Explanation of the cause of capacitor failure: Coated capacitor has failed.
A Must-Read Guide for Circuit Designers: 15 Case Studies on Causes and Countermeasures for Capacitor Failures
The measure is to not coat the entire circumference of the capacitor with a coating agent or resin!
We would like to introduce a case where electrolyte leaked during use, causing a short circuit in the circuit board and resulting in capacitor failure. The electrolyte in aluminum electrolytic capacitors evaporates during operation, releasing gas into the atmosphere through the sealing rubber gasket. Additionally, aluminum electrolytic capacitors are equipped with pressure relief valves. Therefore, if the capacitor is covered with resin or similar materials, it can hinder the release of gas and the operation of the pressure relief valve. In this case, the coating material blocked the pressure relief valve, impairing its function and causing the sealing part of the capacitor to break, leading to electrolyte leakage. As a result, the circuit board wiring short-circuited, and the capacitor failed. **Countermeasures** - Do not cover the entire circumference of the capacitor with coating agents or resin. - Most of our aluminum electrolytic capacitors can withstand vibration tests with acceleration of up to 10G. *For more details, please refer to the PDF document or feel free to contact us.*
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Please be aware of the following: - When using varnish or resin with aluminum electrolytic capacitors, please ensure that those materials, as well as solvents, thinners, and additives, are halogen-free. - Please ensure that flux and cleaning agents are thoroughly dried. *For more details, please refer to the PDF document or feel free to contact us.*
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If you see the following symptoms in a capacitor, it is faulty: ■ The case is swollen (bulging) ■ There are cracks in the case ■ There is a gap between the case and the sealing part ■ The pressure valve has activated (the pressure valve has opened) ■ The case has burst ■ It is hot or generating heat ■ Smoke is coming out ■ There is liquid leakage ■ There are unusual sounds ■ There is an unusual smell *For more details, please refer to the PDF document or feel free to contact us.
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AIC tech handles Aluminum electrolytic capacitors and Film capacitors for industrial market. Our capacitors have a history of more than 70 years and have their origins in technological development in Japan. AIC tech delivers high-value, precision capacitors tailored for power electronics—from renewable energy and industrial systems to transportation, ICT/IoT, healthcare, and infrastructure. Please feel free to contact us if you have any requests.
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