1) :
-- 8
Ca = 8.855 10
S
F
d
Ca Cc
Ca + Cc
10
R (), Z()
10-1
Z
R
10-2
102
103
104
105
106
Frequency (Hz)
Fig. 1 - 8
C Capacitance ( F )
r
R
Fig. 1 - 6
R
= CR
Xc
tan=
DF = tan
Xc
10-3
XL
Xc
Q =
tan
( = 2f)
Fig. 1 - 7
(1 - 3)
100 (%)
PF = cos =
(1/c)
(1 - 2)
R
=
Z
Xc
= R
R
2
R +
(1 - 4)
(1C)
(1 - 5)
NICHICON CORPORATION
10
-25oC
tan
0.01
100
+20oC
tan
+65oC
+105oC
0.1
0.01
100
10k
1k
Frequency (Hz)
at 120HZ
-10
-20
10
-30
-40
20
10
-40
-20
20
40
60
Temperature (o C)
80
100
120
0.01
100
-30
10
-40
-40
ESR
+20oC
-20
-60
Impedance
-25oC
0.1
0
-10
ESR()
Impedance()
-60
-25oC
-20
20
40
60
Temperature (o C)
80
100
120
1k
10k
Frequency (Hz)
+65oC
+105oC
100k
ESR()
Impedance()
10k
1k
Frequency (Hz)
10
+20oC
+65oC
+105oC
0.1
1) Capacitance
The capacitance of aluminum electrolytic capacitors
increases as the temperature increases and decreases as
the temperature decreases. The relationship between
temperature and capacitance is shown in Fig. 1-9.
20
1
Impedance
ESR
0.1
+20oC
+65oC
0.01
100
+105oC
1k
10k
Frequency (Hz)
100k
NICHICON CORPORATION
1000
4) Leakage Current
The leakage current increases as the temperature
increases and decreases as the temperature decreases.
Fig. 1-12 shows the relationship between temperature and
leakage current.
100
10
1
-20
1000
20
40
60
Temperature (oC)
80
100
120
80
100
120
100
10
1
-20
20
40
60
Temperature (oC)
NICHICON CORPORATION
NICHICON CORPORATION
2-1-2. Mounting
( 1 ) Once a capacitor has been assembled in the set and
power applied, Even if a capacitor is discharged, an
electric potential(restriking voltage) may exist
between the terminals.
( 2 ) Electric potential between positive and negative
terminal may exist as a result of returned
electromotive force, so please discharge the
capacitor using a 1k resistor.
NICHICON CORPORATION
5. In an Emergency
( 1 ) If you see smoke due to operation of safety vent, turn
off the main switch or pull out the plug from the outlet.
( 2 ) Do not bring your face near the capacitor when the
pressure relief vent operates. The gasses emitted
o
from that are over 100 C.
If the gas gets into your eyes, please flush your
eyes immediately in pure water.
If you breathe the gas, immediately wash out your
mouth and throat with water.
Do not ingest electrolyte. If your skin is exposed to
electrolyte, please wash it away using soap and
water.
6. Storage
( 1 ) lt is recommended to keep capacitors between the
o
o
ambient temperatures of 5 C to 35 C and a relative
humidity of 75% or below.
( 2 ) Confirm that the environment does not have any of
the following conditions:
qWhere capacitors are exposed to water, high
temperature & high humidity atmosphere, or
condensation of moisture.
wWhere capacitors are exposed to oil or an
atmosphere that is filled with particles of oil.
eWhere capacitors are exposed to salty water, high
temperature & high humidity atmosphere, or
condensation of moisture.
rThe atmosphere is filled with toxic acid gasses
(e.g. hydrogen sulfide, sulfurous acid, nitrous
acid, chlorine, bromine, methy bromide, etc.)
tThe atmosphere is fiIled with toxic alkaline gasses
(e.g. ammonia)
yWhere capacitors are exposed to acidic or
alkaline solutions.
7. Disposal
3. In the equipment
(1)
4. Maintenance Inspection
( 1 ) Please periodically inspect the aluminum capacitors
that are installed in industrial equipment. The
following items should be checked:
q Appearance : Remarkable abnormality such as
TECHNICAL NOTES CAT.8101E-3
NICHICON CORPORATION
NICHICON CORPORATION
Cause
Failure mode
Failure mechanism
Production
Insulation-breakdown of
the oxide layer on the foil
Application
Short circuit
Application of
overvoltage
Insufficient connection of
tab and terminal part
Decreased capacitance
of the anode foil
Severe mechanical
stress
Application of
overvoltage
Decrease of
capacitance
Increase of
tan
Excessive ripple
current flow
Application on reverse
voltage
Decreased capacitance
of the cathode foil
Severe electrical
stress
Increase of
leakage
current
Deterioration of oxide
layer
Corrosion of electrode
and tab
Permeation of
halogeneous substances
Infiltration of halogen
Excessive
charge / discharge
Opened
vent
Deterioration
Insufficient sealing
Electrolyte
leaking
Decreased electrolyte
Deterioration of
sealing materials
NICHICON CORPORATION
2-3-1 Foreword
The relationship between the voltage and leakage
current when voltage is applied to the aluminum
electrolytic capacitor is shown in Fig. 2-2. From Fig. 2-2,
the following can be said:
If voltage is applied in directions of the polarity of the
capacitor, the leakage current will start rapidly to rise
if the applied voltage exceeds the rated voltage.
If voltage is applied in reverse direction of the polarity
of the capacitor, a large amount of current begins to
run through with a low voltage.
The behavior and safety test method of the aluminum
electrolytic capacitor, which withholds the above nature,
under the below conditions is expressed in the following
section.
1) Under reverse polarity
2) Under excess voltage application.
3) Under AC voltage application
(+)
100
50
Rated 47 F
25V
50V 100V
160V
160V
100V
50V
25V
Leakage Current ( A)
200
100
Voltage (V)
300
50
100
( --- )
16V 100F
Applied Voltage
Ambient Temp
20oC
85oC
-- 1 V
-- 2 V
Fig. 2 - 2 V - I Characteristics
(Voltage - Current Characteristics)
0
- 10
- 20
- 30
- 40
0 20
Fig. 2 - 3
100
200
Time (h)
250
300
1
2
C V ) . Therefore, the higher the applied
2
NICHICON CORPORATION
Leakage Current ( A)
103
Table 2-1
at 85oC
102
Electron flow
domain
at 20oC
101
There is about
10% difference.
Rated
Capacitance
( F)
Series
Resistance
(Ohm)
Rated
Capacitance
( F)
Series
Resistance
(Ohm)
1 or below
Over 1 10
Over 10 100
1000 100
100 10
10 1
1 0.1
0.1 0.01
Note 1
10
20
30
35
40
Voltage (V.D.C)
60
50
Forming voltage
44 (S.V)
R
AC power
source
Series resistor
AC Voltage meter
AC Current meter
Sample capacitor
V
~
A
~
50Hz
or 60Hz
Fig. 2 - 5
DC Current (A)
22.4mm or less
1A constant
Over 22.4mm
10A constant
DC power
source
DC ammeter
Sample Capacitor
Fig. 2 - 6
Judging Criteria
If the reuslts of the prior tests show the following
conditions, the safety vent has passed the test.
(1) The vent operates with no dangerous condetions such as
flames or dispersion of pieces of the capacitor element
and/or case.
(2)Nothing abnormal takes places even if the test voltage has
been applied to the capacitor for 30 minutes.
NICHICON CORPORATION
SW
Charge Resistance
Charge / discharge
type capacitor
Discharge Resistance
Standard capacitor
(Example)
10
Fig. 2 - 7
V = Ca Vc + Cc
Ca
Vc =
V
Ca + Cc
Vc
(2 - 1)
-10
-20
-30
Opened vent
-10
0
1,000
6,000
Fig. 2 - 8
NICHICON CORPORATION
V1
C1
r1
R0
V2
C2
r2
R0
V0
Fig. 2 - 9
1.4
100k
V1-V2 . .............
(2-5)
i 2-i 1
imax - i min= C 2 V - C 5 V
= C V
( 21 - 15 )
3
= 10 C V
(A)
(2-6)
NICHICON CORPORATION
Ratings
25V 4700F
400V 120F
Case Size
22 25L
25 30L
Temperature
Room Temperature
Room Temperature
Test Condition
No load storage
No load storage
CAPACITANCE CHANGE(%)
10
0
-10
-20
-30
-40
10
tan
0.1
0.01
LEAKAGE CURRENT(A)
1000
100
10
0.1
0
Fig. 2 - 10
NICHICON CORPORATION
2-7 Restriking-voltage
Altitude (m)
Temp
. .( C)
15.0
1013.3
2,000
2.0
795.0
4,000
- 11.0
616.4
6,000
- 24.0
471.8
8,000
- 37.0
356.0
10,000
- 50.0
264.4
20,000
- 56.5
54.7
NICHICON CORPORATION
Failure Rate ( )
Initial Failure
period
Incidental Failure
period
Time (h)
Ratings
Size (m m)
Test temperature
Criteria on life
99
2-9-1 Foreword
The failure rate () for electronic applications and
components which require no particular maintenance
follows their time transition ( t ) and shows a curve as
shown in Fig.2-11. Because this curve resembles the
shape of a western bathtub, it is called "Bathtub Curve."
The failure mode of aluminum electrolytic capacitors also
forms a "Bathtub Curve." If the results of the life evaluation
test of aluminum electrolytic capacitors is analyzed by
"Weibull Probability Paper" as in Fig. 2-12, the shape
parameter "m" is larger than 1, showing that the failure
mode is a wear-out failure. Although the failure rate or the
life estimation is generally used in designing a device, the
reliability of an aluminum electrolytic capacitor is
generally measured by its life (the expected life, in
practical use) rather than failure rate since the failure
mode of aluminum electrolytic capacitors is wear-out.
In other words it is expected that we have different failure
rates in the same test time (number of speciments x test
time) (e.g. 100 capacitors x 10 hours... zero failures is
expected, 10 capacitors x 10 hours... 100% will be failed.
The factors that most effect the life of aluminum electrolytic
capacitors are acceleration according to the ambient
temperature (F T), acceleration according to the ripple
current (FI) and acceleration according to the applied
voltage (FU). The expected life is calculated by multiplying
the specified life time on Nichicon catalog, FT, F1, and Fu.
The life of aluminum electrolytic capacitors is discussed in
the following.
400V 68F
20 30L
105oC
tan 0.3
Plot
95
90
80
70
60
50
40
30
20
10
5
103
6 7 8 9104
Time (h)
Fig. 2 - 12
NICHICON CORPORATION
Ratings
200V 220 F
400V 68 F
Size
20 25L
20 30L
Temp.
o
105 C
o
105 C
Test Condition
120HZ 1.00Arms+DC191V
120HZ 0.56Arms+DC384V
CAPACITANCE CHANGE(%)
10
0
-10
-20
-30
-40
10
tan
0.1
0.01
LEAKAGE CURRENT(A)
1000
Time(103h)
100
Working
Time
(Day)
10
1
0.1
e r
q w
10
20
100131
24h
1
year
3
5
10
15
years years years years
8h
3
years
9
15
years years
2000
4000
6000
8000
Time (h)
Fig. 2 - 13
Mark
Ratings
50V 1000F
16V 4700F
16
16
Size
25L
31.5L
Temp.
o
105 C
o
105 C
Test Condition
100kHZ 2235mArms+DC48V
100kHZ 3010mArms+DC15V
10
CAPACITANCE CHANGE(%)
105
100
95
90
85
80
75
70
65
60
55
50
45
Mark
-10
-20
-40
10
tan
Test Condition
DC 50V
DC 40V
DC 30V
-10
-20
-30
-40
10
0.01
tan
10000
LEAKAGE CURRENT(A)
Temp.
105oC
105oC
105oC
0.1
0.1
1000
100
0.01
0
10
1
Size
35 45L
35 45L
35 45L
10
CAPACITANCE CHANGE(%)
-30
Ratings
50V 12000F
50V 12000F
50V 12000F
1000
2000
3000
4000
5000
Time (h)
2000
4000
6000
8000
Time (h)
NICHICON CORPORATION
:
:
:
:
:
:
:
Re =
t =
IAC
A
Re
A
10
2.10
0.90
12.5
2.05
0.85
16
2.00
0.80
18
20
22
25
30
35
40
1.96 1.93 1.88 1.84 1.75 1.66 1.58
0.77 0.75 0.74 0.71 0.67 0.64 0.62
:Temperature rise ratio calculated
=ts/tc
R0
R
( 2 - 14 )
I0
Frequency (Hz)
50
60 120
16~100V 0.88 0.90 1.00
Frequency
coefficient 160~250V 0.81 0.85 1.00
(Kf)
315~450V 0.77 0.82 1.00
Frequency
Rated
(Hz)
voltage(V) Cap.(F)
~56
68~330
6.3~100V
390~1000
1200~15000
t =
8
2.13
0.94
( 2 - 10 )
o
5 or less 6.3
2.18 2.16
1.0
(2-9)
IAC
( 2 - 13 )
120
300
1k
10k~
0.20
0.55
0.70
0.80
0.30
0.65
0.75
0.85
0.50
0.75
0.80
0.90
0.80
0.85
0.90
0.95
1.00
1.00
1.00
1.00
Ambient
o
Temperature ( C)
o
tc ( C)
Re
IAC2 tan
A =
A C
50
40
55
65
85
105
30
30
25
15
NICHICON CORPORATION
( KI ) + ( KI )
2
H
fH
fL
( 2 - 17 )
1rms =
1p
1P
2
T1
1rms = 1P
1p
T1
T1
2T
tn = IIn0
1rms = 1P
T1
1rms = 1P
T1
( )
t0
( 2 - 18 )
o
1p
T1
1p
T1
3T
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
(a)
(b)
1p
(a)
(b)
T1
t1
1p
Ln = Lo
T0 -Tn
10
1-
tn t n = t 0
K
In
(Im
)
( 2 - 19 )
o
Fig. 2 - 17
t1
t
( 2 - 16 )
NICHICON CORPORATION
10
1
50
60
70
80
90
100
110
(Miniature type)
There are two formulase for obtaining the estimated life of
a miniature aluminum electrolytic capacitor, depending on
the life specification of series on Nichicon catalog as
shown in formulase 2-20 and 2-21.
(1) Capacitors life time is specified. with rated DC vortage
applied only
L nL o
1 (
22
T0Tn
10
Tn
( T
)
) 2 30
In 2
Im
2 - 2 1
2-20,2-21
2
T0Tn
10
T0Tn
T040
10
Tn() 402
T050
(
)
(
30 ) Tn() 50
30
2
2
o
NICHICON CORPORATION
NICHICON CORPORATION
2-10-4 Others
Wooden package material may be subjected to fumigation
by a halogen(e.g. methyl bromide) before they are
exported in order to protect them against pests. If devices
with aluminum electrolytic capacitors or capacitors
themselves are directly fumigated or packed with the
pallet that is fumigated, the capacitors may internaIly
corrode due to the halogen contents of fumigation agents.
NICHICON CORPORATION
Fig. 2 - 19
t
Vc = V(1 - e
tn = CRln
CR
( 2 - 22 )
( V -VV )
( 2 - 23 )
R : Series resistor ()
C : Capacitance (F)
V : Applied voltage (V)
2-11-3 Discharge Circuit
Figure 2-20 shows the situation where capacitor C is
discharged with resistance Rd by laying down switch SW
toward 2, after it has been charged with applied voltage V
by laying down switch SW toward 1. The relationship
between the terminal voltage Vc (V) and discharge time (t)
may be expressed by formula 2-22. The time "tn" needed
for the terminal voltage "Vc" (V) of a capacitor to reach
voltage "Vn" may be expressed by formula 2-23.
R
t
CRd
( 2 - 24 )
( )
( 2 - 25 )
t n = CRd l n VVn
Rd : Discharge resistor ()
C : Capacitance (F)
V : Applied voltage (V)
SW
1 2
Vc = V X e
Rd
SW
1 2
Vc
C
Rd
Fig. 2 - 20
NICHICON CORPORATION
85oC Type
105oC Type
LS
LN, LG
DM
GU GN, GG
GJ.GJ(15)
DQ
o
AK
GY
AQ,AS(Smaller-sized)
AD
Configuration
Long life
Standard 105 C Type 125 C Type Bi-polarized Low impedance (105 C5000h)
o
5mmL
MA
MT
7mmL
11mmL
or more
SA,SR
ST
VR,RS
VZ,RZ
Table. 2 - 1 0
--
BT
MP
MF
MV
SP
SF
SV
VP
PJ,PM
PV
Feature
Configuration
Standard
3.0mmL
ZD
3.95mmL
ZR
ZG
ZE
105oC Type
4.5mmL
ZS
ZT
ZP
5.5mmL
WX
WT
WF (Low impedance)
WP
6.2mmL
or more
UR
UT
UL (Long life)
UX (High C / V)
UB
UP
Higher capacitance
UG
UJ
UH
UN
NICHICON CORPORATION
N2
33C
WZ
12.5~20
nichicon
330 F
UJ 50V
H0536
NICHICON CORPORATION