Understanding common failure modes of Nippon Chemi-Con (NCC) capacitors and prevention strategies. Our comprehensive failure analysis resources help engineers identify root causes and implement preventive measures for improved system reliability.
Overvoltage, overcurrent, and ESR degradation issues.
Issues related to excessive heat and temperature cycling.
Vibration, shock, and mounting-related failures.
Moisture, corrosion, and chemical exposure issues.
Elevated temperatures accelerate chemical reactions and cause electrolyte evaporation.
Symptoms: Increased ESR, reduced capacitance, venting, case bulging
Causes: High ambient temperature, excessive ripple current, poor thermal management
Prevention: Proper derating, adequate cooling, selecting higher temperature rated parts
Voltage exceeding rated limits causes dielectric breakdown and failure.
Symptoms: Short circuit, physical damage, smoke, electrolyte leakage
Causes: Surge events, reverse voltage, inadequate voltage derating
Prevention: Proper voltage derating, surge protection, correct polarity installation
Excessive ripple current causes internal heating and accelerated aging.
Symptoms: Premature failure, increased ESR, shortened life
Causes: High ripple currents, high frequency operation, parallel resonance
Prevention: Calculate ripple current properly, select appropriate parts, thermal management
Loss of electrolyte reduces capacitance and increases ESR over time.
Symptoms: Gradual capacitance reduction, ESR increase, end-of-life failure
Causes: Normal aging process, elevated temperature, frequent thermal cycling
Prevention: Maintain operating temperature, select extended life parts, proper design
Properly collect and document failed components with operational history.
Examine physical characteristics including case, terminals, and sealing.
Measure capacitance, ESR, leakage current, and insulation resistance.
Determine failure mechanism and contributing factors.
Apply appropriate voltage, temperature, and ripple current derating based on application requirements. NCC recommends at least 20% voltage derating for most applications.
Implement proper heat sinking, ventilation, and layout to maintain capacitors within rated temperature limits.
Ensure proper polarity, mechanical mounting, and electrical connections to prevent stress-related failures.
Protect capacitors from moisture, contamination, and corrosive environments with appropriate enclosures.
Analysis of electrolytic capacitors failing after 12 months in switching power supply.
Root cause: Excessive ripple current due to resonant circuit interaction. Solution: Replaced with higher ripple-rated parts and circuit modification.
Capacitor failures in vehicle ECU units due to thermal cycling.
Root cause: Inadequate thermal relief during soldering and high temperature operation. Solution: Improved mounting and thermal management design.
Our expert FAE team provides detailed failure analysis and recommendations for your specific applications. Submit your failure samples for detailed analysis and preventive measures.
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