Conductive Polymer Hybrid Aluminum Electrolytic Capacitor ZS Series

With the growing demand for eco-friendly cars, energy efficiency, and the need to comply with environmental regulations, vehicles are rapidly shifting from gasoline-powered to hybrid electric and electric vehicles. Now, more vehicles are using drive systems consisting of a gasoline engine with motor assistance (48 V system [1], etc.), and the integration of mechanical and electrical components [2], which involves switching from mechanical to motor drive and electronic control, is underway. These changes have increased the need for the miniaturization and weight reduction of ECUs and stabilization measures for power supply circuits in response to increases in current values. Capacitors mounted in power supply circuits are now increasingly required to correspond to a large current and capacity. To respond to these requirements, Panasonic has commercialized the surface-mounted ZS Series Conductive Polymer Hybrid Aluminum Electrolytic Capacitors.

■ Term Descriptions
[1] 48 V system
System with a 48 V automotive power supply that significantly contributes to achieving low-fuel consumption during cruising by enabling the miniaturization and weight reduction of mounted lithium ion batteries and drive motors. This system is mounted on mild hybrid electric vehicles.
[2] Integration of mechanical and electrical components
This refers to the integration of mechanical drive components and the ECU. Mechanical drive components and the ECU used to be physically separated and interconnected via cables, but demand for high-precision control, more freedom in component layout, fewer cables, etc., has now led to the adoption of an integrated configuration of mechanical and electrical components.

Features of ZS Series

  • Larger
    current
  • Larger
    capacitance
  • High
    vibration-
    resistance
  1. Contribute to ECU miniaturization and weight reduction by achieving a larger current.

    It was difficult for conventional products, with a maximum size of 10 mm in diameter and 10.2 mm in height, to correspond to a larger current of 100 to 200 A. By adopting a unique new structure and a polymer impregnation method, the new products, with a size of 10 mm in diameter and 16.5 mm in height, lower the capacitor's internal resistance value, achieving a current 2.5 times larger than conventional products. This will contribute to ECU miniaturization and weight reduction.

    Ripple current value

    ZC 63V : 1400mA   ZS 63V:3500mA

    [2.5 times the conventional product (ZC)]

  2. Contribute to ECU miniaturization and weight reduction by achieving a larger capacity.

    The new products have achieved a capacity 1.8 times larger than conventional products by increasing the Aluminum foil area through the adoption of a unique Aluminum foil material technology and a new structure design. This will decrease the quantity of capacitors used and required board space, contributing to ECU miniaturization and weight reduction.

    Capacitance

    ZC 63V : 82uF   ZS 63V:150uF

    [1.8 times the conventional product (ZC)]

    Lower resistance低抵抗化の画像 img
    Increased area面積拡大Φ10x10.2mmからΦ10x16.5mmへの画像 img

    Achieving a larger current and capacitance than conventional products with the same board area decreases the quantity of capacitors used and contributes to reductions in required board space and weight.

  3. Excellent vibration resistance eliminates the need for anti-vibration reinforcement during mounting processes, allowing customers to streamline their production processes.

    The conventional ECU board mounting process requires anti-vibration measures, such as anchoring components with adhesives, to make the ECU resistant to vibration if using non-vibration-resistant components. The developed capacitors have achieved anti-vibration performance high enough to withstand a vibration acceleration of 30 G, making such anti-vibration measures unnecessary, thus allowing customers to streamline their production processes.

    Vibration acceleration resistance

    Conventional structure: 10 G

    Arrow

    Vibration-resistant structure: 30 G

    [Approx.3 times the conventional structure]

    Conventional terminal
    Conventional terminal
    Arrow
    Auxiliary terminal
    Auxiliary terminal

    Contributing to the elimination of customers' need to take
    measures against vibration during mounting processes

Specification of ZS Series

Specification
Category temperature range -55 ℃ ~ 125 ℃
Rated voltage range 25 V.DC ~ 63 V.DC
Rated capacitance range 150 uF ~ 560 uF
Size Φ10×16.5 mm
Endurance 125 ℃ 4000 h
Damp heat 85℃ 85% 2000 h
Capacitance / Ripple current (Comparison with ZC Series)
Rated voltage 25 V.DC 35 V.DC 50 V.DC 63 V.DC
Series ZC ZS ZC ZS ZC ZS ZC ZS
capacitance (µF) 330 560 270 470 120 220 82 150
Ripple current (mA) @125 ºC 2,000 4,000 2,000 4,000 1,600 3,700 1,400 3,500

Applications of ZS series

    Automotive applications for hybrid electric vehicles, plug-in hybrid electric vehicles, electric vehicles, and gasoline-powered vehicles

  • ・ Integrated starter generator (ISG)
  • ・ Water pump ECU
  • ・ Electric power steering (EPS),
  • ・ Transmission ECU
  • ・ Oil pump ECU
  • ・ Radiator fan control (RFC), etc.

Case study of ZS Series

● 48V system (Inverter Power Supply) Space saving of board

48V system (Inverter Power Supply) Space saving of board images

DC-Link
smoothing
capacitor

ZC Series arrow ZS Series
Item φ10 x 10.2 mm
63V.DC / 82 μF
φ10 x 16.5 mm
63V.DC / 150 μF
ZC Series ZS Series
quantity 21 pcs 9 pcs
Ripple current Total 29.4 A
(1.4 A x 21 pcs)
Total 31.5 A
(3.5 A x 9 pcs)
Mounting area 100% 43%

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