Document wgL2ZY2gjQdaq0rYG1v9dreLB

Monsanto TO M. F. BABER - ST. LOUIS JUNE 3, 1970 CAPACITOR INDUSTRY INFORMATION H. S. BERGEN P. 0. BENIGNUS R. DAVIS G. R. GRAHAM - NEW YORK R. H. MUNCH D. A. OLSON W. R. RICHARD You will find attached selected background information on the capacitor industry which may be useful in future thinking and planning. Attachment 1 breaks out the domestic industry by type of capacitor; and presents sales forecasts, descriptions and kinds of materials used for each type. Attachment 2 was prepared as a rough indication of the total potential for dielectric TTIms and impregnants in paper-film capacitors. It was estimated that in 1975 approximately $100 K of paper and film will be consumed in domestically produced capacitors. Not all these capacitors will be impregnated. However, if they were, they would consume about $10 K of impregnants (Aroclor, mineral oil, etc.) in 1975- Much of the information in the other attachments comes from the i960 book on capacitors by Drummer and Nordenberg. I have been unable to locate more recent information of this type. MS Attachments MICHAEL F. BABER 0436575 TOWOLDMONOQ57764 ATTACHMENTS PAGE 1. Capacitors By Type, Sales and Materials of Design................................................................................................. 1 - 5 2. Flln;/Paper Capacitor Requirements for Film, Paper and Impregnants.................................................................... 5a - 5b 3. Capacitor Quality Factors........................................................... 6 4. Capacitor Ratings.............................................................................. 6 5. Frequency Coverage of Different Kinds of Capacitors............................................................................................... 6 6. Summary of Some of the Important Characteristics of Fixed Capacitors (i960)........................................................ 7 7. Summary of Some of the Important Characteristics of Variable Capacitors (i960)................................................. 8 8. Common Capacitor Applications................................................. 9 9. Dielectric Constants of Typical Insulating Materials................................................................................................. 10 10. Properties of Some Capacitor Dielectric Materials................................................................................................. 11 11. Title and Contents of FIXED AND VARIABLE CAPACITORS by Drummer and Nordenberg (3 pages) 12. Fixed Capacitors Now and In '69, Electronic Design News reprint, November 11, 1968 (8 pages) OA3<>*7b TOWOLDMONOQ57765 Attachment 1 CAPACITORS BY TYPE SALES AND MATERIALS OF DESION I. SALES AND PROJECTED GROWTH RATE: Estimated^1) 1969 u.s. Sales $ M Estimated1 Annual' Growth Rate 1969 - 1975 $ Sales Units 1. Power Line Factor Correction (Aroclor) $ 35 10# 10# 2. Lighting Ballast (Aroclor) 25 7# 7# 3. Aroclor Motor Run, etc. with Paper and/or Plastic Film 25 5# 5# 4. Paper Dielectric (nonAroclor) - A.C. 22 (8#)(3) (9#) 5. Paper Dielectric (nonAroclor) - D.C. 13 (8*) (9#) 6. Plastic Film Dielectric 43 (1*) (1#) 7. Metallized Paper and Film 49 (4*) (4#) 8. Dual Dielectric 5 0# 0# 9. Tantalum Electrolytic 104 1C# 12# 10. Aluminum Electrolytic 11. Mica Dielectric 96 24 (7#) 4# (6#) 4# 12. Ceramic Dielectric 13. Monolithic Ceramic 14. Other Fixed Dielectrics 43 36 14 2# 2$ -(4) (1#) (1#) - 15. Variable Capacitors, All types. 16 TOTAL $550 (1*) 2% 2# - (1) Source: 1.-3. , revised rough estimates based on information from PGB and capacitor company visits; subject to further revision. 4.-15., Electronic Industries Association (2) Source: 1.-3., MFB rough estimate, does no,t imply growth of Aroclor consumption 4.-15., Stanford Research Institute report (3) Parenthesis represent decline in sales. (4) Unknown growth rate. 0436517 TOWOLDMONOQ57766 -2- II. CAPACITOR DESIGN AND MATERIALS: This section presents for each type of capacitor a. Normal design structure b. Normal electrode material c. Dielectric materials d. Other Important materials used, excluding the case or encapsulating outer coating. 1. Power Line Factor Correction a. Design - Roll of foil, polypropylene film and paper, Impregnated with Aroclor. b. Electrode - Aluminum (Al)* c. Dielectric - polypropylene film, paper, Aroclor 2. Lighting Ballast a. Design - Roll of foil and paper, usually im pregnated with Aroclor. Metallized film is being considered. . b. Electrode - Al c. Dielectric - paper - Aroclor 3. Aroclor Motor Run, Etc., with Paper and/or Plastic Film a. Design - Presently roll of foil and paper im pregnated with Aroclor. Expect conversion from paper to polypropylene film - paper dielectric soon. Within a few years expect redesign to use of metallized film, perhaps with an impregnant. Aluminum (Al) foil is used except where specified otherwise. TOWOLDMONOQ57767 3- b. Electrode - A1 c. Dielectric - Paper and/or polypropylene foil, presently Impregnated with Aroclor. A. & 5* a. b. c. Paper Dielectric (Non-Aroolor) Design - Roll of foil and paper, impregnated. Electrode - A1 Dielectric impregnant - Castor oil, mineral oil, polyisobutylene, silicone fluids, mineral wax, chlorinated naphthalene, dibutyl sebflLcate. 6. Plastic Film Dielectric a. Design - Roll of foil and film frequently impreg nated. Metallized film will see increasing use. b. Electrode - A1 c. Dielectric film - polystyrene, polyester (Myldr), Teflon, crosslinked polyethylene, polycarbonate, polyimide, polypropylene, cellulose acetate. d. Impregnants - Silicone fluids, polystyrene, mineral oil and others used to fill pin holes and improve dielectric properties of the film. 7. Metallized Paper and Film a. Design - Roll of metallized paper or film, usually impregnated (see A.c.) b. Electrode - A1 coating c. Dielectric - impregnated paper or film (mostly Myl^r) 0436579 TOWOLDMONOQ57768 _/)_ .8 Dual Dielectric a. Design - Roll of foil and two dielectrics, pri marily paper-plastic film or plastic filmplastic film. (When paper-polypropylene film dielectrics for Aroclor type capacitors become popular, they will show up in this category, except for powerline factor and lighting ballast types). b. Electrode - Al, usually c. Dielectric - Paper and plastic films shown in 6.c. d. Impregnants - When used, they will be those in 5.c. and 6.d. 9. Tantalum Electrolytic a. Design - Roll of tantalum foil or tantalum slugs, separated from a silver cathode by an electrolyte. b. Electrode - Sintered tantalum slugs, plain or etched tantalum foil; silver cathode in non-foil design. c. Dielectric - TagO^ film on foil or slug d. Electrolyte - Sulfuric acid, lithium chloride, succinic acid, boric acid, or a solid electrolyte of MnOg. 10. Aluminum Electrolytic a. Design - Roll of oxide coated aluminum foil. b. Electrode - Plain or etched aluminum foil, or aluminum-sprayed aluminum gauze. c. Dielectric - AlgOgfilm on foil d. Electrolyte - Aqueous solution of ammonium borate, boric acid and glycol. 11. Mica Dielectric a. Design - Stacked sheets of mica with electrodes in between. 0*36580 -5- b. Electrode - Silver coating or aluminum foil. c. Dielectric - Mica sheet or chip. d. Other - Sometimes Impregnated with wax to separate molded case from electrode. Frequently encapsulated In epoxy or phenolic resins. 12.&13. Ceramic Dielectric (including Monolithic) a. Design - Ceramic tubes, disks or plates, coated on . both sides with silver. , b. Electrode - Silver coating. ,' c. Dielectric - Steatite,! titanium dioxides, magnesium ortho-tltanate, barium titanate, mixed tltanate, fused quartz, bento'ntte film, other metal oxides. d. Other - Frequently encapsulated in epoxy or phenolic resin. 14. Other Fixed Dielectrics a. Design - Various b. Electrode - Various c. Dielectric - Various materials including air, vacuum, gases, vitreous enamel, gldss, and magnesium silicate. 15. Variable capacitors. All Types a. Design - Fixed stator plate and movable rotor plates which can be moved to change capacitance of the unit. b. Electrode - Various c. Dielectric - Various, including air, vacuum, gases, mineral oil, mica, ceramics, glass, polystyrene film, teflon film. 0436881 I TOWOLDMONOQ57770 Attachment 2 FILM/PAPER CAPACITOR REQUIREMENTS FOR FILM, PAPER AND INPREGNANTS (Rough Estimate) Aroclor Types Power Line Factor Lighting Ballast Motor Run, Etc. Sub-Total Estimated U.S. Sales $M 1222 1975 Potential Consumption of^2^ Film/Paper and of Impregnant M Pound $ 35 $ 61 11.2 19.8 25 37 7.0 10.5 $~85 34 $13? 5571 1 6.0 H of Impregnant^) $59.0 M of Film and Papers Other Paper and Film Capacitors Paper Dielectric-A.C. Paper Dielectrlc-D. C. Plastic Film Dlel.U) Metallized Paper^1) & Film Dual Dielectric^) Sub-Total $ 22 $ 13 6.2 3.6 13 8 3.6 2.2 43 40 12.0 11.2 49 38 13.7 10.6 5 1.4 1.4 $104 36T 5970 $ 4.4 H of Impregnant^) $44.0 Ff of Film and Paper' (1) Estimated sales for 1975 are probably low as a large percentage of Aroclor type capacitors will have plastic, metallized and dual dielectrics (with or without Aroclor). (2) Depending upon technological developments, the types of capacitors represented by this table could have dielectrics primarily of paper or primarily of film. They could all be impregnated or none could be impregnated. This column gives estimated combined consumption of film and paper. This is identical to consumption of impregnants, if all these capacitors happen to be impregnated (which is unlikely). 4ssume 0.32 lb. of impregnant and 0.32 lb. of film per $ value for power factor capacitors, and 0.28 lb. of impregnant and 0.28 lb. of film per $ value for other capacitors. 043658? TOWOLDMONOQ57771 -5b- (3) Assume average price of impregnants at 15^/pound. (li) Assume average price of film and paper at $1.50/pound. i ) l l 0^36^83 TOWOLDMONOQ57772 ~ r" Tabic 4*4---Capacitor Quality Factors* Capacitor type Insulation resistance Dielectric strength Dielectric absorption power factor Factor of merit "Q" 1. Air Very high Low 2. Vacuum or gas Very high High 3. Mica High High 4. Ceramic High High 5. Paper Average Average ' C. Plastic High High 7. Aluminum oxidc-f Very low Low l. Tantalum oxiriot Low Very low i_________________ ii------------------------- :--------- From Cor.vair Design Manual. ( Very low Very low Ve-rv With Very low Very low Very high Low Low High Low Low High Average Average Average Low Low High High Hish Low High . K,sh. ,C./ ^ Low 'i:____________________________ G*znu..,, JCo^ A*aeo7-* T Ceramic-type capacitors. " MAKf6m + +*<) Table 4-3--Capacitor Ratings Description Style Min cap . Max cap Max working volts Paper Paper Mica Mica Ceramic Ceramic Ceramic Class Air Tantalum Electrolytic, AC CN CP CB CM CV CC CK CV CT CW CJ 1000 mmf 0.001 m( 10 mmf 0 mmf 1.5 mmf 0.5 mmf 100 mmf 5 mmf 3.5 mmf 0.5 mf 21 mf 0.2 mf ' 20 m 3900 mmf 0.1 mf 125 mmf 1300 mmf 10,000 mmf 5100 mmf M3 mmf 320 mf 552 mf 1000 12500 300 35000 500 500 500 500 t 630 125 . Aluminum. Electrolytic CE # * Paper, high-voltage, suppression. Paper, feed-through, suppression, f Not specified. , 4 mf 0.01 mf 0.01 mf 2000 mf 0.25 mf 2- mt 450 t , /?_......... V. ... Pope^ end wetoliiied poper Mico.Qioti end low.fett celomic AhimVum etecUeiyttc Potjrllyrene,poiy*M>yfcn,potyte('OfltfO'P*th|r(tn* 10' 10* 10* to' 10* ' to7 10* Frequency, ep Flo. 2*10. Frequency coverage of different kinds of capacitors. (Dashed line* Indicate possible variations due to construc tion techniques, rajmritnnce value, etr.) 0*3t>58* TOWOLDMON0057773 Tai\U 3-0. Sl'munr or Soxe or Till Ixtoutant CiiAi\AcTtmTic. or Fixr.u CArACiTou. Typo f eapnritor (military ipvulieatiun) j Cl>et lo!<rance In I pecifiratlon 1 Power (arior (at 1 Kc/aee and 25*0 or Q (at 1 Me/aco and 36*C> Ta inperature rocllirient <ppm/*C) fharectcriitiee where applicable InanUtioa reaiatanre (min at end of life teat, mrgulimi) length of life teat MIL (at^e) Maiimum tapaeitanro varia'.ion after l,f Irata | Maiimum te,,\|-nUfl lor lone Ua Impregnated i|*cr (M1UC*25) *10% 0.004-0.01 1 30% of original 260 In mai itnS .0% j 3*.*C or I25*CI I*eifid k 00 to 10CTC a)< i-n.1,r>c on r*q. of rid. volt. at imt-rrgoant 40*Cdepcndoa imprrtnant A watt-eecoad group Mrtaliinl l*|>er (MIL-C-13312) jk MuMrJ mica eapaeitore co (.\:iuc-j) *10% *5% ClaM dieleelrle (MIL*^11272) *3% 0.005-0.010 0.001-0.005 0.001 * )( of original epeeified ret). I)--not epeelfied C 200 pprn/'C O * 100ppm/*C + 100 j.p.n/*C - 20 ppiii/C F + 70 |ipm/*C - 0 ppm/*C 7,500 140 * 25 ppm/'C 10.000 1000 l>r at rtd. volte d* 10% 96'C or l?5*Ct 1,000 hr mat 9% or 0 5 pf. ainb 160% of whichever le rtd, volute greater 55*C 125C or 160'Ct |.OOOhrat95'C 9% or 1 pf, 35*C or 126*0 at 160% of rtd. a t>lr 1.ever volute la treater Vitrec.ua enamel (none) Ceramic temp. eomjcD*aUng (MIL*C*20) , *1% 0.001 1,000 mlft 115 * 25 r*|im/*C + 100 - 200 0 --330 -:<0 --420 -80 -760 -160 1,000 1.000 )ir 760 volta d* +250 volte n* (|cak to Kali, not to tarred 100 cyclre) 3% or 0.5 pf. whirhevar le greater 35*C 95*0 Ceramic genrrahpurpoee <M!L*C*U015> -----------------i .. - . +100 - 20 0.01 to 0.03 verier -1,600 varieeaon with temp., te. linear " ....... -- 2.000 1.000 2a rtd. wtu d*e ` 95*Cor 150*01 Mica, button type# (MIL*0*10060) Polyatyrcoe film (MIL*C*19979) Polytetrafluoroethyleae (M IL*C* 10028) Pvlyeiliytenr l<* rcplithaleu (MIUC*I1078) 5 Atuminuhi rlt-ctrulytio (MIL-C-C2) *2% 0.001-0.006 *5% 4,000 min *6% 9,000 mta *6% 0.01 variea vallii temperatura * fre<iueney -10 + 150 (up to 50 volta) -M0 -f 100 (up t<> :<60 volta) - 10 4- 60 (over 3.600) 0.02-0.35 (at 120 cpa) 0--not epeeified 0 * 100 ppm/*C -120 *30 ppm/*C * Variea with tern* perature 7.500 or 50,000 (depend! on type of eeal) 250 hr * 1,000 hr at 760 volu for 95*C * I25*C unite, rcapcetively 00%of original 250 hr 116% of ewlfied req. rtd. voluge at 35*C 60 % of original 250 hr at 116% epeelfird req. of rtd. volute at170*C 00 % of original 250 hr at 50% epeeifird req. of rtd. VulUge at I25*C 1.000 hr at rtd. voltage 9% or 0.6 pf, 36*C or 136*Ct whichever ie greater 0% for valuer <0.05. 3% for valuer >0.05 6% 06*0 (36*C) t 170*C (200*C) t 6% 10% 125*0 (160*C) t 06*C or 35*0 Tanuhiin rh-rirvtylU (Mlle*C*.Vi>.6) Tantalum a .l.d-elrctfolyle (M 1 I-C*2l7,ll| . 1'f r.aii.n-tyi'V air dielrririe (c.nr) 92% *10% *0.01 0.02-0.9 0.01-0.00 (at 120 C{) 0.00001 + 000 ppm/*0 + 10 e 'e 2,000 hr at rtd. voltage 36*0, 125*C or 176*C| 1.000 hr at rid. volute 10% *5*0 0 26*0 Nm apt Val-h-. f | (I.M'mJktriritmor*mniM!<i)iiiLuaiioi io|->reniaedi|ou(ptetomptl.erraaatulroem# paejireadtfuiorrde will proper (or different volt**# derating el.arae lefiawra. tod redutiioa ( ||| tipoeUMy. 01.36^8^ -& Tam.k 3*11. Summary ok Some ok the Important CiiARACTKiimncH ok Vaiuaule Capacitors Typo Single unit, precision Capacitance function, law * SI,C Approximate capacitance HWiliR, pf 100-1,500 Power factor At 1 kc/seo end 25*C 0.00001 1 Q At Mc/bcc and 25*C Approximate oper. volta d*c At ACA-lfVCl pressure ' - 1,000 Single unit, Roncrnl*pur* SLC*nd SLF 15-100 and ]>L>SO 350-550 0.001 750 MuStigntig, general* purpose SLCandSLF 15-100 and 350-550 0.001 " 750 miniature, SLC 300-350 0.001 -- 500 Tcim>. corn., ppm/*C + 10 (beat) + 120 +120 + 150 Max oper. temp. for Ioiir life - - - -- Remarks Trimmers, air-dicl. vnni SI.C l.'l'*' Trim.... . Kl;t.svlid. typn SI.C Trunints, rernmic SI.C 3.5-145 0.5-30 7-45 --* Trimmer,, mien com* Non-linear * See CS;\p. M. 15-3,000 0.001 250 min. 500 min. 500 min. -- Cl:850 C2:1,150 C3:1,400 500 00 250-500 +50-150 $5*C Covered by mil. spec. M1L-C-02 100 ]25*C i Covered by 1 mil. spec. | MIIM.-I4400 Cbar. T*C A NPO it N:ioo C N500 D NG5U Covered by mil. sjmt. MJI/*C*S1 Poor - (> 0<,36b*<* TOWOLDMONOQ57775 Table 4-5.--Common Capacitor Applications Description Common applications Blocking Duffer Bypass ' Coupling | Filtering [ Tuning E o0.<0 Z <N -n Cot 2 c wit*--- %6 cU 6 uJi O J3 k s n CP CN; CB CK CW CE CT CC CV CJ J CV L'Temperature < nmpensatn.r. X Indicates uses mentioned in the rtinent MIL or JAN specification. 91 E&c. /J*>4. 0<,3fc587 TOWOLDMONOQ57776 - to- l>lcl< ctrle run lant K Viicunin.................................................................... 1.0 l>ry Mr..................................................................... ) .0005H I'olyslyu m'............................................................. 2.5 rotytilinflnoroctliylniin (Teflon*)....................... 2.0 JV'lyelliyloiii' tcr.pl.tl.iihte(Mylar*)................. 3.0 Jmpn glinted pajur.................................................... 4.0G.0 Mien......................................................................... 0.8 Timtalum oxide...................................................... 25.0J Aluminum oxide........................... ......................... 7.0 (Vriimie (ningm.-ium titunnte, etc.)................. Up to 20 Commie (litania)...................................................00 -100 Cerium*- (liigli-At)................................................ 1,000 mol upwind Iriril nf )), 1. ilu l'nnt <!* N'l iiioins ,( ('ouijcmy. t Ap)i|ii\Ui:tc vnl'lr, will* J'. |n f,it inf plume. ) Tli*' l< >;*l* i 11 i*' con taut in liiyt-A' i < rnui.- i .ip.njtui.s conn s from I In- f;nt that tlf ili r I r if cliaij'i - in tin1 li <T riilrir si rtn line of I In- jnalci ia! jur vciy Inn ily lmiin! iiinl ran mow jilnm.l fmly ntnl' T ll.*- jintai i/inj'. volt ripe, icnUltjug in lii;;li lol.il c aj>ai ily. Table 4-i*--Dielectric Constants of Typical Insulating Materials at 25 C . Material K Power factor (percent) Vacuum 1.0 0 Air 1.0001 0. Teflon 2.0 0.02 Polystyrene 2.5 0.015 Mylar 3.0 0.5 Polyethylene 3.3 0.1 Luciie (or Plexiglass) 3.5 - 6. i Textolite 4. 0.2 to 4. 1 Fused quartz 4.4 0.02 Pyrox 4.7 0.05 Kraft paper 2-6 0.5 to 1.0 t Cellulose acetate 4-6 2.0 Steatite 6.3 0.08 Lead glass 6.6 0.06 Mica 6.B 0.02 Tantalum oxide 11.0 10.0 Titanium dioxide 120. * 0.07 * Mangnesium ortho- titanate Barium titanate 2,000. 2. 6.000. * 2-5tc/i ___ v*v,rnr> 0X36586 *1 TOWOLDMONOQ57777 P*i- 'Krft C[> liMur) T- S.?.*oc .} (iH|it,\(,n\rrif., FSX.";:: - //- Taih.k 1M\ J'h'iii.htu:^ r S-.\: Cai ac:t.u Iu *srJr . "ass i ^ it IntuVion rcrttmte. ..:___ *>j ***< 75*C K.',c ryw.-. s.p: 00..1W-7..-5 O.O-iii S:a G.oolf 2:22:2 00..0000115 4 .0 i:S 15 010- 1 .0 -55 .-5iH . O-I I.M.i ?o,o-*i to.o 2! t . 0 i:TM 1 to 105 -1.0 io ! ; O' o;,r. Z-l 55 50-. M-ilWO 100 ! - IT h ":.vV ve 121 S8:S3! 10,000 j SI.OvO S:S* i:2SK122fe: e 2:221 tZl S:f !! Mc'm-c .,1!2 `52:222 '52:2S: 0.02 1 --1*0 Vr. VOO : l** -Co i-00 In ., IT 8:8IS 2:22! S:SSS? 2:2 2:5. 12? 22 tuxm- 0.0000 5.5 I 100 `2:222 ;S `8S: 'TZ 1 0100.000 .M i1 I . JSX 1:1 irSKSj 2:22 ;:?2i:2? pr:r o,-'ru.o. . i six 0.7 , --00 lt> ICO j 1' I : j ii-Vx? |1 Mc>y Cun t.c mrrrrtl, l-ul low *h*nc U |K)Mil>l, *3&589 TOWOLDMONOQ57778 FIXED AND VARIABLE CAPACITORS GfW; a/dUMMER, M.I.E.E. Head of Components Research, Development and Testing at the Radar Research Establishment, Ministry of Supply HAROLD M. NORDENBERG Head of the Electronic Farts Unit, Bureau of Ships, Navy Department McGRAW-HILL BOOK COMPANY, INC. New York Toronto London 1960 0A36590 TOWOLDMONOQ57779 t CONTENTS I'rt/oee...................................................................................................................... v PART 1. GENERAL INFORMATION ON ELECTRONIC PARTS (COMPONENTS) ]. A Brief History of the Development of Electronic Ports , , . . . A brief history of clcelronie-pnrt development and military-specification evo lution in the United Suite*--Temperature and humidity categories of elec tronic ports including environmental requirements chart 3 2. General Information on Capacitors..............................................................11 Capacitance--Characteristics of dielectric material* including dielectric, conMniil, power factor, dielectric absorption, ami leakage current--Insulation resistance--Dielectric strength--Frequency effects--Table of properties of dielectric materials for capacitor* 3. Characteristics and Selection of Capacitors................................................. 20 Capacitor chnrncterislirs by dielectric material for fixed eapneitors--Table of important fixed capacitor characteristics--Capacitor characteristics by type of construction for variable capacitors--Table of important variable capacitor characteristics--Step-by-stop guide for capacitor selection based ujxm electrical and environmental requirements of the application 4. The Measurement of Capacitance..............................................................60 f/i\v-frequcne.y measurements--High-frequency measurements--Methods of measurement of the dielect ric propcrl ics of materials--Measurement of power factor--Measurement of temperature, coefficient on fixed npd variable capaci tor*--Methods of measurement of trimmer capacitors PART 2. FIXED CAPACITORS 6. General Information on Fixed Capacitors................................................. 77 I'.S. specifications, British specifications, symbols, preferred values, and color codes for fixed capacitors 6. Paper-and-mica-dielectric Fixed Capacitors........................................... 80 Itollod-foil, motnlized- and pressurized-paper capacitors--The properties of mien-stacked and silvcrcd-mica capacitors--Synthetic mica, mica paper, and integrated mica--Mica-paper capacitor*--Mica-transmitter capacitors--But ton mica capacitors vii 0436591 TOWOLDMONOQ57780 7 viii CONTENTS . T. Ceramic-, Glass-, and Vitreous-enamel-dielectrie Capacitors . . . 115 Low-diclcctric-constant (porcelains, etc.), mcdium-diclcctric-constant, and high-dielcctric-constant (barium titnnate, etc.) ceramic capacitors__Ceramicdielectric transmitter capacitors--The properties of glass-ribbon capacitors-- Vitreous-enamel capacitors--Magnesium-silicate capacitors 8. Capacitors with Plastic Dielectrics.............................................................. j4l Polystyrene, cellulose-acetate, polytetrafluoroethylene (Teflon), polyethylene tercphthalate (Mylar), and irradiated-polyethylcne capacitors 8. Electrolytic Capacitors.......................................................................................153 Plain-foil, etchcd-foil, and fnbricatcd-pintc aluminum electrode capacitors__ Sintercd-pcllet, rolled-foil, plain- and ctchcd-wire, liquid- and solid-clcctrolyte tantalum electrolytic capacitors 10. Air-, Vacuum-, and Gas-dielectric Capacitors............................................174 Air-diclcctric types--Vacuum capacitors--Gas-filled capacitors (high voltage) 11. Experimental Types of Fixed Capacitors........................................................179 High-tempcraturc mica capacitor--Rolled-glass capacitor--Solid-electrolyte aluminum-oxide capacitor--Supported- and strip-film plastic capacitor__ Mica-paper capacitor--Silicon-dioxide film capacitor--Miniature metalizedpaper capacitor--Thin-film spinning techniques--Anodized titanium 18. Failures Which May Occur in Fixed Capacitors..................................... 187 Random pulse and noise generation in fixed capacitors 18. Future Developments In Fixed-capacitor Design............................... ...... jgj PART 3. VARIABLE CAPACITORS 14. General Information on Variable Capacitors............................................... 201 U.S. specifications, British specifications, symbols, and marking, for variable capacitors--Laws relating capacitance with shaft rotation 15. General-purpose Variable Capacitors............................................ . 209 Design and construction of multi-gang air-spaced types--Band-spread varia ble capacitors 18. Precision Variable Capacitors.............................................................. Single-unit types--Multigang precision capacitors . 217 17. Transmitter Variable Capacitors ..................................................................227 Air-spaced types--Oil-filled variable capacitors--Pressurized and gas-filled types--Vacuum-dielectric variable capacitors 18. Trimmer Capacitors............................................................................................235 Air-dielectric rotary type*--Fplit-stator air-spaced types--Mica compression trimmers--Ccramic-dielfctric types--Plastic-dielectric trimmer* 0*36592 CONTENTS IX 19. Special Types of Variable Capacitors............................................................. 247 phase-shifting capacitors--Sweep-scanning capacitors--The "sine" eapacitor--Scmibuttcrfly and butterfly capacitors--Electrically variable gas-dielec tric capacitors--Specialized variable capacitors for transmitter-receivers 20. Faults Which May Occur inVariable Capacitors......................................... 257 81. Future Developments in Variable-capacitor Design....................................259 Bibliography on Capacilon............................................................................................260 Index................................................................................................................................. 283 TOWOLDMONOQ57781 FIXED CAPACITORS NOW AND IN '69 Better control over dielectric thickness has led to increased capaci tance and giant-step improvements in the basic property of volumetric efficiency. And more advances in this basic property are on the way. BOB KOEPER, Senior Editor Manufacturer forecasts of improved capacitor capa bilities during the coming 12 months are no more than extensions of the last 2 years' developments, a recent EDN survey shows. Many capacitor builders declined to forecast, but among those who did, most predicted comparable performance from smaller physical size, a trend that ha6 already placed capacitors in the micro class. Both current and anticipated improvements in volu metric efficiency can be linked in part to the growing demand for capacitors in hybrid circuits. This demand will result in more R&D money to further reduce the thickness of dielectric materials; but, because handling becomes more difficult as thickness decreases, the use of deposited dielectrics is expected to advance. Other forecasts for the coming year include: Improvements in reliability brought about by new materials that include polymer films and new coating material for making unglassed, uncased capacitors. Packaging of film capacitors for specific applications and cost improvements. 200'C "Teflon". High voltage-"and current-handling capacitors for SCR applications. Higher K and more stability while still maintaining a high Q. "X" characteristic capacitors with a t 15-percent temperature coefficient. Now for the Present EDN's Basic Property Charts on the following pages reflect what has taken place in capacitors in the past 2 years. Manufacturers' views on the reasons for these improvements are recapped by msgor dielectric cate gories used on the charts. Much of what is manufac tured is not in the strict sense off-the-shelf, and a much larger number of components is available to the de signer who is familiar with trade-offs available among such variables as size, stability and price. Designers should be aware of the broad range of characteristics available to get the best component for an application. The Basic Property Charts furnish a handy reference for comparing dielectric characteristics. Electrolytics In the aluminum electrolytic capacitor, a semisolid, leakproof, nonaqueous electrolyte makes lower-cost seal construction capacitors extremely reliable, elec trically stable and naturally seepageproof. A second development extends the operating temperature of large computer-grade aluminum electrolytics to 125C without derating. This extension results from the new semisolid electrolyte and an improved anodizing process. These 125C units now are available in values from 100 to 200,000 pF over a voltage range from 3 to 100V. Also attributed to electrolyte developments is the extended temperature range for aluminum electroly tics, which now spans from -80 to 150C. And the 125C voltage rating has been increased from 60 to 80 percent of the 85e,C value. All tantalum-type capacitors have increased in volumetric efficiency by a factor of almost 2:1. Top capacitance value of foil units increased from 680 to 8700 p.F and for solids from 680 to 1000 pF. Paper Film While the charts reflect little change in paper capac itors, paper-"Mylar" types hove seen an increase of more than a factor of 6 in the maximum capacitance values available (from 00 to 200 pK). Also, the maxi mum CV product is up from 760 to 120,000, and the maximum dc working voltage has increased from 16 to 125 kV. Film Many of the film capacitor advances are directly related to improvements in basic dielectrics stemming from the use of ultraclean rooms for manufacturing plastic films. Resulting thinner dielectrics have, for example, made possible a 100-pF metallized poly carbonate capacitor. Two years ago EDN reported this type of capacitor Available only to 10 pF. Reduced film thicknesses also have resulted in 50V rated mctal- EDNReprinted from the November 11, 1968 Issue of f ) Magazine, A Cahners Publication IizkI jsilyearbon.ite lines with u 45-pmronl volume re duction over Unit of ''M)V lines. Similar results, with 3.3-percent volume reduction, have occurred in "Mylar" units. Because very thin metallized "Mylar" is not yet available, current 50V unite are J00V devices with voltage derating for 125C operation. Four dielectrics have been added to the film category. They are polypropylene, polyethylene, "Kapton" and "Mctfilm A". Polyethylene raises the film-type capac itor to a new high of400pF, while "Kapton" (a Du Pont trademark) offers a high-voltage temperature-stable device (negative temperature coefficient) over a tem perature range from -80 to 200C. "Metfilm A" (a Sprague trademark) is a metallized acetate capac itor that offers high volumetric efficiency. Special Types One addition has been made to the special-type cate gory. "Amplifilm" (an Amp, Inc. trademark) is a line of wafer capacitors with a maximum capacitance range to 1 pF at 5000V, dropping to 0.15 j*F at 15 kV. Other specials repeated from 2 years ago include synthetic resin capacitors made by impregnating a foil electrode of aluminum (or tin) with a dielectric resin. This capacitor's temperature coefficient is nonlinear, but stays within 35 ppm/C between 2CPC and 125C. "Parylene", a thin-film development by Union Car bide, is a plastic suitable for deposition that yields a good dielectric film. Tantalum oxide (nonelectrolytic) capacitors are available to 0.033 pF and 125V. Except for the fact that they are slightly polar, they can be compared to stable miniature ceramic capacitors. Glass Ceramic The greatest advances in glass ceramic capacitors have been in volumetric efficiency. General-purpose ceramic capacitors, for example, have experienced a uF-V change from 1300 to 55,000 (r improvement factor of 42. This improvement is attributed to new capability of producing uniform, reliable ceramicdielectric materials in very thin form. Porcelain, too, has seen big improvements. In one case the use of a very stable dielectric has shrunk the physical size of a tradit ional M1E-11272B device by 1 to 2 orders of mag nitude. A 1000- pF device with a "Q" of 10,000 at 1 MHz and a 90 ppm TC was packaged in a 0.1-in square. This high-temperature porcelain dielectric is reported to have a higher K than glass or traditional porcelains, giving increased packaging density without sacrific ing stability. Added to this glass-ceramic category are monolithic ceramic, high K glass and fixed composition types. Monolithic units have great volumetric efficiency and a linear temperature coefficient and find their widest use in the manufacture of hybrid circuits. Their fre quency and temperature characteristics make them at tractive where previously only mica could be used. High K glass offers the size advantage of ceramic capacitors but with glass capacitor performance. In chip form these glass K capacitors will be offered for use in hybrid circuitry in a range from 270 pF to 2 pF. Mica Receiving types now have a new low working volt age rating of 50V and a temperature range that ex tends from - 55 to 15(TC. The upper level of working voltage for mica transmitting types has increased, by a factor of 2, to 100 kV. Reconstituted mica paper has been added. These units operate at unusually high temperatures. Their capacitance and dissipation factor change compara tively little over a wide temperature range. Insulation resistance is comparatively good at all temperatures and their resistance to radiation is very good. Vacuum Probably the biggest reported change in vacuum capacitors is extension of their lower operating tem perature, Two years ago the low temperature reported was -35C. Now it is -100C. Volumetric efficiency for this type of capacitor also shows a marked in crease. Acknowledgments BUN is indebted to the following capacitor manufacturers for taking time to provide comments and for their help in updating the basic property churls offixed ca/Hicitors: American Lava Corp., Chattanooga, Tenn.; American Tech nical Ceramics. Huntington Station, N.Y.; Amp, Inc./CapiIron 1 )iv., Harrisburg, I'a.; Cambion, Cambridge, Mass.; Cenlralab, Milwaukee, Wis.; Chicago Condenser Corp., Chicago, HI.; Component Research Co., Santa Monica, Calif.; Components, Inc./Semcor Div., Phoenix, Ariz.; Corncll-Dubilier Electronics/Div. of Federal Pacific Electric Co., Newark, N. J.; Corning Electronics, Corning, N.Y.; Dickson Electronics Corp., Scottsdale, Ariz.; Electro Motive Mfg. Co., Inc., Willimnntic, Conn.; Erie Technological Products, Inc., Erie, Pa.; General Laboratory Assn., Inc., Norwich, N.Y.; ITT Jennings, San Jose, Calif; JFI) Electronics Co./Components Div., Br<x>klyn, N.Y.; Marshall Industries/Capacitor Div. Monro via, Calif; Maxwell Laboratories, Inc., San Diego, Calif; Mepeo, Inc., Morristown, N.J.; Monolithic Dielectrics, Inc., Burbank, Calif; Ohmite Mfg. Co., Skokie, 111.; Plastic Capac itors, Inc., Chicago, III.; Potter Co. CFT Div., Wesson, Miss.; P. R. Mallory Co./Div. of Radio Material Co., Chicago, 111,; RF Interonics, L.I., N.Y.; Solar Mfg. Corp., Ix>s Angelos, Calif; Sprague Electric Co., North^Adams, Mass.; Stackpole Carbon Co., St. Mary's, Pa.; STM Corp., Oakland, Calif; Texas In struments Incorporated, Dallas, Tex.; U.S. Capacitor Corp., Burbank, Calif; Varudyne, Inc., Santa Monica, Calif; Vitramon, Inc., Bridgeport, Conn. TOWOLDMON0057783 Basic Property Charts of Fixed Capacitors i r" *10 PERCENT TO *7) PERCENT > JO PERCENT pteNT rI ET/i --rAIUMINUM wire>n&6e SLUG ANODE LiL- PAPER-MYLAR* 0.01 METALLIZED PAPER-MYLAR" ------------------1---------------'LYCARBONATE I----- POLYPROPYl FNE >70-000 , . 10 (J) ' . .. ' WoOhU'J-pdjj * '' ; -.T;*00|.Iu(, ; 'l,ooo .- 1 ;.\ooo . '. i ' ( i. .* 30.000 70.000 130.000 ^4t! 700.000 .4*^ POLYETHYLENE METALUZED MYLAR" D POLYCARBONATE *S. SYNTHETIC RESIN WOO THIN f iILM(PARYLENC"*)l.O W to OXIDE {noil*etrlri<c} I'lll.'ITl'.l ( I RAMK T Mimoi min 11 k TEMPERATURE -CQMPENfA TED CERAMIC IACI ( I HAMII l 40.000 7000 2000 14.000 *W VO HIGH K GLASS I FIXED COMPOSITION if no MICA^RECElVINC] to.) if Mix, pF |--* F CAPACITANCE 0436595 Ranges of capacitance for commercially available fixed capacitors. Shown are capacitance ranges for each di electric, along witli standard and minimum tolerances commercially available. Maximum CV product (micro farad-volts) indicates maximum voltage available lor a certain capacitance value, and vice versa. TOWOLDMONOQ57784 Voltage ratings (at 85"C) of commercial fixed capacitors. Voltage rating at 125C is indicated as percentage of 8f)"C value. As a guide for operation under transient volt ages, chart shows test voltage as percentage of Vdcw. It you expect transients in your circuit, refer to the manu facturer's test voltage. AC voltage ratings under 200V rms depend almost exclusively on ac current ratings, which are limited by Joule-effect and dielectric losses. At frequencies greater than 400 Hz, the corona start volt age, peak voltage and type of dielectric system must be considered in addition to ac current ratings. To obtain approximate value of the maximum capacitance avail able at each dc working voltage, refer to the maximum CV product listed in the capacitance chart. 0436596 TOWOLDMON0057785 i S e> a ..til \ m *2L- ttfCHL ^eoo ;V METALLIZED PAPER ''t^VAf'ER^YLAB* . . \y, . .. ' ) f. iV.i 1 . * ' ^-- p0MEfALU?Et>PA^e*irLMl* { POLYSTYRENE ?)4 -- teflon- METALLIZED MYLAR' I -- METALLIZED POLYCARBONATE SPECIAL TTPtS "tnIN-FILM(PARYU^E^ , . , V^v j> ^*^TM"** to OXIDE (Aprifloclrjlfllq)^, ''* ' .>" "'f,\lwU, < * -fr i TEMI'T RATURf CQMPt NSATED f I K*AMI<~| GENERAL-PURPOSE CERAMIC S?iO MONOLITHIC CERAMIC Jfl.W FIXED COMPOSITION % Cl ASS >. _ ___ im.ll K l.| AST IJJjMDgjA^APgJJOO S MICA, REVIVING - MICA, TRANSMITTING VOLUMETRIC EFFICIENCY Volumetric efficiency expressed in microfarad-volts per cu in. The values as shown here have been computed by considering only the capacitor case without leads. Cy lindrical units pack more microfarad-volts than rectangu lar ones, although rectangular units can be stacked mote compactly in a circuit. Miniature capacitors have lower volumetric efficiency than the large capacitors because there are two factors that take a proportionately larger share of volume in miniature units. These factors are en capsulation and margin (unused dielectric extending be yond the electrodes to prevent voltage breakdown around edge). 043b*97 TOWOLDMONOQ57786 tance variation is nonlinear, its change at each important able temperature coefficients. 0436596 I TOWOLDMONOQ57787  ................(120H m Urt. 0.0? " 0.03 pol ypropyltne' 0.05 , rtr - 05 PAPER | 1 Ta F61L f , --............ ' T.SOLJt) ` ` l :.:3 i'i 5 i ------ * hj; iallIZED PAPER ' 0.7 o.i1*: 6 j PAPeK-MYWR' * ALLIZEOPAPER-NYURV f' . i. 0.3 0.3 MYLAR' ................ ..... ............ ?,,?5 POLYSTYRENE POLYETHYLENE | 0 IS ___ 0.3 METALLIZED MYLAR- 0.1 0? METALLIZED POLYCARBONATE KAPTON' n. | j .ft*4# O.W ' SYNTHETIC RESIN .^ METFILM A'" 1 kH, '*v` 1 `. -THIN FILM (PARYIENE`1 '' ttl 'i_i'. V.piimiwiiiKwirHri'V' A "it * AMPLIflLM***4] --------,v.' LOW VOLTAGE CERAMIC 0 5 GENERAL-PURPOSE CERAMIC f---A '"""'"'i v MONOLITHIC Cf RAMIC 11 Ml'I RA TURi 1UUI1 NSA I r |) Cl RAMIC 4 HIGH-TEMPERATURE PORCELAIN 0.03 0.0( HIGH K Gt ASS I MICA PAPER M MICA, RECEIVING 0.1 - .ir-u, T-Wt.Hl-' 'MAPBHAPK OH P.,1, * PtMl UABP.MA** tU VHIOH LAAHPI. COIP. ' 1 PADr*AtK Or fARACI/t, ML. 'J9MPFIMWOF AV.IMC. ___1 I..I.LJJ. DISSIPATION FACTOR (25tj Power (actor at 25C, expressed in percentage. Most di electrics exhibit an increase in their losses with increases in both frequency and temperature. Such changes are smaller for polystyrene, ceramics, glass and micas. Data are available typically at 120 Hz (for filtering), at 1 kHz and 1 MHz. Af temperatures above 10 KHz, both the capacitance value and form factor greatly influence the dissipation factor. 0*36599 TOWOLDMONOQ57788 Insulation resistance at 25C. This resistance appears in parallel with the capacitance. Its value is expressed directly in megohms per unit for ceramic, glass and mica capacitors unless noted. Insulation resistance (IR) of rolled capacitors (paper and films) is calculated by dividing megohm-microfarad product by capaci tance of unit. Electrolytic capacitors are specified in terms of their leakage current, because the resistance of an electrolyte is nonlinear, insulation resistance decreases for all dielectrics as temperature increases. Chart shows reduction factor for the key tempera tures, referred to insulation resistance value at 25C. When IR is used as a quality indicator rather than a circuit requirement, the 2$*C measurement loses much of its value and the 125C measurement be comes the better indicator. 0436600 TOWOLDMONOQ57789