The Kynix Blog

Ⅰ IntroductionIf you've been around electrical equipment for a long time, you may have heard of the transformer. Yeah, they're the enormous bulky things found in the corners of the street that make random scary noises and spit sparks sometimes. There is also a sort of small transformer in your phone charger, but much, much smaller and with a different mechanism.CatalogⅠ IntroductionⅡ Transformer DefinitionⅢ Importance of Transformers in Electrical SystemⅣ Transformer SymbolsⅤ Working Principle of a TransformerⅥ Transformer PropertiesⅦ Transformer Construction  7.1 BOBBIN  7.2 CORE  7.3 WINDINGSⅧ Transformers ApplicationⅨ ConclusionⅩ FAQⅡ Transformer DefinitionA transformer is a device that converts one voltage or current to another using the principles of electromagnetism. It consists of a pair of wounds around a magnetic core of the insulated wire. The winding to which the voltage or current to be converted is connected is called the primary winding and the secondary winding is called the output winding. Transformers come in two types: step up, which increases the voltage or current, and step down, which lowers the input of the voltage or current. The transformers in your microwave oven, for example, are a secondary transformer that is used in the microwave oven to supply about 2200Volts to the vacuum tube. One thing to remember is that transformers only operate with AC voltages or adjustments and do not work with DC. We'll understand why now. Ⅲ Importance of Transformers in Electrical SystemIt was around 1856 that there was a rivalry between two brilliant minds, Nikola Tesla and Thomas Edison. Those were the days when electricity and its applications were merely noticed by glowing a lamp and driving a motor. It was Edison and his associates who first discovered the DC (Direct Current) system, and then Tesla developed his AC (Alternating Current) system sometime after that. The two have since tried to show that their scheme is more advantageous than the other. The time has come for houses to get electricity by then. Although Edison was busy showing how dangerous AC is by electrocuting elephants, Tesla and his team came up with the transformers that made it much simpler and more effective to transmit electricity. Also, transformers play a key role in the transmission system today. Let's learn why. High-voltage and low-current transmission of electricity will help us minimize the thickness of the transmission wires and thus the cost, which will also improve the system's performance. For this purpose, a typical transmission system may be anywhere from 22KV to 66KV, although some generators have an output voltage of only 11kV in the power plant and need only 220V/110V for the household AC unit. So where does this transfer of voltage take place and who does it? Transformers are the answer to the issue. There will be transformers in the system from the power plant to your home that will either step-up the voltage (increase voltage) or step-down (decrease voltage) to preserve the system's efficiency. The transformers are therefore referred to as the heart of an electrical transmission system. In this post, we will be learning more about them. Ⅳ Transformer SymbolsFor a transformer, the circuit symbol is simply two inductors placed together side by side that share the same center. The type of core used is shown by the existence of the line between the two windings: a dashed line represents ferrite, two parallel lines represent laminated iron, and no line represents the core of air.The number of 'bumps' is often used as a rough measure of the role of the transformer-less bumps on one side and more on the other which means that there is a lower number of turns on the first side than the other.Ⅴ Working Principle of a TransformerWe need to go back in time, to the laboratory of Michael Faraday, to understand the operation of a transformer. Perhaps the father of the transformer can be named Michael Faraday, as it was his experiments that helped us understand electromagnetism and create devices such as motors and generators. There was a race to try to create a practical system that could harness the strength of magnets to produce electricity in the late 1800s when it was discovered that electricity and magnetism were related phenomena. Faraday figured out that by bringing a magnet close to a coil of wire, electricity could be produced. What he discovered was that only when the magnetic field shifts can the voltage be produced, that is, whether either the coil or the magnet is shifted relative to the other. In DC, the movement of the current is constant and so is the magnetic field. There is no voltage generated on the secondary because the field is constant and not changing and the transformer just looks like a regular coil of resistive wire to the power supply. So, with DC currents, transformers do not operate. He also found that a current flowing in one coil might cause the current in the other coil when two coils of wire were held close to each other. This definition is referred to as mutual inductance, which governs the operation of all modern transformers.The transformer consists of two windings wound on a magnetic core, as shown in the figure. The goal of having a core is that air is not a very good magnetic field supporter, so having a magnetic core increases the magnetic field for a certain amount of current flowing through one winding, which in turn generates a stronger current in the other, improving the device's overall performance. A magnetic field is built up in the core as a current moves through the primary and is limited mostly to the core. This magnetic field passes through the center of the secondary and, thus, the law of reciprocal induction causes a current in the other. The beauty of this method is that the ratio between the input voltage and the output voltage is simply the ratio between the main and the secondary windings, summarized by the following formula:Vout/Vin = Nsec/NpriVin is the input voltage, Nsec is the number of turns in the secondary winding, and Npri is the number of turns in the main winding, where Vout is the output voltage.So if you have two transformers, one with 100 turns on the primary and 1000 turns on the secondary and one with 10 turns on the primary and 100 turns on the secondary, you can measure the ratio of turns to be 1:10 on both of them, so that they both increase voltage to the same degree. Ⅵ Transformer PropertiesIf we take a closer look at the above example, the first transformer would have higher winding resistance (since more wire is used) and will restrict the amount of current that can be drawn from the transformer in certain instances. This property is called winding resistance, but since the copper wire used normally has a low resistance, it does not matter in most cases. Another thing you see is that the main and secondary windings have no direct electrical connection. This is called galvanic isolation and, as we can see, can be very useful. Looking at each of the transformer windings, we can see that they are shaped like inductors and also have an inductance, a coil of wire wrapped around a magnetic center. This inductance, given by this formula, is proportional to the square of the number of turns:Lpri/Lsec = Npri2/Nsec2Where Lpri is the primary winding inductance, Lsec is the secondary winding inductance, Npri is the number of turns on the primary windings and Nsec is the number of turns on the secondary windings. The proportionality constant can be found in the datasheet for a given core and is typically given in μH/turn2 units. The exact value is based on the core form and scale. Suppose you have a transformer core with a 1uH/turn2 specification. If you wind one winding on that heart, the value of the constant multiplied by the number of turns squared will be the inductance, in this case, 1. So the winding inductance of that one will be 1μH. If you wind the same core with another winding with 10 turns, then the inductance will be:(1µH/turn2)*(10 turns)2 = 100µHSince the windings have inductance, they provide an impedance to AC signals, given by the formula:XL = 2π*f*LWhere XL is the impedance in ohms, f is the frequency in ohms and L is the inductance in Henries.Say, you want to design a transformer at 50Hz, which is the standard power line frequency, that draws 3A at 220V AC. Then, by Ohm's law, the impedance of the main will need to be 73.3 Ohms. Now that we know the appropriate impedance and the frequency, we can rearrange the formula to find out the inductance required for the winding:L = (XL)/(2π*f)Substituting the values, we find that 233mH would be the required inductance.We can calculate the windings necessary to get the inductance needed using this information and the value of μH/turns2 from the datasheet.Assuming the value is 50μH/turns2, we can rearrange the formula to evaluate the inductance: Where N is the number of turns, L is the inductance required, and the term t2/μH is just the inverse of the value of the datasheet.We get the necessary number of turns of 2158 when adding our values to the formula. So, as you can see, you can build transformers for almost any application once you get the hang of the formulas! Ⅶ Transformer ConstructionAn awareness of transformer construction is vital for someone who wants to wind their own transformers.A transformer is made up of a few fundamental components: 7.1 BOBBINFor every transformer, the bobbin is the fundamental structure. It provides a spool on which the windings will wind and keeps the core in place as well. It is typically composed of plastic that is heat resistant. It also sometimes involves metal pins onto which, for example, you can weld the ends of the windings if you want to mount it to a PCB. 7.2 COREPerhaps the most significant aspect of the transformer is this. The cores can come in several shapes and sizes, as seen in the image. It is the core's magnetic properties that decide the transformer's electrical properties that are built around the core. 7.3 WINDINGSThe wire used in the house, though it can seem like a trivial item, is as critical as any other element. In general, solid enameled copper wire is used because the insulation is strong and thin, so plastic insulating sheaths do not waste space. Ⅷ Transformers Application • MAINS VOLTAGE CONVERSIONThis is possibly the most common transformer application, stepping down the mains voltage for low voltage devices. This stuff, like microwaves and old TVs and wall brick power supplies, you might even find inside. These transformers have iron cores that make them bulky and much less efficient than other types, providing excellent permeability.Three secondary wires mark them as 12-0-12 or 6-0-6. If you make the center wire the ground reference, this means that the outer two wires have an output of 12V AC RMS. If you calculate the 12v winding over each, you get 24V AC RMS. This gives you the flexibility to use the transformer as you may like. • SWITCH MODE POWER SUPPLIESThese are very specific type of power supplies that generate a DC output and take a DC input. Both modern phone chargers are located here. The transformers used in these PSUs are shaped more like medium- to high-permeability inductors with a limited number of turns and ferrite cores. For a brief period, a DC voltage is applied across the 'primary' so that the current ramps up to a certain amount and retains some magnetic energy in the core. At a lower voltage, this energy is then passed to the secondary, since it has a smaller number of turns. They work and achieve outstanding efficiencies at high frequencies and are very thin. • ELECTRICAL ISOLATIONThere are special transformers with a 1:1 turn ratio, such that the voltages of the input and output are the same. They are used to decouple equipment from the earth's mains. Since mains are referred to as earth, touching even one wire will lead to a shock since the return path is simply the ground. The unit is separated from the main earth by the use of isolation transformers, as transformers are galvanically insulated. • VOLTAGE CONVERSION TRANSFORMERSMany countries use 220V AC as the normal supply voltage around the world, but some countries use 110V AC, such as the US. This means that it is not possible to operate certain devices such as blenders in all countries. To this end, transformers that convert from 110V to 220V or vice versa can be used to ensure that appliances can be used in any region. • IMPEDANCE MATCHINGThere are unique transformer types that are used to balance the source and load impedance. RF and audio circuits are commonly used.The ratio of turns is equal to the source's square root and load impedance. • AUTOTRANSFORMERThis is a special type of transformer that has only one winding that forms the secondary with a 'tap' output. This tap is normally variable, so the output AC voltage can be varied, much like a voltage divider. Ⅸ ConclusionTransformers are useful instruments and it can be very useful to learn how to build and operate with them! Although we have covered the basics here, it is something that can be discussed in another whole article to build a transformer right from scratch, so for some other time. But now, you'll know why it's there and how it works when you see a transformer again. Ⅹ FAQ1. How does a transformer convert AC into DC?The transformer is not designed to convert ac to dc. It is a pure AC device used to step down/up voltage levels keeping frequency, power, FLUX constant. In mobile charger, we use transformer along with bridge rectifier to convert domestic AC supply to dc. (with ripples) Finally, such a transformer that converts ac to dc is not designed yet. 2. Will a transformer work with DC?Transformers work in the principle of Faraday's law of 'mutual induction', in which an EMF is induced in the transformer's secondary coil by the magnetic flux generated by the voltages and currents flowing in the primary coil winding. As in DC(voltage being always constant), the change in flux is zero so no mutual induction, thus transformers can't work with a DC supply. Moreover, if DC or a similar rating of AC(Voltage & Current) is fed into the terminals of a Transformer there is a high possibility that it would burn the primary coil. 3. What is a transformer's simple definition?Transformer, device that transfers electric energy from one alternating-current circuit to one or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage. 4. What is the use of a transformer?Transformers are most commonly used for increasing low AC voltages at high current (a step-up transformer) or decreasing high AC voltages at low current (a step-down transformer) in electric power applications, and for coupling the stages of signal-processing circuits. 5. What is the basic principle of a transformer?A transformer consists of two electrically isolated coils and operates on Faraday's principle of ‘mutual induction’, in which an EMF is induced in the transformer's secondary coil by the magnetic flux generated by the voltages and currents flowing in the primary coil winding. 6. What are the two types of transformer?The different types of transformer are Step up and Step down Transformer, Power Transformer, Distribution Transformer, Instrument transformer comprising current and Potential Transformer, Single phase and Three phase transformer, Auto transformer, etc. 7. What are the main parts of the transformer?There are three basic parts of a transformer:• an iron core that serves as a magnetic conductor,• a primary winding or coil of wire.• a secondary winding or coil of wire. 8. What does a transformer look like?A transformer keeps wired doorbells powered at the right voltage for optimal operation. It looks like a small metal box and can be silver, off-white, or even brass colored. If your doorbell is no longer working, you may need to troubleshoot the transformer in order to perform the repair. 9. What is a transformer ratio?The transformer turns ratio is the number of turns of the primary winding divided by the number of turns of the secondary coil. The transformer turns ratio provides the expected operation of the transformer and the corresponding voltage required on the secondary winding. 10. What are the ideal transformers?A transformer that doesn't have any losses like copper and core is known as an ideal transformer. In this transformer, the output power is equivalent to the input power. The efficiency of this transformer is 100%, which means there is no loss of power within the transformer. 

Ⅰ IntroductionCapacitors are one of the passive components used the most. You can find them being used in many analog and power electronic circuits, from basic amplifier circuits to complicated filter circuits. While we have already learned the fundamentals of a capacitor and how it functions, there is a wide range of capacitor applications. Two application terminology that is commonly used when referring to a capacitor in a circuit is the Bypass capacitors and the Decoupling capacitor. We will learn about these two types of capacitors in this article, how they operate in a design and how to pick a capacitor to be used as a bypass capacitor or decoupling capacitor. While the terms Bypass capacitors and Decoupling capacitors are used interchangeably, they have their distinctions. The primary objective of powering any system would be to provide the input power with very low impedance (relative to the ground). Bypassing is applied to circuits to achieve this condition. To grasp the distinction between the two kinds of capacitors, let's dig deep into them.CatalogⅠ IntroductionⅡ Decoupling capacitorⅢ Positioning a Decoupling CapacitorⅣ Value of the Decoupling CapacitorⅤ Bypass CapacitorⅥ Emitter Bypass CapacitorⅦ Cathode Bypass CapacitorⅧ How to select the value for a Bypass CapacitorⅨ Applications of Bypass CapacitorⅩ Difference between Bypass and Decoupling CapacitorⅪ FAQ Ⅱ Decoupling capacitorFor isolating or decoupling two distinct circuits or a local circuit from an external circuit, decoupling capacitors are used to isolate or decoupling two distinct circuits or a local circuit from an external circuit, i.e. for decoupling AC signals from DC signals or vice versa. The real truth is that the decoupling capacitor is used for both the reason and by providing pure DC supply, we may describe the Decoupling capacitors as the capacitor used to eliminate power distortion and noise and protect the system/IC.When it comes to logic circuits, the decoupling process is really necessary. For example, consider a logic gate that can operate at a 5V supply voltage, it will read as a high signal if the voltage goes above 2.5V and it will read as a low signal if the voltage goes below 2.5V. Therefore, if there is a noise in the supply voltage, the logic circuit will cause highs and lows, so DC Coupling condensers are commonly used for logic circuits. Ⅲ Positioning a Decoupling CapacitorThe decoupling capacitor should be mounted in parallel between the power supply and the load/IC. The decoupling capacitor would have infinite reactance on DC signals as the DC power supply provides the power to the circuit and they will have no impact on them, so it has far less reactance on AC signals so that they can move through the decoupling capacitor and, if possible, they will be shunted to the field. In order to get shunted, the capacitor can create a low impedance path for the high-frequency signals, resulting in a clean DC signal.The positioning includes two separate capacitors, a 10μF capacitance capacitor positioned away from the IC that is used to smooth out the changes in the power supply's low frequency and a 0.1 μF capacitor held closer to the IC that is used to smooth out the changes in the power supply's high frequency. Electrolytic capacitors are the most used type of capacitors for low-frequency smoothing, and surface mount ceramic capacitors are the capacitors used for high-frequency smoothing. Ⅳ Value of the Decoupling CapacitorUnlike Bypass capacitors, the value of a decoupling capacitor does not have many riles to select. There are certain criteria for choosing the value since decoupling capacitors are commonly used.• Usually, the low-frequency noise decoupling capacitor value should range from 1 μF to 100 μF.• Usually, the high-frequency noise decoupling capacitor should be between 0.01 μF and 0.1 μF.The datasheet for the ICs is often supplied with the exact value of the capacitors to be used. For their efficient operation, the decoupling capacitors should always be connected directly to a low impedance ground plane. Ⅴ Bypass CapacitorTo avoid noise from entering the device by bypassing it to the ground, the Bypass capacitor is used. In order to eliminate both the power supply noise and the result of the spikes on the supply lines, the bypass capacitor is mounted between the supply voltage (Vcc) and ground (GND) pins. The capacitor can suppress both inter-and intra-system noises for various devices and different components.The capacitor shorts any form of AC signal to the ground during operation so that the AC noise in a DC signal is eliminated, resulting in a cleaner and pure DC signal. Let's look at the Emitter and Cathode Bypass capacitors, for instance. Ⅵ Emitter Bypass CapacitorIf a bypass capacitor is attached parallel to an emitter resistance, consider a Typical Emitter (CE) amplifier with an emitter resistance, the voltage gain of the CE amplifier increases and if the capacitor is removed, extreme degeneration is produced in the circuit of the amplifier and the voltage gain will be reduced. Ⅶ Cathode Bypass CapacitorIf a capacitor is connected across the cathode resistance and if the capacitor is sufficiently high, it will function as an audio frequency short circuit and remove negative feedback. It also functions as a DC open circuit and retains the bias of the DC grid. Ⅷ How to select the value for a Bypass CapacitorThe capacitor reactivity applied to the circuit should be parallel to 1/10th or less of the resistance. We all know that the current always takes a low resistance course, so the capacitor should have a lower resistance if you want to shunt the AC signal to the field. You can measure the capacitance value of the bypass capacitor to be used using the formula.Let's remember that you need to find the capacitance of the capacitor connected across the resistance resistor 440 with the above bypass capacitor formulae, we understand that the reactance is always 1/10th of the resistance, so the reactance is 44 and the normal frequency of the Indian electrical network is 50Hz, so the bypass capacitor value can be calculated as73μF should be the capacitance of the capacitor around the 440 x resistor. You will find out the importance of condensers that can be used in a circuit using the same thing. Ⅸ Applications of Bypass CapacitorThe bypass capacitors, some of the notable applications where they are used, are almost used in both analog and digital circuits to eliminate unnecessary signal from the supply voltage.They are used to create a consistent sound between the amplifier and the loudspeaker.• Used when converting to DC/DC• Used in coupling and decoupling signals• Used in Filters for High Pass(HP) and Low Pass (LP) Ⅹ Difference between Bypass and Decoupling CapacitorThere is not much difference between the two types of capacitors when you look at the reason they are used for. Surprisingly, the decoupling capacitors are often called Bypass capacitors much of the time. This is because often they are shunted to the ground. The bypass capacitor is designed to shunt the noise signals while the decoupling capacitors are intended to smooth the signal by stabilizing the distorted signal, some of the few visible distinctions between the bypass capacitor and decoupling capacitors. We can only use a single electrolytic capacitor for shunting the signal, but we would need two separate types of capacitors for calming the signal. Ⅺ FAQ1. How do coupling and bypass capacitors differ?A coupling capacitor goes between the output, usually a collector of a transistor or drain of a FET to the input of the next stage, the base of another transistor or gate of another FET. It should be a high enough value to have a reactance below the impedance at the lowest desired frequency.A bypass capacitor is to conduct the frequency to ground, typically on a power supply to minimize noise or ripple or can be across the emitter/ source resistor to ground to increase gain. In RF circuits there are often two bypass capacitors in parallel. A ceramic capacitor in the 1nF to 0.1uF range, and an electrolytic or tantalum in the 1 to 1,000uF range. 2. Is there a difference between a decoupling capacitor and a by-pass capacitor?Decoupling is used to decouple noise or other transients from say, a power supply IC output. This is usually a ceramic capacitor of low value.Next, a bypass capacitor is usually an electrolytic capacitor used to bypass a resistor which is mainly used to set the DC biasing of the amplifier. This cap is used to avoid the negative feedback of the signal and to improve the gain of the amplifier. 3. What is the function of an output decoupling capacitor?A typical function is to convey an audio frequency ac signal from amplifier output to a speaker, whilst blocking the DC supply from the speaker voice coil.Also used for coupling audio/radio frequency signals between stages of an amplification chain, whilst isolating dc between stages to simplify biasing, etc.A typical function of a DEcoupling capacitor is to try to isolate unwanted signals from power supply rails or between stages in multi-stage af/rf/whatever circuitry. 4. What is coupling decoupling and bypass capacitor explain with an application example?While decoupling capacitors are connected in parallel to the signal path and are used to filter out the AC component, coupling capacitors, on the other hand, are connected in series to the signal path and are used to filter out the DC component of a signal. They are used in both analog and digital circuit applications. 5. What is the significance of bypass capacitors define their functions and applications?A Bypass Capacitor is usually applied between the VCC and GND pins of an integrated circuit. The Bypass Capacitor eliminates the effect of voltage spikes on the power supply and also reduces the power supply noise. The name Bypass Capacitor is used as it bypasses the high-frequency components of the power supply. 6. What is the purpose of the bypass capacitor?Bypass capacitors are used to maintain low power supply impedance at the point of load. Parasitic resistance and inductance in supply lines mean that the power supply impedance can be quite high. As frequency goes up, the inductive parasitic becomes particularly troublesome. 7. What is the use of coupling and decoupling capacitor?Coupling capacitors allow AC components to pass while blocking DC components. Decoupling capacitors are used in electronic circuits as energy reservoirs to prevent quick voltage changes. Bypassing capacitors clean DC signals by shunting unwanted AC components to the ground. 8. What is the effect of a coupling capacitor?Coupling capacitors (or dc blocking capacitors) are used to decouple ac and dc signals so as not to disturb the quiescent point of the circuit when ac signals are injected at the input. Bypass capacitors are used to force signal currents around elements by providing a low impedance path at the frequency. 9. What is the purpose of using decoupling capacitors in PCB?The decoupling functions as a reservoir and acts in two ways to stabilize the voltage. When the voltage increases above the rated value, the decoupling capacitor absorbs the excessive charges. Meanwhile, the decoupling capacitor releases the charges when the voltage drops to ensure the supply is stable. 10. Where should a bypass capacitor be placed?The ideal location to place bypass capacitors is as close as possible to the supply pin of the component. By placing the bypass capacitor very close to the power supply pin, it reduces the impact of the current spikes during the switching. It also provides a low impedance path to the ground for AC noise signals.

Ⅰ IntroductionThere are 400 types of scent receptors in a typical human nose that allow us to detect about 1 trillion different odors. But many of us also can't define the form or concentration of gas in our atmosphere. There are several kinds of sensors to calculate various parameters and a gas sensor is one that is useful in applications where we have to detect changes in the concentration of harmful gases to keep the device safe and prevent any unwanted threats. To detect gases such as oxygen, carbon dioxide, nitrogen, methane, etc., there are different gas sensors. They can also be widely used in devices that are used in factories and offices to detect the leakage of toxic gases, track air quality, etc. We will learn more about gas sensors, their construction, types, function, and how they can be used to calculate the type and concentration of gas required in our atmosphere in this article. There are several kinds of gas sensors, but gas sensors of the MQ type are frequently used and widely popular, so this article will concentrate more on these types of sensors.CatalogⅠ IntroductionⅡ Introduction of Gas SensorⅢ Different Types of Gas sensorsⅣ Construction of Gas SensorⅤ Working of Gas SensorⅥ Working Principle of Gas SensorⅦ How can a gas sensor be used?Ⅷ Gas Sensors List and What Gases They SenseⅨ Gas Sensors ApplicationsⅩ FAQⅡ Introduction of Gas SensorA gas sensor is a device that senses the atmosphere's presence or concentration of gases. The sensor creates a corresponding potential difference depending on the concentration of the gas by adjusting the resistance of the material within the sensor, which can be determined as the output voltage. The type and concentration of the gas can be calculated based on this voltage value.The type of gas that can be detected by the sensor depends on the sensing material within the sensor. As shown above, these sensors are usually available as modules with comparators. A specific threshold value of the concentration of gas may be set for these comparators. The automated pin goes up when the concentration of the gas reaches this threshold. It is possible to use the analog pin to measure the gas concentration.Ⅲ Different Types of Gas sensorsBased on the type of sensing element it is designed with, gas sensors are usually categorized into different categories. Below is the classification based on the sensing aspect of the different types of gas sensors that are commonly used in different applications:• Metal Oxide Based Gas Sensor.• Optical Gas Sensor.• Electrochemical Gas Sensor.• Capacitance-based Gas Sensor.• Calorimetric Gas Sensor.• Acoustic Based Gas Sensor.Ⅳ Construction of Gas SensorThe Metal Oxide Semiconductor Based Gas Sensor is the most widely used gas sensor of all the above types. A sensing component containing the following elements will consist of all gas sensors.• Gas Sensing Layer• Heater Coil• Electrode Line• Tubular Ceramic• ElectrodeThe picture below shows the components of a metal oxide gas sensor.The goal of each of these elements is as shown below.:• Gas sensing layer: It is the main component of the sensor that can be used to detect changes in gas concentration and produce electrical resistance changes. The gas sensing layer is essentially a chemical resistor that adjusts its resistance value depending on the environment's real gas concentration. The sensing factor consists of a Tin Dioxide (SnO2) here, which generally has excess electrons (donor element). Therefore, the resistance of the element changes and the current flown through it varies as toxic gases are detected, which reflects the shift in gas concentration. • Heater coil: The purpose of the heater coil is to burn the sensing component to increase the sensitivity and efficiency of the sensing component. It is made of nickel-chromium with a high melting point that allows it to remain heated without melting. • Electrode line: Since a very small current is generated by the sensing element when the gas is detected, preserving the efficiency of carrying those small currents is more critical. So Platinum wires come into play where they help to efficiently transfer the electrons. • Electrode: It is a junction where the sensing layer output is attached to the line of the electrode. So that the output current may flow to the terminal that is needed. Gold (Au-Aurum), which is a very good conductor, is an electrode here. • Tubular ceramic: There is a tubular ceramic made from aluminum oxide between the heater coil and the gas sensing layer (Al2O3). As it has a high melting point, it helps to preserve the sensing layer's burn-in (preheating), which provides the sensing layer with high sensitivity to obtain an effective output current. • Mesh over the sensing element: A metal mesh is used over it to cover the sensing elements and the setup, which is also used to prevent/hold dust particles from entering the mesh and to prevent damage from corrosive particles to the gas sensing layer.Ⅴ Working of Gas SensorA gas sensor's ability to detect gases relies on the chemiresistor to conduct current. Tin Dioxide (SnO2), which is an n-type semiconductor with free electrons, is the most widely used chemical resistor (also called a donor). The atmosphere usually contains more oxygen than combustible gases. The particles of oxygen attract the free electrons present in SnO2, bringing them to the surface of SnO2.  As there are no free electrons available, there will be a zero output current. The gif below shows the oxygen molecules (blue color) within the SnO2 attracting the free electrons (black color) and preventing them from having free electrons to perform the current.Ⅵ Working Principle of Gas SensorThis decreasing gas (orange color) interacts with the adsorbed oxygen particles when the sensor is put in the atmosphere of toxic or combustible gases and breaks the chemical bond between oxygen and free electrons, thereby releasing free electrons. As the free electrons return to their original location they will now conduct current, this conduction would be proportional to the number of free electrons available in SnO2 if more free electrons are available for the gas to be highly toxic.Ⅶ How can a gas sensor be used?There are 6 terminals in a simple gas sensor in which 4 terminals (A, A, B, B) serve as input or output and the remaining 2 terminals (H, H) are used to heat the coil. Of these 4 terminals, 2 terminals from each side can be used as either input or output (as seen in the circuit diagram, these terminals are reversible) and vice versa.MQ2 Gas sensor PinoutThese sensors are usually available as modules (shown on the right), consisting of a gas sensor and an IC comparator. Now let's see the gas sensor module pin definition that we normally use with an Arduino. The module for the gas sensor consists of 4 terminals.• Vcc – Power supply• GND – Power supply• Digital output – This pin produces an output that is either logically high or logically low (0 or 1), indicating that it shows any harmful or combustible gases near the sensor.• Analog output – This pin provides a continuous voltage output that varies depending on the gas concentration added to the gas sensor.The output of a gas sensor alone would be very small (in mV) as discussed earlier, so an external circuit has to be used to get a digital high low output from the sensor. A comparator (LM393), adjustable potentiometer, some resistors and capacitors are used for this purpose. The goal of LM393 is to get the sensor output, compare it to a reference voltage, and show whether or not the output is logically high. Whereas the potentiometer is intended to set the gas threshold value needed above which the digital output pin should go high. A simple circuit diagram of a gas sensor in a gas sensor module is shown in the diagram below.The input and output terminals here are A and B (these are reversible - meaning either of the paired terminals can be used as input or output) and H is the terminal for the heater coil. The purpose of the variable resistor is to change the voltage of the output and maintain high sensitivity. If the heater coil has no input voltage, so the output current would be much smaller (which is negligible or approximately 0). The sensing layer wakes up when an appropriate voltage is applied to the input terminal and heater coil and is ready to detect any combustible gases near it. Let's first presume that there is no poisonous gas near the sensor, so the layer's resistance does not shift and the output current and voltage are also unchanged and insignificant (approximately 0). Now, let's say that poisonous gas is nearby. Since the heater coil is pre-heated, any combustible gases can now be easily detected. The resistance of the material varies as the sensing layer interacts with the gases, and the current flowing through the circuit often varies. This variation shift can then be observed in the load resistance (RL). The load resistance (RL) value can be anywhere from 10K to 47K. It is possible to pick the exact value of the load resistance by calibrating it with the known gas concentration. The circuit has lower sensitivity if the low load resistance is chosen, and if the high load resistance is selected, then the circuit has high sensitivity.Ⅷ Gas Sensors List and What Gases They SenseSensor NameGas to measureMQ-2Methane, Butane, LPG, SmokeMQ-3Alcohol, Ethanol, SmokeMQ-4Methane, CNG GasMQ-5Natural gas, LPGMQ-6LPG, butaneMQ-7Carbon MonoxideMQ-8Hydrogen GasMQ-9Carbon Monoxide, flammable gassesMQ131 Ozone............Ⅸ Gas Sensors Applications• It is used to track the concentration of toxic gases in industries.• Used in homes to recognize activities in an emergency.• The concentration of the gases that are emitted is tracked at oil rig locations.• Used at hotels to discourage smoking by clients.• Used in workplace air quality inspections.• It is used to track CO2 levels in air conditioners.• Used in fire detection.• Used for gas concentration regulation in mines.• The analyzer of breath.Ⅹ FAQ1. What is a gas sensor?As the name suggests, it senses gas. It's a component used to detect fluctuations in the gaseous state. There are so many gas sensors based on the element they sense, some are given below:• Carbon Dioxide Sensor: Used for detection of pollution caused by vehicles emitting CO2.• Alcohol Sensor: I know alcohol is not a gas but it senses the smell of it. Traffic police use devices based on this sensor.• LPG Sensor: It is used for avoiding the destruction caused by leaked LPG cylinders. 2. What are gas sensor arrays?A gas sensor that is commonly available in the market is an MQ-x series sensor - MQ2, MQ3, MQ6, etc. The module for this series sensor gives a digital output but can even be modified to have an analog output. MQ2 sensor can detect gasses like propane, butane, LPG, smoke and alcohol. An array of gas sensors would mean that all the sensors of this category are interfaced to the same controller and are laid at different locations to monitor the aspect. 3. How does a gas sensor work?Gas detectors use a sensor to measure the concentration of particular gases in the atmosphere. The sensor serves as a reference point and scale, producing a measurable electric current when a chemical reaction caused by a specific gas occurs. 4. How do MQ5 gas sensors work?In any sensor, a physical change contributes to a chemical change that generates an electrical impulse which then drives a circuit.Similarly here, the MQ5 gas sensor which is made of SnO2 is less conductive normally. In LPG or any combustible gas environment like propane-butane etc., it becomes more conductive.A circuit similar to the Wheatstone bridge will be available inside the sensor with one of its resistance made of SnO2. Assume a bridge balanced condition. When the conductivity changes bridge becomes unbalanced. Hence current flows through the center galvanometer showing deflection.  5. What is the difference between a gas analyzer and a gas detector?A gas detector has simple structures, consisting only of the sensor and sensor conversion circuit. However, a gas analyzer not only has sensors inside but also has a complete set of pneumatic systems, which introduces the sample gas into the instrument firstly and then discharges or retrieves the gas. 6. What is the use of a gas sensor?Gas sensors (also known as gas detectors) are electronic devices that detect and identify different types of gasses. They are commonly used to detect toxic or explosive gasses and measure gas concentration. 7. How long do gas detectors last?The typical life span of an electrochemical sensor is usually between 2-3 years. Whereas a more exotic gas sensor may only last 12-18 months. I would advise anyone who uses a gas detector to get the instrument serviced every 6 months as this will ensure that your instrument will be working perfectly. 8. What is gas sensor sensitivity?Usually, sensitivity (S) can be defined as Ra/Rg for reducing gases or Rg/Ra for oxidizing gases, where Ra stands for the resistance of gas sensors in the reference gas (usually the air) and Rg stands for the resistance in the reference gas containing target gases. 9. What is the most important sensor in a gas monitor?The most important technical aspect of all gas detectors is the heart of the instrument - the sensor. All the bells and whistles that can be crammed into one instrument can't take away from the simple fact that sensors must technically process incoming gases and vapors and provide an accurate response. 10. What is a gas sensor made of?Highly sensitive and selective sensors are needed for the detection and prevention of hazardous gas leaks from industries. Generally used gas-sensing materials comprise vapor-sensitive polymers, semiconductor metal oxides, and other porous materials such as silicon.

IntroductionOver voltage protection is necessary to prevent damage as a result of electrical transients. It is a power supply feature which shuts down the supply, or clamps the output, when the voltage exceeds a preset level. Most power supplies use an over-voltage protection circuit to prevent damage to the electronic components. They offer some form of overvoltage-protect (OVP) circuit to detect and then quickly pull down the overvoltage. When the voltage exceed the rated maximum breakdown voltage, do you know using Zener diode to make overvoltage protection circuit? Here introduces the Zener diode overvoltage protection circuit, which is the most common way.CatalogIntroductionⅠ Over Voltage BackgroundⅡ Zener Diode Input Protection BasicsⅢ Simple Overvoltage Protection Circuit Using Zener DiodeⅣ How Do You Choose a Zener Diode to Protect a Circuit?Ⅴ Zener Overvoltage Protection OverviewⅠ Over Voltage BackgroundEvery circuit design operates at various voltage levels, with 3.3V, 5V, and 12V being the most common voltage levels for a digital circuit. But every design is special, and having more than one operating voltage is also normal for a circuit. For example, a standard computer SMPS system will work at six different levels of voltage, namely ±3.3V, ±5V, and ±12V. In these cases, if a low-power device is operated by a high voltage, the component will be permanently impaired if various voltage levels are used to power different types of components. Therefore, to avoid over-voltage harm, the designer should always concentrate on implementing an over-voltage security circuit in his designs.There will be three different voltage ratings for any part or circuit, namely the minimum operating voltage, the suggested or normal operating voltage and the maximum operating voltage. For any circuits or parts, any value over the maximum operating voltage can be fatal. Using a Zener diode over voltage protection circuit is a very common and cost-effective solution. Ⅱ Zener Diode Input Protection BasicsIn order to protect the circuit from overvoltage conditions, Zener diodes are often the first option. A Zener diode follows the same diode theory, which blocks the current flow in the reverse direction. However, there is a drawback that the Zener diode blocks the flow of current in the reverse direction only for a restricted voltage defined by the voltage rating of the Zener diode. A 5.1V Zener diode blocks current to flow in the opposite direction up to 5.1V If the voltage is greater than 5.1V through the Zener diode, it allows the current to pass through it. This Zener diode function makes it an excellent over-voltage security component.Over-Voltage Protection Circuit using Zener DiodesⅢ Simple Overvoltage Protection Circuit Using Zener DiodeConsider a circuit, where need microcontroller over-voltage protection. Anything that has a maximum rating of 5V across the microcontroller IO pins. So voltage more than 5V will damage the microcontroller.Figure 1. Overvoltage Protection for MicrocontrollerThe diode used in the circuit above is a Zener diode of 5.1V. During an over-voltage case, it will work perfectly. It can transfer the current and regulate the voltage up to 5.1V if the voltage is more than 5.1V. In practice, however, it will behave as a regular diode and block less than 5.1V The image below is a simulation of the spice circuit of Zener diode protection. For the full simulation description, you can make it based on your need.Figure 2. Simulating Overvoltage Protection CircuitThere is an input voltage in the schematic above, which is dc supply. The R1 and D1 are two components that protect the output from protection from over-voltage. The D1, 1N4099, in this case, is a Zener diode. When the V1 reaches 6.8V, the output will be protected. The output would remain at a maximum of 6.8V as a reference voltage of 1N4099.Let's see how the above circuit works as the protection circuit of the Zener diode input and protects the output from more than 6.8V voltage.Using pspice cadence, the above circuit is simulated. The output remains constant at 5.99V at the 6V input voltage across the V1 (Which is 6.0V).The input voltage in the above simulation is 6.8V. The performance, therefore, is 6.78V, which is similar to 6.8V. Let's further raise the input voltage and create a situation of overvoltage.Now, 7.5V, which is more than 6.8V, is the input voltage. The performance is now now at 6.88V. This is how a Zener diode is successful in saving the connected circuit from a situation of overvoltage, even when the voltage returns to less than 6.8V, as shown in the previous stage, the circuit will operate normally again. In other words, a Zener diode does not get fried even during an overvoltage state, unlike a fuse.To pick different overvoltage margins in the above circuit, any other Zener diodes with different values such as 3.3V, 5.1V, 9.1V, 10.2V can be used. Ⅳ How Do You Choose a Zener Diode to Protect a Circuit?The next critical part is choosing the value of the Zener Diode. The points below will assist you in selecting the correct Zener Diode value and part number.1) Choose the voltage of the Zener diode first. It is the voltage value that will serve as a close circuit for the Zener diode and protect the load from overvoltage. The Zener voltage is 6.8V in Pspice, for the above example.There will be some cases where there is no usable targeted Zener diode voltage. In such instances, it is possible to choose a near value of the Zener diode. For example, for overvoltage security up to 7V, a near value is a 6.8V Zener diode.2) Calculate the load current that is linked across the circuit of overvoltage safety. This is 50mA for our example discussed above. Other than the load current, biasing current is required by Zener diodes. Therefore, the total current, plus the Zener diode biasing current, should be equal to the load current. For the above mentioned example, it can be total current=50mA+10mA=60mA.3) There is a power ranking for Zener diodes. Therefore, for proper heat dissipation, the correct Zener diode power rating is required. Based on the measured total current in Phase - 2, which is 60mA, the power rating can be calculated. Therefore, the power rating of the Zener diode would be equal to the voltage of the Zener diode, which connects the total current flowing through the diode.4) Calculate the value of the resistor by differentiating the voltage of the source and the general voltage. The limit which can be applied to the circuit would be the source voltage. For example, it can be 13V to maximize overvoltage that can occur or can be added as a supply voltage.The voltage drop through the resistor will then be = 13V-6.8V = 6.2V According to the law of the ohm, the resistor value will be = 6.2V / 0.060 A = 103R It is possible to choose the standard value 100R resistor.5) Zener diode typical values are 5.1V, 5.6V, 6.2V, 12V and 15V -most common; they are also have 3V, 5V, 12V, 18V, 24V.Ⅴ Zener Overvoltage Protection OverviewZener diode as a voltage regulator, it is suitable for overvoltage protection circuit. Because the easiest and simplest process to protect devices from overvoltage is overvoltage-protect circuit using Zener diodes. The voltage remains regulated in this technique and the cost of this circuit is much lower compared to other techniques.Although, surely, there are disadvantages to this sort of circuit. Power dissipation is the main downside of this type of circuit. It still dissipates heat due to the linked series resistor and results in energy wastage. Frequently Asked Questions about Zener Diode Overvoltage Protection Circuit Design1. What is overvoltage protection?Over voltage protection is a power supply feature which shuts down the supply, or clamps the output, when the voltage exceeds a preset level. Most power supplies use an over-voltage protection circuit to prevent damage to the electronic components. 2. Which is most common circuit protection device?The SPD(surge protection device) device is allied in parallel in the power supply circuit, which can be used on all stages of the power supply system. The surge protection device is the most frequently used and also well-organized kind of over-voltage protective devices. 3. What can cause overvoltage?The main causes include insulation failure, arcing ground and resonance etc. 4. How does a Zener diode regulate voltage?Zener diodes are widely used as voltage references and as shunt regulators to regulate the voltage across small circuits. When connected in parallel with a variable voltage source so that it is reverse biased, a Zener diode conducts when the voltage reaches the diode's reverse breakdown voltage.

Ⅰ IntroductionInvented by Boykin in 1959, resistors are today commonly used in almost all electronic circuits. Resistors can be described as a device that resists the flow of current flowing through itself, back when the resistor size was very huge and the tolerance value reached as high as 10 percent when it was implemented. Besides, they are usually made of compressed carbon. Resistors are mostly made from metal films and are available in small SMD packets with a tolerance value of as little as 2%, or even less, in the case of precision resistors. Carmet, KWK, Epcos India Pvt Ltd. and more are some of the leading manufacturers of resistors in India. If you didn't know, India accounts for some 34% of the market for passive components such as resistors by importing them, the remainder being imported. If you are interested in learning more about the work and characteristics of resistors, then you can try reading this article. We will address the difference between carbon film resistors and metal film resistors in this article.CatalogⅠ IntroductionⅡ Brief Intro to the ResistorsⅢ Carbon Film ResistorsⅣ Metal Oxide Film ResistorsⅤ Carbon Film Resistors VS Metal Oxide Film ResistorsⅥ Voltage and Temperature CoefficientⅦ SizeⅧ FAQⅡ Brief Intro to the ResistorsThe word "resistor" is born from the word "resist," meaning to withstand the impact. A resistor resists the movement of electrons that move through it, guides it, or controls it. With the support of the conductive material that it is made of, this is achieved. Now, the name makes sense, does it not? In parallel and series, resistors are connected according to the specifications for current and voltage. These small devices monitor, attenuate or decrease voltage and current, but do not have a power source of their own. The current flows through them in a controlled manner, resulting in a heat-like loss of energy. Only when there is a potential difference do two resistors bind and carry on a current between them. Yeah, they obey the Rule of Ohm. You must have heard, we're sure, of this statute. Oh, in the field of electronics and electrics, it is something to swear by. Moving on, depending on their characteristics, there is an infinite list of various types of resistors including composition form, film type, and wire-wound type of resistors. Physical size, durability, temperature rating, noise, temperature coefficient, and voltage coefficient, to name a few of these features. Well, the drill is known to you. We are here, however, to address two very significant types of resistors that are capable of transforming your electronic circuits.Ⅲ Carbon Film ResistorsLet us first contemplate what film resistors are before we begin talking about this. Well, after depositing oxide film or pure metals on a substrate or some insulating ceramic, these are simply those resistors that are formed. The layer is extremely thin and sputtering is known as the entire process. By depositing carbon film on the ceramic substrate that is an insulator, the carbon film resistor is prepared. The electric current is blocked by the carbon film to a certain degree. The insulating ceramic, on the other hand, does not allow heat to move through it, which in turn allows the carbon film resistor to withstand massive temperatures without being harmed. Carbon film resistors have a good tolerance rating, available from 1 ohm to 1 megaohm. Speaking of the resistance coefficient of negative temperature - the property of observing a decrease in resistance in response to a rise in temperature, these have a high coefficient of negative temperature that makes them susceptible to decreasing resistance as the temperature increases.These resistors are also available and have a very low tolerance at a low cost. They have a large variety of activities. Carbon film resistor applications are commonly used in X-Rays, power supplies and RADAR.Ⅳ Metal Oxide Film ResistorsMetal oxide film resistors use thin metal oxide films to coat an insulating ceramic rod, in contrast to carbon film resistors. Informing a coating film, the compound made from oxygen atoms and other atoms performs wonders. Using tin oxide, however, metal oxide film resistors are made. To produce better resistance, antimony oxide is also added. Because of the existence of an insulating ceramic rod that does not let heat pass through itself, these resistors are capable of withstanding high temperatures. Metal oxide resists the current at the same time. The greater the sum of antimony, the greater the resistance. But that doesn't even stop here, for good resistance metal oxide film resistors rely heavily on the thickness of the metal oxide and the width of the helical metal oxide film cut. The helical metal oxide film cut width and metal oxide thickness are inversely proportional to the resistance.Wondering what makes them special? Resistors come at a very low cost and withstand high temperatures while making much less sound. Also, along with high reliability and stability, they are small in scale.Ⅴ Carbon Film Resistor VS Metal Oxide Film ResistorWell, engineers are still in a dilemma about which to use one. Whether to use the resistor for the carbon film or the resistor for the metal oxide film. All right, let us break it down, bit by bit, for you. You want your experiments, after all, to go spot on. According to our contrast between Metal Film and Carbon Film Resistors, due to certain properties they possess that are listed below, we feel that metal-oxide film resistors prevail over carbon film resistors.Ⅵ Voltage and Temperature CoefficientThere are a stronger voltage coefficient and temperature coefficient for Metal Oxide film resistors than for carbon film resistors. The coefficient of voltage is the change in resistance concerning the change in voltage. In short, it is the ratio of the resistance change to the voltage change. Metal oxide film resistors operate in a wide range of resistors and can withstand a higher temperature than the resistors of the carbon film. Noise Design In contrast to carbon film resistors, metal oxide film resistors has a low noise design. They keep the minimum current. Therefore, it ensures less noise. If you didn't know, metal oxide film resistors, relative to carbon film resistors, make up for stronger resistors for radio frequency or high-frequency applications. Tolerance The 2 percent minimum carbon film resistor tolerance level does not stand a chance against metal oxide film resistors that can go as low as 0.1 percent.Ⅶ SizeFinally, compared to the carbon film resistors, the size of the metal oxide film resistors is smaller, making them a safer choice to go for. Now that we've done our bit to make you see the complexities of the resistors of both kinds, you can take your pick.Ⅷ FAQ1. What is a carbon film resistor?The resistive film deposited on the glass or ceramic rod is of pure carbon that is why they are called carbon film resistors. The thickness of the film will decide the value of the resistor. Spiralling is done on it in order to adjust the value of resistance.Some important features:• Tolerance =0.5% to 10%• Negative temperature coefficient of resistivity.• Wide temperature range from 55°c to 155°c• These are low power resistors typically of 1/8W, 1/4W, or 1/2W capacity. 2. What are the advantages of using metal film resistors versus carbon composition resistors?Metal film resistors produce less thermal noise than carbon composition resistors. Metal film resistors also typically have a much lower inductance/capacitance than carbon comp resistors so they (metal film) work better at higher frequencies. Carbon composition resistors have no real performance advantage over metal film resistors except that they are cheaper. 3. Are carbon film and metal film resistors interchangeable?No. They simply have less noise and do not drift in value. In short, they behave more like an ideal resistor. You can find metal films in 1% tolerance so the amps with those are very consistent in sound from amp to amp. 4. What is the advantage of a metal film resistor over a carbon resistor?The advantages that a metal film resistor has over a carbon composition resistor is that they don't change their value with age and their tolerance is better than the carbon resistor. 5. How do you identify a metal film resistor?Common carbon film resistors are mostly yellow or pink due to their low accuracy and low production costs, while most metal film resistors are blue. There is a layer of black protective paint on the surface of carbon film resistors, while metal film resistors are usually coated with bright white protective films. 6. What is the advantage of a metal film resistor?Metal film resistor has a low-temperature co-efficient of resistance. The rate at which the resistance of the material changes with a change in temperature is called the temperature coefficient of resistance. Metal film resistors have a low-temperature coefficient of resistance. 7. What is a carbon film resistor used for?The carbon film resistor is a type of fixed resistor that uses carbon film to restrict the electric current to a certain level. These types of resistors are widely used in electronic circuits. 8. Are metal film resistors inductive?Film resistors may be approximately classified as follows: values < 100Ω are inductive. values between 100Ω and 470Ω are practically true resistive. 9. What is a film resistor?Film Resistor is a general term referring to different types such as Carbon Film, Metal Film, and Metal Oxide Film resistors. They are generally manufactured by depositing pure metals (e.g., nickel) or oxide film (e.g., tin-oxide) onto an insulating ceramic or substrate. 10. What are carbon film resistors made of?Carbon film resistors are a fixed form type resistors. They are constructed out of a ceramic carrier with a thin pure carbon film around it, that functions as resistive material.

Ⅰ IntroductionOne of those imperative passive electrical components that are present in a large range of circuits is capacitors. If you are a DIY enthusiast who is enthusiastic about electronic circuits, it is a must to understand the condenser types to use them correctly in suitable circuits. We help you decode and understand the uses of one of the most common types of capacitors are called the film capacitors here in this article. The fundamentals of capacitors, their forms and when to use them, have already been discussed. Notice that Film Capacitors are known by several names, Polyester Capacitors and Mylar Capacitor are some common ones, all of them, in general, are covered in this article. Capacitors can generally be divided into two broad categories: polarized and nonpolarized. Due to its flexibility and low cost, the film capacitor is a form of non-polarized capacitor and is very common. Read on to learn more about a film condenser: what a film condenser is, how it is made, and what makes it so famous. Let's start with this little passive gadget with a brief introduction.CatalogⅠ IntroductionⅡ Definition of Film CapacitorsⅢ A Variety of CapacitorsⅣ Brief History of Film CapacitorsⅤ Types of Film Capacitors and Their Applications  5.1 Film/Foil Capacitors  5.2 Metalized Film CapacitorsⅥ Features and Applications of Film CapacitorsⅦ How is Film Capacitor different from Electrolytic Capacitor and Ceramic Capacitor?Ⅷ Construction of Film CapacitorⅨ FAQⅡ Definition of Film CapacitorsThe film capacitor is a non-polarized capacitor and thin plastic films are used to produce its dielectric. These plastic films are often metalized and are available under the name of 'metalized condenser' on the market. Such capacitors are also often referred to as plastic capacitors or metalized capacitors. A Thin Film Capacitor is nothing but a plastic film with bipolar capacitors as their dielectric. To form a roll or a candy-like rectangular shape, these films are either metalized or just put in layers. Polypropylene(PP) /Polyethylene terephthalate (PET)/ Polytetrafluoroethylene(PTFE)/Polyphenylene Sulfide (PET) are the dielectrics widely used (PPS) The primary benefit of using a film capacitor is that it has a very low distortion factor and excellent frequency features. The wide variety of plastic film used for various film condensers makes them flexible. These capacitors often do not wear off easily and are ideal for applications such as coupling/decoupling circuits, ADC, audio circuits, and many more for high voltage and high-frequency applications. Bypass and decoupling capacitors, which are popular applications for condensers, have also been addressed previously.Ⅲ A Variety of CapacitorsWe need to understand the context behind the common words Film Capacitor, Polyester Capacitor, Mylar Capacitor, and Polypropylene Capacitor before we continue with our post. There are several types of film capacitors depending on the type of dielectric plastic material used in the capacitor, one of which is the most widely used polyester condenser and polypropylene condenser. Often known as Polyester Film Capacitors, the polyester capacitor has a dielectric material made of a polymer named polyethylene terephthalate (PET). This is why often this capacitor is referred to as the PET Film Capacitor. There are several Polyester Capacitor manufacturers, of which Hostaphan is the leading one. The Polyester Capacitor is also often called a Mylar Capacitor to address the vendor term. Below, a typical Mylar capacitor is shown.Another type of film capacitor in which the dielectric material is made of polymer caller polypropylene (PP), is the polypropylene film capacitor, hence the name Polypropylene Film Capacitor or PP Film Capacitor. Below is a typical polypropylene capacitor.Similarly, depending on the type of polymer used for the dielectric, there are more than 10 different types of film capacitors, the properties of which vary slightly, but the overall functionality and application almost remain the same. We will get into the specifics later, but let's dive into history before that.Ⅳ Brief History of Film CapacitorsPaper capacitors were used in the decoupling circuits before film capacitors came into the picture. Impregnated paper that was placed with metal strips and rolled into cylindrical forms was used by paper condensers. Since these capacitors had paper as a dielectric, however, they were not only likely to be vulnerable to environmental defects and were very voluminous in size. Scientists have therefore started to look for a solution that would mitigate these problems. It was at a time when the plastic industry was booming and scientists discovered how long-term stability in terms of its electrical parameters was given by the use of complex plastic films as a dielectric. As multilayers of paper were replaced by only a few sheets of plastic, it also helped to reduce the bulk. As technology progressed, thinner plastics with high reliability decreased the size of these capacitors.Ⅴ Types of Film Capacitors and Their ApplicationsThe plastic industry saw growth in the production of thinner and more robust goods soon after the first film capacitor was introduced. Different kinds of plastic film capacitors have been used as a dielectric to accommodate various circuit applications over the years. There are several film condensers in which the plastic films are actually put between the aluminum foils and there are others in which the plastic film is metalized by a phase in which the metal is coated on the film itself. In general, based on construction, film capacitors can be divided narrowly into two groups. Notice that only the construction is based on the classification.5.1 Film/Foil CapacitorsThe film/foil capacitor, as the name implies, uses plastic films as a dielectric and is mounted within two layers of aluminum foil electrodes. These interleaved layers are so organized that they do not touch each other with the metallic layers. Such capacitors can be either non-inductive or inductive.In such a way that the aluminum foils are located in the middle of the two films, an inductive film foil capacitor is wound. The aluminum foils are not directly attached but through a leading wire that carries the entire winding. A pictorial representation of it is shown in Figure 1.In a non-inductive fill foil capacitor, the aluminum foils are arranged in such a way that each foil is positioned to a certain degree out of the films, such as that shown in Figure 2.Plastic Film Capacitor Characteristics:• High insulation resistance• Good capacitance stability• High efficiency even at high frequency• Dielectric used: Polypropelene(PP)/ Polyethylene terephthalate (PET)/Polytetrafluoroethylene(PTFE)Plastic Film Capacitor ApplicationThe film/foil capacitor application depends on the type of dielectric used. For coupling, decoupling, and bypassing, PET Film/foil capacitors are great. PP Film/Foil (PP) capacitors are a good choice for use in circuits requiring high switching frequencies, such as resonant and oscillator circuits, power supplies, etc.5.2 Metalized Film CapacitorsThe primary distinction between a film foil capacitor and a metalized capacitor is that the metallic electrodes are fused into either side of the dielectric plastic in the latter instead of layering. While it raises the cost and also adds a step in the production process, it has greater reliability and smaller dimensions than in a film foil condenser. To get the desired capacitance value, the thickness of the plastic film can be as low as 0.6μm.Metalized Film Capacitor Characteristics:• Self-healing property: This property helps the capacitor to repair itself if the electrodes are exposed to each other instead of being short-circuited. This increases the capacitor reliability• Compact in dimension and form• Polypropylene(PP)/polyethylene terephthalate(PET)/ polytetrafluoroethylene(PTFE)/ polyphenylene sulfide Dielectric used: polypropylene(PP)/polyethylene terephthalate (PET) (PPS)Metalized Film Capacitor Application:In electronic control circuits, including DC link circuits, pulse circuits, switching circuits, etc., metallic film capacitors are commonly used.  In decoupling and filtering applications, the low power metalized film capacitor finds use.Ⅵ Features and Applications of Film CapacitorsThe film capacitors often provide other features, in addition to the normal use of condensers to accumulate electrical charges. In high-frequency circuits, their bipolar nature and exceptional frequency characteristics make them famous. The standard capacitance value for these capacitors, in general, ranges from 1nF to 30muF. These small passive parts can have a voltage level of as low as 50 V and as high as 2 kV, so they can be used in a wide variety of applications. One of the fascinating facts is that various types of plastic film are used by these film capacitors as a dielectric. In general, each type of film provides a condenser with different temperature and frequency characteristics. Therefore, one can select the best solution for their needs in their circuits with the correct choice of the dielectric. For example, the PP film capacitor would be the best choice if you are looking for a film capacitor to be mounted in a circuit intended for high-power/high-frequency applications, such as induction heaters, for example. A comparison of the frequency and temperature characteristics of 4 different plastic film dielectrics, namely PP, PPS, PEN, and PET, is shown in the figure below. The only difference is the dielectric material between these capacitors and you will note the shift in temperature and frequency is very obvious.Among other aspects, film capacitors are mainly known for their low dissipation factor, stable capacitance, and high insulation resistance, such as negative temperature and high-reliability characteristics. Hence, for a wide range of applications, they are common choices. These film capacitors generate optimum output from simple sample/hold circuits for ADCs, oscillatory circuits, timers, to finding a position in the coupling/decoupling units of high-end electronic power circuits. Over the past few decades, these capacitors have replaced the use of ceramic and electrolyte capacitors in many circuits in automotive and industrial applications. For some applications, let's compare the film capacitor with the other common capacitors and get to know what makes them a better option.Ⅶ How is Film Capacitor different from Electrolytic Capacitor and Ceramic Capacitor?The first difference between these three capacitors that is quite obvious is the type of dielectric used and their construction. While film capacitors use thin sheets of plastic film, ceramic capacitors, like the dielectric, use sheets made of ceramic material. In nature, both of them are bipolar. On the other hand, electrolytic capacitors have oxides that act as dielectrics and are polar. The differences in their production and dielectrics have an enormous impact on their results. As discussed above, a wide variety of capacitance values are available for plastic film/metalized film capacitors. Ceramic capacitors, on the other hand, are only ideal for circuits that have low requirements for capacitance. For specific applications such as analog signal processing and audio circuits, due to the low distortion factor they offer, film capacitors are preferred over ceramic capacitors. Ceramic capacitors also tend to have high nonlinearities at high capacitances that affect the performance of the circuits. Capacitors with high capacitance and a low cost are favored for applications such as coupling/decoupling circuits. Both electrolytic and film capacitors are also good choices to choose from. The ESR (Equivalent Series Resistance) and ESL (Equivalent Series Inductance) value of the capacitor is another major factor that is considered when designing such circuits. As already discussed, in contrast to electrolytic capacitors, film capacitors have a stronger ESR and ESL performance and a much lower distortion factor and are thus favored over aluminum electrolytic capacitors. Also, if the aging time between these three capacitors is compared, film capacitors appear to avoid the wearing out process between them for the longest time. For high voltage and high-frequency applications, this makes them a safer option.Ⅷ Construction of Film CapacitorThe generic method of development for these capacitors begins with the removal of a thin layer of plastic film. This film's thickness determines the capacitance value. Since the capacitance value increases with a decrease in the gap between the electrodes, the higher capacitance value is thus indicated by the lower film thickness. The standard capacitance value for these capacitors, in general, ranges from 1nF to 30muF. Once the film is removed according to the desired capacitance value and the breakdown voltage, either aluminum or zinc is metalized and rolled over to form a' mother roll.' The films are only interlaced between sheets of aluminum foil to form the roll in the case of a film/foil capacitor. A flow diagram of the different steps involved in producing a metalized film capacitor is shown in the figure below.This roll is then manipulated to accommodate the capacitor size and the desired electrical characteristics by several processes such as slitting, winding and flattening. The projecting electrodes are subjected to a metalizing process called 'Schoopage' until the capacitor obtains its desired shape and size. To create a protective coating on the electrodes, liquefied metals such as zinc, aluminum, or tin are used here. To burn away any existing defects on the electrode surface, the lateral ends of the winding are then sprayed with compressed air and then exposed to a voltage. Since the capacitors can be easily influenced by moisture, silicone oil, or some other insulating fluid is impregnated with the winding. Finally, this winding is prepared to be soldered to the capacitor's metallic terminals. The capacitor is subjected to a final round of protection coating until soldered, where its body is dipped into a protected coating or potted on the outer casing.Ⅸ FAQ1. What is a film capacitor?A film capacitor is a plastic capacitor that is used to construct the dielectric and aluminum or zinc is used to construct the electrodes of the capacitor. 2. Can film capacitors explode when overloaded (like electrolytic)?If the overvoltage is very large you can damage them, eventually burn them, as with any electronic component you abuse. But IMHO explosion of film capacitors is not very likely. The danger when dealing with liquid electrolytic capacitors is that the electrolyte is acid, and if they explode they can cause severe injuries, for instance in the eyes. When they are 'abused' with over-voltage or with high reverse voltage (they are polarized, remember…) the pressure inside increases and they eventually explode. To avoid the pressure increases too much, they have 'escape valves' in the same way as high-pressure kitchen boilers have. In the capacitors those escape valves are thin 'weakened spots' in the plastic cover or there are cross-shaped grooves in the aluminum.  3. What is a film capacitor used for?Film capacitors can also be used in a more conventional way as voltage smoothing capacitors, filters, audio crossovers. They can be used to store energy and release it in a high-current pulse when needed. High-current electrical pulses are used to power pulsed lasers or generate lightning discharges. 4. What is the preferred application of a film capacitor?For particular applications like analog signal processing and audio circuits, film capacitors are preferred over ceramic capacitors due to the low distortion factor which they offer. Also at high capacitances, ceramic capacitors tend to have high nonlinearities which affect the performance of the circuits. 5. How do you determine the polarity of a film capacitor?Based on the height of the capacitor leads we can identify which is negative polarity and which is positive polarity. Capacitor whose terminal is longer is a positive polarity terminal or an anode and the capacitor whose terminal is shorter is a negative polarity or cathode. 6. What is an electrolytic or film capacitor?While the active part of electrolytic capacitors, the so-called wound cell, consists of aluminum (anode and cathode foil), paper, and electrolyte, the film capacitor is made of metal-coated plastic film that builds its electrodes. 7. Can I replace the film capacitor with ceramic?Yes, they are interchangeable, but ceramic disc capacitors are considerably more nonlinear in their voltage and frequency response compared to film capacitors. Ceramic caps can also be microphonic. 8. How do you use a film capacitor?Most power capacitors, the largest capacitors made, generally use polypropylene film as the dielectric. PP film capacitors are used for high-frequency high-power applications such as induction heating, pulsed power energy discharge applications, and AC capacitors for electrical distribution. 9. How long do film capacitors last?The MKP1848 film capacitor has a life quoted as 100000 hrs at 70 degC. The life of a Rubycon BXC series wet electrolytic capacitor is quoted as 12000 hrs at 105degC. By way of the '10 degree rule', we can say that the lifetime of the Rubycon electrolytic capacitor at 70 degC would be 96000 hrs. 10. Do film capacitors degrade?The degradation of metalized film capacitors is a concern in applications exposed to high humidity environments. The metalized electrode layer in metalized film capacitors is very thin, typically less than 50 nm, which is susceptible to corrosion due to the ingress of atmospheric moisture.