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Hybrid Capacitors at CODICO

2020-05-22  Passive Components   
CODICO is able to provide the best hybrid capacitor solution for your application, both technically and commercially.

How to improve cost & space of demanding applications

CODICO is able to provide the best solution for your application, both technically and commercially. The right selection is based on real requirements and needs according to your mission-/load profile. This is the key to increase efficiency and avoid cost intensive over-specifications.



We, as team with our suppliers, can provide detailed lifetime calculations tailored to your application. If the selection is made only according to the basic application requirement and pure item specification, the total costs and space used may be unnecessarily high. The evaluation of the detailed requirement and the consideration of the item performance through mission profile and lifetime calculation leads to improvement of cost, space requirement and thermal management.



The following examples show how to reduce cost by using a hybrid capacitor above the specified temperature range or exceeding the rated ripple current. Use our experience to increase your profit!



Example 1: Over temperature usage



Even though your application causes the capacitor to be exposed to 135°C or more for some time, using a 135°C specified component is not mandatory. Depending on the application’s mission profile the capacitor requirement often has a chance to be relieved. With the mission profile below our supplier can suggest a 125°C specified capacitor.



  • Rated Voltage 25V
  • Rated Capacitance 560uF
  • Max. Temperature: 125°C
  • Rated Lifetime: 4.000hrs
  • Rated Ripple Current: 3,2A
  • ΔTj when rated ripple is applied (ΔT0): 10K
  • Number of pcs: 6pcs


Lifetime calculation:

Ambient Temperature
(°C)

Total Time*
(Hrs)

Total Ripple Current (Arms)

Capacitor's Ripple Current (Arms)

Delta Tj
(K)

Tj**
(°C)

Consumed
Lifetime rate
(%)

-30

100

18

3,00

8,8

40,0

0,00

-20

500

18

3,00

8,8

40,0

0,02

40

1.500

18

3,00

8,8

48,8

0,10

95

4.000

18

3,00

8,8

103,8

11,49

125

1.500

18

3,00

8,8

133,8

34,48

135

500

18

3,00

8,8

143,8

22,99

150

10

0

0,00

0,0

150,0

0,71

Total

8.110

 

 

 

 

69,78

* : Each lifetime is total time of all cycles with considering intervals.
**: When Tj is 40°C or lower, Tj shall be 40°C



Example 2: Over ripple current usage



Also for higher ripple current in your application, you do not need to consider the rated ripple current of a capacitor as limitation. For example, if you have significantly higher ripple current applied for limited time at e.g. 95°C and 125°C like in below mission profile, even though you still can use the same capacitor as in example 1.



Lifetime calculation:

Ambient Temperature
(°C)

Total Time*
(Hrs)

Total Ripple Current (Arms)

Capacitor's Ripple Current (Arms)

Delta Tj
(K)

Tj**
(°C)

Consumed
Lifetime rate
(%)

-30

100

18

3,00

8,8

40,0

0,00

-20

100

18

3,00

8,8

40,0

0,00

40

2.000

18

3,00

8,8

48,8

0,13

95

4.000

18

3,00

8,8

103,8

11,49

95

750

30

5,00

24,4

119,4

6,37

125

2.000

18

3,00

8,8

133,8

45,97

125

50

30

5,00

24,4

149,4

3,39

Total

9.000

 

 

 

 

67,36

* : Each lifetime is total time of all cycles with considering intervals.
**: When Tj is 40°C or lower, Tj shall be 40°C.



Example 3: Solderstar/Axial type replacement



Axial and “Solderstar” capacitors are often used for extremely high ripple current requirements. If ESR or ripple current rather than capacitance is the key, a replacement by hybrid capacitors will be a more robust and downsized solution.



Customer condition example:

  • Rated Voltage: 63V usage
  • Total ripple current demand: 80A
  • Max. Temperature: 135°C
  • Rated Lifetime: 4.000hrs


Capacitor comparison:

  • Solderstar solution: 18x25mm 750uF 23pcs
  • Our hybrid capacitor offer: 10x20mm 150uF 36pcs


Solution comparison:

  • PCB area: Solderstar 414mm² vs hybrid 360mm² (13% saving)
  • Height: Solderstar 25mm vs hybrid 20mm (20% saving)


Our design-in goal is to support engineers to select the best fitting capacitor solution for the application, high quality with enough margin but avoiding cost intensive over-specification. For more information please contact Yasunobu Ikonu or Roland Trimmel.

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