Market analysis of military capacitors

2023-11-09

The global military-grade multilayer ceramic capacitor (MLCC) market is experiencing several emerging trends. One key trend is the increasing demand for MLCCs in the defense sector, driven by the rising need for high-performance electronics in military applications. The market is also witnessing a shift towards smaller and more compact MLCCs to accommodate modern and advanced defense systems. Additionally, the adoption of MLCCs with higher voltage ratings and lower equivalent series resistance (ESR) is gaining traction. Furthermore, the development of MLCCs with enhanced reliability, longer lifespans, and improved performance in extreme environments is also an emerging trend in the market.

The Military Grade Multilayer Ceramic Capacitor (MLCC) market includes two major types: PME MLCC and BME MLCC. PME MLCC (platinum-metallized electrode) are ceramic capacitors that utilize platinum electrodes and are renowned for their high reliability and robustness in extreme conditions. On the other hand, BME MLCC (base metal electrode) employ base metal electrodes such as nickel or palladium, making them cost-effective alternatives without compromising performance. These MLCC types are widely used in military applications where durability, performance, and cost-effectiveness are crucial factors.

Industrial, medical, and military demand for high quality, high-voltage multi-layer ceramic capacitors (MLCCs) has been hit hard by a shift in production by the world’s largest MLCC manufacturers who are focusing on a seemingly insatiable demand for smaller, lower voltage – and in some way – lower performance MLCCs. This demand has been fueled by the global growth of 5G networks and continued advancements in smart phones and mobile devices who are consuming significantly more MLCCs per device.

As the principal manufacturers pivot away from the larger high voltage, high Q (High Quality) MLCCs used by industry and the military, OEMs are experiencing significant delays in MLCCs of up to six months. The extent of the supply shortage jeopardizes product release schedules, industrial market share, and potentially even military readiness

We have the most power dense capacitor technology in the industry and are routinely specified for defense, aerospace, and energy exploration applications where high reliability and SWaP (space, weight, and power) savings are critical design considerations

Methods to reduce DC-DC converter output ripple

From military electronic equipment in weapons systems, unmanned aerial vehicles and radar to aerospace and industrial-grade communications systems, DC-DC converters often require tightly regulated outputs to the load with minimal ripple. The power rails for many modern electronics applications such as networking equipment, high-speed digital communications and industrial Ethernet-connected sensors involving supply voltages that grow smaller (1.2 V, 3.3 V, 5 V) while maintaining the current. This tightens the power requirements of the system where noise-sensitive devices such as high-resolution analog-to-digital converters (ADCs) may require a low output ripple on the order of a few millivolts peak-to-peak (mVp-p) or less. This principle holds true for systems that employ DC-DC converters with higher rated powers and voltages. Any sensitive load device – low noise amplifiers (LNAs), voltage-controlled oscillators (VCOs) and field-programmable gate arrays (FPGAs) – will suffer adverse effects from having high output voltage ripple on the output of a connected DC-DC converter.

VPT, Inc. has specialized in the design and development of DC-DC converters and custom power electronics design services for over 20 years, allowing the customer to leverage their expertise to design robust power systems for an end application. Their products include a wide range of high- reliability DC-DC converters, EMI filters, accessory power products, and custom engineering services for the rapid development of critical power systems, which are designed and engineered to the highest industry standards.

What is output ripple?

In any DC-DC converter topology, a voltage ripple will occur at the output capacitor. In a forward topology, the current in the inductor is sawtooth and flows through the capacitor to create a voltage ripple. A flyback topology generates a pulsating current that also flows through the output capacitor to create a ripple (Figure 1). The output ripple of the DC-DC converter can include both differential mode currents and common mode currents from parasitic capacitances. Generally, the fundamental switching frequency ripple at the output of the DC-DC converter primarily consists of differential mode noise while the higher frequency spikes are common mode.

From military electronic equipment in weapons systems, unmanned aerial vehicles and radar to aerospace and industrial-grade communications systems, DC-DC converters often require tightly regulated outputs to the load with minimal ripple. The power rails for many modern electronics applications such as networking equipment, high-speed digital communications and industrial Ethernet-connected sensors involving supply voltages that grow smaller (1.2 V, 3.3 V, 5 V) while maintaining the current. This tightens the power requirements of the system where noise-sensitive devices such as high-resolution analog-to-digital converters (ADCs) may require a low output ripple on the order of a few millivolts peak-to-peak (mVp-p) or less. This principle holds true for systems that employ DC-DC converters with higher rated powers and voltages. Any sensitive load device – low noise amplifiers (LNAs), voltage-controlled oscillators (VCOs) and field-programmable gate arrays (FPGAs) – will suffer adverse effects from having high output voltage ripple on the output of a connected DC-DC converter.

HD has specialized in the design and development of DC-DC converters and custom power electronics design services for over 20 years, allowing the customer to leverage their expertise to design robust power systems for an end application. Our products include a wide range of high- reliability DC-DC converters, EMI filters, accessory power products, and custom engineering services for the rapid development of critical power systems, which are designed and engineered to the highest industry standards. This article dives into the various methods to reduce DC-DC converter output ripple, their effectiveness and the considerations that come with these techniques. Several testing approaches are discussed to ascertain both the output ripple at the switching frequency, as well as the level of attenuation seen in its output harmonics.

What is output ripple?

In any DC-DC converter topology, a voltage ripple will occur at the output capacitor. In a forward topology, the current in the inductor is sawtooth and flows through the capacitor to create a voltage ripple. A flyback topology generates a pulsating current that also flows through the output capacitor to create a ripple (Figure 1). The output ripple of the DC-DC converter can include both differential mode currents and common mode currents from parasitic capacitances. Generally, the fundamental switching frequency ripple at the output of the DC-DC converter primarily consists of differential mode noise while the higher frequency spikes are common mode.