Box DC link capacitors in automotive and industrial applications.

1. September 4th, 2017
KEMET Webinar - 85/85, Box DC link Standard & Auto

2. Products
EMI Film Capacitors
✓ Box - Polypropylene F862, F863
DC Link
✓ Box – Polypropylene C4AE
✓ Box - Polypropylene C4AQ (AEC Q200)

3. EMI Film Capacitors

4. Purpose of EMI capacitors: Noise Filtering
• To reduce/mitigate generated EMI energy in
the range of 150 kHz to 30 MHz
ofr m leaving the equipment and then interfering
with other devices connected to the Mains
EN/IEC 60384-14 (2013)
IEC 60384-14
UL 60384-14
CAN/CSA E60384-14
CQC IEC 60384-14
0.15 30.000.50 1.00 5.00 10.00
0
100
10
20
30
40
50
60
70
80
90
周波数
レベル
[MHz]
[dB(μV)]
R
4
6
,
R
4
1
Noise
generated by
the device
Noise level to be
granted by
capacitors
CISPR11 QP Limit
CISPR11 AV Limit
Frequency
• EMI Film Capacitors are directly connected to
the mains: safety in performance is a must.
Failure mode must be open circuit
• cUL, ENEC, CQC are the international
standards applied to EMI Capacitors
• Standard X2
• Special X2 for harsh environmental
conditions F862, F863

5. Purpose of EMI Capacitors:
Capacitive Power Supply
• Capacitance stability is a must to control
current flowing to the load.
• EMI Film Capacitors are directly connected to
the mains: safety in performance is a must.
Failure mode must be open circuit
• cUL, ENEC, CQC are the international
standards applied to EMI Capacitors
F862, F863
EN/IEC 60384-14 (2013)
IEC 60384-14
UL 60384-14
CAN/CSA E60384-14
CQC IEC 60384-14

6. EMI Film Capacitors Main Features
- High safety performances
- Good volumetric efficience
- Low/medium costs
- Small size
- High competition
- New generation with better resistance to humidity
Agencies Approvals
(cUL, ENEC, CQC)
In Parallel to the
Mains
In Series to the
Mains
In Series to the
Mains - In door
application
X2 Required – Cx
F862, F863 or
Standard X2 F862 F862,F863

7. Market Trend Demand New
The 85°C/85%.R.H. @ 240 Vac test on the component ensure that the capacitor has been designed to be
stable in Capacitance and Dissipation Factor even in outstanding applications
Customers more and more ask for EMI Film components having better performances than usual in terms
of capacitance stability and also considering harsh environmental conditions.
EMI Filtering in Harsh Environmental conditions

8. Harsh Environmental Conditions
and Potential Effects
• Harsh environmental conditions
High Relative Humidity (R.H.) combined with temperature can deteriorate the internal film metalization
and then cause the following:
Capacitance drop
• the device will emit EMI and damage
other devices (X2 in parallel)
• In series connection the device
doesn’t work anymore
Dissipation Factor increase
• the capacitor will be overheating and damaging
the device (X2 in Parallel to the mains)

9. Humidity Impact to Capacitance Stability
4. Electrochemical Corrosion
Reactions in the electrochemical cell are driven by applied voltage
Corrosion rate is directly proportional to: Temperature, Humidity
and Bias
Phenomena is fixed selecting special materials and setting up a
special production process
Electrochemical cell
Applied AC voltage
Air gap induced voltage
Zn° → Zn2+ + 2 e-
2 H2O + 2 e- → H2 + 2 OH-

10. F862 – F863 EMI Capacitors Stability and Safety
Combination
Safety
Self-healing mechanism allows to withstand high voltage peaks without causing catastrophic phenomena.
The self-healing property allows a local evaporation of the metallized coating layer isolating the affected fault area and
restoring the insulation resistance between the electrodes. Capacitance drop is negligible.
Capacitor section and self healing mechanism
Stability
The metallized coating layer on the dielectric must be extremely thin to facilitate
the correct evaporation of the deposited metal.
Severe environmental conditions, high temperature and humidity, can determine
corrosion phenomena: dissipation factor increase and capacitance drop reducing
the reliability of the component.
New technologies that results in special materials and manufacturing processes
allows to make components stable in capacity and dissipation factor.
Metalized Film

11. Reasons to Choose Polypropylene Dielectric -
Self Healing Performances for Safety
– In general alyphatic polymers as polypropylene (and paper) are
highly efficient at self-healing because the pyrolisis reaction during
clearing results in stable gaseous products which allow full recovery
of insulation resistance.
– X2 capacitor have to withstand to high voltage pulse and
good selfhealing property is required for safety reasons
PolyPropylene
CH4, CO2
Polypropylene and Polyester comparison

12. – Self-healing of Polyester type polymers is lower: the aromatic group in the polymer is very
stable and pyrolisis will result less effective. High magnitude clearings could result in ‘carbon’
byproducts (soot), which could be detrimental for insulation resistance.
– Among commonly used polyesters, PET is performing good: the fraction of aromatic groups in
the polymer chain is lower than e.g. PEN.
PET
PolyethyleneTerephthalate
PEN
PolyethyleneNapthalate
Polypropylene Zn metalized has much better performances
than Polyester in case of peak voltage from the mains
Reasons to Choose Polypropylene Dielectric -
Self Healing Performances for Safety

13. F862 – F863 How to Detect Stability
The Temperature-Humidity-Bias
(THB) test @ 85°C, 85% relative
humidity and 240 Vac of operating
voltage allows to detect
the significant improvement in the
capacity stability and dissipation
factor of the new components
compared to those
currently used in standard
applications
F862 85/85/1000 Hours
• Big size
F863 85/85/500 Hours
• Reduced size

14. Heavy Duty Series: F863
Suppressor Capacitors Applications and Benefits
INDUSTRIAL
The use of polypropylene dielectric not only provides excellent self-healing performance, but thanks to its low and stable dissipation factor, greatly
improves the ability to withstand the high frequency ripple currents coming back from the switching stage of the inverter.
F863
• Small size
• Long life
• Capacitance and DF Stability
• THB test 85/85/500 Hours

15. Heavy Duty Series: F863
Suppressor Capacitors Applications and Benefits
AUTOMOTIVE Battery Chargers
The improved environmental performances and self-healing ability of these components also meet the requirements of the automotive industry when
used in the Plug-in Hybrid Electric Vehicles (PHEVs) and Electric Vehicles (Evs) Battery Chargers. For this reason these new components meet the
AEC-Q200 qualification requirements in addition to the international safety regulations according to ENEC, UL, cUL and CQC approvals.
F863
• Small size
• Long life
• Capacitance and DF Stability
• THB test 85/85/500 Hours

16. Heavy Duty Series: F863
Suppressor Capacitors Applications and Benefits
In door application Capacitive Power Supply
F863
• Small size
• Long life
• Capacitance and DF Stability
• THB test 85/85/500 Hours

17. Heavy Duty Series: F862 – F863
Suppressor Capacitors Applications and Benefits
SMART METER
F862 is suitable for application in the capacitive Power Supply or in the coupling stage of data transmission
F863 can be applied in parallel tp the mains when SMPS needs EMI filter
F862
• Larger size
• Very Long life
• Very high Capacitance and DF Stability
• THB test 85/85/1000 Hours
F863
• Small size
• Long life
• Capacitance and DF Stability
• THB test 85/85/500 Hours

18. DC Link Film Capacitors

19. C4AE Boxed DC Link
Input Voltage Filtered Voltage
Rectifier IGBT
Output Voltage
Converted to
other frequency
C
DC-Link capacitors are important components in the majority of power electronic equipment to improve the
efficiency of the systems, balancing the power difference between the input source and output load, and
minimizing voltage variation.
Film capacitor advantages:
- Handle a reverse voltage
- Able to withstand fast charge/discharge conditions
- Designed for high rms currents
- High reliability due to self-healing properties
- Long life expectancy
- Storage without any problems

20. C4AE C4AQ Boxed DC Link AEC Q200
C4AE
C4AQ
• Samples now
• Mass production Oct 2017
➢ Higher operating temperature 105°C;
➢ Higher Lifetime at 105°C;
➢ AEC – Q200 qualification;
➢ Operating range -55°/+105°C;
Rated voltage VR 450 – 1,100 VDC (@85°C)
Capacitance range 1.0 µF to 130.0 µF
Capacitance Tolerance ±5%, ±10%
Temperature Range ‐40°C to 85°C
Dissipation Factor PP typical (tgδ0) ≤ 0.0002 at 10 kHz and +25°C (±5°C)
Surge voltage 1.5 * VNDC for maximum 10 times in life time at 25°C
Overvoltage
(IEC 61071)
1.15 * VNDC for maximum 30 minutes - once per day
1.3 * VNDC for maximum 1 minute - once per day
Peak non Repetitive Current 1.5 * IPKR - maximum 1,000 times in life time
Insulation Resistance IR x C ≥ 30.000 seconds at 100 VDC 1 minute (+25°C)
Capacitance deviation in operation
±2% maximum on capacitance value measured at
(+25°C)
Test Voltage between terminations 1.5 * UNDC for 10s or 1.65 * UNDC for 2s @ +25°C.
Permissible Relative Humidity -
Storage
Annual average ≤ 70%; 85% on 30 days/year randomly
distributed throughout the year. Dewing not admissible
Rated Voltage (VDC) @ 85°C 450 600 700 900 1100
Operative Voltage (VDC) @ 70°C 500 650 800 1100 1300
Operative Voltage (VDC) @ 105°C 350 450 550 700 850
Rated voltage VR 500 – 1,300 VDC (@70°C)
Capacitance range 1.0 µF to 130.0 µF
Capacitance Tolerance ±5%, ±10%
Temperature Range ‐55°C to 105°C
Dissipation Factor PP typical (tgδ0) ≤ 0.0002 at 10 kHz and +25°C (±5°C)
Surge voltage 1.5 * VNDC for maximum 10 times in life time at 25°C
Overvoltage
(IEC 61071)
1.15 * VNDC for maximum 30 minutes - once per day
1.3 * VNDC for maximum 1 minute - once per day
Peak non Repetitive Current 1.5 * IPKR - maximum 1,000 times in life time
Insulation Resistance IR x C ≥ 30.000 seconds at 100 VDC 1 minute (+25°C)
Capacitance deviation in operation
±2% maximum on capacitance value measured at
(+25°C)
Test Voltage between terminations 1.5 * UNDC for 10s or 1.65 * UNDC for 2s @ +25°C.
Permissible Relative Humidity -
Storage
Annual average ≤ 70%; 85% on 30 days/year randomly
distributed throughout the year. Dewing not admissible
Rated Voltage (VDC) @ 70°C 500 650 800 1100 1300
Operative Voltage (VDC) @ 85°C 450 600 700 900 1100
Operative Voltage (VDC) @ 105°C 350 450 550 700 850

21. DC Link Film Capacitors Applications – Industrial C4AE
• Regenerative drives
• Motor drives
• Inverters
• Welding machines
• Rectifiers
• SMPS
• Solar converters
• Ventilation systems

22. Electrical Vehicle DC Onboard EMI Filter
AC
protection
DC Filter
C4AQ C4AQ
R41 R41 R41 R41
On board

23. Electric Vehicle Charging Stations/On Board Battery
Chargers
C1
C2
C2
C3 C4 C5
C6
85V~265Va
c C6 –Output
FilteringC4AQF863
R41
R41
R75
R74