KEMET AEC Reliability 2016 Workshop Slides
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The document discusses the evolution of tantalum sourcing and capacitor technology, particularly highlighting changes in practices due to regulations like the Dodd-Frank Act. It addresses safety concerns with traditional MNO2 cathodes and the transition to polymer capacitors, which offer several performance advantages. Additionally, it outlines the complexities in the tantalum supply chain, including conflict minerals issues and the dynamics of global production and sourcing.
KEMET AEC Reliability 2016 Workshop Slides
- 1. 1 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Last Decade’s MnO2 Experiences Are Not This Decade’s Polymer Reality
- 2. 2 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Tantalum Last Decade’s MnO2 Experiences Are Not This Decade’s Polymer Reality AEC Reliability Workshop 2016 Jayson Young
- 3. 3 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Tantalum #TRUTH Issues in the Past • Shortages/Price Fluctuation – 2000 (dot-com Bubble) – 2011 (Dodd-Frank Act) • Safety – MnO2 cathodes - popular in automotive - have safety concerns • Conflict Minerals – Tungsten, Tin, Tantalum, Gold The Great Ammo Shortage of 2013
- 4. 4 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Increased production to meet demand by electronic manufac- turers in response to the “dot-com boom” Reduced mine production in response to decreased demand from the burst of the “dot-com bubble” and offtake from excess inventory Reduced production at Greenbushes Mine, Australia, and termination of US National Defense Stockpile Increased global production largely originating from the Democratic Republic of the Congo and Rwanda Start of the global recession and suspension of tantalum mining at the Greenbushes and Wodgina Mines in Australia Decreased production caused by a global recession and reduced demand Increased production resulting from higher demand with the recovery from the global recession Significant increases in Rwandan mine production Difficulties in aligning the tantalum ore supply chain with market demand from 2000 to 2010 Annualproductionoftantalumcontainedinconcentrates,metrictons Market trajectory of Tantalum Capacitors (No scale included) 2015 2016F 2015E Passage of Dodd-Frank Act
- 5. 5 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Tantalum Ore Sources More than Sufficient June-2014 US Geological Survey Fact Sheet 2014-3054 Until recently, Africa was believed to hold nearly 80% of the world’s deposits.
- 6. 6 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Conflict Free: Section 1502 of Dodd-Frank Why Dodd-Frank Mattered • Established a “play book” for responsible DRC sourcing. • Companies registered with the SEC must perform due diligence. 1 iTSCi 2014 Program Report 2 USGS Mineral Commodities Survey Report 96% 63% 58% 57% Since Dodd-Frank • 2011-2014 tantalum exports from DRC region increased 4x 1 • 79% of tantalum now sourced from Africa 2 • 96% of all tantalum smelters now validated as conflict free Conflict-Free Sourcing Initiative • Smelters are “pinch-point” in the supply chain • Established audit protocol/ procedures to validate compliant smelters only source conflict free minerals.
- 7. 7 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved The Automotive Industry’s Active Role (CFSI Partner Association) Over 300 Member Companies including Automotive
- 8. 8 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved The Supply Chain has Evolved US Geological Survey Fact Sheet 2015-3079 Dec- 2015 KEMET Ore Source 2000-2010 KEMET Ore Sources 2010-2015 2000-2010 • Single mining region for capacitor producers (controlled supply). • Traders were middle men between mine and smelter (controlled price). 2010-Present • Multiple mines from multiple regions of the world (competition). • Cap makers buy directly from the mine - vertically integrated process (remove traders) Break-Even Cost Australia Hard Rock Brazil Hard Rock Brazil Artisanal Africa Hard Rock Africa Artisanal
- 9. 9 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Tantalite Ore Prices Post Dodd-Frank Passage of Dodd-Frank Number of Certified Mines Increases Australian Mines in decline Panic over uncertainty of new law Prices returning to Pre-DF levels Cost primarily absorbed by Ta supply chain African Mines increase production
- 10. 10 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Cutting Tools High Temp furnace parts Chem process equip, cathodic system Prosthetic devices Sputtering targets High temp alloys Projectile for missiles Surface acoustic wave filters, X-ray film, etc. Ta carbides (7%) Ta fab sheets, plates, rods, wires (22%) Ta Powder (41%) Ta Ingot (12%) Others: Ta oxide, lithium tantalite, etc. (18%) Medical appliances Automotive components Electronic components Semiconductor Turbine blade Machinery and equipment Medical industry Automotive Electronics Aerospace Military Various industries Capacitors Electronic parts Austria (2) Brazil (3) China (18) Estonia (1) Germany (4) India (1) Japan (4) Kazakhstan (1) Mexico (1) Russia (1) Thailand (1) United States (9) Certified Smelters (96%) 12% 79% 5% Tantalum - More than just Capacitors 2014 Mine Sources 4% Camera Lens Consumer
- 11. 11 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Safety
- 12. 12 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Safety Concerns are the Cathode systems, not the Tantalum anode Tantalum Capacitor Classes: – Wet Cathodes – Solid Polymer Cathodes – Solid MnO2 Cathodes Ta Ta2O5 MnO2PolyWet + - No external reactions can occur Crack/Imperfection Reform Dielectric Oxidize Polymer Oxidize MnO2 Too rapid of heating can result in ignition of the MnO2 Self-Healing Anode Dielectric Cathode Options
- 13. 13 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Breakdown Voltage Test (100uF/16V: MnO2 Cathode vs Polymer Cathode) MnO2 (Ignition) Polymer (No Ignition) Surface residue from neighboring MnO2 Failure 10pc Sample Sizes Post Test Board Test Board Layout BDV Test Condition • 2 Reflow Passes • 85ºC • 3.3V/sec ramp • 1.0 Amp • No series resistance No External Damage External Damage (Part was Yellow) MnO2 Polymer
- 14. 14 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Understanding the Advantages of Polymer
- 15. 15 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved DC/DC Converter USB/SSD5V CPU0.9V/1.05V DDR1.5V I/O3.3V 48V DC/DC Converter 12V MLCC (X5R) Polymer IC Decoupling Power Assist for USB Cap Retention of Poly Ta minimizes ripple Stabilizes the power source Removes High Frequency noise USB IC 5V High Energy Density Peak Power Assist V Time Power from Battery Power from CapacitorI Time - High Cap - Low ESR Why Polymer? Today’s Actives need Today’s Passives!
- 16. 16 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Recommended Voltage Derating Based on Cathode Selection Application Voltage MnO2 Voltage Rating Polymer Voltage Rating 1-1.5 4 2.5 3.3 6.3 4 5 10 6.3 12 25 16 24 50 35 28 50? 35 & 50 36 N/A 50 48 N/A 63 & 75 10V Replacing MnO2 with Polymer 5V 6V 12V 25V 16V 100uF 100uF 220uF 47uF 100uF 6V MnO2 Option Poly Opt. #1 Poly Opt. #2 16V 47uF Low Profile MnO2 Polymer %ofRatedVoltage %ofRatedVoltage Smaller Footprint Smaller Footprint + Higher Capacitance Higher Capacitance Lower Profile
- 17. 17 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Polymer Tantalum Attributes Cap vs Voltage Cap vs FreqCap vs Temp Cap vs Time Delivered Capacitance No Piezo Noise No Flex Cracks Non-Ignition Failure Mode Low Profile High Ripple Handling Stability (MnO2)
- 18. 18 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Electrical Performance of Polymer vs MnO2 Polymer Tantalum MnO2 Tantalum MnO2 Tantalum Polymer Tantalum Cap/Voltage Range of Poly Ta
- 19. 19 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved The Shift from MnO2 to Polymer Cathodes 2000 2015 Polymer (Growth Phase) MnO2 (Declining Phase) Consumer Enterprise Telecomm Military/Aero Space AEC-Q200 Sales Characteristic MnO2 Poly High Reliability ✓ ✓ Long Life ✓ ✓ Stable Capacitance ✓ ✓ Volumetrically Efficient ✓ ✓ Military Drawing ✓ ✓ AEC-Q200 Qualified ✓ Low ESR ✓ High Ripple Handling ✓ Improved Derating ✓ Safe Failure Mode ✓ Highest Energy Density ✓ Industrial Dot-com Boom Time 1999 Release 1987 Release Intersection Point (2015) Medical Polymer Pros Polymer Cons Characteristic MnO2 Poly Leakage 0.01x CV 0.1x CV Max Temp Range 230ºC 125ºC Polymer MnO2
- 20. 20 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Automotive Grade (T598 Series) Full AEC-Q200 Qualified AEC Q-200 Rev D Table of Methods for Tantalum Capacitors Stress Test Name Conditions Std Poly Series T591 Series T598 Series High Temp Exposure (Storage) 125° C, Unbiased, 1000 Hrs ✗ ✓* ✓ Temperature Cycling -55° C to 125° C, 1000 Cycles ✗ ✓ ✓ Biased Humidity 85° C, 85% RH, Biased, 1000 Hrs ✗ (500Hr) ✓ Operational Life 125° C, Biased, 1000 Hrs ✗ ✓ ✓ Resistance to Solvents Mil-Std-202, Meth. 215 ✓ ✓ ✓ Mechanical Shock Mil-Std-202, Meth. 213, Cond F ✓ ✓ ✓ Vibration Mil-Std-202, Meth. 208, 5G’s-20min ✓ ✓ ✓ Resistance to Soldering Heat Mil-Std-202, Meth. 210, Cond D ✓ ✓ ✓ ESD AEC-Q200- 002 or ISO/DIS 10605 ✓ ✓ ✓ Solderability J-STD-002 ✓ ✓ ✓ Terminal Strength AEC Q200-006 ✓ ✓ ✓ *105°C & 125°C Offerings. See Part Number Table. T591/T598 Series are PPAP/PSW and Change Control Notification. Produced in an ISO TS 16949 Certified Facility.
- 21. 21 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved Polymer Caps in Automotive Applications T591 (Partial Q200) T598 (Full AEC-Q200)
- 22. 22 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved T598 Series: 125ºC Life Testing Extended from 1000 Hrs to 5000 Hrs (7343-30, 220uF, 10V, 25mOhm) Q200 Time Limit Q200 Time Limit Q200 Time Limit Q200 Time Limit 95 pcs sample size
- 23. 23 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved T598 Series: 125ºC Life Testing Extended from 1000 Hrs to 5000 Hrs (3528-20, 47uF, 10V, 70mOhm) Q200 Time Limit Q200 Time Limit Q200 Time Limit Q200 Time Limit 95 pcs sample size
- 24. 24 AEC2016 – ©2016 KEMET Corporation, All Rights Reserved For More Information: www.kemet.com/kocap