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KEMET Webinar - KEMET ceramic reliability grades- which one should I choose?
- 1. © KEMET Electronics Corporation. All Rights Reserved. KEMET Ceramic Reliability Grades: Which one should I choose? June, 2019
- 2. © KEMET Electronics Corporation. All Rights Reserved. Agenda • Introduction • Reliability in Ceramic Capacitors • Full Grade Range • Commercial • Automotive • COTS (Commercial off the Shelf) • Military • Space • Custom • Medical • Conclusion
- 3. © KEMET Electronics Corporation. All Rights Reserved. MLCCs are Everywhere MLCC’s per car ICE = 2,500 & growing EV = >10,000 & growing AUTOMATED ELECTRIFIED CONNECTED SHARED ~500 ~700 > 1000 S7 i6S S8 i7 S9 iX MLCC’s per Smartphone MLCC DEMAND DRIVERS
- 4. © KEMET Electronics Corporation. All Rights Reserved. Why are Ceramic Capacitors so Popular? • Very reliable • Low ppm failure rates • Long life – Billions of hours • Small form factor • Wide operating temperature range • Low cost
- 5. © KEMET Electronics Corporation. All Rights Reserved. MLCCs C = Design Capacitance K = Dielectric Constant A = Overlap Area d = Ceramic Thickness n = Number of Electrodes C = e0KA(n-1) d Detailed Cross Section Inner Electrode End Termination Barrier Layer Termination Finish Dielectric Material CV = Capacitance x Voltage
- 6. © KEMET Electronics Corporation. All Rights Reserved. MLCCs Layer Count Progression 0.1 µF/50V (PME) (12 µm layers, n= 30 ) 1.0 µF/25V (PME) (8 µm layers, n=100 ) 2000- 4.7 µF/16V (225 4 µm layers) 10 µF/6V (300 3 µm layers) 22 µF/6V (500 1.8 µm layers) 47 µF/4V (600 1 µm layers)Class 2 1206 (EIA) 1988 Today
- 7. © KEMET Electronics Corporation. All Rights Reserved. Reliability in Ceramic Capacitors What do we mean? Ability for the capacitor, under normal conditions, to operate within the specification over it’s lifetime with few or no failures. What we don’t mean Excessive Mechanical Stress (Flex) Excessive Voltage Excessive Temperature Voltage Transients
- 8. © KEMET Electronics Corporation. All Rights Reserved. The Bathtub Curve Time FailureRate Infant Mortalities Decreasing Failure Rate Wear-Out Increasing Failure Rate Normal life Material and processing defects End of life Latent defects
- 9. © KEMET Electronics Corporation. All Rights Reserved. The Bathtub Curve What does higher reliability do? Time FailureRate Normal life Decrease/Remove infant mortalities Push wear-out region further out in time Decrease normal life failure rate
- 10. © KEMET Electronics Corporation. All Rights Reserved. Increasing Reliability in Ceramic Capacitors How is it done? More conservative designs Design and change control Full material traceability In process testing End of Line testing Burn-in / Voltage conditioning Strict oversight on materials and processes
- 11. © KEMET Electronics Corporation. All Rights Reserved. What Drives Higher Reliability in Capacitors? Cost of Failure SafetyInability to Fix
- 12. © KEMET Electronics Corporation. All Rights Reserved. There’s Always a Tradeoff Reliability Grade
- 13. © KEMET Electronics Corporation. All Rights Reserved. 13 KEMET Ceramics Reliability Grades Commercial Automotive COTS Military Space Custom KEMET M3 Medical Grade
- 14. © KEMET Electronics Corporation. All Rights Reserved. 14 Commercial Grade • Features • Highest CVs possible • Smallest case sizes • Highest volumes • Lowest Cost • Qualification – Determined by manufacturer • Base Testing Protocol: • Electrical Testing - 100% Cap / DF / IR & DWV • Physical Inspection - 100% Sample basis • Solderability - 100% Sample basis • Applications – General purpose, consumer electronics, etc Max CV CVScale
- 15. © KEMET Electronics Corporation. All Rights Reserved. 15 Automotive Grade • Features • Increased Reliability vs Commercial Grade • High CVs (close to Commercial) • Small case sizes • Volumes ~10x lower than commercial • Low cost slightly above commercial • Qualification - Automotive Electronics Council’s AEC-Q200 • Base Testing Protocol + Additions: • 100% Visual Inspection • End of Line Testing • PPAP • Product Change Notification • Applications – Under the hood, power train, sensors, infotainment Max CV CVScale
- 16. © KEMET Electronics Corporation. All Rights Reserved. 16 Detailed Comparison
- 17. © KEMET Electronics Corporation. All Rights Reserved. 17 COTS Commercial Off the shelf • Features • Higher Reliability Applications • High CVs (close to Commercial and Automotive) • Much lower volumes than Commercial and Automotive • Lower Cost vs Military Grade • Qualification – By manufacturer. KEMET’s COTS based on AEC-Q200 • Base Testing Protocol + Additions: • 100% Visual Inspection • Burn-in, Voltage conditioning with PDA • Electricals with PDA • Destructive Physical Analysis (DPA) • Humidity Testing • Customizable with drawing • Applications – Military applications Max CV CVScale
- 18. © KEMET Electronics Corporation. All Rights Reserved. 18 Detailed Comparison
- 19. © KEMET Electronics Corporation. All Rights Reserved. 19 Military Grade “Standard” and “Established” Reliability • Features • Military Defined Standard and Established Reliability • Very conservative designs • Constructed per MIL Standards • Lower CVs • Qualification and Testing – Defined by DLA (Defense Logistics Agency) • MIL-PRF-55681 • MIL-PRF-32535 M-Level • Additional • Periodic inspection for electrical, environmental, and mechanical. • Group Data and Test Summaries • Single Lot Date Code • Applications – Non-critical military applications such as communications devices, ground weapons, military equipment not used for navigation and Safety Max CV CVScale
- 20. © KEMET Electronics Corporation. All Rights Reserved. 20 Space Grade • Features • Military Defined High Reliability • Very conservative designs • Constructed per MIL Standards • Lowest CVs • Qualification and Testing – Defined by DLA (Defense Logistics Agency) • MIL-PRF-123 • MIL-PRF-32535 T-Level • Additional • Every lot receives electrical, environmental, and mechanical. • Group Data and Test Summaries • Single Lot Date Code • Applications – Space, missiles, avionic safety and navigation equipment Max CV CVScale
- 21. © KEMET Electronics Corporation. All Rights Reserved. 21
- 22. © KEMET Electronics Corporation. All Rights Reserved. 22 KEMET Custom Per customer request • Customer Drawing ✓ Design per customer spec ✓ Custom In Process Screening ✓ Custom Group Testing ✓ Application Specific SCD’s ✓ Group Data and Test Summaries ✓ Material Analytics & Test Reports ✓ Single Lot Date Code per spec • Qualification per customer spec. • Change Control per spec.
- 23. © KEMET Electronics Corporation. All Rights Reserved. Medical Grade What is Medical Grade? Automotive Grade Reliability Grade AEC-Q200 VW AUDI 80808 Specification Military Grade MIL-PRF-55681 MIL-PRF-32535, M-Level MIL-PRF-49470, B-Level Space Grade MIL-PRF-123 MIL-PRF-32535, T-Level MIL-PRF-49470, T-Level Medical Grade ???????
- 24. © KEMET Electronics Corporation. All Rights Reserved. Medical Grade What is Medical Grade? Medical Customer 1 Medical Customer 2 Medical Customer 3 Medical Customer 4 “Medical Grade” Capacitor Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Medical Customer Major Medical OEMs New Medical Customers
- 25. © KEMET Electronics Corporation. All Rights Reserved. 25 Medical Grade • Features • Baseline solution for Class III medical devices • Custom testing and screening available upon request • Enhanced designs • Lot traceability down to raw materials • 100% voltage conditioning • End of Line Screening • Data Submission • Change Approval • Applications – Class III Medical Devices, Cardiac Pacemakers, Neuromodulation devices, Implantable cardioverter-defibrillator (ICD Max CV CVScale
- 26. © KEMET Electronics Corporation. All Rights Reserved. 26 Medical Grade M3 SCD M3+CSPEC Customer Specific Testing Customer Specific Data Customer Specific Change Approval Customer Specific Designs Customer Specific Requirement Customer Specific Requirement Customer Specific Requirement Customer Specific Requirement Customer Specific Requirement Baseline Solution for FDA Class III Medical Devices ✓ Enhanced designs ✓ Lot traceability down to raw materials ✓ 100% voltage conditioning ✓ End of line screening ✓ Data submission, ✓ Change approval
- 27. © KEMET Electronics Corporation. All Rights Reserved. Summarizing KEMET Ceramics Reliability Grades From Left to Right Benefits of Moving to the Right • More robust and conservative designs • Improved processes with design and change control • Enhanced in-process testing • Burn-in and PDA • Lot testing with data submission Tradeoffs of Moving to the Right • Increased cost • Decreased volume • Decreased CV values Effect on Reliability • Reduction and/or elimination of infant mortals • Reduction of normal life failures • Increase in MTTF
- 28. © KEMET Electronics Corporation. All Rights Reserved. MAKING THE WORLD A BETTER, SAFER, MORE CONNECTED PLACE TO LIVE. KEMET100.COM #KEMET100 Thank you! Mark Laps Technical Product Manager - Ceramics KEMET Electronics [email protected]