484:
618:
increased briefly, before dropping abruptly when gas pressure opened the vent. The report of
Hillman and Helmold proved that the cause of the failed capacitors was a faulty electrolyte mixture used by the Taiwanese manufacturers, which lacked the necessary chemical ingredients to ensure the correct pH of the electrolyte over time, for long-term stability of the electrolytic capacitors. Their further conclusion, that the electrolyte with its alkaline pH value had the fatal flaw of a continual buildup of hydroxide without its being converted into the stable oxide, was verified on the surface of the anode foil both photographically and with an EDX-fingerprint analysis of the chemical components.
496:
614:, can be used to produce long-term stable capacitors with high-aqueous electrolytes. Phosphate compounds are mentioned in patents regarding electrolytic capacitors with aqueous electrolytic systems. Since phosphate ions were missing and the electrolyte was also alkaline in the investigated Taiwanese electrolytes, the capacitor evidently lacked any protection against water damage, and the formation of more-stable alumina oxides was inhibited. Therefore, only aluminium hydroxide was generated.
413:
508:
460:
472:
448:
33:
135:
602:
value of the electrolyte could be measured. The electrolyte of the faulty
Taiwanese capacitors was alkaline, with a pH of between 7 and 8. Good comparable Japanese capacitors had an electrolyte that was acidic, with a pH of around 4. As it is known that aluminium can be dissolved by alkaline liquids,
365:
The capacitance should normally degrade to as low as 70% of the rated value, and the ESR increase to twice the rated value, over the normal life span of the component, before it should be considered as a "degradation failure". The life of an electrolytic capacitor with defective electrolyte can be as
218:
The motherboard manufacturer ABIT Computer Corp. was the only affected manufacturer that publicly admitted to defective capacitors obtained from Taiwan capacitor makers being used in its products. However, the company would not reveal the name of the capacitor maker that supplied the faulty products.
146:
The news from the
Holzman publication spread quickly on the Internet and in newspapers, partly due to the spectacular images of the failures – bulging or burst capacitors, expelled sealing rubber and leaking electrolyte on countless circuit boards. Many PC users were affected, and caused an avalanche
542:
left the company, taking the secret water-based electrolyte formula for
Rubycon's ZA and ZL series capacitors, and began working for a Chinese company. The scientist then developed a copy of this electrolyte. Then, some staff members who defected from the Chinese company copied an incomplete version
547:
electrolytic manufacturers in Taiwan, undercutting the prices of the
Japanese manufacturers. This incomplete electrolyte lacked important proprietary ingredients which were essential to the long-term stability of the capacitors and was unstable when packaged in a finished aluminium capacitor. This
431:
Capacitor casing sitting crooked on the circuit board, caused by the bottom rubber plug being pushed out, sometimes with electrolyte having leaked onto the motherboard from the base of the capacitor, visible as dark-brown or black surface deposits on the PCB. The leaked electrolyte can be confused
551:
There are no public court proceedings related to the alleged theft, as
Rubycon's complete electrolyte formula remained secure. However, independent laboratory analysis of defective capacitors has shown that many of the premature failures appear to be associated with high water content and missing
96:
in Japan stole a mis-copied formula for capacitors' electrolytes. He then took the faulty formula to the
Luminous Town Electric company in China, where he had previously been employed. In the same year, the scientist's staff left China, stealing again the mis-copied formula and moving to Taiwan,
214:
While industrial customers confirmed the failures, they were not able to trace the source of the faulty components. The defective capacitors were marked with previously unknown brands such as "Tayeh", "Choyo", or "Chhsi". The marks were not easily linked to familiar companies or product brands.
389:
E-caps can fail without any visible symptoms. Since the electrical characteristics of electrolytic capacitors are the reason for their use, these parameters must be tested with instruments to definitively decide if the devices have failed. But even if the electrical parameters are out of their
617:
The results of chemical analysis were confirmed by measuring electrical capacitance and leakage current in a long-term test lasting 56 days. Due to the chemical corrosion, the oxide layer of these capacitors had been weakened, so after a short time the capacitance and the leakage current
483:
560:
Unimpeded formation of hydroxide (hydration) and associated hydrogen gas production, occurring during "capacitor plague" or "bad capacitors" incidents involving the failure of large numbers of aluminium electrolytic capacitors, has been demonstrated by two researchers at the
595:, to relieve the resulting pressure, the researchers then searched for compounds of this type. Although the analysis methods were very sensitive in detecting such pressure-relieving compounds, no traces of such agents were found within the failed capacitors.
385:
Electrolytic capacitors with an open vent are in the process of drying out, regardless of whether they have good or bad electrolyte. They always show low capacitance values and very high ohmic ESR values. Dry e-caps are therefore electrically useless.
580:, that there was hydrogen gas present in failed capacitors, leading to bulging of the capacitor's case or bursting of the vent. Thus it was proved that the oxidation takes place in accordance with the first step of aluminium oxide formation.
158:
Most of the affected capacitors were produced from 1999 to 2003 and failed between 2002 and 2005. Problems with capacitors produced with an incorrectly formulated electrolyte have affected equipment manufactured up to at least 2007.
361:
at 40 °C, is roughly 6 years. It can be more than 10 years for a 1000 h/105 °C capacitor operating at 40 °C. Electrolytic capacitors that operate at a lower temperature can have a considerably longer lifespan.
121:
These publications informed engineers and other technically interested specialists, but the issue did not receive widespread public exposure until Carey
Holzman published his experiences about "leaking capacitors" in the
424:
Bulging of the vent on top of the capacitor. (The "vent" is stamped into the top of the casing of a can-shaped capacitor, forming a seam that is meant to split to relieve pressure build-up inside, preventing an
495:
432:
with thick elastic glue sometimes used to secure the capacitors against shock. A dark brown or black crust up the side of a capacitor is invariably glue, not electrolyte. The glue itself is harmless.
717:
192:
Many other equipment manufacturers unknowingly assembled and sold boards with faulty capacitors, and as a result the effect of the capacitor plague could be seen in all kinds of devices worldwide.
118:
in
September 2002. Shortly thereafter, two mainstream electronics journals reported the discovery of widespread prematurely failing capacitors, from Taiwanese manufacturers, in motherboards.
211:, following its initial story about defective electrolyte, reported that some large Taiwanese manufacturers of electrolytic capacitors were denying responsibility for defective products.
935:
507:
907:
357:
usually decreases and the ESR usually increases. The normal lifespan of a non-solid electrolytic capacitor of consumer quality, typically rated at 2000 h/85 °C and
150:
The quick spread of the news also resulted in many misinformed users and blogs posting pictures of capacitors that had failed due to reasons other than faulty electrolyte.
240:", or "high ripple current" e-cap series. The advantage of e-caps using an electrolyte composed of 70% water or more is, in particular, a low ESR, which allows a higher
1185:
1151:
Uzawa, Shigeru; Komatsu, Akihiko; Ogawara, Tetsushi; Rubycon
Corporation (2002). "Ultra Low Impedance Aluminium Electrolytic Capacitor with Water based Electrolyte".
849:
471:
808:
879:
654:
1085:
1003:
393:
Non-solid aluminium electrolytic capacitors without visible symptoms, which have improperly formulated electrolyte, typically show two electrical symptoms:
709:
189:
In 2005, Dell spent some US$ 420 million replacing motherboards outright and on the logistics of determining whether a system was in need of replacement.
979:
959:
562:
447:
1391:
Chang, Jeng-Kuei, Liao, Chi-Min, Chen, Chih-Hsiung, Tsai, Wen-Ta, Effect of electrolyte composition on hydration resistance of anodized aluminium oxide
598:
In capacitors in which the internal pressure build-up was so great that the capacitor case was already bulging but the vent had not opened yet, the
1342:
489:
Failed electrolytic capacitors with swollen can tops and expelled rubber seals, dates of manufacture "0106" and "0206" (January and February 2006)
420:
When examining a failed electronic device, the failed capacitors can easily be recognized by clearly visible symptoms that include the following:
1394:
923:
607:(EDX or EDS) fingerprint analysis of the electrolyte of the faulty capacitors was made, which detected dissolved aluminium in the electrolyte.
459:
1450:
1435:
1427:
1417:
1212:
832:
604:
566:
36:
Failed aluminium electrolytic capacitors with open vents in the top of the can, and visible dried electrolyte residue (reddish-brown color)
1031:
97:
where they created their own company, producing capacitors and propagating even more of this faulty formula of capacitor electrolytes.
696:
1471:
1460:
1261:
750:
905:
1285:
534:
was implicated in the capacitor plague, in connection with the theft of an electrolyte formula. A materials scientist working for
1501:
45:
1440:
W. J. Bernard, J. J. Randall Jr., The Reaction between Anodic Aluminium Oxide and Water, 1961 ECS - The Electrochemical Society
1412:
H. Kaesche, Die Korrosion der Metalle - Physikalisch-chemische Prinzipien und aktuelle Probleme, Springer-Verlag, Berlin, 2011,
1301:
1178:
232:
The non-solid aluminium electrolytic capacitors with improperly formulated electrolyte mostly belonged to the so-called "low
904:
W. BONOMO, G. HOOPER, D. RICHARDSON, D. ROBERTS, and TH. VAN DE STEEG, Vishay Intertechnology, Failure modes in capacitors,
610:
To protect the metallic aluminium against the aggressiveness of the water, some phosphate compounds, known as inhibitors or
1370:
1125:
857:
403:
increased capacitance value, up to twice the rated value, which fluctuates after heating and cooling of the capacitor body
366:
little as two years. The capacitor may fail prematurely after reaching approximately 30% to 50% of its expected lifetime.
1227:
The Aluminium Electrolytic Condenser, H. 0. Siegmund, Bell System Technical Journal, v8, 1. January 1229, pp. 41–63
233:
76:
1496:
829:
Carey Holzman, Overclockers, Capacitors: Not Just For Abit Owners, Motherboards with leaking capacitors, 10/9, 2002,
92:
claimed that the cause of the faulty capacitors was due to a mis-copied formula. In 2001, a scientist working in the
883:
669:
1100:
1001:
56:
accompanied by gas generation; this often resulted in rupturing of the case of the capacitor from the build-up of
353:
All electrolytic capacitors with non-solid electrolyte age over time, due to evaporation of the electrolyte. The
428:
Ruptured or cracked vent, often accompanied by visible crusty rust-like brown or red dried electrolyte deposits.
1335:
Identification of Missing or Insufficient Electrolyte Constituents in Failed Aluminium Electrolytic Capacitors
975:
957:
611:
501:
Failed capacitor has exploded and exposed internal elements, and another has partially blown off its casing
1059:
583:
Because it has been customary in electrolytic capacitors to bind the excess hydrogen by using reducing or
1333:
398:
358:
374:
The electrical characteristics of a failed electrolytic capacitor with an open vent are the following:
1491:
1392:
531:
237:
778:
1486:
830:
535:
412:
241:
93:
1210:
32:
1236:
A. Güntherschulze, H. Betz, Elektrolytkondensatoren, Verlag Herbert Cram, Berlin, 2. Auflage 1952
573:
513:
Failed Choyo capacitors (black color) which have leaked brownish electrolyte onto the motherboard
1467:
1456:
1446:
1431:
1423:
1422:
C. Vargel, Corrosion of Aluminium, 1st Edition, 2 October 2004, Elsevier Science, Print Book
1413:
1282:
Blown, Burst and Leaking Motherboard Capacitors - A Serious Problem, PCSTATS, 15 January 2005
1160:
800:
577:
80:
1023:
792:
548:
faulty electrolyte allowed the unimpeded formation of hydroxide and produced hydrogen gas.
1398:
1289:
1216:
1007:
1000:
The guardian technology blog, How a stolen capacitor formula ended up costing Dell $ 300m
963:
911:
836:
179:
88:
1249:
740:
390:
specifications, the assignment of failure to the electrolyte problem is not a certainty.
48:
between 1999 and 2007, especially those from some Taiwanese manufacturers, due to faulty
244:, and decreased production costs, water being the least costly material in a capacitor.
1283:
1209:
Sam G. Parler, Cornell Dubilier, Deriving Life Multipliers for Electrolytic Capacitors
196:
163:
1480:
1310:
783:
139:
67:
occurred in many well-known brands of electronics, and were particularly evident in
1445:
Ch. Vargel, M. Jacques, M. P. Schmidt, Corrosion of Aluminium, 2004 Elsevier B.V.,
1019:
853:
655:"Low-ESR Aluminium Electrolytic Failures Linked to Taiwanese Raw Material Problems"
123:
64:
1367:"Low-ESR Aluminum Electrolytic Failures Linked to Taiwanese Raw Material Problems"
1303:
Low-ESR Aluminium Electrolytic Failures Linked to Taiwanese Raw Material Problems
1366:
588:
584:
354:
134:
68:
49:
17:
1129:
796:
138:
Results of fire on a printed circuit board, caused by leaked electrolyte which
175:
72:
1164:
804:
477:
Failed Tayeh capacitors which have vented subtly through their aluminium tops
416:
Closeup of a broken electrolytic capacitor vent and dried electrolyte residue
1257:
544:
53:
956:
Michael Singer, CNET News, Bulging capacitors haunt Dell, 31 October 2005
44:
was a problem related to a higher-than-expected failure rate of non-solid
1441:
745:
627:
147:
of reports and comments on thousands of blogs and other web communities.
57:
931:
1466:
Wiberg, E. and Holleman, A. F. (2001). Inorganic Chemistry. Elsevier.
880:"Capacitor failures plague motherboard vendors, GEEK, 7 February 2003"
248:
Comparison of aluminium e-caps with different non-solid electrolytes
111:
1126:"Capacitor plague, identifizierte Hersteller (~identified vendors)"
1455:
Patnaik, P. (2002). Handbook of Inorganic Chemicals. McGraw-Hill.
592:
539:
411:
183:
133:
31:
739:
Sperling, Ed; Soderstrom, Thomas; Holzman, Carey (October 2002).
453:
Failed Chhsi capacitor with crusty electrolyte buildup on the top
1053:
779:"Faults & Failures: Leaking capacitors muck up motherboards"
199:
repair instructions were written and published on the Internet.
171:
114:
raw material problems were reported by the specialist magazine
195:
Because not all manufacturers had offered recalls or repairs,
167:
710:"Stolen formula for capacitors causing computers to burn out"
697:
The Capacitor Plague, Posted on 26 November 2010 by PC Tools
599:
1179:"A. Albertsen, Electrolytic Capacitor Lifetime Estimation"
976:"Michael Singer, CNET News, PCs plagued by bad capacitors"
1153:
Journal of Reliability Engineering Association of Japan
1024:"Suit Over Faulty Computers Highlights Dell's Decline"
668:(5). Paumanok Publications: 10, 12, 31. Archived from
186:
were affected by capacitors with faulty electrolytes.
850:"Taiwanese component problems may cause mass recalls"
543:
of the formula and began to market it to many of the
378:
capacitance value decreases to below the rated value
1128:. Opencircuits.com. 10 January 2012. Archived from
1099:(6). Paumanok Publications: 6, 8–10. Archived from
924:"Mainboardhersteller steht für Elko-Ausfall gerade"
552:inhibitors in the electrolyte, as described below.
438:Visible symptoms of failed electrolytic capacitors
772:
770:
768:
465:Failed capacitors next to CPU motherboard socket
777:Chiu, Yu-Tzu; Moore, Samuel K (February 2003).
1244:
1242:
8:
572:The two scientists initially determined, by
1327:
1325:
1323:
1086:"Taiwanese Cap Makers Deny Responsibility"
648:
646:
644:
642:
563:Center for Advanced Life Cycle Engineering
246:
1079:
1077:
692:
690:
27:Period of high failure rate of capacitors
1332:Hillman, Craig; Helmold, Norman (2004),
1250:"Motherboard Capacitor Problem Blows Up"
603:but not that which is mildly acidic, an
638:
443:
207:In the November/December 2002 issue of
162:Major vendors of motherboards such as
110:The first flawed capacitors linked to
982:from the original on 14 December 2014
938:from the original on 25 December 2014
753:from the original on 28 February 2014
7:
1191:from the original on 17 January 2015
1055:Repair and bad capacitor information
1034:from the original on 28 January 2021
605:energy-dispersive X-ray spectroscopy
569:who analyzed the failed capacitors.
527:Implications of industrial espionage
811:from the original on 5 January 2018
1084:Liotta, Bettyann (November 2002).
1062:from the original on 12 April 2022
381:ESR increases to very high values.
25:
1373:from the original on 22 June 2017
1348:from the original on 26 June 2011
1264:from the original on 14 June 2012
46:aluminium electrolytic capacitors
720:from the original on 25 May 2015
506:
494:
482:
470:
458:
446:
397:relatively high and fluctuating
930:(in German) (online ed.),
848:Hales, Paul (5 November 2002).
708:Arthur, Charles (31 May 2003).
291:036 RSP, 100 μF, 10 V
1167:. Accession number 02A0509168.
653:D. M. Zogbi (September 2002).
556:Incomplete electrolyte formula
307:boric-acid (borax) electrolyte
1:
234:equivalent series resistance
312:SMQ, 100 μF, 10 V
305:Non-solid, ethylene-glycol,
270:at 100 kHz, 20 °C
1518:
1093:Passive Component Industry
797:10.1109/MSPEC.2003.1176509
662:Passive Component Industry
333:ZL, 100 μF, 10 V
209:Passive Component Industry
116:Passive Component Industry
1397:24 September 2015 at the
1309:, Molalla, archived from
142:conductors carrying power
962:14 December 2014 at the
910:14 December 2014 at the
52:composition that caused
1502:Product safety scandals
835:18 October 2014 at the
328:water-based electrolyte
126:performance community.
1288:16 August 2016 at the
591:nitrogen compounds or
567:University of Maryland
417:
228:Common characteristics
143:
37:
415:
137:
35:
1215:4 March 2016 at the
1006:3 March 2016 at the
532:Industrial espionage
1106:on 20 November 2015
587:compounds, such as
370:Electrical symptoms
286:organic electrolyte
275:Max. ripple current
249:
106:First announcements
94:Rubycon Corporation
1497:Corporate scandals
1028:The New York Times
886:on 13 January 2015
574:ion chromatography
418:
247:
144:
86:A 2003 article in
81:personal computers
38:
1451:978-0-08-044495-6
1436:978-0-08-047236-2
1428:978-0-08-044495-6
1418:978-3-642-18427-7
1341:, DFR solutions,
1058:, Capacitor Lab,
712:. Business News.
578:mass spectrometry
349:Premature failure
346:
345:
277:at 85/105 °C
16:(Redirected from
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1316:on 26 April 2012
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1132:on 11 March 2015
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1022:(28 June 2010).
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914:
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882:. Archived from
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856:. Archived from
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408:Visible symptoms
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130:Public attention
42:capacitor plague
21:
18:Capacitor Plague
1517:
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1512:
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1407:Further reading
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1399:Wayback Machine
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1290:Wayback Machine
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1260:. 11 May 2003.
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1217:Wayback Machine
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714:The Independent
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675:on 3 March 2016
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140:short-circuited
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89:The Independent
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1159:(4): 276–283.
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860:on 10 May 2011
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203:Responsibility
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197:do it yourself
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77:power supplies
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1472:0-12-352651-5
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1461:0-07-049439-8
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65:failure rates
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1387:
1375:. Retrieved
1361:
1350:, retrieved
1334:
1311:the original
1302:
1296:
1278:
1266:. Retrieved
1254:Silicon Chip
1253:
1232:
1223:
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1193:. Retrieved
1173:
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1134:. Retrieved
1130:the original
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1101:the original
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1036:. Retrieved
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940:, retrieved
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884:the original
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862:. Retrieved
858:the original
854:The Inquirer
843:
825:
813:. Retrieved
791:(2): 16–17.
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755:. Retrieved
744:
741:"Got Juice?"
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253:Electrolyte
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124:overclocking
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69:motherboards
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1492:Motherboard
1195:4 September
1136:3 September
986:14 December
942:14 December
890:14 December
757:11 February
612:passivators
425:explosion.)
355:capacitance
73:video cards
50:electrolyte
1487:Capacitors
1481:Categories
1110:3 November
724:16 January
634:References
261:Dimensions
154:Prevalence
1352:2 January
1165:0919-2697
815:22 August
805:0018-9235
545:aluminium
359:operating
326:Non-solid
284:Non-solid
238:impedance
112:Taiwanese
54:corrosion
1430:, eBook
1395:Archived
1377:16 March
1371:Archived
1343:archived
1286:Archived
1262:Archived
1213:Archived
1186:Archived
1066:26 April
1060:archived
1032:Archived
1004:Archived
980:Archived
960:Archived
936:archived
908:Archived
864:20 March
833:Archived
809:Archived
751:Archived
746:EE Times
718:Archived
628:RKM code
622:See also
589:aromatic
268:Max. ESR
223:Symptoms
58:pressure
1268:7 March
1038:8 March
679:15 June
565:of the
536:Rubycon
331:Rubycon
101:History
1470:
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1416:
1163:
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593:amines
336:5 × 11
315:5 × 11
294:5 × 11
289:Vishay
182:, and
75:, and
1346:(PDF)
1339:(PDF)
1314:(PDF)
1307:(PDF)
1189:(PDF)
1182:(PDF)
1104:(PDF)
1089:(PDF)
928:Heise
673:(PDF)
658:(PDF)
540:Japan
279:(mA)
272:(mΩ)
265:(mm)
263:D × L
184:Intel
176:Apple
63:High
1468:ISBN
1457:ISBN
1447:ISBN
1432:ISBN
1424:ISBN
1414:ISBN
1379:2022
1354:2009
1270:2012
1197:2014
1161:ISSN
1138:2014
1112:2015
1068:2022
1040:2012
988:2014
944:2014
892:2014
866:2023
817:2014
801:ISSN
759:2014
726:2020
681:2018
576:and
342:250
321:180
300:160
297:1000
172:Dell
164:Abit
40:The
793:doi
538:in
339:300
318:900
310:NCC
168:IBM
79:of
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1258:AU
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1157:24
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600:pH
180:HP
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