1. Overview of Polymer Hybrid Capacitors

Polymer Hybrid Capacitors (PHCs) are advanced aluminum electrolytic capacitors that combine liquid electrolytes with conductive polymers. This hybrid design offers improved electrical characteristics, including low Equivalent Series Resistance (ESR) and high reliability, making them suitable for demanding applications such as automotive and industrial equipment.

Key Features:

• Low ESR

• High ripple current handling capability

• Extended operational life

• Noise reduction

• Open failure mode for enhanced safety

 

2. Structural Composition

Components:

Aluminum Foil (Anode and Cathode): Acts as the primary conductive elements.

Dielectric Layer (Al2O3): Provides insulation and capacitance.

Electrolyte: A combination of liquid and conductive polymer for enhanced performance.

Separator: Impregnated with the electrolyte to maintain separation between electrodes.

External Components:

Terminals and sealing rubber

Ni+Cu-Ni/Sn plated external electrodes

 

Comparison with Traditional Capacitors:

Electrolytic Capacitors: Use only liquid electrolytes.

Polymer Capacitors: Use only conductive polymers.

Polymer Hybrid Capacitors: Combine both for optimized performance.

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3. Performance Characteristics

Low ESR: Superior at high and low temperatures compared to traditional aluminum electrolytic capacitors.

Maintains performance even under high-frequency operations.

Durability: Provides extended operational life.

Minimal leakage current (LC) changes post-reflow soldering.

Ripple Current: Handles higher ripple currents, enhancing performance in dynamic environments.

Failure Mode: Open failure mode ensures device safety during operational stress.

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4. Applications

Automotive:

• Advanced Driver Assistance Systems (ADAS)

• Body Control Modules

• Braking and Parking Assistance Systems

• Electric Power Steering (EPS)

• Engine and Sensor Systems

 

Industrial:

• Base Stations

• Servers

• Security Cameras

 

Advantages for Applications:

• Improved efficiency due to low ESR.

• Stable power delivery with high ripple current handling.

• Resistance to high temperatures and vibrations.

 

Key Applications:

• Automotive Electronics: ADAS, electric power steering, braking systems, etc.

• Industrial Equipment: Servers, network base stations, DC/DC power supplies.

• Medical Devices: Diagnostic equipment requiring precision and stability.

• Energy Systems: Solar inverters, ESS.

 

5. Comparative Analysis

Superior to other types with excellent ESR, leakage current, high-frequency response, and durability, plus a safer open failure mode.

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6. Product Lineup and Specifications

Voltage Range: Available from 6.3V to 100V, meeting various power requirements.

Capacitance Range: From 10µF to 1000µF, suitable for applications requiring high capacitance.

Temperature Ratings:

• 105°C: Standard grade for general use.

• 125°C: Ensures stable operation under higher temperature conditions.

• 135°C: Optimized for high-temperature environments.

• 150°C: Suitable for extreme conditions requiring high reliability.

 

Case Size: Width from 5mm to 18mm and height up to 21.5mm.

Custom Products:

• Designed to flexibly respond to individual customer requirements.

• Available as both catalog products and customized solutions.

• Standard and vibration-resistant options available.

 

7. Development Roadmap

Goals:

High Capacitance: Achieve capacities exceeding 1,800µF by developing larger sizes.

High Voltage: Expand rated voltage up to 250V to support high-voltage applications.

Durability: Achieve operational life of up to 20,000 hours at 105°C. Maintain over 4,000 hours in 150°C environments.

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Planned Innovations:

Expansion: Offer a range of sizes from D6.3x7.7mm to D12.5x16.5mm to cater to diverse applications.

High Capacitance: Provide up to 1,500µF in a D12.5x16.5mm case size.

Enhanced Performance: Improve ripple current performance for power-intensive systems.

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Expanded Case Size Lineup: Upcoming sizes: Υ16x21.5mm and Υ18x21.5mm

 

8. Vibration-Resistant Features

Design Enhancements:

Vibration-resistant seat plates to secure the capacitor body.

Dummy terminals to strengthen soldering and prevent detachment.

Performance:

Tested to AEC-Q200 standards.

Withstands acceleration up to 30G and frequencies of 10~2000Hz.

 

9. Competitive Advantages

Wide Case Size Options: Industry-leading lineup, including large sizes such as Φ12.5x16.5mm.

High Reliability: Compliant with AEC-Q200 for automotive-grade components.

Flexibility: Offers customized specifications and flexible production schedules.

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10. Conclusion

Polymer Hybrid Capacitors provide a unique balance of reliability, performance, and adaptability. Their advanced structure addresses critical challenges in automotive, industrial, and high-performance applications, offering a superior alternative to traditional capacitor technologies.

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*Part Numbering System

The part numbering system for Polymer Hybrid Capacitors follows this structure:

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Description

Product Code - Series identifier (e.g., HV1, HT1)

Rated Voltage - Code Rated voltage (e.g., 25V = 2E)

Capacitance Code - Rated capacitance (e.g., 100µF = 101)

Tolerance Code - Capacitance tolerance (e.g., M = ±20%)

Case Size Code - Width and height (e.g., D6.3x7.7mm = E63)

Packaging Code - Packaging type (e.g., R = tape and reel)

Additional Code - Special requirements (e.g., V = vibration-resistant)

Example:

HV1-2E101M-E63R: HV1 series, 25V, 100µF, ±20% tolerance, D6.3x7.7mm case, tape and reel packaging.