With the automotive industry moving towards electrification, intelligence, and connectivity, new automotive electronic engineering architectures are rapidly shifting from traditional distributed ECUs to domain control, zone architecture, and central computing platforms. The increased system integration, significant enhancement of processor computing performance, and the introduction of high-speed sensors and communication interfaces pose unprecedented challenges to in-vehicle power quality, signal stability, and environmental tolerance. To ensure the precise operation of the entire vehicle's electronic system under harsh conditions such as high temperature, high vibration, and strong electromagnetic interference, automotive-grade passive components (including polymer capacitors, multilayer ceramic capacitors, and in-vehicle high-speed connectors, etc.) are playing an indispensable foundational role. This article briefly introduces the roles these passive components play in automotive electronics and the related product characteristics of the YAGEO Group (including KEMET and Pulse).
Evolution of automotive electronic engineering architectures ushers in new application requirements
Automotive electronics are experiencing rapid growth, with a Compound Annual Growth Rate (CAGR) of approximately 8.0%, and the market size is projected to reach $315 billion by 2025. Within this, ADAS has a CAGR of 11.8%, with an expected market size of $21 billion by 2025. The ADAS LiDAR market, driven by vehicle automation, has shown significant growth, projected to increase from $230 million in 2021 to $5 billion in 2025.
The evolution of automotive electronic engineering architectures is progressing from modularization, where each function corresponds to an independent ECU, towards integration - merging ECUs and integrating hardware/software functions into a reduced number of ECUs. This further advances to centralization, focusing on Domain Control Units (DCUs) and standardization of basic control units. It gradually evolves to DCU fusion and ultimately to consolidating all DCU functions into a centralized vehicle computer. The latest trend involves shifting embedded functions to the cloud, realizing automotive cloud computing.
Within these development trends, polymer capacitors, multilayer ceramic capacitors, and communication connectors each play crucial roles in automotive applications. Polymer capacitors, known for their low Equivalent Series Resistance (ESR), high ripple current capability, and excellent temperature and lifetime characteristics, are key components in automotive power management and high-load environments. They are used for power supply filtering and decoupling, high current load buffering, enhancing system reliability, and supporting EV/HEV high-voltage systems.
Multilayer Ceramic Capacitors (MLCCs), valued for their small size, fast frequency response, and high reliability, are the most widely used passive components in automotive electronics. They are primarily used for high-speed decoupling and bypass, power supply filtering and noise suppression (EMI/EMC), ADAS, and electric vehicle power control. They must withstand high temperatures, offer high reliability, comply with AEC-Q200 standards, and endure high temperatures, vibration, and long-term operation.
Communication connectors are evolving alongside the vehicle's electronic architecture towards domain control/zone architecture. These connectors ensure the reliable transmission of high-speed data, power, and safety signals within the vehicle. Key applications include high-speed data transmission channels, connections for critical control systems, power and mixed-signal transmission, with requirements for environmental resistance, vibration resistance, and EMI immunity.
Automotive grade polymer tantalum capacitors with multiple technical advantages
YAGEO Group provides automotive-grade components compliant with industry standards such as AEC-Q200 and VW AUDI 80808, designed with safer failure mechanisms. YAGEO's components have been validated on the road and in the lab, demonstrating an outstanding track record of reliability. YAGEO's automotive-grade products are verified to operate within harsh temperature ranges from -55°C to 165°C and are certified for automotive applications like powertrain, onboard electronics, and charging systems. YAGEO offers a wide variety of AEC-Q200 certified components for automotive applications. These automotive-grade components are available for the Production Part Approval Process (PPAP) and many custom solutions are offered to meet stringent automotive requirements.
YAGEO's automotive-grade polymer tantalum capacitor products cover the T59x polymer series (T591, T597, T598, T599), supporting a capacitance range (µF, RT, 120Hz) from 1.5 to 680µF, a voltage range (Vdc) from 2.5 to 75V, maximum operating temperatures from 105°C to 150°C, a lowest ESR (mΩ, RT, 100kHz) of 6mΩ, and a maximum allowable ripple current ((rms) A, +45°C, 100 kHz) up to 8.7A. Additionally, YAGEO offers MnO₂ automotive product series (T49x-T510, T498, T499), supporting a capacitance range (µF, RT, 120Hz) from 0.1 to 1000µF, a voltage range (Vdc) from 4 to 50V, maximum operating temperatures up to 175°C, a lowest ESR (mΩ, RT, 100kHz) of 175mΩ, and a maximum allowable ripple current ((rms) A, +45°C, 100 kHz) up to 3.9A.
YAGEO's automotive-grade polymer capacitors can be applied in various automotive functions: connectivity (e.g., T598 at 125°C), sensing (e.g., T597/T598 at 125°C), cognitive functions (T598), chassis & safety (T598 at 125°C and T599 at 150°C), and cockpit display (T597/T598 at 125°C). In power battery modules, the T598 and T599 series product lines can be utilized.
YAGEO's polymer capacitors possess multiple technical advantages: high volumetric efficiency saving board space, high energy density (47µF, 35V), solid technology, long life and capacitance stability, with superior performance in capacitance change over time, against DC voltage, across temperature, and versus frequency. Regarding safety, they support a benign failure mode and produce no noise due to the piezoelectric effect. Mechanically, they feature a robust board flex construction. For aerospace applications, they have no altitude limitation. Their derating performance is better than MnO₂ products, and they exhibit superior performance in DC/DC conversion for ripple reduction, enabling reduced component count, saved board space, and lower voltage ripple.
YAGEO's polymer capacitors demonstrate exceptional high-temperature stability, verified by 150°C storage life tests, capable of 5000 hours at 125°C (model: T598D477M004ATE025). They exhibit outstanding performance in capacitance loss/ESR aging. Taking the KEMET T598/T599 series as an example, which utilizes miniaturization and 100% solid technology, they offer longer service life and stable capacitance. After 10,000 hours of continuous operation, capacitance drop is only -10% to -20%, and during 2,000 to 4,000 hours of operation, it's only -20% to -30%. YAGEO's polymer capacitors also feature improved failure models and reliability, with a Random Failure (FR) rate at the 0.1~10ppm level in production line random failure models. YAGEO's polymer capacitors also possess excellent surge current capability, with all conventional reliability testing conducted under steady-state DC voltage.
High voltage MLCCs for charging station applications
Convenient charging stations are a crucial factor for the popularization of electric vehicles. EV charging piles can be segmented into Level 1: AC <2kW, small size for residential use; Level 2: AC 3.9~19.2kW, small size for indoor public spaces; and Level 3: DC 24~300kW, high voltage for public use. The future trend points towards wireless charging, which avoids electric shock risks, reduces power transmission components, and offers greater convenience. High Voltage Multilayer Ceramic Capacitors (MLCCs) play a critical role in the high-power conversion circuits of fast-charging piles.
Key components of an EV charger include EMI filters, PFC (Power Factor Correction), AC-DC and DC-DC converters, as well as filters. Safety capacitors are required in EMI filters. Snubber circuits and High Voltage NPO decoupling capacitors, such as 1210 47pF 1KV types, are used in PFC and converters. Filters require decoupling capacitors like 1210 47pF 2KV. Furthermore, high-frequency capacitors are needed in the communication modules of the Central System Unit (CSU), such as NPO decoupling capacitors rated 16V ~ 500V, and 01005 ~ 0805 size capacitors from 0.1pF ~ 100pF. For power controllers, microprocessors, and displays, general-purpose NPO, X7R capacitors rated 4V ~ 250V, from 0.2pF ~ 47µF, in 0201 ~ 2220 sizes can be used.
YAGEO offers multiple High Voltage NPO MLCCs for commercial high-voltage and automotive high-voltage applications. The automotive high-voltage product line covers specifications like 0805 ~ 1210, 500V ~ 2KV, 10pF ~ 33nF. They are available in various sizes, offer high capacitance options, and can be customized to unique customer specifications. For instance, options available for 500V ~ 3kV ratings include NPO and X7R dielectrics, case sizes (inch) from 0805 ~ 2220, capacitance range from 0.2pF ~ 220nF, encompassing CC General Grade and AC Automotive Grade, presenting the most comprehensive high-voltage portfolio.
YAGEO High Voltage NPO MLCCs feature improved breakdown voltage, enhancing protection against voltage surges and transient spikes. This provides higher safety margins for high-voltage applications, reducing failure risk and ensuring product longevity. Additionally, they exhibit lower temperature rise, offering superior thermal management to minimize overheating risks, extending component lifespan, and improving efficiency in high-load operations. Consequently, they achieve higher reliability: inner electrode continuity has been increased from 85% to 93%, making them more reliable and dependable under stress, providing consistent performance and stronger resistance, and delivering exceptionally reliable performance in challenging environments.
YAGEO also offers safety capacitors certified by UL/TUV, supporting surge protection and high-frequency EMI filtering. They are available in both SC General Termination and ST Soft Termination types. Case sizes include 1808, 2211, 2220. Dielectrics are NPO & X7R. Voltage ratings are X1/Y2, X2 with a rating of 250 VAC, withstanding 1,500 VAC, and impulse voltage of 5,000V (X1/Y2) | 2,500V (X2). The capacitance range is 100pF ~ 5.6nF, with a production lead time of 90 days.
Connectors meeting communication needs for EV charging station applications
In EV charging station applications, for wired communication, YAGEO can provide Common Mode Chokes (CMC) for CAN networks. These support speeds for CAN class I, CAN class II, and CAN-FD class I, with an inductance range covering 11 ~ 100 µH, in 1812 or 1210 packages, operating within a temperature range of -40 to 125°C.
Furthermore, YAGEO/Pulse offers Ethernet connectors suitable for EV charging stations, such as the JXD2 series. It features a 1x1 structure, top entry, supports speeds from 10/100 to 1 Gb, uses voltage/current IC drive, has G/Y, GY/GY, GO/Y (customizable) LEDs, no EMI spring, and uses wave soldering / reflow soldering processes. Another series is the JXD7-06, featuring a 1x1 structure, Tab up, supports PoE, is halogen-free, supports speeds from 10/100 to 2.5 Gb, uses voltage/current IC drive, has G/Y, GY/GY, GO/Y (customizable) LEDs, offers an EMI spring option, and uses wave soldering / reflow soldering processes.
Additionally, YAGEO offers RJ45 connectors (E5J88, E6588 series) for EV charging stations. They feature a small footprint, increasing usable PCB area, use a 1x1 design suitable for 100/1000 Ethernet or RS232/485, have bi-color LEDs for indicating operation mode, and a rugged design operating from -40 to +85°C.
YAGEO/Pulse also introduces a PLC transformer for automotive charging station applications – the BM6154NL. It operates from -40 to 125°C, has a turns ratio of 1:1:1, polarity is determined according to the circuit schematic, DC Resistance (DCR) is 1-3=2-4=5-8= 60mΩ Max, Inductance (OCL) is 8 µH Min at 100kHz, 10mV, Dielectric Withstanding Voltage is 60 sec at 3000 VAC Min for 1-4 to 5-8 (short pins 2 to 3), Insulation Resistance is 1mΩ Min at 100 VDC, and Insertion Loss is 2.25 dB Max (1.5MHz-30MHz) for (1-3) – (2-4) to 8-5.
Conclusion
Facing the challenges brought by new automotive electronic engineering architectures - high-speed computing, high power density, and high integration - the importance of automotive-grade passive components has shifted from a supporting role to a key enabler of system reliability. Whether it's ensuring stable power for domain control and central computing platforms, guaranteeing signal integrity for ADAS and high-speed communication links, or enhancing the safety and durability of electric vehicle high-voltage systems, capacitors, filters, and specialized in-vehicle connectors have become indispensable foundations for ensuring the operation of vehicle electronic functions. The related passive components offered by YAGEO, featuring higher reliability, lower losses, smaller size, and stronger environmental adaptability, can assist you in gaining a key advantage in the next stage of automotive technology competition and drive the realization of safer, more efficient, and more stable system performance in the new generation of intelligent vehicles.