In early May, an “Honor Delegation”—comprising company team leaders and outstanding performers selected for the 2025 cohort—embarked on a four-day, three-night trip to Fujian.

The breezes of Dongshan Island, the ancient banyan trees of Yunshuiyao, and the bustling, authentic atmosphere of Zhangzhou Ancient City all bore witness to the laughter and camaraderie shared by these dedicated Xuansn team members.

Every effort finds its reward. This trip served as both a well-deserved treat and a source of inspiration; may all these team leaders and outstanding performers carry the joy and energy of the journey forward, continuing to shine brightly in their roles!

As the summer heat begins to rise, the company cafeteria has thoughtfully introduced mung bean paste and fruit tea. The mung bean paste is smooth, sweet, and perfect for cooling off, while the freshly prepared fruit tea offers a delightful balance of sweet and tart flavors. During a midday break, a bowl or a glass helps dispel the heat and replenish one’s energy. It is about eating well, not just eating one’s fill—staying comfortable and happy even as the temperature climbs.

On the morning of May 31st, the company hosted the “Xuansn: Childhood Dreams & Smart Fun” event to celebrate International Children’s Day in the open area outside the dormitory building.

The event featured a variety of activities: the bouncy fun of “Kangaroo Hop,” the teamwork required for “Happy Catch,” the wacky “Crazy Post-it Shake-off,” the collaborative challenge of “Water Relay,” and heartwarming parent-child DIY sessions—where families crafted dried-flower lamps and pen holders, turning their love into tangible keepsakes to take home.

Children who completed the games could collect stamps to redeem gifts, and they also got to keep their handmade creations as souvenirs. It was a day for parents to set aside their busy schedules and join their children in playing, laughing, and creating sparkling childhood memories together.

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A low temperature aluminum electrolytic capacitor is a capacitor specifically designed to maintain stable capacitance, acceptable ESR (Equivalent Series Resistance), and reliable startup performance in extreme cold environments, typically from -40°C to -65°C. Unlike standard aluminum electrolytic capacitors, low-temperature versions use specially formulated electrolytes that remain conductive at low temperatures, preventing severe capacitance loss and excessive ESR increase. These capacitors are commonly used in military electronics, railway auxiliary power systems, radar equipment, outdoor EV charging stations, and industrial power supplies operating in harsh climates.

Why this matters:
In extreme cold, capacitor performance often determines whether a power system can start successfully.

Why Do Standard Aluminum Electrolytic Capacitors Fail in Low Temperature Environments?

The performance degradation at low temperature is mainly caused by changes in the electrolyte.

1. Increased Electrolyte Viscosity

At low temperatures, the electrolyte becomes thicker, slowing down ion movement.

2. Reduced Ionic Conductivity

Ion transfer efficiency drops, directly affecting capacitance performance.

3. ESR Increase

Equivalent Series Resistance rises sharply, causing:

• Higher heat generation
• Lower efficiency
• Startup instability

4. Capacitance Drop

In extreme cases (-55°C or below), usable capacitance may drop to 30–40% of rated value.

👉 Conclusion:

The real limitation is not the capacitor structure, but electrolyte behavior under extreme cold.

What happens to capacitor ESR at low temperatures?

At low temperatures, the ESR (Equivalent Series Resistance) of aluminum electrolytic capacitors rises significantly because ion transfer inside the electrolyte slows down. Higher ESR causes increased power loss, more internal heating, poorer ripple current handling, and reduced startup efficiency. In power supplies, this can lead to unstable voltage during cold startup conditions.

👉In practical engineering, ESR increase is often a bigger problem than capacitance reduction, especially in high-voltage startup circuits.

Technical Approach to Improve Low Temperature Performance

Advanced low temperature aluminum electrolytic capacitors improve performance through two key innovations:

1. Low Temperature Electrolyte Formula

A specially designed electrolyte maintains higher ionic conductivity even at extremely low temperatures, preventing freezing and reducing capacitance loss.

2. Optimized Internal Electrode Structure

Improved contact stability between electrode foil and electrolyte ensures consistent performance under thermal stress.

Why Low Temperature Aluminum Electrolytic Capacitors Are Critical in Modern Power Systems

Modern power systems must operate in increasingly harsh environments, such as:

• Military communication systems in cold regions
• Radar systems in Arctic environments
• Railway auxiliary power systems in high-latitude areas
• Outdoor EV charging stations in winter
• Export power supplies for Russia, Canada, and Northern Europe

In all these cases, cold start reliability is a key requirement.

👉 A failure in capacitor performance can directly lead to:

• Startup delay
• System reset
• Complete power failure

Can aluminum electrolytic capacitors work at -55°C or -65°C?

Standard aluminum electrolytic capacitors are usually rated for -25°C to -40°C, and many experience severe performance degradation below those temperatures. However, specially designed low temperature aluminum electrolytic capacitors can operate reliably at -55°C or even -65°C by using optimized electrolyte formulations and internal structures.

At these temperatures, performance is mainly evaluated by:

• Capacitance retention
• ESR stability
• Cold startup reliability

A capacitor that maintains stable energy storage at -65°C is considered suitable for ultra-low-temperature power applications.

Why -65°C Capability Matters for Low Temperature Aluminum Electrolytic Capacitors

Although many power systems are designed for -40°C or -55°C operation, real-world environmental conditions are often far more demanding than laboratory specifications suggest. In military equipment, railway auxiliary power systems, outdoor EV charging stations, and exported power supplies for cold regions, components are frequently exposed to temperatures lower than expected.

Several real-world factors can push operating conditions beyond nominal design limits:

• Wind chill and airflow exposure can accelerate temperature drop around electronic enclosures.
• Overnight outdoor exposure may result in equipment experiencing temperatures well below daytime averages.
• High-latitude winter environments such as Russia, Canada, and Northern Europe often see prolonged periods below -40°C.
• Rapid thermal cycling between operating and standby conditions can place additional stress on capacitor performance.

For a low temperature aluminum electrolytic capacitor, operating close to its temperature limit may result in significant capacitance loss and a sharp ESR increase, reducing cold startup reliability.

👉This is why -65°C  capability matters.

A -65°C rated low temperature aluminum electrolytic capacitor provides additional engineering margin, allowing the system to maintain stable performance even when actual temperatures temporarily exceed design expectations.

Key benefits include:

Stable Cold Start Performance

Reliable capacitance retention and controlled ESR help ensure the power supply can deliver sufficient startup energy under extreme cold conditions.

Reduced System Failure Risk

Additional temperature margin minimizes unexpected failures caused by capacitance collapse or excessive internal resistance.

Longer Service Life in Harsh Environments

Operating below the capacitor’s maximum temperature limit helps reduce long-term stress, improving reliability and lifecycle performance.

Better Reliability for Critical Applications

In mission-critical systems such as military communication equipment, radar systems, railway power supplies, and outdoor charging infrastructure, additional low-temperature margin can significantly improve operational stability.

Engineering takeaway:
👉For systems expected to operate around -40°C to -55°C, selecting a -65°C low temperature aluminum electrolytic capacitor is not overengineering—it is a practical strategy for improving reliability and ensuring successful cold startup.

Can low temperature aluminum electrolytic capacitors replace film capacitors?

In some ultra-low-temperature applications, low temperature aluminum electrolytic capacitors can replace film capacitors, especially when engineers need higher capacitance density and smaller size.

Compared with film capacitors, aluminum electrolytic capacitors offer:

• Higher capacitance per volume
• Smaller footprint
• Lower system cost

The main challenge is maintaining stable performance at extremely low temperatures. Advanced low-temperature designs with optimized electrolytes can overcome this limitation and become viable alternatives for certain power systems.

What industries need low temperature aluminum electrolytic capacitors?

Low temperature aluminum electrolytic capacitors are commonly used in industries where reliable cold startup is critical.

Typical applications include:

• Military communication systems
• Radar equipment
• Railway auxiliary power supplies
• Outdoor EV charging stations
• Industrial power systems in cold regions
• Exported power electronics for Russia, Canada, and Northern Europe

These environments often require reliable operation between -40°C and -65°C.

FAQ

Q1: What happens to aluminum electrolytic capacitors at low temperature?

At low temperature, electrolyte viscosity increases, reducing ionic conductivity and causing ESR rise and capacitance loss.

Q2: What is the main limitation of capacitors in cold environments?

The main limitation is electrolyte performance degradation, not the capacitor structure itself.

Q3: Can aluminum electrolytic capacitors work at -55°C or lower?

Standard products struggle below -40°C, but optimized low temperature designs can operate reliably at -55°C and even -65°C.

Q4: Why choose a -65°C rated capacitor for -40°C applications?

Because it provides design margin, improving reliability and reducing failure risk in real-world conditions.

Conclusion

In extreme cold environments, capacitor reliability directly affects whether a power system can start and operate normally. As temperatures drop below -40°C, conventional capacitors often experience severe capacitance loss and rising ESR, increasing the risk of cold-start failure.

A low temperature aluminum electrolytic capacitor rated for -65°C provides greater engineering margin, helping ensure stable startup performance, improved reliability, and longer service life in harsh environments.

👉In extreme cold, real low-temperature performance matters more than room-temperature specifications.

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Looking back on these thirty days, the people of Xuansn enriched their minds through learning, honored time with craftsmanship, and shared warmth through care. Every step we took is worth remembering.

Warm Hearts, Strong Steps

The smiles of our employees are the most beautiful part of our company.

On April 15, Ms. Yan Qiong, a National Level II Psychological Counselor, joined Xuansn to share her session Positive Psychology, A Happier Life, bringing a warm and meaningful conversation to our team.

Through practical examples and sincere insights, she guided us to better understand emotions, relieve stress, and build a stronger sense of well-being. Her session reminded us how to care for ourselves amid busy schedules and remain optimistic when facing challenges.

At Xuansn, we believe that people who are treated with kindness can pass that warmth on—to their families, to our products, to our customers, and to the wider world.

Caring for Youth, Building the Future

Caring for young people means caring for the future of the company.

In April, representatives from the Zhangmutou Town Committee for the Care of the Next Generation and the Xiegang Town Committee visited Xuansn to review and guide our youth development initiatives.

Through on-site visits and open discussions, their encouragement recognized the work we have done and expressed high expectations for the future.

Young people are the roots of an enterprise. Only when the roots grow deep can the branches flourish.

This visit strengthened our commitment to supporting young talent with higher standards and stronger initiatives. We will continue moving forward with confidence and responsibility.

The Fragrance of Books, The Energy of Youth

The spirit of learning among young people is one of the strongest foundations of an enterprise.

Co-organized by Xuansn and the Xiegang Youth League Committee, our Youth Cadre Reading Exchange was held on a bright April afternoon.

Young participants gathered with books in hand, connecting through reading, exchanging ideas, and sharing reflections.

Reading is one of the best investments we can make in ourselves. Sharing is one of the most genuine gifts we can offer others.

These young people, with light in their eyes and ambition in their hearts, are the driving force behind Xuansn’s journey toward the future.

Family Education, Quiet Strength

Family is the smallest unit of society, and society is built upon families.

The Women’s Federation continues to care for the supportive families behind every Xuansn employee. This April, we invited Mr. Shi Changqing to deliver a special lecture titled Parent Roles and Home-School Cooperation.

How can parents be present without overstepping? How can families and schools work together with shared purpose?

Through thoughtful perspectives and real-life examples, Mr. Shi offered valuable guidance. His 90-minute session appeared to focus on parenting, but in many ways, it spoke to the lifelong responsibility of being a parent.

Nurturing future generations begins at home. Quiet love often shapes the strongest foundations.

Every child who grows up with the right kind of love becomes part of the nation’s future.

Honoring Dedication, Celebrating Craftsmanship

From emotional well-being to craftsmanship, from community support to youth development, from family education to building the future—Xuansn has continued to move forward with calm determination throughout this spring.

As May approaches, our original purpose remains unchanged. We will keep moving forward with confidence, grow with the times, and continue our journey toward wider horizons.

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As the new year begins, everything is renewed. With the arrival of the new year, Xuansn Electronics officially welcomes this important moment of resuming work. The start of the new year not only signifies new business goals but also symbolizes a new starting point for the company’s team culture.
Over the past year, team members have grown through daily collaboration and continuous efforts, and the stable team culture has laid a solid foundation for the company’s steady development in the capacitor field.

Red Envelopes as a Symbol of Team Care

On the first day back to work after the New Year holiday, the company prepared red envelopes for its employees, reflecting genuine care and recognition through practical action. These red envelopes were more than a festive gesture; they represented the company’s respect and appreciation for the contributions of its people.
This people-centered approach strengthens employees’ sense of belonging and fosters greater unity and collaboration across the organization as the new year begins.

Quality Built on Strong Teamwork and Team Culture

Throughout Xuansn Electronics’ development, a strong collaborative spirit has always been closely linked to product quality. The company adheres to a quality-oriented approach, continuously providing customers with reliable capacitor products through consistent teamwork.
It is this commitment to collaboration and attention to detail that ensures the long-term stable performance of its products across different markets.

Shared Growth in the New Year

Looking ahead to the new year, Xuansn Electronics will continue to prioritize its team culture, encouraging collaboration, innovation, and growth. In the ever-changing market environment, the company will work hand-in-hand with its employees to embrace new opportunities and challenges.
Starting work in the new year is not only a time milestone, but also a new starting point for the continuous development of team culture.
For more information about capacitors, please click: https://capacitorsfilm.com/

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December is a season of harvest and reflection. At Xuansn Capacitors Company, we reviewed the achievements of the past year and strengthened ourselves for future sustainable development., we have conducted a series of diverse activities centered around the core themes of “individual growth” and “organizational development.” From the innovation of management thinking to the refinement of professional skills, from the expansion of strategic vision to the reaffirmation of our original aspirations as a team, every step reflects our shared progress and commitment to excellence.

Strengthening the Management Foundation

Team leaders are the “nerve endings” of on-site management and the “key hubs” connecting different levels. This month, the Chairman personally conducted a comprehensive training session for all management personnel at the team leader level and above, injecting new thinking energy into the grassroots management team.

Thinking Transformation: From “managing tasks” to “leading people,” managers need to go deep into the front lines, understand employee needs, and solve problems at the source. Three core principles: Upholding the work credo of “diligence, focus, and critical thinking” to achieve excellent management. Core path: Believing that “continuous improvement” is the only way to improve management levels, striving for endless betterment. Intelligent work: Advocating “working smartly” rather than “working hard,” making good use of systematic thinking and resource coordination to achieve a double leap in efficiency and quality. Health foundation: Reminding all managers to pay attention to their physical and mental health under high-intensity work, arranging rest reasonably, maintaining a balanced diet, and strengthening exercise to accumulate energy for sustained efforts.

This training was not only a transfer of knowledge but also a profound reflection of the company’s emphasis on talent development and strengthening its management foundation.

Refining Professional Skills

“Project-Based” Capacitor Manufacturing Worker Training

To actively respond to the “project-based” skills training policy of Xiegang Town and improve the professional quality of frontline employees, we successfully organized a special skills training program for [Capacitor Manufacturing Workers] this month.

This training focused on the assembly process of electrolytic capacitors, providing systematic and standardized skills guidance through a combination of theory and practice. This effectively improved the overall skill level of the production team, laying a solid talent foundation for the continuous improvement of the company’s product quality and production efficiency.

Xuansn Capacitors-Empowering Strategic Future

To support the company’s high-quality development and keep pace with cutting-edge industry trends, under the strategic decision of the Chairman, the company officially signed a contract with a well-known domestic training institution—Zhongxu Education Company—to launch a one-year “Joint Growth Business School” training project.

This project aims to systematically improve the learning ability and strategic vision of the management team and strengthen the effectiveness of management tools. Subsequent courses will be closely integrated with the business needs of each department, and will include coordinated arrangements for external learning and exchange programs. This will inject new ideas and methods into the company’s core management team and help them jointly develop a blueprint for the company’s future growth.

In December, at Xuansn Capacitors, we evolved through learning, refined our skills through practical work, and drew strength from our original aspirations. Every training session is an accumulation of energy; every activity is a strengthening of team cohesion.For more information about Xuansn capacitors, please visit https://capacitorsfilm.com

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1.Walk ten miles to welcome the sunrise

A journey of a thousand miles begins with a single step. When you first enter the xuansn family, you may feel a little anxious or troubled. Don’t be afraid, as long as we take the initiative to take a small step every day, we can go further if we accumulate slowly!

Maybe you will feel tired every step up, but the satisfaction when you appreciate the different scenery at a high place is enough to eliminate the hard work you put in when you climbed up.

2.Tea talk is always with growth

There will always be bumps on the road to growth, but the guidance of predecessors will make us take fewer detours. The XUANSN family can give all employees the opportunity to learn and grow. Everyone’s growth is the cornerstone of the transformation and development of our XUANSN family.

New employees are the new force of the enterprise and the reserve force of the enterprise. XUANSN Electronics Co., Ltd. has always attached great importance to the introduction and training of talents, providing a learning and development platform for new employees, and encouraging and supporting the career growth of employees.

This welcome event has given new employees a deeper understanding of the company’s history and culture, while also inspiring their work morale and enhancing their problem-solving ability. It also provides new employees with effective ways and methods to seek help, effectively alleviating the anxiety of new employees when they first enter the company. Everyone said that they will get into work as soon as possible, integrate into the team, and devote themselves to their jobs with full enthusiasm.

Summary:

Xuansn New Employees Spring Outing- ended successfully. Thank you for your participation and enthusiasm! We are very happy to welcome new members to join us. We believe that with everyone’s joint efforts, the Xuansn family will become stronger and better. The addition of each new member is a step towards a higher goal. I look forward to working hand in hand with everyone to witness a more brilliant future for Xuansn! For more information about Xuansn Electronics, please click：https://xuansncapacitor.com/

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In order to build a safe enterprise, create a safe factory environment, improve the company’s fire safety awareness and self-protection capabilities, and maintain the company’s bottom line of safe production, Dongguan Xuansn Electronics Co., Ltd. conducted a fire safety evacuation drill on the afternoon of April 29 and fire safety training activities. This Xuansn electronic fire drill is an important activity organized by the company to ensure that employees know how to evacuate correctly and quickly in an emergency and how to respond to emergencies such as fires. Such drills and training activities can effectively improve employees’ fire safety awareness and self-protection capabilities, and lay a solid foundation for the company’s safe production. Not only that, through such activities, potential safety hazards can also be discovered and solved, and the fire protection facilities and emergency plans in the factory can be improved and improved in a timely manner.

2.Xuansn Electronic Fire Drill—Simulate actual combat to promote defense through practice

This Xuansn electronic fire drill simulated a sudden fire incident in the factory. After the drill began, the office building was quickly filled with thick smoke. Fire safety directors from each department immediately organized employees to evacuate and rescue themselves in accordance with the fire protection plan. They guided employees to cover their mouths and noses, bow their heads and bend down, and evacuate to safe areas quickly and orderly. During the evacuation process, all personnel were step-by-step and orderly, showing good emergency literacy and teamwork skills. Immediately afterwards, the Chang’an Town Fire Brigade rushed to the scene and quickly launched rescue and fire-fighting operations. The whole process was well organized, tense and orderly, which fully demonstrated Xuansn Electronics’ great emphasis on fire safety and its ability to respond to emergencies. This Xuansn electronic fire drill effectively improved employees’ emergency response capabilities and further consolidated all employees’ understanding and emphasis on fire safety.

3.Xuansn Electronic Fire Drill—Fire knowledge to prevent disasters before they happen

After the Xuansn electronic fire drill, the deputy captain of the Chang’an full-time fire brigade explained the use of fire extinguishers and indoor fire hydrants to all participants. Through detailed operation demonstrations, each employee has a more intuitive understanding of the operating procedures of fire extinguishing equipment, which enhances their ability to respond in actual emergency situations. At the same time, the deputy captain also gave an in-depth introduction to the dangers of fire, fire prevention knowledge and escape techniques, giving everyone a deeper understanding of fire safety. Such explanations not only improve employees’ fire prevention awareness, but also provide more response strategies and skill support for dealing with possible future fire incidents.

Through the conduct of this fire safety evacuation drill, everyone has improved their awareness of safety precautions and mastered the methods of escaping in the event of a fire. This drill has achieved the expected purpose and achieved good results. Next, we will also integrate fire protection knowledge into our daily work, so that every Xuansn family member understands fire protection knowledge and prevent problems before they happen!

Summarize:

In order to enhance the fire safety awareness of Xuansn’s family and ensure that they can respond correctly in an emergency, Xuansn Electronics Co., Ltd. held a fire safety evacuation drill. This Xuansn electronic fire drill aims to enable each employee to have a clear understanding of fire evacuation procedures through practical operations and to be able to act quickly and effectively. Through such practice, we hope to be able to prevent problems before they occur, so that every Xuansn family member can stay calm in critical moments, effectively respond to emergencies, and ensure the safety of themselves and others.To learn more about Xuansn electronic related products, please click:https://xuansncapacitor.com/

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Xuansn Electronics Events-Spring Outing

Spring is warm, flowers are blooming, catkins are flying

A warm force quietly grows in my heart

The spring breeze is gentle and the feeling of spring is strong

How can we live up to this beautiful scene?

New members joining the Xuansn family

Let us join hands with new energy to help hundreds of thousands of projects

Join hands with new energy

In order to provide new employees with an opportunity to get to know each other and further enhance their sense of integration and belonging, on the morning of March 17, Dongguan Xuansn Electronics Co., Ltd. party members and cadres, trade union members, members of the related work committee and management at all levels joined hands to All employees went to Jiudong Forest Park for spring outing activities

The team arrived at Jiudong Forest Park and then walked to Yixin Bay, enjoying the beautiful scenery of Jiudong Forest Park along the way.

After arriving at the destination, Vice President Hou will lead a fun game to keep all new employees entertained.

Helping millions of projects

After the fun game, all members were divided into 13 groups and everyone introduced themselves.

Every new member is a new driving force for the Xuansn family. Only with new driving forces joining and uniting together can we continue to move forward at a high speed! Thank you all for choosing the Xuansn family, and let us build a warm Xuansn family together in the days to come. Everyone can eat well, live well, have a good environment, and be in good health! When you encounter difficulties, there is someone to help you, and there is someone to teach you on your way to growth!

Explanation of knowledge points

The full name of “Hundreds and Thousands Project” is “High-quality Development Project of Hundreds of Counties, Thousands of Towns and Tens of Thousands of Villages”. “Hundred” refers to the 122 counties (cities, districts) in the province, “thousands” refers to the 1,609 towns (streets) in the province, and “ten thousand” refers to the 26,500 administrative villages (communities) in the province.
The “Hundreds and Thousands Project” is Guangdong’s advantage shaping project, structural adjustment project, power enhancement project, and value realization project. It is the number one project to promote high-quality development and one of the “Ten New Breakthroughs” specifically deployed by the Provincial Party Committee’s “1310” one

Summarize:

Xuansn Electronics – Welcome new members to join the Xuansn family, let us unite and strive for a better tomorrow of Xuansn with new vitality. For more information about Xuansn Electronics, please clickhttps:https://solidcapacitor.com/

Introduction to Xuansn Electronics

Dongguan Xuanxuan Electronics Co., Ltd. was founded in June 2004. Specializing in the production of mid-to-high-end solid and liquid aluminum electrolytic capacitors. Products are mainly used in switching power supplies, power adapters, chargers, various household appliances, audio equipment, stage lighting, LED lamp driving power supplies, electric vehicle chargers, computer power supplies, welding machines, inverters and other fields.

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XuansnCapacitor luck starting work of CNY—Kick-off meeting

Xuansn Capacitor luck starting work of CNY—The happy Spring Festival holiday has passed, and we are about to start a new year of work. Wish you good luck in the new year. The chairman has put forward three wishes for everyone. The first hope is that you can take good care of your body and stay healthy; the second hope is that you can take good care of yourself and stay healthy. Everyone can work hard and take it seriously; the third is to be helpful to others. I hope everyone can learn to put themselves in others’ shoes, think more about others, care for others, and help each other.

President Hou Yanqing also put forward three hopes for everyone. First, he hopes that everyone can abandon the baggage of the past, dare to take risks and dare to innovate; second, he hopes that everyone can have the courage to take responsibility, do their job well, and contribute more to the team and Chuanghui; Thirdly, I hope everyone will stop having fun as soon as possible and devote themselves to work wholeheartedly as quickly as possible.

Xuansn starts work in new year—Good luck with the start of construction

In the new year, we will face new opportunities and challenges. As long as we work together and work hard, we will surely be able to create a new chapter in the development of the enterprise and create a better future!

Summary:

Xuansn Capacitor luck starting work of CNY—The new year brings a new atmosphere and everything is off to a good start. Let us work together to strive for a better tomorrow for the company.​To learn more about Xuansn capacitors, please click:https://xuansncapacitor.com/

Company Profile:

Xuansn Electronic is located in Chang’an Town, Dongguan.Our factory currently has an independent production base industrial park with a construction area of 40,000 square meters and complete facilities. Our company currently mainly produces aluminum electrolytic capacitors，is a high-tech enterprise integrating R&D, design, manufacturing, sales and service.

Drawing on advanced international management experience, we have established a research and development system and laboratories, and have passed ISO9001, IS014001, and QC080000 system certifications. At present, all products have passed ROHS, REACH, and TSCA tests and meet international environmental protection requirements.
The company has industry-leading production equipment, more than 250 fully automatic production lines, and a full range of production supporting capabilities. The main products include ultra-small, ordinary, low leakage, high frequency and low resistance, high voltage, conductive foil and other series capacitors.
We have a professional customization team to meet customer needs and can tailor personalized product solutions for customers in various aspects such as hardware and services.
Our production capacity reaches more than 300 million pieces per month, and we are equipped with a 3,000 square meter finished product warehouse to store regular products and create conditions for rapid delivery.
In the future, Dongguan Xuansn Electronics Co., Ltd. will continue to be oriented by customer needs, driven by technological innovation, adhering to a pragmatic, enterprising, rigorous, outstanding and efficient style, actively exploring international and domestic markets, paying close attention to quality as a guarantee, and continuing to provide customers with More competitive products and solutions.​

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The positive and negative lead-out electrodes and shells of aluminum electrolytic capacitors are made of high-purity aluminum. The medium of aluminum electrolytic capacitors is an aluminum oxide film formed on the surface of the positive electrode. The real negative electrode is the electrolyte, which is equivalent to an electrolytic cell when working, except that The anodized layer on the surface of the positive electrode has been formed, no electrochemical reaction occurs, and the current is theoretically zero. Due to the presence of impurities in the electrode and electrolyte, a small leakage current will be caused. From the perspective of phenomena, the common failure phenomena and failure modes of aluminum electrolytic capacitors include electrolyte drying up, pressure release device action, short circuit, open circuit (no capacitance), excessive leakage current, etc. Therefore, the factors that cause the failure of aluminum electrolytic capacitors can be divided into two parts: the characteristics of aluminum electrolytic capacitors and the application environment of aluminum electrolytic capacitors.

2 Characteristics of aluminum electrolytic capacitors

These include the selection and formula of manufacturing materials (electrode, electrolyte, sealing, etc.), manufacturing process, and technology (sealing method, heat dissipation technology, etc.).

2.1 Manufacturing materials

In a pure capacitor, no electrochemical reaction should occur, which is the essential difference between a capacitor and a battery. The electrochemical reaction in the battery can output or store electrical energy, while the electrochemical reaction not in the capacitor will store out electrical energy, but will also damage or even damage the capacitor.

Due to the presence of electrolytes in the aluminum electrolyte capacitor, once there are impurities in the electrode material, the primary battery effect will be formed, causing excessive leakage current and corrosion of the aluminum electrode. be high-purity aluminum, and it cannot be doped with any other impurities during the manufacturing process of aluminum electrolyte capacitors.

Since the medium of aluminum electrolyte capacitors is aluminum, once chloride ions exist in the electrolyte, the chloride ions will replace the oxygen ions in the aluminum and become aluminum chloride and dissolve in the electrolyte, thereby destroying the aluminum medium and causing an increase in leakage current to the extent that it cannot be used, it may even cause a short circuit.

In addition to electrode materials and electrolytes, sealing materials are also one of the keys to eliminating premature failure of aluminum electrolyte capacitors. If the sealing materials do not match, liquid leakage will occur, causing a period to aluminum electrolyte fail capacitors.
Strict material quality control can prevent early failure problems caused by manufacturing materials.

2.2 Manufacturing Process and technical aspects

In terms of the manufacturing process, the cutting of the electrode sheet, the riveting of the lead wire, the winding of the core package, the immersion or filling of the electrolyte, and the sealing process are not done well, which may cause the performance of the aluminum electrolytic capacitor to decline or fail.

In the process of cutting the electrode sheet and riveting the lead wire, it will cause certain damage to the aluminum oxide dielectric film. If the damage is too large, it cannot be repaired even through aging in time, resulting in early failure of excessive leakage current or breakdown short circuit; electrolysis Insufficient liquid entry or insufficient filling may cause the failure of aluminum electrolytic capacitors with insufficient capacitance or insufficient life; poor sealing of the aluminum electrolytic capacitor will cause the electrolyte to dry up prematurely and cause failure with insufficient life.

If the aluminum electrolytic capacitor is placed for some time and white salt stains or oil-like electrolytes appear near the lead wire or the seal, it means that the electrolyte has leaked due to poor sealing, and this type of electrolytic capacitor cannot be used.

Only when the above-mentioned manufacturing problems are all solved, the aluminum electrolytic capacitors shipped are qualified, and the early failure problems caused by manufacturing problems can be avoided.

3 Influence of application environment on the failure of aluminum electrolytic capacitors

If there is no problem with the quality of the electrolytic capacitor, the failure problem is in the application environment. The design and application environment of aluminum electrolytic capacitors mainly includes ambient temperature, heat dissipation method, voltage, and current parameters. For capacitor users, short circuits and open circuits are “catastrophic failures”, or “fatal failures”, which completely lose the function of capacitors. The other types of failure modes (that is, the failure caused by the second type of factors) are generally classified as “deterioration failure” or “depletion failure”.

The analysis of the influence of the application environment on the failure of aluminum electrolytic capacitors is as follows: the failure of aluminum electrolytic capacitors can be divided into overvoltage failure, exhaustion failure, open circuit, short circuit, pressure release device action, etc.

3.1 Overvoltage failure

In the application of aluminum electrolytic capacitors, various overvoltages may lead to failure modes such as performance degradation and breakdown.
The main cause of overvoltage is instantaneous overvoltage or surge voltage. If the rated voltage of the aluminum electrolytic capacitor is improperly selected (for example, the possible overvoltage is not considered) or the power supply environment is harsh, the overvoltage failure of aluminum electrolytic capacitors may occur.

3.2 Depletion failure

The so-called depletion failure is when the performance of aluminum electrolytic capacitors deteriorates due to the gradual drying of the electrolyte during use. Usually, the deterioration failure of aluminum electrolytic capacitors is generally defined as the end of life caused by the decline of one of the four key parameters of capacitance C, leakage current (IL), loss tangent (tan δ), and ESR increase beyond a certain range.

(1) The capacity decreases and the loss increases. Usually, the end of life of an electrolytic capacitor is judged based on the capacitance falling below 80% of the rated (initial value),lead to the failure of aluminum electrolytic capacitors. Due to the filling of electrolyte electrolytes in early aluminum electrolytic capacitors, the capacitance of aluminum electrolytic capacitors decreases slowly in the early stage of operation. The electrolyte gradually decreases as the working electrolyte continuously repairs the anodic oxide film damaged by impurities during the load process. In the later stage of use, due to the decrease of the electrolyte volatilization, it is difficult for the electrolyte with increased viscosity to fully contact the oxide film layer on the surface of the corroded rough aluminum foil, so that the effective area of the plate of the aluminum electrolytic capacitor begins to decrease rapidly. Small, that is, the capacity of the anode and cathode foils decreases rapidly, causing a sharp drop in capacitance. Therefore, it can be considered that the capacity reduction of the aluminum electrolytic capacitor is caused by the volatilization of the electrolyte,then lead to the failure of aluminum electrolytic capacitors. The most important reason for the volatilization of the electrolyte is the high-temperature environment or heat. The usually high-temperature environment is better understood.

The reason why the aluminum electrolytic capacitor heats up due to the application conditions is that the ripple (or pulsation) current flows through the aluminum electrolytic capacitor when it is working in rectification and filtering (including high-frequency rectification and filtering of switching power supply output) and power supply bypass of the power circuit. For electrolytic capacitors, the ESR of aluminum electrolytic capacitors generates losses and converts them into heat to generate heat.

When the electrolyte of an aluminum electrolytic capacitor evaporates more and the solution becomes thicker, the resistivity increases due to the increase of viscosity, which increases the equivalent series resistance of the working electrolyte, resulting in a significant increase in capacitor loss and loss angle,lead to the failure of aluminum electrolytic capacitors. For example, for an electrolytic capacitor with a working temperature of 105C, when the maximum core package temperature is higher than 125C, the viscosity of the electrolyte will increase sharply, and the ESR of the electrolyte will increase by nearly ten times. The increased equivalent series resistance will generate more heat, resulting in Faster volatilization of electrolyte. Such a cycle goes on and on, and the capacity of the aluminum electrolytic capacitor drops sharply, and may even cause an explosion.

In addition, if the viscosity of the working electrolyte increases too much at low temperatures, it will also cause increased loss and a sharp drop in capacitance. The low-temperature performance of the boric acid-ethylene glycol system working electrolyte is not good, and the viscosity is too high, resulting in a sharp increase in equivalent series resistance, increased loss, and reduced effective capacitance, which will cause aluminum electrolytic capacitors to fail when used in severe cold environments.

(2) Leakage current rises. Increased leakage current often causes aluminum electrolytic capacitors to fail.
The main reasons for excessive leakage current are: low level of empowerment process, insufficient density and firmness of the formed oxide film, backward chip opening process, serious damage and contamination of the oxide film, poor working electrolyte formula, low purity of raw materials, The chemical and electrochemical properties of the electrolyte are difficult to stabilize for a long time, the purity of the aluminum foil is not high, and the content of impurities is high.

Among them, the oxide film damage and serious contamination are the main reasons for the increased increasing leakage current. The flaws and defects of the oxide film itself, as well as the impurities such as chloride ions and sulfate ions in the electrolyte, damage the characteristics of the oxide film. Under the rated conditions, the oxygen generated by the electrolysis inside the aluminum electrolytic capacitor will repair the oxide film, that is, aluminum electrolysis The self-healing function of electrical appliances.

However, when the external positive voltage is increased to exceed the rated voltage (this situation is common in the circuit), the negative polar acid ions such as chloride ions and sulfate ions will accelerate the movement under the action of a strong electric field and dioxide Aluminum reacts, causing oxide film damage and serious contamination. At this time, the oxygen generated by the electrolyte in the aluminum electrolytic capacitor is not enough to completely repair the oxide film, increasing leakage current. The leakage current causes the oxide film on the contaminated part to decompose, resulting in a perforation. causing the current to increase further.

The impurity content of the aluminum foil is relatively high, and the size of the iron impurity particles is generally larger than the thickness of the anodized film, which makes the current easy to conduct. The existence of copper and silicon impurities affects the transformation of aluminum oxide to the crystalline structure, and copper and aluminum can also form micro-batteries in the electrolyte, which causes the aluminum foil to be corroded and damaged. In short, the presence of metal impurities in aluminum foil will increase the leakage current of aluminum electrolytic capacitors.

With the increase in use and storage time, the solution in the electrolyte is gradually consumed and volatilized, which increases the acid value of the solution and corrodes the oxide layer during storage. At the same time, due to the aging and dryness of the electrolyte, oxygen ions cannot be provided to repair the oxide film under the action of the electric field, thus losing the self-healing effect, the oxide film is damaged, and the leakage current increases.

If the anodic oxide film formed during the energization process is not dense and firm enough, the oxide film will be severely damaged in the subsequent cutting and riveting process. This kind of anodic oxide film is difficult to repair and perfect in the final aging process so during the use of the capacitor, local self-healing cannot repair the oxidation barrier, resulting in a large leakage current.

If the leakage current is too large, it will cause fatal failures such as the action and breakdown of the pressure release device (explosion-proof valve) of the aluminum electrolytic capacitor:
① When the leakage current is large, the rate of gas generated by electrolysis is faster, and the consumed electrolyte is used to repair the anodic oxide film, and the generated gas is stored in the capacitor shell. The longer the working time, the greater the leakage current, the more gas in the shell, and the higher the temperature. The air pressure difference inside and outside the metal shell of the capacitor will increase with the increase of the working voltage and working time. If the product is not well sealed, it will cause liquid leakage; if the seal is good, and there are no explosion-proof measures, the capacitor will explode when the air pressure increases to a certain extent. High-voltage large-capacity capacitors have a large leakage current and are more likely to explode.

② If the leakage current is too large, the insulation effect of the oxide film will be damaged, and the direct contact between the cathode and the anode will cause a short circuit breakdown. For example, when the riveting process is not good, the burrs on the lead-out chaff will seriously puncture the oxide film, the leakage current at the punctured part will be large, and the local overheating will cause thermal breakdown of the capacitor.

3.3 Causes of open circuits

Aluminum electrolytic capacitors may fail in an open circuit when they work in a high temperature or hot flash environment for a long time. The reason is that the anode lead-out foil is broken due to electrochemical corrosion. For high-voltage large-capacity capacitors, this failure mode is more common. In addition, if the anode lead-out foil and the anode foil are riveted, if they are not fully leveled, it will cause poor contact and intermittent open circuit of the capacitor.
When the working electrolyte with DMF (dimethylamine) as the solvent is used in the aluminum electrolytic capacitor, the DMF solution is an oxidizing agent, and its oxidation ability is stronger at high temperatures. After working for some time, the capacitor may be opened due to the oxide film formed on the riveting part of the anode lead-out foil and the welding piece. If an ultrasonic welding machine is used to connect the lead-out foil and the solder joint, this type of failure can be reduced.

4 Action of the pressure relief device

The electrolyte in the aluminum electrolytic capacitor is caused by the gas generated by internal high-temperature boiling or the gas generated by the electrochemical process, which causes the internal high pressure to cause the explosion of the electrolytic capacitor. To eliminate the explosion of aluminum electrolytic capacitors, aluminum electrolytic capacitors with a diameter of more than 8mm are equipped with pressure-release devices. These pressure-release devices operate before the air pressure inside the electrolytic capacitor reaches the dangerous pressure that has not yet caused the aluminum electrolytic capacitor to explode, and release the gas. With the action of the pressure relief device, the aluminum electrolytic capacitor is declared invalid. (1) The electrochemical process causes the pressure relief device to operate. The leakage current of aluminum electrolytic capacitors is a violent electrochemical process, which has been discussed in detail before and will not be repeated. The electrochemical process will generate gas, and the accumulation of these gases will cause the internal pressure of the aluminum electrolytic capacitor to rise, and finally reach the pressure release device to release the pressure,lead to the failure of aluminum electrolytic capacitors.

(2) Excessive temperature causes the pressure release device to operate. If the temperature of the aluminum electrolytic capacitor is too high, it may be that the ambient temperature is too high. For example, there are heating elements near the aluminum electrolytic capacitor or the entire electronic device is in a high-temperature environment.

The second reason why the aluminum electrolytic capacitor temperature is too high is that the core package temperature is too high. The root cause of excessive core package temperature is excessive ripple current flowing through aluminum electrolytic capacitors. Excessive ripple current produces an excessive loss in the ESR of the aluminum electrolytic capacitor and generates excessive heat, causing the electrolyte to boil to generate a large amount of gas, causing the internal pressure of the aluminum electrolytic capacitor and the pressure release device to operate when it rises sharply,lead to the failure of aluminum electrolytic capacitors.

(3) Action of the pressure release device caused by low ambient air pressure. If the aluminum electrolytic capacitor works in an application environment where the air pressure is too low such as high altitude or high altitude, the pressure release device will act prematurely, causing the aluminum electrolytic capacitor to fail prematurely. This is the limitation of the aluminum electrolytic capacitor to the application environment

5 Special failure modes

In high-voltage aluminum electrolytic capacitors, a special failure mode often occurs: burning. Aluminum electrolytic capacitors can cause both primary combustion and secondary combustion.

5.1 Combustion of Aluminum Electrolytic Capacitors

(1) Primary combustion mode. Primary combustion means that the electrolytic capacitor burns itself under certain conditions, which is the so-called “active combustion”.

In the formation of the fire source, the electrostatic energy accumulated in the capacitor can be connected to the spark discharge through the arc between the electrodes under certain conditions, and this spark is the “fire source”. The electrostatic energy gain is W=1/2CV2, where C is the electrostatic capacity and V is the charging voltage, which is proportional to the square of the charging voltage, so high voltage will greatly increase the amount of static electricity accumulated on the capacitor electrodes. Generally speaking, aluminum electrolytic capacitors for power input are more likely to cause internal spark discharge due to their high operating voltage, which will directly cause the overflowing electrolyte to burn. The working voltage of the aluminum electrolytic capacitor used for power output is relatively low, and it usually does not reach the electrostatic energy required for internal spark discharge, so primary combustion rarely occurs.

Combustible substances that can be burned: due to the presence of combustible substances such as electrolyte, isolation liner and hydrogen gas around the fire source, it is easy to catch fire and burn.

Oxygen supply: Due to the impact of heat generation and arcing between electrodes, the internal pressure of the capacitor will rise sharply until the safety valve opens. At this time, the combustibles will be ignited and continue to burn when they come into contact with the outside air. The larger the opening area of the safety valve, the more oxygen will be supplied and the more intense the combustion will be. Conversely, the opening area is so small that the combustibles cannot fly out to contact with the outside air, and the combustion will not continue at this time, and at most there will be a little burnt trace in the arcing part.

(2) Mode of secondary combustion. Secondary combustion means that the aluminum electrolytic capacitor is ignited by an external fire source, or the electrolyte is sprayed to a nearby high-energy area, causing a short circuit, arcing, and then a fire, lead to the failure of aluminum electrolytic capacitors,which is the so-called passive flammability.

Leakage or overflow of electrolyte: When the airtightness of the seal is poor or the safety valve is opened, the electrolyte will leak or overflow from the inside of the capacitor and circulate to the high-energy area (such as the high-energy part on the circuit board) , cause short circuit, flashover, cause the electrolyte to catch fire and then trigger the combustion of combustibles other than the electrolyte,lead to the failure of aluminum electrolytic capacitors.

External fire source: The combustible material around the capacitor burns to become a fire source. When the capacitor sealing material catches fire or the capacitor is heated by an external heat source and the safety valve opens, the electrolyte leaks and is ignited,lead to the failure of aluminum electrolytic capacitors.

(3) Instantaneous overheating. As mentioned earlier, usually the core temperature of aluminum electrolytic capacitors is reduced by 10C, and its life will be doubled. This core is located roughly in the center of the capacitor and is the hottest point inside the capacitor. However, when the capacitor heats up close to its maximum allowable temperature, for most types of capacitors, at 125C, the electrolyte will be squeezed out by the capacitor core package, causing the ESR of the capacitor to increase to 10 times the original. Under this effect, instantaneous over-temperature or over-current can permanently increase ESR, lead to the failure of aluminum electrolytic capacitors. In the application of high temperature and large ripple current, special attention should be paid to the possibility of instantaneous overtemperature, and special attention should be paid to the cooling of electrolytic capacitors.

6 Prevention of Failure of Aluminum Electrolytic Capacitors

6.1 Prevention of overvoltage failure of Aluminum Electrolytic Capacitors

Capacitors are easily broken down under overvoltage conditions,cause failure of aluminum electrolytic capacitors and instantaneous high voltages often appear in practical applications.

Figure 5.16 Schematic diagram of aluminum electrolytic capacitors suffering from surge voltage and transient overvoltage in rectification and filtering

In the figure, VR, VS, and .VT are rated voltage and surge voltage respectively. The transient high voltage test condition is 1000 cycles, 330s without load, 30s with load; VS is generally 110%~115% times VR.

It can be seen in the figure that due to the frequent transient overvoltage or surge voltage in the AC power grid, this transient overvoltage or surge voltage is transmitted to the electrolytic capacitor that completes the filtering function through the rectifier, resulting in overvoltage or transient overvoltage of the filter electrolytic capacitor ，cause failure of aluminum electrolytic capacitors.

The rectifier filter capacitor will cause instantaneous overvoltage or surge voltage of the filter capacitor due to the instantaneous overvoltage or surge voltage of the AC grid. Similar transient overvoltages or surge voltages also occur during power-up of circuits, especially in LC filters. For example, during the power-on process, because the filter inductor releases the stored energy into the filter capacitor, the filter capacitor will experience an instantaneous overvoltage,lead to the failure of aluminum electrolytic capacitors,as shown in Figure 5.17.

Figure 517 Transient overvoltage generated during switching action in LC filter
Figure 5.18 Figure 5.17 Overvoltage surge generated by the circuit
Figure 5.19 Using a negative source coefficient thermistor to prevent overvoltage in the circuit shown in Figure 5.17

This instantaneous overvoltage will produce “overshock” on the capacitor (Figure 5.18)，cause failure of aluminum electrolytic capacitors. Soft switching techniques, which can employ NTC thermistors, are effective against transient overvoltages (Figure 5.19).
The filter before the rectifier can filter out some high-speed transient high voltage, but not all.

6.2 Prevention of reverse polarity

If the positive and negative terminals of the aluminum electrolytic capacitor are connected incorrectly, it will only take a short time to cause damage to the capacitor,lead to the failure of aluminum electrolytic capacitors. Therefore, in order to avoid similar connection errors, the direction of the positive terminal of the capacitor will be rotated 90°, that is, the direction perpendicular to the axis of the two bolt terminals is the positive pole, and the direction along the axis of the two bolt terminals is the negative pole.

6.3 Protection against overheating

The current exceeding the rated value will cause the internal temperature of the capacitor to rise too high, and shorten its working life,lead to the failure of aluminum electrolytic capacitors.However, if the duration of the ripple current is short compared to the heat conduction time constant, it will generally not cause damage to the capacitor.

(1) Infer whether it is overheated by measuring the temperature of the aluminum electrolytic capacitor shell. The temperature of the core package inside the capacitor determines the working life of the aluminum electrolytic capacitor. A temperature sensor can be used to measure the internal temperature rise of the aluminum electrolytic capacitor during operation (the temperature sensor must directly contact the aluminum shell of the aluminum electrolytic capacitor).

Figure 5.20 Rules for preventing wrong polarity connection when aluminum electrolytic capacitors are placed horizontally

(2) Place the temperature sensor inside the core package of the aluminum electrolytic capacitor to detect whether it is overheated. For aluminum electrolytic capacitors connected by bolt ends, it can be measured by inserting a thermocouple inside the capacitor. In engineering practice, Figure 5.21 is relatively easy to implement, while Figure 5.22 can only be used in aluminum electrolytic capacitor product testing. The reason is that it is impossible for aluminum electrolytic capacitors connected by bolts to reserve a cavity for inserting a thermocouple in the sealed end cover or shell for measuring the temperature of the core package.

Figure 5.21 Temperature test points for aluminum electrolytic capacitors with various shapes
Figure 5.22 Test the temperature of the core package of an aluminum electrolytic capacitor with a bolted end connection by inserting a thermocouple inside the capacitor

(3) Estimation of core pack temperature under intermittent load. Aluminum electrolytic capacitors do not always work under continuous load conditions. For intermittent load conditions, the equivalent circuit of heat conduction shown in Figure 5.23 can be used for calculation.

In the figure, Rthhc is the thermal resistance from the aluminum electrolytic capacitor core package to the shell, Rthca is the thermal resistance from the aluminum electrolytic capacitor shell to the surrounding environment, Ch is the heat capacity of the aluminum electrolytic capacitor, and Cc is the heat capacity of the aluminum electrolytic capacitor shell.
The heat transfer parameters and ESR data for this example are available on the RIFA website.

Figure 5.23 Equivalent circuit of core package temperature heat conduction at intermittent load

For example, if PEG126KL427BM type aluminum electrolytic capacitor (40V/2700uF) is selected, the thermal resistance from the core package to the shell is 7.7°C/W, and the thermal resistance from the shell to the environment is 18°C/W. Natural cooling does not use forced air cooling) , The heat capacity of the core package is 21J/℃, and the heat capacity of the shell is 2.5J/℃.
Find the ripple current.
Working state: 20A, 5kHz within 5min.
Closed state: no current within 15min.
Cycle: 20min.
Ambient temperature: 93°C., without forced air cooling.
ESR=8.7mΩ.
Power loss: I2rmsResr = 3.5W (“working” state).
Based on the given heat conduction parameters and the calculated power loss, the core package temperature (Th and case temperature (Tc) can be calculated by computer simulation, as shown in Figure 5.24

Figure 5.24 Computer simulation results

From the above analysis, we can see that the limit of intermittent work is as follows
(1) The intermittent operation mode with a duty cycle of 25% can increase the ripple current by 95% compared to the value during continuous operation.
(2) When the core package temperature Th reaches 135°C, the maximum ripple current can still be applied
(3) Within 100h, the core package temperature Th≦45℃, can work at the maximum ripple current

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