1. Aluminum Electrolytic Capacitors
Cornell Dubilier
North American Market

2. While surface mount v-chip styles and solid electrolyte chip style aluminum electrolytic capacitors are more than a third of the North American aluminum electrolytic market, they are only a few percent of Cornell Dubilier’s aluminum electrolytic sales. Our strength is in the larger capacitors for power electronics markets as shown here.

3. Aluminum electrolytic capacitors are 20% of the 1½ billion dollar North American market for capacitors, and aluminum electrolytic sales are up about 40% over last year, an admittedly bad year. Cornell Dubilier’s market share for aluminum electrolytic is over 20%.
$223.5 M
2010: $311.3 M est

4. Aluminum Electrolytic Strengths
Wide voltage range, 5–700 V
High capacitance, up to 3 farads
High energy density, 1.5 J/g or 2 J/cm³
Low cost for high capacitance
Aluminum electrolytic capacitors are the favorites for more-is-better applications. Their affordable high capacitance and wide voltage range makes them the choice for power electronics.

5. Aluminum Electrolytic Weaknesses
Loose cap tolerance, ±20 % typical
Limited high frequency, < 100 kHz
Limited current handling from high DF
Perceived as less reliable due to wear out and explosion failures.
However, they have limited use in instrumentation because of loose tolerance and limited high frequency capability. Generally, can’t be used in AC applications because of high dissipation factor. And even though their self-healing characteristic actually gives them expected lifetimes that are as good or better than other types, the fact that they wearout and can fail by exploding feeds the perception that they are less reliable.

6. Compared to Film Capacitors
Metallized polypropylene capacitors take the lead in high voltage, AC voltage and tight tolerance.
Aluminum electrolytics excel in capacitance and energy storage.
New Type 947C is growingly popular in green applications, e.g. Wind Turbines, Solar Converters, and Hybrid / Electric Vehicles
Metallized polypropylene film capacitors are much more expensive than aluminum electrolytic capacitors but are popular is AC applications and green applications.

7. Aluminum Electrolytic Applications
General circuit applications
Audio coupling
Photoflash and strobe flash
Power Electronics applications
Input capacitors
Output capacitors
Inverter dc-link
Motor drive bus
Welders
Aluminum electrolytic capacitor excel in more-is-better applications: applications in which more capacitance works better and there is little need for tight tolerance capacitance, temperature stability or high frequency performance. Cornell Dubilier is focused on the power electronics applications because they need the larger types in which we are tops.

8. Aluminum Electrolytic Application Guide http://www. cde
A complete course on aluminum electrolytic capacitors is in our new Power Electronics Capacitors catalog and at our website at this URL. So, for a refresher on aluminum electrolytic capacitors, go to the Aluminum Electrolytic Capacitor Application guide at CDE.com, or link directly to this URL.

9. Aluminum Electrolytic Capacitors
So what are the aluminum electrolytic capacitors available from Cornell Dubilier? Let’s start with the V-chip aluminum electrolytic SMDs.

10. Important CDE Aluminum Types
Screw terminal
Snap-in
Plug-in
Flatpack
V-Chips
Our largest volume is in screw terminal capacitors and then snap-in capacitors. Plug-in capacitors are based on the screw terminal ratings and have copper plug-in pins and more capacitance per can size but only in sizes up to 2 by 5⅝. Our MLP and MLS flatpack capacitors are long life and a ½ inch tall. We also offer small radial leaded and axial leaded capacitors, but the volume is small because printed circuit assembly is mostly in the Far East.

11. The Snap-in Capacitors
Cornell Dubilier offers a wide range of snap-in capacitors.

12. CDE Snap-ins Comparison
Type
Ripple
Life Test
Max Op Temp °C
Pins
Cases (mm) µF
@200 V
Volts
381EL
55%
7000 h
105 2
22x25 to 35x50
1500
160 to 450
381LR
100%
3000 h
2200
200 to 450
381L/LX
75%
20x25 to 40x80
4700
10 to 450
383L/LX
4-5
35x25 to 50x105
6800
SLP
70%
1800
SLPX
50% 85
380L/LX
5600
16 to 500
382L/LX
8200
381LQ
2000 h
380LQ
2700
And on the basis of ripple current and life, the new high value Types SLP and SLPX are a highly competitive middle of the pack. Other types offer 4 or 5 pins, smaller and larger sizes and more capacitance.

13. 25% Smaller, 380LQ & 381LQ 380LQ – 85°C, 381LQ – 105°C
Up to 55% Smaller Volume
Up to 30 mm shorter
More capacitance per case
You can shrink equipment size and keep original performance.
2000 hours life at rated temp.

14. 25% More Ripple,381LR,105°C Up to 40% more ripple capability
Compared to 381L
Achieved by new electrolyte and dramatic reduction in ESR
The high performance choice for motor drives, UPS systems & high-ripple power supplies.

15. The LX Largest Selection
Available in 4 mm and 6.3 mm lead lengths
Large selection of case sizes up to 50 by 105 mm
Available from 10 to 500 Vdc.
Good performance for motor drives, UPS systems & switching power supplies.

16. Snap-in Aluminum Electrolytic
SLPX
SLP
Snap-in capacitors have become the general purpose power supply capacitor, and Cornell Dubilier has a highly competitive offering with the new Types SLPX and SLP 16

17. SLPX and SLP Series Features:
Cost savings average 30% over Type 380, 381 offerings
Long Life performance
Targeted for applications in next-generation power supplies and inverters
Over 400 ratings available
3000 hour load and ripple life-test capability at rated voltage 17

18. SLPX Series 3000 Hour Load Life/Ripple Life: HIGHLIGHTS:
-40°C to +85°C
For DC filtering and switching power supplies
Best value package pricing when compared to other snap ins
HIGHLIGHTS:
3000 hour ripple load life and ripple at rated voltage
22mm to 35mm diameter, 10 mm lead space
Voltage Range: 10 Vdc to 250 Vdc
Capacitance Range: 220μF to 82,000μF 18

19. SLP Series 3000 Hour Load Life: HIGHLIGHTS:
-40°C to +105°C (10 Vdc to 100 Vdc
-25°C to +105°C (160Vdc to 250 Vdc)
For DC filtering and switching power supplies
Best value package pricing when compared to other snap ins
HIGHLIGHTS:
3000 hour ripple load life and ripple at rated voltage
22mm to 35mm diameter, 10 mm lead space
Voltage Range: 10 Vdc to 250 Vdc
Capacitance Range: 180μF to 56,000μF 19

20. Screw Terminal Capacitors

21. Screw-terminal Types Extended Paper & Extended Cathode
Over much of the history of screw terminal aluminum electrolytic capacitors the standard construction was the pitch construction shown in the center. It had the disadvantage that should the capacitors be mounted sideways, horizontally, the tar could melt, block the safety vent and allow the capacitor to explode. By comparison, the superior constructions available from us are Rilled and ThermalPak. Both have extended cathode as shown in the top left. With extended cathode the solid metal-to-metal connection between the capacitor element and the can bottom assures that the element isn’t hotter than the can. This keeps the capacitor cool and extends its life.
ThermalPak™ Construction
Pitch Construction
Rilled Construction

22. Screw Terminal Competitors
UCC United Chem-Icon
KEMET Corp.
TDK-EPC Corp.
Jianghai (Nantong Jianghai Capacitor Co. Ltd)
Hitachi AIC Inc.
These are our major competitors worldwide. For the North American market the principal competitors are UCC and KEMET. UCC has anode forming in Moses Lake Washington and capacitor production in Lansing North Carolina. KEMET entered the business by acquiring the BHC/EVOX/Rifa operations in the Netherlands and England. TDK-EPC is the combination of the electronic components businesses of TDK and the EPCOS Group and markets its products as TDK and EPCOS brands. Jianghai is the largest aluminum electrolytic maker in China and operates in the US as JianghaiUS. Hitachi makes a broad line of aluminum capacitors and competes with us principally with 350–500 V high-ripple current, long life screw terminal types for which it has leading specifications. Generally we can meet all competitor technical and life specifications, and Hitachi is the most challenging.

23. Screw-terminal Comparison
3186
85 °C, 16–500 V, lower cost
DCMC
85 °C, 6.3–550 V, hi-cap
500R
95 °C, 350–500 V, long life, hi ripple
500C
95 °C, 6.3–500 V, long life
3188
85 °C, 16–450 V, long life
520C
85 °C, 200–500 V, high ripple
101C
-55–105 ºC, 7.5–250 V, high ripple
550C
105 ºC , 200–500 V, ultra-high ripple
Cornell Dubilier makes eight major series of screw terminal capacitors. The best selling types are 3186 and DCMC. New Type 500R has been introduced to compete with UCC’s U36F capacitors and it out performs the 520C. The Type 101C operates down to –55 °C as required for military applications.

24. Type 550C, The 105 °C Inverter Capacitor
The Type 550C is the top of the line, ultra-ripple capability type.

25. Type 550C, The 105 °C Inverter Capacitor
Longest life, highest ripple current type
Standard of comparison
200 V to 500 V, inverter range
Compares with UCC LXR Series
Special specifications, part number 550CExxxx
Type 550, 6.3–450 V on website
The Type 550 on the website is the older version of the capacitor and we offer it for its wide temperature range.

26. 4700 µF 450 V Comparison 60 °C, 12 A @ 120 Hz, 400 V
Type
Case Size (in)
Life (years)
DCMC
3 x 5⅛
4.6
500C
3 x 5⅝
9.5
520C
23.7
550C
3½ x 5⅝
48.8
As an illustration of what the Type 550C can deliver, consider this comparison of 4700 µF, 450 V capacitors operating at 60 °C and 400 volts with 12 amps of 120 Hz ripple current. The 550C is expected to last more than ten times as long as the DCMC; the 500C, more than twice as long and the 520C, five times. The penalty is a 15–20% higher price and a larger case size.

27. Type DCMC, Highest Cap

28. Type DCMC, Highest Capacitance
General purpose, first-choice for capacitance
6.3 V to 550 V, widest range
150% of Type 550C capacitance
> 40% of Type 550C ripple capability
Compares with lower cost Type Aerovox Type CGS UCC U36D Series
Special specifications, assigned part number DCMCExxxx
Type DCMC is the do everything type. If the application does not have high ripple current or exceptionally long life requirements and the cold temperature requirement is not lower than –40 °C, the DCMC is a great choice.

29. Plug-in Almost Screw Terminals
Alternate construction – 3 copper pins and standoffs replace screw terminals
Up to 50% more ripple current
Up to 20% more capacitance
Type DCMC becomes 4CMC
Type 520C becomes 420C
Type 550C becomes 450C
Up to 2 by 5 ¾ case size
Including 3 ⅛ inch standoffs

30. Type MLP/MLS

31. Type MLP Flat capacitor can provide optimal fits for tight spaces.
Now available 7.5 to 450 V
Double the ripple capability with a heatsink
Long life with nearly hermetic welded seal
MLS with stainless case, for higher temp and longer life

32. Benefits of MLP/MLS Capacitors
High capacitance density in 12.5 mm pitch
Efficient stackable form factor
Heatsinking is simple and effective
Extremely long life due to near-hermetic seal and high-purity materials
Superior low-temperature impedance up to 250 V

33. High Capacitance Density
Over twice the energy density of 35 mm ºC screw-terminal capacitors
About quadruple the energy density of bank of ½” diameter 105 ºC capacitors
Rectangular package amplifies this performance by 4/π, an extra 27%

34. MLP / MLS Flat Capacitors
Efficient Stacking

35. MLP/MLS Flatpack Capacitors
MLP is aluminum package useful to 85 ºC unless clamped
MLP to 105 °C if clamp at 50 psi or 250 lbs total
MLS package is grade 316 stainless steel useful to 125 ºC
Weight is 40% heavier (90 g instead of 65)
Cost is higher, about double
Use MLS for high ripple and above 85°C

36. New MLS Sizes
New one inch wide MLS caps provide increased board layout options
Dual section caps offer options for low voltage balanced banks

37. New High Vibration MLS “HV” prefix parts Are available
These parts will handle more than the 10g’s 10 to 2000 Hz vibration that we currently publish
Controlled winding size and side body grooves add consistency.
Target is 20 to 30 g’s 10 to 2000 Hz.

38. Concept Summary
Aluminum capacitors are 1/5 of the North American market
Strengths are hi cap and low cost per µF
Commonly as input capacitors
ESR causes heating and limits life
Rectification is AC-DC conversion and uses diodes

39. Product Summary Type AVRF is the best V-chip up to 35 V
SLP and SLPX snap-ins are 30% cheaper.
Switch to a 4 for plug-in capacitors, e.g. DCMC to 4CMC
Major screw terminal competitors are UCC and KEMET
Type 550C, best; DCMC, most popular
MLP is a long life hi-tech capacitor.
See it all again at

40. TX