epcos product brief 2014 film capacitors pcc power capacitor chip for 650-v r semiconductor modules in e-mobility applications www.epcos.com
technology ? epcos ag - edition august 2014 film assembly process flow 1) metal-end spray layer 4) heavy-edge 2) free margin 5) precise extension and 3) metallization, flat or csp wavy-smooth cut w. / wo. structuring 1) winding of capacitor elemen t 5) testing of active winding with metallized film 6) wiring, e.g. with busbar and 2) metal-end spray encapsulation 3) thermal treatment 7) 100% final inspection 4) sawing of active winding fig. 1: cross sections of film/foil assembly fig. 2: main working steps film assembly at least two dielectric films are wound in parallel to form a cap- acitor element. fig. 1 shows the film/foil arrangements in a cross- sectional view for common pcc designs: the diagram shows the most common standard version with the metallization on one side. the winding technology this developed winding tech- nology can be used to implement absolutely flat and wrinkle-free stacked windings in power cap dimensions for pcc 1) using metallized polymer films, starting with pp down to 2.5 m and pet of 1.8 m, fig. 2, 3. the pcc process flowchar t describes the main production steps. the flexibility and extremely high process quality of the production line and the polygon winder (pw) are important for this application. a special wavy-smooth cut combination produces a maxi- mum effective contact surface via a defined small offset and pre- cisely wound master capacitors allowing a specially optimized metal-spraying and contacting process. the result is an out- standingly high pulse-current handling capability far beyond the minimum requirements laid down in iec and en standards and without the contact edge problem, a well-known and dangerous constriction effect at the film edges of low-cost mkp windings. process flow the process flow for pcc with power cap formatted stacked windings is shown in fig. 2. contacting of windings the end faces of the windings are contacted by metal spraying (schooping) to ensure a reliable and low-inductance connection between the metallized film layers and to the connection system. after this working step the cap- acitor windings will be connected with leads e. g. busbars which are welded onto the metal-end spray layer, fig. 3. impregnation and sealing the active winding elements are heated and dried for a defined period in vacuum. in this way, air and moisture are extracted from the inner capacitor to avoid any oxidation effects at the electrodes or any partial discharges. this process step ensures excellent - +capacitance stability and a long useful life. the low power designs are boxed (resin-filled) or unpackaged (naked). 1) pccs can naturally also be designed with flat windings. fig. 3: left - stacked-winding; right - flat capacitor winding with copper busbars which are welded onto the metal-end spray layer, ready for assembly
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 hp1 platform C fs200r07 / fs400r07 ordering code c r f i max 1) a l self nh r s m ? ? ka i s ka tan ? b25655p4467k000 2) 460 80 25 0.6 1.4 5.5 5 10 -4 140 x 72 x 50 c 1 b25655p4567k000 560 80 25 0.5 1.6 6.0 5 10 -4 140 x 72 x 50 b 1 hp2 platform C fs400r12 / fs600r07 / fs800r07 ordering code c r f i max 1) a l self nh r s m ? ? ka i s ka tan ? 3) 500 120 15 0.5 2 8 5 10 -4 237 x 54 x 50 f 2 b25655p4707k000 2) 700 135 15 0.4 3 9 5 10 -4 237 x 72 x 50 e 2 b25655p4847k000 840 135 15 0.4 3.6 10.5 5 10 -4 237 x 72 x 50 e 2 B25655P4907K000 2) 900 135 15 0.4 3.6 10.5 5 10 -4 237 x 72 x 50 e 2 b25655p4108k000 1000 135 15 0.4 4.0 11.5 5 10 -4 237 x 72 x 50 e 2 1) considering maximum hot spot temperature at +105 c and cooling efficiency to be validated. 2) preferred types. 3) samples only available in prototype housing. picture 1 picture 2 for hp1 platform for hp2 platform sample for laboratory use only
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 hp1 platform C fs200r07 / fs400r07 3) ordering code c r f i max 1) a l self nh r s m ? ? ka i s ka tan ? b25655p4467k001 2) 460 80 25 0.6 1.4 5.5 5 10 -4 140 x 72 x 50 c 3 b25655p4567k001 560 80 25 0.5 1.6 6.0 5 10 -4 140 x 72 x 50 b 3 hp2 platform C fs400r12 / fs600r07 / fs800r07 3) ordering code c r f i max 1) a l self nh r s m ? ? ka i s ka tan ? b25655p4707k001 2) 700 135 15 0.4 3 9 5 10 -4 237 x 72 x 50 e 4 b25655p4847k001 840 135 15 0.4 3.6 10.5 5 10 -4 237 x 72 x 50 e 4 b25655p4907k001 2) 900 135 15 0.4 3.6 10.5 5 10 -4 237 x 72 x 50 e 4 b25655p4108k001 1000 135 15 0.4 4.0 11.5 5 10 -4 237 x 72 x 50 e 4 1) considering maximum hot spot temperature at +105 c and cooling efficiency to be validated. 2) preferred types. 3) samples only available in prototype housing. picture 3 picture 4 for hp1 platform for hp2 platform
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 maximum ambient temperature diagrams for hybridpack tm - hp1 platform graph a maximum ambient temperature graph b maximum ambient temperature graph c maximum ambient temperature dotted line shows the maximum current possible when the bottom plate of the capacitor is firmly fixed on a cooling plate at +85 c. the continuous line shows the maximum current possible without cooling at given ambient temperature .
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 maximum ambient temperature diagrams for hybridpack tm C hp2 platform graph d maximum ambient temperature graph e maximum ambient temperature graph f maximum ambient temperature dotted line shows the maximum current possible when the bottom plate of the capacitor is firmly fixed on a cooling plate at +85 c. the continuous line shows the maximum current possible without cooling at given ambient temperature .
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 dimensional drawing fig. 1 fig. 2
pcc for infineon / hybridpack C 2 nd generation preliminary ? epcos ag - edition august 2014 dimensional drawing fig. 3 fig. 4
general data preliminary ? epcos ag - edition august 2014 specifications and characteristics capacitance tolerance 10% tan 0 2 ? 10 -4 v r 450 vdc v s 600 vdc test data voltage between terminals vtt 675 vdc, 10 s voltage between terminals and case vtc 3000 vdc, 10 s rins c 10000 s life expectancy up to 15 000 hours 1) afq 300 fit values after test ca, iec 68-2 (21 days, 40 c, 93% rel. humidity) | ? c/c| 5% ? tan ? 5 ? 10 -4 rins c 3000 s climatic category 40/105/21 t stg -45 ... +110 c t min -40 c t max +105 c ths (maximum hot spot temperature) +105 c max. permissible humidity 95% construction and general data resin filling polyurethane resin case plastic (polycarbonate) terminals flat copper (tinned) creepage and clearance distance figure 1: 9 mm figure 2: 8 mm cooling to be confirmed degree of protection indoor mounting (ip54) rohs compliance halogen free 1) to be confirmed; depending on the application display of ordering codes for epcos products the ordering code for one and the same product can be represented differently in data sheets, data books, other publications and the website of epcos, or in order-related documents such as shipping notes, order confirmations and product labels. the varying representations of the ordering code s are due to different processes employed and do not affect the specifications of the respective products . detailed information can be found on the internet under www.epcos.com/orderingcodes
cautions and warnings preliminary cautions & warnings ? in case of dents of more than 1 mm depth or an y other mechanical damage, capacitors must not be used at all. ? check tightness of the connections/terminals periodically. ? the energy stored in capacitors may be lethal. ? to prevent any chance of shock, discharge and short-circuit the capacitor before handling. ? failure to follow cautions may result, worst case, in premature failures, bursting and fire. safety ? electrical or mechanical misapplication of capacitor s may be hazardous. personal injury or property damage may result from bursting of the capacitor or from expulsion of melted material due to mechanical disruption of the capacitor. ? ensure good, effective grounding for capacitor enclosures. ? observe appropriate safety precautions during operation (self recharging phenomena and the high energy stored in capacitors). ? handle capacitors carefully, because they may still be charged even afte r disconnection. the terminals of capacitors, connected bus bars and cables as well as the devices may also be energized. ? follow good engineering practice. thermal load after installation of the capacitor it is necessary to verify that ma ximum hot-spot temperature is not exceeded at extreme service conditions. mechanical protection the capacitor has to be installed in a way that mechanical damages and dents in the case are avoided. storage and operating conditions do not use or store capacitors in corrosive atmosphere , especially where chloride gas, sulfide gas, acid, alkali, salt or the like are present. in dusty environmen ts regular maintenance and cleaning especially of the terminals is required to avoi d conductive path be tween phases and/or phases and ground. useful life expectancy electrical components do not have an unlimited service life expectancy; this applies to self-healing capacitors too. the maximum service life expectancy may vary depending on the application the capacitor is used in. hybridpack is a trademark of infineon technologies ag important information some parts of this publication contain statements about the su itability of our products for certain areas of application. thes e statements are based on our knowledge of typical requirements that are often placed on our pr oducts. we expressly point out that these statements cannot be regarded as binding statemen ts about the suitability of our products for a particular customer application. it is incu mbent on the customer to check an d decide whether a product is su itable for use in a particular application. this publication is only a brief product survey which may be changed from time to time. our products are described in detail in our data sheets. the important notes (www.epcos.com/importantnotes) and the product-specific cautions and warnings must be observed. all relevant information is available through our sales office s. ? epcos ag ? a member of tdk-epc corporation edition august, 2014 ? printed in germany
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