473:
607:
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.
485:
603:, 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.
402:
497:
449:
461:
437:
22:
124:
591:
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,
354:
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
207:
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.
135:
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
531:
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
536:
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
420:
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
540:
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
85:
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,
203:
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.
378:
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
606:
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
472:
549:
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
584:, 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.
374:
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.
569:, 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.
147:
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.
350:
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.
110:
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
413:
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
484:
421:
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.
706:
181:
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.
107:
in
September 2002. Shortly thereafter, two mainstream electronics journals reported the discovery of widespread prematurely failing capacitors, from Taiwanese manufacturers, in motherboards.
200:, following its initial story about defective electrolyte, reported that some large Taiwanese manufacturers of electrolytic capacitors were denying responsibility for defective products.
924:
496:
896:
346:
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
139:
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.
229:", 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
1174:
1140:
Uzawa, Shigeru; Komatsu, Akihiko; Ogawara, Tetsushi; Rubycon
Corporation (2002). "Ultra Low Impedance Aluminium Electrolytic Capacitor with Water based Electrolyte".
838:
460:
797:
868:
643:
1074:
992:
382:
Non-solid aluminium electrolytic capacitors without visible symptoms, which have improperly formulated electrolyte, typically show two electrical symptoms:
698:
178:
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.
968:
948:
551:
436:
1380:
Chang, Jeng-Kuei, Liao, Chi-Min, Chen, Chih-Hsiung, Tsai, Wen-Ta, Effect of electrolyte composition on hydration resistance of anodized aluminium oxide
587:
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
1331:
478:
Failed electrolytic capacitors with swollen can tops and expelled rubber seals, dates of manufacture "0106" and "0206" (January and February 2006)
409:
When examining a failed electronic device, the failed capacitors can easily be recognized by clearly visible symptoms that include the following:
1383:
912:
596:(EDX or EDS) fingerprint analysis of the electrolyte of the faulty capacitors was made, which detected dissolved aluminium in the electrolyte.
448:
1439:
1424:
1416:
1406:
1201:
821:
593:
555:
25:
Failed aluminium electrolytic capacitors with open vents in the top of the can, and visible dried electrolyte residue (reddish-brown color)
1020:
86:
where they created their own company, producing capacitors and propagating even more of this faulty formula of capacitor electrolytes.
685:
1460:
1449:
1250:
739:
894:
1274:
523:
was implicated in the capacitor plague, in connection with the theft of an electrolyte formula. A materials scientist working for
1490:
34:
1429:
W. J. Bernard, J. J. Randall Jr., The Reaction between Anodic Aluminium Oxide and Water, 1961 ECS - The Electrochemical Society
1401:
H. Kaesche, Die Korrosion der Metalle - Physikalisch-chemische Prinzipien und aktuelle Probleme, Springer-Verlag, Berlin, 2011,
1290:
1167:
221:
The non-solid aluminium electrolytic capacitors with improperly formulated electrolyte mostly belonged to the so-called "low
893:
W. BONOMO, G. HOOPER, D. RICHARDSON, D. ROBERTS, and TH. VAN DE STEEG, Vishay Intertechnology, Failure modes in capacitors,
599:
To protect the metallic aluminium against the aggressiveness of the water, some phosphate compounds, known as inhibitors or
1359:
1114:
846:
392:
increased capacitance value, up to twice the rated value, which fluctuates after heating and cooling of the capacitor body
355:
little as two years. The capacitor may fail prematurely after reaching approximately 30% to 50% of its expected lifetime.
1216:
The Aluminium Electrolytic Condenser, H. 0. Siegmund, Bell System Technical Journal, v8, 1. January 1229, pp. 41–63
222:
65:
1485:
818:
Carey Holzman, Overclockers, Capacitors: Not Just For Abit Owners, Motherboards with leaking capacitors, 10/9, 2002,
81:
claimed that the cause of the faulty capacitors was due to a mis-copied formula. In 2001, a scientist working in the
872:
658:
1089:
990:
45:
accompanied by gas generation; this often resulted in rupturing of the case of the capacitor from the build-up of
342:
All electrolytic capacitors with non-solid electrolyte age over time, due to evaporation of the electrolyte. The
417:
Ruptured or cracked vent, often accompanied by visible crusty rust-like brown or red dried electrolyte deposits.
1324:
Identification of Missing or Insufficient Electrolyte Constituents in Failed Aluminium Electrolytic Capacitors
964:
946:
600:
490:
Failed capacitor has exploded and exposed internal elements, and another has partially blown off its casing
1048:
572:
Because it has been customary in electrolytic capacitors to bind the excess hydrogen by using reducing or
1322:
387:
347:
363:
The electrical characteristics of a failed electrolytic capacitor with an open vent are the following:
1480:
1381:
520:
226:
767:
1475:
819:
524:
401:
230:
82:
1199:
21:
1225:
A. Güntherschulze, H. Betz, Elektrolytkondensatoren, Verlag Herbert Cram, Berlin, 2. Auflage 1952
562:
502:
Failed Choyo capacitors (black color) which have leaked brownish electrolyte onto the motherboard
1456:
1445:
1435:
1420:
1412:
1411:
C. Vargel, Corrosion of Aluminium, 1st Edition, 2 October 2004, Elsevier Science, Print Book
1402:
1271:
Blown, Burst and Leaking Motherboard Capacitors - A Serious Problem, PCSTATS, 15 January 2005
1149:
789:
566:
69:
1012:
781:
537:
faulty electrolyte allowed the unimpeded formation of hydroxide and produced hydrogen gas.
1387:
1278:
1205:
996:
989:
The guardian technology blog, How a stolen capacitor formula ended up costing Dell $ 300m
952:
900:
825:
168:
77:
1238:
729:
379:
specifications, the assignment of failure to the electrolyte problem is not a certainty.
37:
between 1999 and 2007, especially those from some Taiwanese manufacturers, due to faulty
233:, and decreased production costs, water being the least costly material in a capacitor.
1272:
1198:
Sam G. Parler, Cornell Dubilier, Deriving Life Multipliers for Electrolytic Capacitors
185:
152:
1469:
1299:
772:
128:
56:
occurred in many well-known brands of electronics, and were particularly evident in
1434:
Ch. Vargel, M. Jacques, M. P. Schmidt, Corrosion of Aluminium, 2004 Elsevier B.V.,
1008:
842:
644:"Low-ESR Aluminium Electrolytic Failures Linked to Taiwanese Raw Material Problems"
112:
53:
1356:"Low-ESR Aluminum Electrolytic Failures Linked to Taiwanese Raw Material Problems"
1292:
Low-ESR Aluminium Electrolytic Failures Linked to Taiwanese Raw Material Problems
1355:
577:
573:
343:
123:
57:
38:
1118:
785:
127:
Results of fire on a printed circuit board, caused by leaked electrolyte which
164:
61:
1153:
793:
466:
Failed Tayeh capacitors which have vented subtly through their aluminium tops
405:
Closeup of a broken electrolytic capacitor vent and dried electrolyte residue
1246:
533:
42:
945:
Michael Singer, CNET News, Bulging capacitors haunt Dell, 31 October 2005
33:
was a problem related to a higher-than-expected failure rate of non-solid
1430:
734:
616:
136:
of reports and comments on thousands of blogs and other web communities.
46:
920:
1455:
Wiberg, E. and Holleman, A. F. (2001). Inorganic Chemistry. Elsevier.
869:"Capacitor failures plague motherboard vendors, GEEK, 7 February 2003"
237:
Comparison of aluminium e-caps with different non-solid electrolytes
100:
1115:"Capacitor plague, identifizierte Hersteller (~identified vendors)"
1444:
Patnaik, P. (2002). Handbook of Inorganic Chemicals. McGraw-Hill.
581:
528:
400:
172:
122:
20:
728:
Sperling, Ed; Soderstrom, Thomas; Holzman, Carey (October 2002).
442:
Failed Chhsi capacitor with crusty electrolyte buildup on the top
1042:
768:"Faults & Failures: Leaking capacitors muck up motherboards"
188:
repair instructions were written and published on the Internet.
160:
103:
raw material problems were reported by the specialist magazine
184:
Because not all manufacturers had offered recalls or repairs,
156:
699:"Stolen formula for capacitors causing computers to burn out"
686:
The Capacitor Plague, Posted on 26 November 2010 by PC Tools
588:
1168:"A. Albertsen, Electrolytic Capacitor Lifetime Estimation"
965:"Michael Singer, CNET News, PCs plagued by bad capacitors"
1142:
Journal of Reliability Engineering Association of Japan
1013:"Suit Over Faulty Computers Highlights Dell's Decline"
657:(5). Paumanok Publications: 10, 12, 31. Archived from
175:
were affected by capacitors with faulty electrolytes.
839:"Taiwanese component problems may cause mass recalls"
532:
of the formula and began to market it to many of the
367:
capacitance value decreases to below the rated value
1117:. Opencircuits.com. 10 January 2012. Archived from
1088:(6). Paumanok Publications: 6, 8–10. Archived from
913:"Mainboardhersteller steht für Elko-Ausfall gerade"
541:inhibitors in the electrolyte, as described below.
427:Visible symptoms of failed electrolytic capacitors
761:
759:
757:
454:Failed capacitors next to CPU motherboard socket
766:Chiu, Yu-Tzu; Moore, Samuel K (February 2003).
1233:
1231:
8:
561:The two scientists initially determined, by
1316:
1314:
1312:
1075:"Taiwanese Cap Makers Deny Responsibility"
637:
635:
633:
631:
552:Center for Advanced Life Cycle Engineering
235:
1068:
1066:
681:
679:
16:Period of high failure rate of capacitors
1321:Hillman, Craig; Helmold, Norman (2004),
1239:"Motherboard Capacitor Problem Blows Up"
592:but not that which is mildly acidic, an
627:
432:
196:In the November/December 2002 issue of
151:Major vendors of motherboards such as
99:The first flawed capacitors linked to
971:from the original on 14 December 2014
927:from the original on 25 December 2014
742:from the original on 28 February 2014
7:
1180:from the original on 17 January 2015
1044:Repair and bad capacitor information
1023:from the original on 28 January 2021
594:energy-dispersive X-ray spectroscopy
558:who analyzed the failed capacitors.
516:Implications of industrial espionage
800:from the original on 5 January 2018
1073:Liotta, Bettyann (November 2002).
1051:from the original on 12 April 2022
370:ESR increases to very high values.
14:
1362:from the original on 22 June 2017
1337:from the original on 26 June 2011
1253:from the original on 14 June 2012
35:aluminium electrolytic capacitors
709:from the original on 25 May 2015
495:
483:
471:
459:
447:
435:
386:relatively high and fluctuating
919:(in German) (online ed.),
837:Hales, Paul (5 November 2002).
697:Arthur, Charles (31 May 2003).
280:036 RSP, 100 μF, 10 V
1156:. Accession number 02A0509168.
642:D. M. Zogbi (September 2002).
545:Incomplete electrolyte formula
296:boric-acid (borax) electrolyte
1:
223:equivalent series resistance
301:SMQ, 100 μF, 10 V
294:Non-solid, ethylene-glycol,
259:at 100 kHz, 20 °C
1507:
1082:Passive Component Industry
786:10.1109/MSPEC.2003.1176509
651:Passive Component Industry
322:ZL, 100 μF, 10 V
198:Passive Component Industry
105:Passive Component Industry
1386:24 September 2015 at the
1298:, Molalla, archived from
131:conductors carrying power
951:14 December 2014 at the
899:14 December 2014 at the
41:composition that caused
1491:Product safety scandals
824:18 October 2014 at the
317:water-based electrolyte
115:performance community.
1277:16 August 2016 at the
580:nitrogen compounds or
556:University of Maryland
406:
217:Common characteristics
132:
26:
404:
126:
24:
1204:4 March 2016 at the
995:3 March 2016 at the
521:Industrial espionage
1095:on 20 November 2015
576:compounds, such as
359:Electrical symptoms
275:organic electrolyte
264:Max. ripple current
238:
95:First announcements
83:Rubycon Corporation
1486:Corporate scandals
1017:The New York Times
875:on 13 January 2015
563:ion chromatography
407:
236:
133:
75:A 2003 article in
70:personal computers
27:
1440:978-0-08-044495-6
1425:978-0-08-047236-2
1417:978-0-08-044495-6
1407:978-3-642-18427-7
1330:, DFR solutions,
1047:, Capacitor Lab,
701:. Business News.
567:mass spectrometry
338:Premature failure
335:
334:
266:at 85/105 °C
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1369:
1367:
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1305:on 26 April 2012
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1126:
1121:on 11 March 2015
1111:
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1079:
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1061:
1059:
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1056:
1039:
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1011:(28 June 2010).
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871:. Archived from
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845:. Archived from
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397:Visible symptoms
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119:Public attention
31:capacitor plague
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1396:Further reading
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1388:Wayback Machine
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1249:. 11 May 2003.
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703:The Independent
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664:on 3 March 2016
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388:leakage current
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129:short-circuited
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78:The Independent
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1148:(4): 276–283.
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849:on 10 May 2011
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192:Responsibility
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186:do it yourself
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66:power supplies
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1461:0-12-352651-5
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1450:0-07-049439-8
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1300:the original
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1255:. Retrieved
1243:Silicon Chip
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1119:the original
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847:the original
843:The Inquirer
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780:(2): 16–17.
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730:"Got Juice?"
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1481:Motherboard
1184:4 September
1125:3 September
975:14 December
931:14 December
879:14 December
746:11 February
601:passivators
414:explosion.)
344:capacitance
62:video cards
39:electrolyte
1476:Capacitors
1470:Categories
1099:3 November
713:16 January
623:References
250:Dimensions
143:Prevalence
1341:2 January
1154:0919-2697
804:22 August
794:0018-9235
534:aluminium
348:operating
315:Non-solid
273:Non-solid
227:impedance
101:Taiwanese
43:corrosion
1419:, eBook
1384:Archived
1366:16 March
1360:Archived
1332:archived
1275:Archived
1251:Archived
1202:Archived
1175:Archived
1055:26 April
1049:archived
1021:Archived
993:Archived
969:Archived
949:Archived
925:archived
897:Archived
853:20 March
822:Archived
798:Archived
740:Archived
735:EE Times
707:Archived
617:RKM code
611:See also
578:aromatic
257:Max. ESR
212:Symptoms
47:pressure
1257:7 March
1027:8 March
668:15 June
554:of the
525:Rubycon
320:Rubycon
90:History
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582:amines
325:5 × 11
304:5 × 11
283:5 × 11
278:Vishay
171:, and
64:, and
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917:Heise
662:(PDF)
647:(PDF)
529:Japan
268:(mA)
261:(mΩ)
254:(mm)
252:D × L
173:Intel
165:Apple
52:High
1457:ISBN
1446:ISBN
1436:ISBN
1421:ISBN
1413:ISBN
1403:ISBN
1368:2022
1343:2009
1259:2012
1186:2014
1150:ISSN
1127:2014
1101:2015
1057:2022
1029:2012
977:2014
933:2014
881:2014
855:2023
806:2014
790:ISSN
748:2014
715:2020
670:2018
565:and
331:250
310:180
289:160
286:1000
161:Dell
153:Abit
29:The
782:doi
527:in
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307:900
299:NCC
157:IBM
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