Download Understanding Polymer and Hybrid Capacitors Advanced capacitors based on conductive polymers

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Understanding Polymer and
Hybrid Capacitors
Advanced capacitors based on conductive polymers
maximize performance and reliability
The various polymer and hybrid capacitors have distinct sweet
spots in terms of their ideal voltages, frequency characteristics,
environmental conditions and other application requirements.
In this paper, we’ll show you how to identify the best uses for
each type of advanced capacitor. We’ll also highlight specific
applications in which a polymer or hybrid capacitor will
outperform traditional electrolytic or even ceramic capacitors.
POLYMER CAPACITOR VARIETIES
Polymer capacitors come in four main varieties, including
the hybrid. Each type has different electrolytic and electrode
Hybrid capacitor technology combines the performance benefits of
electrolytic and polymer capacitors.
Capacitors may seem simple enough, but specifying them has
actually grown more complex in recent years. The reason why
comes down to freedom of choice. The universe of capacitors
has expanded greatly over the past few years, in large part
because of capacitor designs that take advantage of advances
in conductive polymers.
These advanced capacitors sometimes use conductive polymers
to form the entire electrolyte. Or the conductive polymers can be
materials, packaging and application targets:
• Layered polymer aluminum capacitors use conductive
polymer as the electrolyte and have an aluminum cathode
(see Figure 1). Depending on the specific model, these
capacitors cover a voltage range from 2-25V and offer
capacitances between 2.2-560µF. The distinguishing
electrical characteristic of these polymer capacitors is
their extremely low equivalent series resistance (ESR). For
example, some of our SP-Cap™ polymer capacitors have
ESR values as low as 3mΩ, which is among the lowest in
used in conjunction with a liquid electrolyte in a design known as
a hybrid capacitor. Either way, these polymer-based capacitors
offer a performance edge over conventional electrolytic and
ceramic capacitors when it comes to:
Molding
Resin
Silver Paste
Terminal
•Electrical characteristics.
•Stability.
•Longevity.
•Reliability.
•Safety.
Terminal
Silver Paste
Carbon
Al2O3
Aluminum Foil
Polymer
Figure 1
•Life cycle cost.
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Two Riverfront Plaza, 7th Floor, Newark, NJ 07102-5490 www.panasonic.com/industrial
Aluminum Case
the industry. Packaged in a molded resin as compact
surface mount devices, these layered polymer capacitors
have a low profile. As a result of the electrical and form
factor characteristics, they have applications in a variety
Back Plate
of handheld electronic devices or other applications that
require a low-profile capacitor that will not interfere with a
nearby heat sink.
Rubber Seal
Terminal
• Wound polymer aluminum capacitors are also based on
conductive polymers and aluminum, but they have a wound
cover a wider range of voltages and capacitance values
than other types of polymer capacitors. Voltages extend
Aluminum
Foil
Al2O3
from 2.5 to 100V, while capacitances run from 3.3 to 2700µF.
Like the layered polymer capacitors, the wound style
has extremely low ESR values. Some of our OS-CON™
Aluminum
Foil
Spacer
foil structure (see Figure 2). The wound polymer capacitors
Electrolyte Impregnated in Spacer
Polymer
Figure 2
capacitors, for instance, have ESR values
below 5mΩ. The wound style can
also be surface mounted,
though they are not
Molding
Resin
Terminal
quite as compact as
the layered capacitors.
Terminal
•
Polymer tantalum capacitors employ a conductive
Silver paste
Ta2O5
Carbon
Polymer
polymer as the electrolyte and have a tantalum cathode
(see Figure 3). They span voltages from 1.8 to 35V and
Sintered Tantalum
Figure 3
capacitances from 2.7 to 680µF. They, too, have low
ESR values. They, too, have low ESR, with some of our
POSCAP™ capacitors exhibiting ESR values as low as
5mΩ. Packaged in a molded resin case, the tantalum
polymer capacitors are among the
most compact on the market. Our
POSCAP M size, for example,
measures just 2.0 by 1.25 mm.
Though compact, a wide range
of sizes is available for this
capacitor type.
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•
Aluminum Case
Polymer hybrid aluminum capacitors. As their name
suggests, these capacitors use a combination of a liquid and
conductive polymer to serve as the electrolyte (see Figure
4) and aluminum as the cathode. Think of this technical
Back Plate
approach as the best of both worlds: The polymer offers high
conductivity—and a correspondingly low ESR. The liquid
portion of the electrolyte, meanwhile, can withstand high
voltages and provide higher capacitance ratings due to its
Terminal
Rubber Seal
large effective surface area. The hybrid capacitors offer a
voltage range from 25 to 80V and capacitances between 10
than other types of polymer capacitors, but still very low
considering the higher power applications they address (see
Aluminum
Foil
sidebar).
Al2O3
POLYMER CAPACITOR ADVANTAGES
Despite differences in their materials and construction, the four
Aluminum
Foil
Spacer
and 330µF. At 20 to 120mΩ, ESR values for hybrids are higher
Hybrid Electrolyte
Impregnated in Spacer
Polymer + Electrolyte Liquid
Figure 4
types of polymer capacitors share a collection of desirable electrical
properties:
•
Great frequency characteristics. Thanks to their ultra low
ESR values, polymer capacitors have a low impedance near
their resonance point (see Figure 5). And lower impedance
Figure 5
reduces AC ripple in power circuits. Our testing has
ESR lowers impedance near the
resonance point, reducing AC ripple.
Impedance (Z)
Impedance
Capacitance: ½πfC
Inductance: 2πfL, where L = ESL
Resistance: ESR
Frequency
Impedance (Z)
IMPEDANCE CHARACTERISTICS
Frequency
Z Large:
Z Small:
Ripple
Ripple
Z Large:
Z Small:
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Reliable Capacitors For IT
Infrastructure
weak link: The capacitors in their power supplies.
Conventional electrolytic capacitors tend to fail prematurely
when their liquid electrolyte dries up‚ which happens in
response to elevated temperatures and long on times.
DC Bias
10
0
10
0
-10
0
-10
-20
dC / dC
C (%)
/C
dC(%)
/ C (%)
Information technology infrastructures have a little-known
DC Bias
STABLE CAPACITANCE
DC Bias
10
-10
-20
-30
-20
-30
-40
-30
-40
-50
-40
-50
-60
-50
-60
-70
-60
-70
-80
Conventional tantalum capacitors are one possible solution
-70
-80
-90
to these premature failures. However, tantalums require
-80 0
-90
0
-90
0
voltage derating to avoid a very undesirable failure mode—
namely, the potential for fires.
1
2
1
2
1
2
3
4
DC Bias (V)
3
4
DC Bias (V)
3
4
DC Bias (V)
as a way to improve lifecycle and reliability of IT equipment
C/C (%)
C/C (%)
C/C (%)
such as servers, switches, routers and modems.
Polymer wound capacitors such as OS-CON do not have a
liquid electrolyte and therefore can have extremely long life.
POSCAP polymer-tantalum capacitors contain no oxygen
in their formulation. So they are not prone to combustion
upon failure. SP-Caps also have a similar benign failure
-55
-35
-15
5
-55
-35
-15
5
-55
-35
-15
5
mode.
All three families of advanced capacitor also offer the
features required for information infrastructure:
Compact size.
•
High Ripple Current
•
•
6
7
5
6
7
5
6
7
Temperature Range
20
Temperature
Range
20
Temperature Range
More advanced polymer-based capacitors have emerged
•
5
20
10
10
10
0
25
45
65
85
105
25
0
-10 25
45
65
85
105
45
65
Temp. ( )
85
105
0
-10
Temp. ( )
-10
-20
Temp. ( )
-20
-20
-30
Low ESR
-30
-30
MLCC
Multilayer ceramic capacitor (6.3V47µF/3216/X5R)
MLCC
Multilayer ceramic capacitor (6.3V47µF/3216/X5R)
MLCC capacitor
Polymer
Multilayer ceramic
(6.3V47µF/3216/X5R)
POSCAP,
SP-Cap capacitor
or OS-CON
(6.3V47µF)
Polymer capacitor
POSCAP, SP-Cap Figure
or OS-CON
6 (6.3V47µF)
Polymer capacitor
Long Life.
POSCAP, SP-Cap or OS-CON (6.3V47µF)
revealed as much as a fivefold reduction in peak-to-peak
deliver subpar performance in the field. Hybrid capacitors
voltage changes when comparing polymer capacitors to
add another dimension to capacitance stability. They keep
conventional low-ESR tantalum capacitors.
•
a stable capacitance in the face of common operating
conditions—high frequencies and low temperatures—that
Stable capacitance. With ceramic capacitors, capacitance
reduce the capacitance of conventional liquid electrolytic
drifts in response to temperature changes and DC bias.
capacitors.
Polymer capacitors have no such problem and remain
(see Figure 7).
stable over time (see Figure 6). This stability is particularly
important in industrial and automotive applications, which
tend to experience fluctuations in operating temperatures.
We’ve seen cases where elevated temperatures caused
an effective capacitance loss of 90% or more for ceramic
capacitors, meaning that the conventional capacitors
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Two Riverfront Plaza, 7th Floor, Newark, NJ 07102-5490 •
Enhanced safety. Conventional electrolytic capacitors
can suffer from safety issues that could cause them to
short circuit and fail. The problem arises when electrical
or mechanical stresses create defects or discontinuities in
the oxide film that forms the capacitor’s dielectric. Polymer
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HYBRID CAPACITOR
PERFORMANCE
Capacitance
vs. Frequency
capacitors have a self-healing capability that eliminates
this failure mode. The repair takes place in response to the
short circuit. The heating breaks the molecular chain of the
1000.0000
conductive polymer near the defect, driving up its resistance
capacitors, an additional self-healing mechanism comes
into play—because the liquid electrolyte causes current
flow near the defect to reoxidize the aluminum. We have
C ( F)
C (C F)
( F)
from the electrode (see Figure 8). In the case of hybrid
100.0000
100.0000
Good
Good
Good
and effectively forming a barrier against any current leaking
Capacitance vs. Frequency
Capacitance vs. Frequency
1000.0000
1000.0000
joule heating that occurs when a dielectric defect triggers a
100.0000
10.0000
10.0000
10.0000
1.0000
1.0000
conducted numerous over-voltage tests to demonstrate
the self-repairing nature of polymer and hybrid capacitors.
1.0000
One such test compared our SP-Cap polymer capacitors
0.1000
0.1000 100
to a conventional tantalum-MnO2 capacitors. The polymer
0.1000
model withstood short currents as high as 7 amps, while the
tantalum capacitor started smoking at 3 amps and ignited
100
1,000
1,000
100
1,000
normally derated in use by 30 to 50% their labeled voltage
100
100
to ensure that they operate safely. This derating, while a
common and accepted engineering practice, results in an
100
upsizing of capacitors and increased cost. For our polymer
Polymer capacitors are seeing increasing use in automotive
electronic applications. Our polymer and hybrid capacitors
meet the following automotive production requirements:
•
OS-CON, Hybrid and POSCAP models comply with
AEC standards.
•
Capacitors are produced in a TS16949 certified
production facility.
•
Production Part Approval Process (PPAP).
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10 M
ESR vs. Temperature
ESR vs. Temperature
ESR vs. Temperature
( ) ( () )
10
10
Good
Good
Good
Polymer And Hybrid
Capacitors Are Road Ready
10 M
10 M
Hybrid capacitors offer stable capacitance at high frequencies.
and cost implications. Conventional tantalum capacitors are
the full-rated voltage.
1M
1M
Frequency (Hz)
at 5 amps. This safety enhancement has important design
capacitors, by contrast, we guarantee operation at 90% of
10,000
100,000
10,000
100,000
Frequency (Hz)
Frequency100,000
(Hz)
10,000
10
1
1
1
0 .1
0 .1
0 .1
0. 01
0. 01-60
0. 01-60
-60
-20
-20
-20
20
60
20
60
Temperature (
Temperature
20
60(
ESR (100kHz)
)
)
( )
Temperature
ESR (100kHz)
100
100
140
140
100
140
ESR (100kHz)
E-Cap
E-Cap
Hybrid
Hybrid
E-Cap
Hybrid capacitors offer stable Hybrid
ESR even at temperatures as
low as -55ºC.
Figure 7
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Pre-Short
Electrode Element
Dielectric Oxidation Film
Short
Heating
Defect Isolation
Micro Defect
Short Circuit Current
Isolated Conductive Polymer
Conductive Polymer Layer
Figure 8
and their sizing. Consider our aluminum polymer capacitor line,
Robust Capacitors For
Industrial Use
capacitance even higher—to 2mΩ and 680µF, respectively.
The increased use of electronics in industrial applications
reductions in ESR in smaller surface mount packages. For
These demanding applications often have unforgiving
in ESR from 9 to 6mΩ.
conventional capacitor technology such as aluminum
Polymer capacitors have been in production since 1990. But they
continue to evolve, both in terms of their electrical characteristics
for example. Upcoming models will drive ESR even lower and
Or looking at the tantalum polymer line, new models will offer
has created a need for more robust capacitor solutions.
example, the 3.5x2.8-mm B-Size capacitors will likely see a drop
operating environments that are not friendly to
Our hybrid capacitor line is evolving too. We are expanding the
voltage coverage with new 16 and 100V capacitors. Life cycle
and ripple current specifications are also slated for improvement
in upcoming product releases.
These continuous technical improvements will make polymer
and hybrid capacitors an increasingly attractive alternative to
conventional tantalum-MnO2 and multi-layer ceramic capacitor
(MLCC) technologies.
electrolytics.
Capacitors utilizing polymer technology, such as our
OS-CON and Hybrid models, are ideally suited for these
applications because they offer a combination of:
•
Long Life
•
High Ripple Current
•
•
•
•
Low ESR
High Temperature
High Voltage
High Capacitance
Industrial applications that can benefit from advanced
polymer and hybrid capacitors include motor drives, power
inverters and specialty lighting.
Controller applications can take advantage of polymerbased capacitors too. Our POSCAP polymer tantalum
and SP-Cap models have all the electrical characteristics
we just mentioned but also have compact form factors
that make it easy to integrate them in industrial control
systems.
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Hybrid Capacitor Performance Advantages
Driven by miniaturization of electrical components and higher
Hybrids maximize reliability. Capacitors cannot just
capacitors have started to get more traction.
electrical and environmental conditions. By nearly every
be small, they also need to hold up under challenging
switching frequencies of many electrical devices, hybrid
measure, hybrid capacitors outperform equivalent aluminum
Hybrids are known for their stable electrical characteristics
electrolytic and polymer capacitors hands down. To take
at high frequencies. These robust capacitors also have other
a few examples, hybrid capacitors have significantly
compelling advantages that make a difference in applications
better endurance and humidity resistance than either their
such as computer servers, backup devices and networking
electrolytic or polymer counterparts. Hybrids also have
gear as well as industrial motors, automotive engine control
significantly higher tolerance for large ripple currents, inrush
units, security cameras and LED lighting. Among the
currents and elevated temperature (See Figure 9).
advantages:
Taken together, the size and reliability produce a strong cost
Hybrids are compact. Given the ongoing push to miniaturize
benefit for using hybrid capacitors—in spite of their higher
electrical equipment, the size of capacitors has taken on
upfront prices. The higher ripple current specification alone
a growing importance. Surface mount hybrid capacitors
can result in a 20% reduction in cost by increasing the life
measuring just 6.3 x 5.8 mm can handle 35V and offer a
cycle of the capacitor. In the 48V power supply application
capacitance of 47µF. The small size can save a significant
we just mentioned, the hybrid capacitors had a total cost
amount of board space. In a recent 48V power supply
50% lower than the equivalent aluminum electrolytic
application, hybrid capacitors occupied just 13% of the
capacitors, with the savings coming from reductions in
board space required by aluminum electrolytic capacitors.
board cost, warranty cost and ability to withstand high ripple
current.
Capacitance Change
40
ESR (Ω)
0.140
Upper Limit
30
0.100
10
ESR (Ω)
∆cap. (%)
20
0mA
Upper Limit
0.120
0
-10
0.080
0.060
0.040
-20
0.020
-30
Lower Limit
-40
0
1,000
2,000
3,000
4,000
5,000
0.000
0
6,000
1,000
2,000
Time (h)
40
0.140
Upper Limit
ESR (Ω)
0
-10
0
0.080
0.060
1,000
2,000
3,000
4,000
5,000
0.000
6,000
0
Time (h)
1,000
2,000
3,000
4,000
5,000
6,000
Time (h)
40
0.140
Upper Limit
30
Upper Limit
0.120
20
0.100
10
ESR (Ω)
∆cap. (%)
Upper Limit
0.020
Lower Limit
-40
(overripple)
6,000
0.040
-20
0
-10
0.080
0.060
0.040
-20
0.020
-30
Lower Limit
-40
0
1,000
2,000
3,000
4,000
Time (h)
Panasonic
5,000
0.100
10
-30
3600mA
Hybrid capacitors exhibit high
reliability when subjected to high
ripple currents. In recent testing,
the capacitors had the electrical
characteristics at no load and
rated ripple current (1300 mA)
conditions. At three times
the rated ripple current (3600
mA), the capacitor’s electrical
characteristics did change, but
no shortage took place.
4,000
0.120
20
∆cap. (%)
1300mA
(standard ripple)
30
Figure 9
3,000
Time (h)
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0.000
6,000
0
1,000
2,000
3,000
4,000
5,000
6,000
Time (h)
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