Application Notes

Vishay Sprague
AC Ripple Current Calculations

INTRODUCTION
Solid tantalum capacitors are preferred for filtering Looking closely at the internal structure of the pellet, we see
applications in small power supplies and DC/DC converters that it is made of grains of tantalum powder sintered to each
in a broad range of military, industrial and commercial other. A solid tantalum capacitor is equivalent to many small
systems including computers, telecommunications, capacitors in parallel, one for each grain of powder. This
instruments and controls and automotive equipment. Solid configuration produces a very large surface area, therefore
tantalum capacitors are preferred for their high reliability, long a large capacitance in a relatively small volume.
life, extended shelf life, exceptional stability with temperature
and their small size. Their voltage range is 4 to 50 volts for
the most common types. Tantalum chip capacitors for surface TANTALUM PELLET
mount applications are manufactured in very small sizes and Simplified View
are compatible with standard pick-and-place equipment. Tantalum Anode Lead

Tantalum
The electronics industry has moved to smaller and smaller
power supplies and higher switching frequencies, with an Ta2O5
increased requirement for capacitors with smaller size and
MnO2
operating characteristics better suited to high frequencies.
This application note briefly describes the construction of Carbon
solid tantalum capacitors, the concept of Equivalent Series Metallized Outer
Resistance (ESR) and presents calculations for power Electrode

dissipation and voltage limitations for both low and high

frequency applications.

CONSTRUCTION
The solid tantalum capacitor consists of a sintered tantalum
pellet, the anode, on which a tantalum oxide dielectric is formed EQUIVALENT SERIES RESISTANCE (ESR)
by electrolysis. The pellet is then coated with manganese A capacitor offers internal resistance to AC current, called the
dioxide for the cathode. Positive and negative terminations are Equivalent Series Resistance (ESR). At lower frequencies, this
attached to this pellet and the assembly may be conformally- is mainly the resistance of the dielectric. At higher frequencies,
coated, molded or sealed in a metal case. the resistance of the manganese dioxide in the voids between
the grains is predominant. Because the resistivity of manganese
dioxide is inversely proportional to temperature, the ESR of
SOLID DIPPED TANTALUM CAPACITOR
solid tantalum capacitors at high frequencies decreases as
Cross Section temperature increases.
Sintered Tantalum
Epoxy Coating Pellet (Anode)

Nickel Lead
Weld Tantalum Pentoxide POWER DISSIPATION LIMITATION
(Dielectric)
(Positive)
When AC current is applied to a solid tantalum capacitor, the
Manganese Dioxide
(Solid Electrolye) resistance (ESR) that opposes the flow of current results in
Graphite heat generation, according to the formula:
Silver
(1) P = I2 x ESR

Cathode Lead Soldered The power (P) dissipated in the capacitor results in an
Tantalum Wire
to Silvered Area of
Welded to
Capacitor Section
elevation of temperature. The allowable temperature rise of
Tantalum
Nickel Lead Pellet a capacitor due to power dissipation is determined by
(Negative)
experience. For example, this value is + 20°C maximum for
molded chip capacitors. This in turn limits the power that the
capacitor can dissipate.

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 Application Notes
AC Ripple Current Calculations Vishay Sprague

VOLTAGE LIMITATION CURRENT LIMITATION (HIGH FREQUENCY)

The power a capacitor can dissipate is also limited by the At frequencies in the 10kHz to several hundred kilohertz
applied DC voltage. The operating voltage should not be range, the power dissipation becomes the limiting factor. The
allowed to rise above the rated voltage (nor should it drop following formula gives the maximum permissible ripple
below zero, since the solid tantalum capacitor is a polarized current for a sinusoidal wave form:
component). Assuming the capacitor is biased at half the
rated voltage, which is the optimum use condition, the limiting
value of the voltage is, for a sinusoidal waveform: (9) Irms = Pmax/ESR
(2) Vrms = Vpp/ 2 2 = Rv/ 2 2
Vrms for each value of Rv (Rated voltage) are: Pmax is the maximum power dissipation the capacitor can
RATED VOLTAGE Vrms MAXIMUM tolerate. The ESR value in the formula is the maximum ESR
4 1.42 of the capacitor at the required frequency. This can be
10 5.30 determined by measuring capacitors and determining a
20 7.07 maximum value by using the mean value and adding 3 or
25 8.84
more standard deviations. Some manufacturers specify the
35 12.37
40 14.14 maximum impedance at 100kHz or 1 MHz. Either value may
50 17.68 be used in ripple current calculations.

CURRENT LIMITATION (LOW FREQUENCY) Power dissipation limits calculated for the most popular types
To find the limiting current Irms, we divide Vrms by the of solid tantalum capacitors are:
impedance at the desired frequency.
1. Hermetic Axial (150D, CSR13):
(3) Irms = Vrms/Z
CASE MAXIMUM POWER @ + 25°C
using the formula: SIZE (WATTS)
(4) Z = X2 + ESR2 A 0.115
B 0.145
where X is 1/Cw + Lw (w = 2πf)
C 0.185
Since inductance of a solid tantalum capacitor is usually in D 0.225
the nanohenry range, the Lw factor becomes important only
when the frequency is higher than a few megahertz. For
filtering applications at 100kHz and lower, the inductance
2. Dipped Tantalum (199D, 299D):
factor will generally be ignored in the calculation. At 120 Hz,
the impedance can be determined by calculation. MAXIMUM POWER @ + 25°C
(WATTS)
(5) Z = (1/2πfC)2 + (DF/2πfC)2 CASE
SIZE 199D 299D
= (1/2πfC) (1 + DF2) A 0.140
0.080
At 120 Hz, DF2 is relatively small compared with 1 and the B 0.090 0.160
formula can be simplified to: C 0.100 0.180
(6) Z = 1/2πfC D 0.120 0.210
E 0.140 0.240
More generally, DF values of less than 10% will not affect
the final result by more than 1%. It is important to use the F 0.180 0.270
lowest value for C, including the capacitance tolerance. At
120Hz, the formula can be simplified to:
(7) Irms = .266 x CV 3. Molded Case Chip (293D):
where Irms is the maximum permissible rms current in As a general guideline, it is also worth mentioning that
milliamperes, C the capacitance minus the capacitance rectangular pellets for large case size ratings have lower
tolerance in microfarads and V the rated voltage in volts. All ESR than cylindrical ones. Since cylindrical pellets are widely
above calculations assume the capacitor is properly biased used in leaded capacitors and rectangular pellets for surface
at half the rated voltage. If this is not the case, Vrms becomes mount chips, it is safe to assume that a tantalum chip will
(8) Vp/ 2 have the same or lower ESR than the same capacitance/
where Vp = V rated - V bias or V bias, whichever is lower. voltage capacitor in a leaded package.

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Revision 04-Nov-02 135
Application Notes
Vishay Sprague AC Ripple Current Calculations

ESR SCREENING RIPPLE CURRENT/VOLTAGE

For parallel operation, the ESR spread can be minimized by CALCULATIONS EXAMPLE
screening. This reduces the risk of excess ripple current As an example, we will determine the ripple voltage and
exposure to any one of the capacitors. power dissipation capability for a 1µF, ± 20% tolerance,
35 volt, dipped tantalum capacitor.
Some equipment will only measure impedance. At 120 Hz:
An impedance limit can be calculated to insure that the ESR
Vrms = Rv/2 2 = 12.37 volts
stays in the required range. Use the formula:
Irms = Vrms/Z
(10) Zmax = Xc2 + ESR2 = 12.37 x 2 x 3.14 x 120 x 0.8 x 10-6
Xc = 1/Cw = 0.007 Amp.
If we used
Impedance can be measured using an impedance meter and
a fixture that is appropriate for the task. With the most Irms = Pmax/ESR
sophisticated fixtures, several capacitors may be tested at With ESR = DF/2πfC
the same time, reducing the test cycle time.
= (04/2 x 3.14 x 120 x 0.8 x 10-6)
CORRECTIVE FACTORS = 66 ohms
The calculations for high frequency ripple current are shown Irms = Pmax/ESR = .080/66
in formula (9) for a sinusoidal waveform and an ambient
= 0.035 Amp.
temperature of + 25°C. If the waveform is not sinusoidal,
the ripple current limitations may differ. Generally speaking, At 120Hz, the voltage is the limiting factor.
the ripple current limit calculated by formula (9) can be divided At 100kHz:
by the duty cycle of the signal. If the temperature is higher
Irms = Pmax/ESR
than + 25°C, the ripple current limit should also be multiplied
At 100kHz, the typical ESR for a 1µF/35 volts dipped tantalum
by the factors shown:
is:
TEMPERATURE MULTIPLYING ESR = 1.5 ohms (Z = 3 ohms)
°C FACTOR
Irms = .080/1.5 = .231 Amp.
+ 55°C 0.9
If we now look at the maximum ripple voltage, the above
+ 85°C 0.8
limitation translates into:
+ 125°C 0.4
Vrms = Z x Irms = 3 x 0.231 = 0.69 volts
At 100kHz, the power dissipation is the limiting factor.

TYPICAL CURVES OF IMPEDANCE AND ESR VS FREQUENCY

100

IMPEDANCE
ESR

10

1µF, 35 V, A CASE

4.7µF, 35 V, C CASE

0.1
100 1K 10K 100K 1M 10M
FREQUENCY

[Link] For technical questions, contact tantalum@[Link] Document Number: 40057

136 Revision 04-Nov-02
 Application Notes
AC Ripple Current Calculations Vishay Sprague

CONCLUSIONS
The industry is moving towards smaller and smaller power supplies and DC/DC converters operating at higher frequencies.
The three factors shown become more and more important in capacitor selection.

1. Higher Switching Frequencies:

The switching frequency of power supplies has increased from the 10kHz range a decade ago to the 100kHz range and up
today. The ESR of solid tantalum capacitors is either the same or lower at higher frequencies and impedance is at a minimum
in the 100kHz to megahertz range. Higher switching frequencies and the need for smaller sizes will increase the use of solid
tantalum capacitors.

2. Surface Mount Technology:

The application of surface mount technology not only reduces the size of power supplies and converters but also uses the
substrate on which the components are mounted to dissipate some of the heat generated by the switching elements. Solid
tantalum chip capacitors are well suited for this application. They have superior operating characteristics, do not leak electrolyte
and are compatible with common automated surface assembly equipment.

3. Tighter High Frequency Parameters:

The reduction of the maximum ESR of a solid tantalum capacitor may produce tradeoffs in size or DC characteristics. Rather
than looking at lower ESR in terms of process average, it may be advisable to try to reduce ESR variation, producing a lower
maximum ESR with a tighter distribution. This improvement may be achieved by using statistical process control, an approach
already being implemented at Vishay Sprague Solid Tantalum manufacturing facilities.

Document Number: 40057 For technical questions, contact tantalum@[Link] [Link]

Revision 04-Nov-02 137