Conductive Polymer Hybrid Aluminum Electrolytic Capacitor: Proposed Solutions

We would like to introduce examples of Panasonic hybrid capacitors adopted by customers.

Component proposal flow

STEP❶
Confirm information on power elements used by the customer.

Please give us information on the power circuits and related components you are using.

[Power circuit] input voltage, output voltage, load current, switching frequency, etc.
[Components used] power IC, capacitor, inductor, etc.

STEP❷
Choosing a capacitor

Based on design information given by the customer, we choose a capacitor that best fits the customer’s product.

STEP❸
Examining the capacitor

Based on the chosen capacitor and information on power elements used by the customer, we conduct a simulation for a circuit in which the capacitor will operate under using service conditions specified by the user.

STEP❹
Propose an optimum capacitor

After analyzing simulation results, we propose an optimum capacitor.

Choose a capacitor as a solution for a problem the customer needs to clear.

Case 1: Space saving in the board mounting area by reducing the number of output capacitors

STEP❶ Confirm information on power elements used by the customer.
Input voltage Vin 24V
Output voltage Vout 12V
Load current 10A
Switching frequency 300kHz
Response to load transient current
Rising 1A→10A
Falling 10A→1A
Through rate 10A/us
STEP❷ Choosing a capacitor

■Comparative evaluation of voltage changes that occur when the capacitor responds to load transient current

＜Evaluation results＞

Present product design
Series ZC
Rated voltage 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2Arms
ESR 20mΩ
Number of components 3
Space 360 mm2
Target performance
Total capacitance 1000uF
Size φ10 or less
Total ripple current 6 Arms
Total ESR 6.7mΩ
Number of components 1 or 2
Space 240 mm2
Choose a capacitor to review
Series ZK ZKU ZSU
Product number EEHZK1E471P EEHZK1E561UP EEHZS1E102UP
Rated voltage 25V 25V 25V
Capacitance 470uF 560uF 1000uF
Size φ10x10.2mm φ10x10.2mm φ10x16.5mm
Number of capacitors (estimate) 2 2 1~2
Present product design
Series ZC
Rated voltage 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2Arms
ESR 20mΩ
Number of components 3
Space 360 mm2
Target performance
Total capacitance 1000uF
Size φ10 or less
Total ripple current 6 Arms
Total ESR 6.7mΩ
Number of components 1 or 2
Space 240 mm2
Choose a capacitor to review
Series ZK ZKU ZSU
Product number EEHZK1E471P EEHZK1E561UP EEHZS1E102UP
Rated voltage 25V 25V 25V
Capacitance 470uF 560uF 1000uF
Size φ10x10.2mm φ10x10.2mm φ10x16.5mm
Number of capacitors (estimate) 2 2 1~2
STEP❸ Examining the capacitor
Capacitor
Series		 Mounting area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)		 Space
saving		 Output
voltage
Stability
ZC
25V 330uF
ø10x10.2mm
 		 224mV - 234mV - - -
ZK
(EEHZK1E471P)
25V 470uF
ø10x10.2mm

-33%

 225mV Equal to the
conventional
type		 235mV Equal to the
conventional
type		 〇 〇
ZKU
(EEHZK1E561UP)
25V 560uF
ø10x10.2mm

-33%

 214mV Improved 222mV Improved 〇 ◎
ZSU
(EEHZS1E102UP)
25V 1000uF
ø10x16.5mm

-66%

 222mV Equal to the
conventional
type		 234mV Equal to the
conventional
type		 ◎ 〇
Capacitor Series Mounting
area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)
ZC
 		 224mV - 234mV -
ZK
(EEHZK1E471P)

-33%

 225mV Equal to the
conventional
type		 235mV Equal to the
conventional
type
ZKU
(EEHZK1E561UP)

-33%

 214mV Improved 222mV Improved
ZSU
(EEHZS1E102UP)

-66%

 222mV Equal to the
conventional
type		 234mV Equal to the
conventional
type
Capacitor Series Space
saving		 Output
voltage
Stability
ZC
 - -
ZK
(EEHZK1E471P) 		〇 〇
ZKU
(EEHZK1E561UP) 		〇 ◎
ZSU
(EEHZS1E102UP) 		◎ 〇
Equal performance in important power-related characteristics (a voltage change in response to a sharp change in load current) has been confirmed. Reducing the number of capacitors is possible.
STEP❹ Propose an optimum capacitor
Product numberRated voltage
(V)		Capacitance
(µF)		Rated ripple current
(Arms)		Product dimensions
(mm)		Durability
EEHZS1E102UP2510004
(125℃/100kHz)		Φ10×16.5125°C/4000h
EEHZS1E102UV
(Vibration-resistant product)		2510004
(125℃/100kHz)		Φ10×16.8125°C/4000h

Case 2: Low-height app design achieved by a reduction in the size and height of output capacitors

STEP❶ Confirm information on power elements used by the customer.
Input voltage Vin 24V
Output voltage Vout 12V
Load current 10A
Switching frequency 300kHz
Response to load transient current
Rising 1A→10A
Falling 10A→1A
Through rate 10A/us
STEP❷ Choosing a capacitor

■Comparative evaluation of voltage changes that occur when the capacitor responds to load transient current

＜Evaluation results＞

Present product design
Series ZC
Rated voltage 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2 Arms
ESR 20 mΩ
Number of components 2
Space 240 mm2
Target performance
Total capacitance 660uF
Size 8 mm or less in height
Total ripple current 4 Arms
Total ESR 10 mΩ
Number of components -
Space -
Choose a capacitor to review
Series ZK ZKU
Product number EEHZK1E151XP EEHZKE181XUP
Rated voltage 25V 25V
Capacitance 150uF 180uF
Size Ø6.3x7.7 mm Ø6.3x7.7 mm
Number of capacitors (estimate) 5 4
Present product design
Series ZC
Rated voltage 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2 Arms
ESR 20 mΩ
Number of components 2
Space 240 mm2
Target performance
Total capacitance 660uF
Size 8 mm or less in height
Total ripple current 4 Arms
Total ESR 10 mΩ
Number of components -
Space -
Choose a capacitor to review
Series ZK ZKU
Product number EEHZK1E151XP EEHZKE181XUP
Rated voltage 25V 25V
Capacitance 150uF 180uF
Size Ø6.3x7.7 mm Ø6.3x7.7 mm
Number of capacitors (estimate) 5 4
STEP❸ Examining the capacitor
Capacitor
Series		 Mounting area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)		 Space
saving		 Output
voltage
Stability
ZC
25V 330uF
ø10x10.2mm
 		 255mV - 260mV - - -
ZK
(EEHZK1E151XP)
25V 150uF
ø6.3x7.7mm

+10%

 249mV Improved 251mV Improved × 〇
ZKU
(EEHZKE181XUP)
25V 180uF
ø6.3x7.7mm

-10%

 250mV Improved 253mV Improved 〇 〇
Capacitor Series Mounting
area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)
ZC
 		 255mV - 260mV -
ZK
(EEHZK1E151XP)

+10%

 249mV Improved 251mV Improved
ZKU
(EEHZKE181XUP)

-10%

 250mV Improved 253mV Improved
Capacitor Series Space
saving		 Output
voltage
Stability
ZC
 - -
ZK
(EEHZK1E151XP) 		× 〇
ZKU
(EEHZKE181XUP) 		〇 〇
Equal performance in important power-related characteristics (a voltage change in response to a sharp change in load current) has been confirmed. Replacing the current capacitor with a smaller capacitor in size is possible.
STEP❹ Propose an optimum capacitor
Product numberRated voltage
(V)		Capacitance
(µF)		Rated ripple current
(Arms)		Product dimensions
(mm)		Durability
EEHZKE181XUP251801.8
(125℃/100kHz)		Φ6.3×7.7125°C/4000h
EEHZKE181XUV
(Vibration-resistant product)		251804
(125℃/100kHz)		Φ6.3×7.7125°C/4000h

Case 3: Space saving in the board mounting area by a reduction in the size of output capacitors

STEP❶ Confirm information on power elements used by the customer.
Input voltage Vin 24V
Output voltage Vout 12V
Load current 10A
Switching frequency 300kHz
Response to load transient current
Rising 1A→10A
Falling 10A→1A
Through rate 10A/us
STEP❷ Choosing a capacitor

■ Comparative evaluation of voltage changes that occur when the capacitor responds to load transient current

＜Evaluation results＞

Present product design
Series ZC
Rated voltage 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2 Arms
ESR 20 mΩ
Number of components 3
Space 360 mm2
Target performance
Total capacitance 1000uF
Size φ10 or less
Total ripple current 6 Arms
Total ESR 6.7 mΩ
Number of components 3
Space 360 mm2or less
Choose a capacitor to review
Series ZKU
Product number EEHZK1E331UP
Rated voltage 25V
Capacitance 330uF
Size ø8x10.2 mm
Number of capacitors (estimate) 3
Present product design
Series ZC
Capacitance 25V
Capacitance 330uF
Size φ10x10.2
Ripple current 2 Arms
ESR 20 mΩ
Number of components 3
Space 360 mm2
Target performance
Total capacitance 1000uF
Size φ10 or less
Total ripple current 6 Arms
Total ESR 6.7 mΩ
Number of components 1～2
Space 240 mm2
Choose a capacitor to review
Series ZKU
Product number EEHZK1E331UP
Rated voltage 25V
Capacitance 330uF
Size ø8x10.2 mm
Number of capacitors (estimate) 3
STEP❸ Examining the capacitor
Capacitor
Series		 Mounting area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)		 Space
saving		 Output
voltage
Stability
ZC
25V330uF
ø10x10.2mm
 		 224mV - 234mV - - -
ZKU
(EEHZK1E331UP)
25V 330uF
ø8x10.2mm

-25%

 222mV Equal to the
conventional
type		 230mV Equal to the
conventional
type		 〇 〇
Capacitor Series Mounting
area
Reduction
effects		 Rising 1 A → 10 A
(spec:△V=600mV)		 Falling 10 A → 1 A
(spec:△V=600mV)
ZC
 		 224mV - 234mV -
ZKU
(EEHZK1E331UP)

-25%

 222mV Equal to the
conventional
type		 230mV Equal to the
conventional
type
Capacitor Series Space
saving		 Output
voltage
Stability
ZC
 - -
ZKU
(EEHZK1E331UP) 		〇 〇
Equal performance in important power-related characteristics (a voltage change in response to a sharp change in load current) has been confirmed. Replacing the current capacitor with a smaller capacitor in size is possible.
STEP❹ Propose an optimum capacitor
Product numberRated voltage
(V)		Capacitance
(µF)		Rated ripple current
(Arms)		Product dimensions
(mm)		Durability
EEHZK1E331UP253302
(125℃/100kHz)		Φ8×10.2125°C/4000h
EEHZK1E331UV
(Vibration-resistant product)		253304
(125℃/100kHz)		Φ8×10.2125°C/4000h

Case 4: Saving space on the board mounting surface by reducing the number of input capacitors

STEP❶ Confirmation of customer information
Details of the customer's requests Miniaturize the DC power circuit. ➡ Reduce the number of input capacitors.
Customer's problems ① Selecting a capacitor takes time.
② Connecting capacitors in parallel results in unbalanced ripple current flows in the capacitors.
■ Customer's power circuit conditions
Input voltage Vin 48V
Output voltage Vout 12V
Load current 84A
Switching frequency 150kHz
Incoming ripple current Iripple Unknown
  
Input capacitor Hybrid capacitor
63V 180μF
capacitor x 8
入力コンデンサ説明図

We select an optimum hybrid capacitor and discuss the number of capacitors the customer needs. These capacitors need to meet the customer's requests and solve problems the customer is facing.

STEP❷ Capacitor selection
Procedure 1: Based on the customer's circuit conditions and requests, select a replacement series capacitor from products the company offers.
The customer decides the number of replacement series capacitors used as taking this measure against the ripple current problem is very serious.
➡ To achieve a reduction in the number of capacitors, select ZU and ZUU series,, which curb heat generation caused by a large ripple current and are advantageous in terms of capacitance.
Capacitor selected by the customer Capacitor initially selected by the company
SeriesZSUZUZUU
Part numberEHZS1J181UPEEHZU1J151PEEHZU1J181P
Rated capacitance63V 180uF63V 150uF63V 180uF
Allowable ripple current3.5 Arms5.2 Arms5.5 Arms
Sizeø10x16.5ø10x16.5ø10x16.5
Number of capacitors8ーー
STEP❸ Examining the capacitor
Procedure 2: Select the optimum replacement series capacitor using a simple circuit simulation and estimate the number of capacitors needed.
  • Carry out a circuit simulation under the circuit conditions specified by the customer to confirm the ripple current flowing through the input capacitors.　→　Select the replacement series capacitor.
■Circuit simulation conditions
Input voltage Vin 48V
Output voltage Vout 12V
Load current 84A
Switching frequency 150kHz
入力コンデンサ説明図
■Results of simulation for a ripple current flowing through the input capacitors
Specifications Number of
capacitors		 On-board
mounting
image		 Simulation of a ripple current flow
in the input capacitor		 Total ripple
current		 Ripple
current
per
capacitor		 Result
ZSU series
EEHZS1J181UP
63V 180uF
Ripple current
3.5Arms
ø10x16.5mm
 8pcs 23.4 Arms 2.9 Arms OK
Specifications Number of
capacitors		 On-board
mounting
image		 Simulation of a ripple current flow
in the input capacitor		 Total ripple
current		 Ripple
current
per
capacitor		 Result
ZU series
EEHZU1J151P
63V 150uF
Ripple current
5.2Arms
ø10x16.5mm
 6pcs 22.6 Arms 3.8 Arms OK
4pcs 22.7 Arms 5.7 Arms Insufficient
(verification
required)
ZUU series
EEHZU1J181UP
63V 180uF
Ripple current
5.5Arms
ø10x16.5mm
6pcs 22.8 Arms 3.8 Arms OK
4pcs 23.1 Arms 5.8 Arms Insufficient
(verification
required)
■ Conclusion of the discussion on use of the replacement series capacitors, ZU and ZUU series
Verification itemConclusion
Ripple currentBoth ZU series and ZUU series can be used in a set of 6 capacitors if the unbalanced ripple current is not to be taken into consideration.
➡Find the optimum number of capacitors, including when there are only 4 capacitors, by carrying out a detailed heat generation simulation.
CapacitanceComparing the ZU series (150 uF) and ZUU series (180 uF) finds no significant difference in capacitance between both products.
➡Adopt the ZU series.
Procedure 3: Taking into account and confirming the influence of unbalanced ripple current through a heat generation simulation, determine the optimum number of capacitors.
Carry out a heat generation simulation that takes the customer's problems into consideration.
  • Unbalance of ripple currents applied respectively to capacitors caused by variations in wiring configurations on the board
  • Influence of a heat-generating device near the input capacitor
Points of discussion:
Check the self-heat generation of the hybrid capacitor carrying the maximum ripple current flow and determine whether or not to use the capacitor.
■ Evaluation of the heat-generation simulation
Specifications Number
of
capacitors		 Heat generation simulation
(temperature rise at the heat-generating capacitor)		 Determination
on heat generation
ZSU series
EEHZS1J181UP
63V 180uF
ø10x16.5mm
 8pcs OK
Within the heat
generation
tolerance
ZU series
EEHZU1J151P
63V 150uF
ø10x16.5mm
 6pcs OK
Within the heat
generation
tolerance
4pcs OK
Within the heat
generation
tolerance
A detailed simulation taking into account unbalanced ripple current and heat-generating devices near the capacitors has revealed that four capacitors can keep the heat generation, resulting from the maximum ripple current flow, within an allowable range. The current capacitors, therefore, can be replaced with replacement series capacitors (reducing the number of capacitors).
STEP❹ Propose an optimum capacitor
■ Simulation results summary
Capacitor selected by the customer Capacitor initially selected by the company
SeriesZSUZU
Part numberEHZS1J181UPEEHZU1J151P
Rated capacitance63V 180uF63V 150uF
Allowable ripple current3.5 Arms5.2 Arms
Sizeø10x16.5 mmø10x16.5 mm
Number of capacitors8pcs4pcs
Mounting area ratio150% reduction
Part numberRated
voltage
(V)		Capacitance
(µF)		Rated
ripple
current
(Arms)		Product size
(mm)		Durability
EEHZU1J151P631505.2
(125℃/100kHz)		Φ10×16.5125°C/4000h
EEHZU1J151V
(vibration-resistant
product)		631505.2
(125℃/100kHz)		Φ10×16.8125°C/4000h
Elements to which the capacitors can be applied:：

↑Page top