The classic capacitor failure mechanism is dielectric breakdown. The dielectric in the capacitor is subjected to the full potential to which the device is charged and, due to small capacitor physical sizes, high electrical stresses are common. Dielectric breakdowns may develop after many hours of satisfactory operation. Open capacitors usually occur as a result of overstress in an application. For instance, operation of DC rated capacitors at high AC current levels. The following list is a summary of the most common environmentally "critical factors" with respect to capacitors. The design engineer must take into consideration his own applications and the.
In addition to these failures, capacitors may fail due to capacitance drift, instability with temperature, high dissipation factor or low insulation resistance. Failures can be the result of electrical, mechanical, or environmental overstress, "wear-out" due to dielectric degradation during operation, or manufacturing defects.
Paper and plastic film capacitors are subject to two classic failure modes: opens or shorts. Included in these categories are intermittent opens, shorts or high resistance shorts. In addition to these failures, capacitors may fail due to capacitance drift, instability with temperature, high dissipation factor or low insulation resistance.
Catastrophic failure is the complete loss of function of the capacitor in a circuit. Catastrophic failure, such as open or short circuit, is the complete loss of function of the capacitor. This failure can cause the enclosure to explode, smoke, ignite, harm other electrical components, or leak liquid or gas from inside the capacitor.
Common and less well known failure modes associated with capacitor manufacture defects, device and product assembly problems, inappropriate specification for the application, and product misuse are discussed for ceramic, aluminium electrolytic, tantalum and thin film capacitors.
The failure mode of electrolytic capacitors is relatively slow and manifests over periods of months rather than seconds which can be the case with short circuit capacitor failure modes. Therefore condition monitoring may be practical and useful for these components.
The open circuit failure mode results in an almost complete loss of capacitance. The high ESR failure can result in self heating of the capacitor which leads to an increase of internal pressure in the case and loss of electrolyte as the case seal fails and areas local to the capacitor are contaminated with acidic liquid.
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