Systems and methods for determining an operational condition of a capacitor package

Systems and methods for determining an operational condition of a capacitor package are disclosed. According to an aspect, a system may include a capacitor package including a dielectric material operatively connected between a first terminal and a second terminal. The system may include a Zener diode being operatively connected with its cathode at a third terminal and its anode at the second terminal. The system may also include a test pin being conductively connected to the third terminal. The system may also include a testing module configured to receive an electrical output from the test pin. The testing module may also be configured to determine an operational condition of the capacitor package based on the electrical output. The testing module may further be configured to present the operational condition of the capacitor package.

TECHNICAL FIELD

The present disclosure relates to monitoring of electrical components, and more specifically, to determining an operational condition of a capacitor package.

BACKGROUND

Capacitors are prevalent throughout a variety of electrical devices and systems due to their ability to store voltage potential. Capacitors possess this capability due to a dielectric material contained between two terminals of the capacitor. The amount of voltage potential a capacitor can store effectively is based on the type of dielectric material within the capacitor. A dielectric material may be associated with a breakdown voltage, or a maximum voltage level at which the dielectric material can operate efficiently. Once a capacitor begins to operate at a voltage higher equal to or higher than the breakdown voltage level of the dielectric material, the capacitor may begin to operate out of specification. A capacitor operating out of specification may cause an electrical device or system that it is installed in to fail to operate.

Unfortunately, current systems and techniques for detecting whether the dielectric material of a capacitor is beginning to breakdown are either inefficient or not possible. In the manufacturing environment, each capacitor may require to be individually tested prior to installation in electrical devices or systems. Such a testing methodology is oftentimes too expensive. Further, once a capacitor is installed in an electronic device or system, it is difficult to determine when and if the capacitor is beginning to operate out of specification. For at least these reasons, there is a need for identifying when a capacitor is operating out of specification efficiently in a testing environment or deployed in electrical devices and systems.

SUMMARY

Systems and methods for determining an operational condition of a capacitor package are disclosed. According to an aspect, a system may include a capacitor package including a dielectric material operatively connected between a first terminal and a second terminal. The system may include a Zener diode being operatively connected with its cathode at a third terminal and its anode at the second terminal. The system may also include a test pin being conductively connected at a third terminal, at the cathode of the Zener diode between the third terminal and the second terminal. The system may also include a testing module configured to receive an electrical output from the test pin. The testing module may also be configured to determine an operational condition of the capacitor package based on the electrical output. The testing module may further be configured to present the operational condition of the capacitor package.

According to another aspect, a method may be implemented at a computing device include one or more processors and memory. More particularly, the method may provide a capacitor package comprising a dielectric material operatively connected between a first terminal and a second terminal. The method may also provide a Zener diode being operatively connected between the first terminal and the third terminal. The method may also provide a test pin being conductively connected in a path with the Zener diode between the first and third terminal. The method may also comprise determining an operational condition of the capacitor package based on the electrical output. The method may further comprise presenting the operational condition of the capacitor package.

According to another aspect, a system may include a plurality of capacitor packages that each comprise a dielectric material operatively connected between a first terminal and a second terminal. They system may also include a plurality of Zener diodes, each Zener diode being operatively connected between the first terminal and the third terminal of a respective one of the capacitor packages. The system may also include a plurality of test pins that are each conductively connected in a path with the Zener diode between respective first and third terminals. The system may also include a testing module configured to receive an electrical output from the test pins. The testing module may also be configured to determine an operational condition of the capacitor packages based on the electrical outputs. The testing module may further be configured to present the operational condition of the capacitor packages.

DETAILED DESCRIPTION

As referred to herein, the term “computing device” should be broadly construed. It can include any type of device capable of presenting content to a user. The computing device may be server. In another example, the computing device may include a display, one or more speakers, a printer, or other user interface for presenting content and for receiving input from a user. In another example, a computing device may be a mobile device such as, for example, but not limited to, a smart phone, a cell phone, a pager, a personal digital assistant (PDA, e.g., with GPRS NIC), a mobile computer with a smart phone client, or the like. A computing device can also include any type of conventional computer, for example, a desktop computer or a laptop computer.

As referred to herein, a “user interface” (UI) is generally a system by which users interact with a computing device. An interface can include an input for allowing users to manipulate a computing device, and can include an output for allowing the system to present information (e.g., e-book content) and/or data, indicate the effects of the user's manipulation, etc. An example of an interface on a computing device includes a graphical user interface (GUI) that allows users to interact with programs in more ways than typing. A GUI typically can offer display objects, and visual indicators, as opposed to text-based interfaces, typed command labels or text navigation to represent information and actions available to a user. For example, an interface can be a display window or display object, which is selectable by a user of a computing device for interaction. The display object can be displayed on a display screen of a computing device and can be selected by and interacted with by a user using the interface. In an example, the display of the computing device can be a touch screen, which can display the display icon and content.

The present disclosure is now described in more detail. For example,FIG. 1illustrates a schematic diagram of an example capacitor package100in accordance with embodiments of the present disclosure. Referring toFIG. 1, the capacitor package100includes a first terminal102, a second terminal104, and a dielectric material106operatively connected between the first and second terminals102and104. In examples, the dielectric material106may be made of, but is not limited to, ceramic, plastic film, liquid or gel electrolyte, solid polymer electrolyte, glass, mica. However, it should be understood that any type of dielectric material may be used in accordance with embodiments of the present disclosure and are not limited to the examples provided herein above.

With continuing reference toFIG. 1, the capacitor package100may include a Zener diode108and a resistor110operatively connected to a third terminal112. It is noted that the resistor110is optional and may be omitted. In the instance of the resistor110being omitted, the diode108may be connected in any suitable electrical path between the terminals104and112.

The diode108and the resistor110may be operatively connected in series between the first terminal102and the second terminal104via a conductive material114as depicted. In examples, the conductive material114may be made of, but is not limited to, a metal layer in a semiconductor, wire bonds, metal plating, and the like. However, it should be understood that any type of conductive material may be used in accordance with embodiments of the present disclosure and are not limited to the examples provided herein above. As shown inFIG. 1, the dielectric material106, the diode108, and the resistor110are separated by a non-conductive material116. In accordance with embodiments, the non-conductive material116may be silicon dioxide, silicon nitride, and the like. However, it should be understood that any type of non-conductive material may be used in accordance with embodiments of the present disclosure and are not limited to the examples provided herein above. The capacitor package100may be operated as disclosed herein for testing its operational condition.

FIG. 2illustrates a circuit diagram of an example capacitor package connected to a voltage source in accordance with embodiments of the present disclosure. This may be, for example, the circuit diagram corresponding to the capacitor package100shown inFIG. 1. Referring toFIG. 2, the capacitor package200may include a first terminal202operatively connected to a reference ground203and a second terminal204operatively connected to a voltage source205. The capacitor package200may include a capacitor206operatively connected between the first and second terminals202and204. The capacitor206may be representative of the capacitor formed by the dielectric material106and the terminals102and104shown inFIG. 1.

With continuing reference toFIG. 2, the capacitor package200includes a diode208and a resistor210operatively connected to a third terminal212and being operatively connected in series between the first terminal202and the second terminal204. The resistor210may be omitted as mentioned with respect toFIG. 1. The diode208and the resistor210corresponds to the diode108and the resistor110, respectively, shown inFIG. 1. The diode208and the resistor210may be operatively connected in parallel to the capacitor206as shown inFIG. 2.

FIG. 3illustrates a schematic diagram of an example system for determining an operational condition of a capacitor package in accordance with embodiments of the present disclosure. The operational condition may be determined based on an electrical output of the capacitor package. For example, the system may include a testing module300configured to determine an operational condition of capacitor package302based on an electrical output of the capacitor package302. In accordance with embodiments, the testing module300may include any computing device or system configured for determining the operational condition of the capacitor package200.

As an example, the test module300may be an In-Circuit Test (ICT) fixture and system on a circuit board assembly line. An ICT fixture may have probes, sometimes likened to a ‘bed of nails,’ that can touch a circuit board assembly in predefined places. A system which controls the fixture can apply power, measure voltages, measure impedances, drive signals, and the like. After the parts are assembled (soldered) on the board, the board may be placed in the fixture and the ICT system can subsequently apply power, measure the voltage between the capacitor terminals204and202, and compare that with the voltage measured between terminal212and202. The avalanche breakdown of the Zener diode may be tuned to indicate the rated voltage of the capacitor between terminals212and b, e.g. 2V, 3.3V, 5V, etc. If the actual voltage across the capacitor (between terminals212and202) is greater than the rated voltage (between terminals204and202) then the ICT system may flag the test as a failure, since the capacitor has been placed in a dangerous environment.

In accordance with embodiments of the present disclosure,FIG. 4illustrates a flowchart of an example method of determining an operational condition of the capacitor package based on an electrical output of the capacitor package. The method ofFIG. 4is described by example as being implemented by the system ofFIG. 3, which is the circuit that corresponds to the capacitor package shown inFIG. 2. However, it should be understood the method may alternatively be implemented by any suitable system.

Referring toFIG. 4, the method includes providing400a capacitor package comprising a dielectric material operatively connected between a first terminal and a second terminal. For example, the system ofFIG. 3provides the capacitor package200including a capacitor206comprising a dielectric material operatively connected between a first terminal202and a second terminal204.

The method ofFIG. 4also includes providing402a Zener diode which is operatively connected at a third terminal and the second terminal. Continuing the aforementioned example, the capacitor package shown inFIG. 3includes a diode208and resistor210operatively connected at a third terminal212. The diode208and resistor210are operatively connected in series between the first terminal202and the second terminal204. The method ofFIG. 4also includes providing404a test pin that is conductively connected to the third terminal. For example, the terminal212of the capacitor package200shown inFIG. 3may function as a test pin.

Returning toFIG. 4, the method also includes receiving406an electrical output from the test pin. Continuing the aforementioned example, as shown inFIG. 3, the testing module300may be configured to receive an electrical output from the third terminal212of the capacitor package200via the test pin at terminal212. The method ofFIG. 4also includes determining408an operational condition of the capacitor package based on the electrical output. For example, the testing module300ofFIG. 3may be configured to determine an operational condition of the capacitor package200based on the electrical output from the test pin at terminal212. In accordance with embodiments, the step of determining408may include applying a voltage across the first and second terminals while the operational condition of the capacitor package is being determined. For example,FIG. 3illustrates the testing module300may be configured to apply a voltage VS across the first terminal204and the second terminal203while the operational condition of the capacitor package200is determined.

FIG. 5illustrates another example method of determining an operational condition of an capacitor package in accordance with embodiments of the present disclosure. The method is described as being implemented by the system shown inFIG. 3, although it should be understood that the method may alternatively be implemented by any suitable system.

Referring toFIG. 5, the method includes determining500a voltage at a test pin. The method also includes comparing502the voltage to the voltage measured across the capacitor. For example, after applying power to the PCB assembly containing the capacitor, the testing module300ofFIG. 3may determine a voltage at the test pin at terminal212with respect to terminal202, using a method consistent with testing Zener diodes. The testing module300may assume that the voltage measured at terminal212is the pre-determined rated voltage for the capacitor, above which dielectric breakdown may start to occur. The testing module may subsequently determine the voltage at terminal204with respect to terminal202. The testing module300may compare the voltage at the test pin at terminal212to the voltage at terminal204, and if the voltage at terminal204is larger then the capacitor has been placed in an environment beyond its rated voltage. In an example, the predetermined voltage may be associated with a breakdown voltage. There can be a large range of max voltage ratings for capacitors depending on capacitor type, size, and value, from under 10V to over 7500V, but typically the capacitors of interest at a PCB level are in the under 10V to 50V range (examples are 2.5V, 3.0V, 4.0V, 6.3V, 10V, 16V, 25V, 35V, 40V, 50V, etc.)

The method ofFIG. 5includes determining504the operational condition of the capacitor package based on the comparison. Continuing the aforementioned example, the testing module300may determine the operational condition of the capacitor package200based on the comparison of the voltage measured at the test pin at terminal212to the voltage associated with capacitor206. In accordance with embodiments, the method may include indicating whether the capacitor package is operating out of specification. For example, the testing module300may determine the voltage measured at the test pin at terminal212is less than the voltage associated with capacitor206. In another example, the testing module300may determine the measured voltage at the test pin at terminal212is equal to n a breakdown voltage associated with the capacitor206. In either of these examples, testing module300may indicate the capacitor package200is operating out of specification.

In accordance with embodiments of the present disclosure,FIG. 6illustrates an example method of indicating that the capacitor package is operating out of specification in response to determining that a diode of the capacitor package is activated. The method is described in this example as being implemented by the system shown inFIG. 3, but it should be understood that the method can be implemented by any suitable system.

Referring toFIG. 6, the method includes determining600that the diode is activated. For example, the testing module300shown inFIG. 3may determine that the diode208is activated. As an example, the diode208may be configured to activate in response to a voltage across the first terminal202and the second terminal204being greater than a predetermined voltage value. Also, the resistor210may be configured to operate with the diode208such that diode208activates when voltage applied across the first and second terminals202and204is greater than a predetermined voltage value.

The resistor210may have a resistance value such that the diode208activates when the voltage across the first terminal202and the second terminal204is greater than the predetermined voltage value. In an example, the resistor210may be a trimming resistor. It is noted that in embodiments the resistor210may be omitted or not included.

The method ofFIG. 6includes indicating600that the capacitor package is operating out of specification in response to determining that the diode is activated. For example, the testing module300may indicate that the capacitor package200is operating out of specification in response to determining the diode208is activated.

Returning toFIG. 4, the method also includes presenting410the operational condition of the capacitor package. For example, the testing module300may be configured to present the operational condition of capacitor package200. In an example, the testing module may include a user interface configured to present the operational condition of the capacitor package200to a user. In an example, operational condition information may be in the form of a report on all tested components after an ICT run. As an example, a failure report on a video screen may be displayed to point out a measured capacitor max voltage rating and a voltage across the capacitor during the powered test.

FIG. 7is a system diagram illustrating an example testing module configured to determine an operational condition of a plurality of capacitor packages based on electrical outputs of the plurality of capacitor packages in accordance with embodiments of the present disclosure. Referring toFIG. 7, the system includes a testing module300and multiple capacitor packages100that each comprise a dielectric material operatively connected between a first terminal and a second terminal. The capacitor packages can be the capacitor package100shown inFIG. 1, or any other suitable capacitor package. Also, shown inFIG. 7are multiple test pins704,706,708, and710, that are each conductively connected to a respective third terminal of the capacitor packages100.

The testing module300ofFIG. 7may be configured to receive electrical outputs from each of the test pins704,706,708, and710. For example, the testing module300can be configured to receive the electrical outputs from the test pins704,706,708, and710, and712via a test rail712. The testing module300may determine operational conditions of the capacitor packages100based on the electrical outputs from the test pins704,706,708, and710. In accordance with embodiments, the testing module700may also be configured to determine whether each diode of the diode and resistor pairs of the plurality of capacitor packages702is activated. In a similar manner as the diode208ofFIG. 3, the diodes of each diode and resistor pair ofFIG. 7are configured to activate in response to a voltage across the respective first terminal and the respective second terminal of the respective capacitor package being greater than a predetermined voltage value. Also in similar manner as the resistor210ofFIG. 3, the resistor of each diode and resistor pair ofFIG. 7is configured to operate with the diode such that the diode activates when the voltage across the respective first and second terminals is greater than the predetermined voltage value.

In response to determining that one of the diodes is activated, the testing module300may be configured to indicate that a capacitor package is operating out of specification. In an example, a Zener diode may be specifically tuned to avalanche at the rated voltage of the capacitor, so the testing module may always “discover” the rated voltage of each capacitor prior to comparing it with the actual voltage across the cap.

Returning toFIG. 7, the testing module300may present the operational conditions of the capacitor packages. In accordance with embodiments, system ofFIG. 7may comprise a user interface configured to present the operational conditions of the capacitor packages100to a user.

The described methods and apparatus may also be embodied in the form of program code that is transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via any other form of transmission, wherein, when the program code is received and loaded into and executed by a machine, such as an EPROM, a gate array, a programmable logic device (PLD), a client computer, a video recorder or the like, the machine becomes an apparatus for practicing the presently disclosed subject matter. When implemented on a general-purpose processor, the program code combines with the processor to provide a unique apparatus that operates to perform the processing of the presently disclosed subject matter.

Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, system, product, or component aspects of embodiments and vice versa.