YMIN MDP Film Capacitors Provide OBC With A 'Long Life' Solution

(MENAFN- Market Press Release) December 16, 2025 11:12 pm - Overcoming the Reliability Challenges of the 800V Platform: YMIN MDP Series Film Capacitors Provide a Long-Life Mass Production Solution for OBCs

Problem Type: High-Temperature Lifespan Bottleneck

Q: How to ensure that the lifespan of key filter components in the OBC module matches that of the vehicle under harsh operating conditions with a core temperature of 85°C?

A: High-temperature lifespan is a system-level challenge requiring comprehensive evaluation. During the prototype stage after selection, the capacitor core temperature (not surface temperature) must be measured to prevent exceeding limits. It is recommended to establish a supplier lifespan data traceability mechanism.

Problem Type: PCB and Structural Layout Adaptation

Q: What are the main challenges of using film capacitors in PCB and structural layout?

A: Layout challenges require early review to avoid high modification costs. The core challenges are heat dissipation-space conflict, mechanical stress, and vibration risks. Solutions: Thermal simulation to optimize layout; PCB with stress relief holes; mechanical fixation for large capacitors; prototype thermal imaging verification; mandatory -40°C to 125°C temperature cycle solder joint reliability testing for through-hole capacitors.

Problem Type: Long Lifespan Design of OBC Capacitors

Q: How to meet the requirement of 15 years/300,000 km no replacement for OBC capacitors through design, selection, and testing?

A: The specifications need to be locked in from the design stage and written into the technical agreement. Selection: Metallized polypropylene film capacitors, lifespan?100,000 hours (approximately 11.5 years) at 85?; Design: Reserve?30% capacitance and ripple tolerance margin, control temperature rise?15?; Testing: Calculate lifespan using 125?/1000 hours high-temperature accelerated aging, add environmental testing, and add simulated aging test under 85? target ripple conditions >3000 hours.

Problem Type: High-Frequency Filtering Challenge

Q: After increasing the switching frequency of the OBC PFC circuit, how to ensure that the DC-Link capacitor effectively suppresses high-frequency ripple and avoids system protection triggering due to bus voltage fluctuations?

A: This needs to be addressed from three dimensions: "capacitor-layout-control". Prioritize obtaining impedance curves for capacitors above 100kHz, minimize the capacitor input/output loop area on the PCB, and use multilayer busbars when necessary.

Question Type: 800V Platform Withstand Voltage

Q: In an 800V high-voltage platform, how can capacitors ensure long-term reliability under high-voltage, high-ripple impact?

A: Triple protection: Select capacitors with a rated voltage?1000V; conduct batch sampling inspections at 1.2 times the rated voltage, 85?, and 96 hours of high-voltage steady-state load testing; strengthen process control.

Question Type: Cost and Performance

Q: How to balance the cost and performance of film capacitors?

A: Implement tiered selection: use high-performance film capacitors for critical paths, and hybrid/optimized electrolytic capacitors for non-critical paths; negotiate annual cost reduction plans with suppliers and establish a clear cost-performance model.

Question Type: PFC Circuit Failure

Q: How does a failure of a DC-Link capacitor in a PFC circuit trigger system protection and interrupt charging?

A: The system-level propagation path of the failure needs to be clearly defined. It is recommended to add ripple voltage detection to the hardware and set an effective ripple value warning threshold in the software to provide early warning and avoid hard protection.

Problem Type: Substitution Cost Considerations

Q: How to assess and accept the BOM cost premium of high-performance film capacitors compared to electrolytic capacitors?

A: Explain the premium using value engineering; create a TCO analysis template to quantify after-sales costs and brand loss; high-end models can promote "long-life capacitors" as a market highlight.

Problem Type: Failure Mode Avoidance

Q: How to avoid frequent after-sales failures of OBCs due to capacitor issues from a design perspective?

A: Set electrolytic capacitor failure modes as a mandatory improvement item in DFMEA, and force the adoption of solid-state solutions such as film capacitors; establish quality files for key component suppliers.

Problem Type: Miniaturization and Performance Balance

Q: After miniaturizing OBC capacitors, how to ensure performance and lifespan?

A: Jointly develop customized sizes with suppliers; adopt an "integrated structural heat dissipation" design, attaching the capacitor mounting surface to a heat dissipation plate to offset the temperature rise pressure caused by the reduction in size.

Problem Type: Charging Performance Degradation

Q: Why do 800V platform vehicles experience slower charging and incomplete charging after several years of use?

A: First, rule out external factors such as charging stations and batteries. The most likely cause is performance degradation of the OBC's internal capacitors. It is recommended to check the "capacitor performance warning" during annual maintenance and prioritize models that support OBC status monitoring.

Problem Type: Physical Capacitor Failure

Q: What causes the OBC module capacitor to "bulge"?

A: This is a typical failure of traditional electrolytic capacitors. The root cause is that the internal electrolyte heats up and produces gas under high temperature and high frequency conditions, leading to increased pressure and pushing up the casing. Once discovered, fast charging should be stopped immediately, and timely repairs should be carried out to prevent the fault from escalating.

Problem Type: High Voltage Withstand Voltage Protection

Q: How to prevent high voltage breakdown of the OBC capacitor on an 800V platform?

A: Prioritize models marked "film capacitor" or "reinforced insulation design." These configurations offer better high voltage safety. This can be confirmed through the configuration table or by consulting a salesperson.

Problem Type: High Temperature Environment Adaptability

Q: Does the OBC's own heat affect its lifespan? How should capacitors cope with high temperatures?

A: High temperatures accelerate component aging. Avoid immediate high-power fast charging after prolonged exposure to direct sunlight in summer. Allow the battery to cool down for a short time to significantly reduce the OBC startup temperature and extend capacitor life.

Problem Type: Charging System Aging

Q: Are vehicles using 800V fast charging platforms more prone to charging system aging?

A: No. Pay attention to automakers' "lifetime warranty on core components" and "long-life design" clauses. These models often use high-performance components such as film capacitors, which have a lower risk of aging.

Problem Type: High-Frequency Operating Condition Adaptation

Q: Does high-frequency OBC operation affect the capacitor?

A: Yes. If, under the same fast charging station, the vehicle's charging efficiency is significantly lower than the same model, or the OBC area experiences abnormal overheating, it may be due to poor high-frequency capacitor performance.

Problem Type: System and Reliability

Q: Can simply replacing the capacitor significantly improve overall vehicle reliability?

A: Yes. The capacitor acts as a "voltage regulator" and "fault firewall" for the charging system. Long-life capacitors can prevent the OBC from malfunctioning due to voltage fluctuations, reducing the risk of major repairs.

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