MML : Capacitors + Bus Bar

This natural mineral insulator has outstanding dielectric properties that are ideal for long-life high-stability capacitors with low loss at all frequencies, and high dielectric strength. This type of capacitor is used particularly for high frequency and delay line applications, oscillating circuits, emission devices and calibrators.

Mica dielectric capacitor technology allows for several custom design applications including: 

• High voltage capacitors (up to 50 kV)
• High temperature capacitors (up to 250°C)
• Precision capacitors (up to ± 0.1%)
• High stability capacitors (– 20 + 30 ppm/°C)
• High frequency capacitors ( up to several GHz). 

The majority of these capacitors are manufactured to comply to specifications NF-C-83120;MIL-C-5 and MIL-PRF-39001 standards.

Mica capacitors are noted for the following characteristics:

• Temperature performance
• Low loss at all frequencies
• High dielectric strength
• Stability over time

Silver mica capacitors provide superior stability and low loss when used in RF power circuits that require low pico farad (pF) and nano farad (nF) ranges. Older silver mica capacitors were manufactured in layers of mica and silver, but the layering allowed room for air gaps that reduced the stability and could also create stress fractures in the assembly.

Modern manufacturing uses silver plated to mica layers, eliminating the gaps. When the desired number of layers is obtained, the assembly is coated in an epoxy or ceramic resin. The coating reduces fracturing of the layers and seals the assembly from moisture and particles that could interfere with the capacitance value.

Mica capacitors are useful in circuits for ripple filtering and are often found in time constant, coupling or resonance circuits. In addition to radio circuits, they are used in TV transmitters and Cable TV amplification circuits. Mica is also a superior choice in high-voltage inversion and power conversion for energy absorbing snubber applications with capacitances of up to 10 nF.

Standard silver mica capacitors are normally designed to handle voltages from 100 to 1000 volts. High-voltage RF transmitter applications can call for higher tolerances. Mica capacitors are available for voltages up to 20kV.

Our expert engineering team can create the mica capacitor with the characteristics you require. Send us your drawing or file and we will work with you to manufacture the correct size, lead style and capacitance you desire.

Yes, Exxelia offers custom configurations and extended/intermediate values upon request. This flexibility allows for tailored solutions to meet specific application requirements and could help your design with easiest integration, cost saving, thermal management optimization, sensors or filter integrations etc...

The MML capacitors feature:

• Non-Inductive Stacked Metallized Polymer Film: Ensures high performance and reliability.
• Encapsulation: Encapsulated in a flame-retardant high-temperature epoxy resin or molded diallyl phthalate (DAP) housing for mechanical and environmental protection.

The MML Series includes several types:

• D Series (bus bars integrated for power electronic conversion or filtering)
• M Series (Small package with radial, DIL or SMD connections)
• C Series (Flat package with DIL connections)
• Custom solution with specific casing and connections to optimize the integration, the heat management and some electrical characteristics.

Each type offers various configurations to suit different applications.

Exxelia's MML Series capacitors boast several key features:

• High Energy Density and High Temperature Capability: Operates effectively up to 140°C.
• Size and Weight Reduction: Up to 50% reduction compared to traditional film technologies and up to 10 times lighers comparing to the ceramic capacitors.
• Stable Performance: Maintains consistent performance across a wide temperature and voltage range.
• Open circuit defect mode with self healing advantage
• Rugged and Lightweight Construction: Ideal for demanding applications.
• Self-Healing Properties: Ensures long-term reliability and safety.

MML Series capacitors are suitable for aerospace & defense: withstand harsh environments and high reliability requirements.

• Inverter
• DC-Link
• Rectifier
• Energy storage

General Electrical Specifications:

• Capacitance Range: From 1µF to 2 000µF depending on the series.
• Voltage Range: From 50V to 2000V DC.
• Operating Temperature: From -55°C to +140°C, with some derating above 125°C.
• Dissipation Factor (Tg d): Typically 60 . 10^-4
• Insulation Resistance: Minimum of 10,000 MΩ-µF at rat ed voltage and 25°C.
• Current: few Amps to hundreds of Amps (according to  the capacitor construction)

MML capacitors are tested to meet various environmental and durability standards:

• Humidity (Steady-State): MIL-STD-202 Method 103.
• Barometric Pressure (Reduced): MIL-STD-202 Method 105.
• Thermal Shock: MIL-STD-202 Method 107.
• Life Test (Elevated Ambient Temperature): MIL-STD-202 Method 108.

Exxelia SVM is a company within the Exxelia Group with over 35 years of experience in the design, development, and manufacturing of coils and transformers, for both high-frequency and low-frequency applications. This extensive expertise allows Exxelia SVM to offer reliable technical solutions tailored to a wide range of demanding and often critical requirements.

For more than 12 years, Exxelia SVM has also specialized in the design and production of busbars with a variety of technologies and finishes, including:

• epoxy powder coating,

• PVC coating,

• laminated busbars,

• flexible busbars,

• resin-cast busbars,

• and surface finishes such as nickel plating, gold plating, silver plating, brazing, and tin plating.

These busbars are used in demanding environments, particularly in the healthcare and automotive industries, where high quality, reliability, and performance are essential.

Exxelia SVM’s mission is to address the complex and critical needs of design and manufacturing engineers in the electronics and electrical industries. The company supports its customers from design to mass production, offering full technical support to turn design concepts into manufacturable products.

With its long-standing experience in the design of transformers, inductors, and various electromagnetic components, Exxelia SVM continuously improves product quality. This know-how also enables productivity gains without compromising quality, ensuring consistent performance and competitive pricing for its customers.

Exxelia SVM is also characterized by strong vertical integration, which provides a high degree of flexibility and self-sufficiency in its manufacturing processes. This integration includes:

• the design of bobbins,

• the design and fabrication of injection molds,

• the manufacture of bobbins using both thermoset (phenolic) and thermoplastic materials, from standard to high-performance grades,

• an in-house tool room for precision machining of plastics and metals to meet exacting specifications, especially for rigid mounting systems,

• the design and production of customized packaging materials to meet specific transportation needs, whether by road, air, or sea.

With a monthly production capacity exceeding 10 million parts, Exxelia SVM is one of the largest manufacturers of coils and transformers in India, serving low-, mid-, and high-volume production demands.

Exxelia SVM’s components are used across a variety of sectors, including:

• power supply,

• lighting,

• medical electronics,

• electric vehicles,

• automotive,

• communications,

• and many other industrial electronic applications.

Exxelia SVM serves international customers in the United States, Israel, France, China, and India, demonstrating its ability to meet global technical, regulatory, and logistical standards across a wide range of industries.

For safety purposes, these types of capacitors need to be forward biased in their configuration. This is mainly due to the characteristics of the electrolyte that has been used in their construction. The positive terminal always needs to have a larger amount of voltage than that of the negative terminal. If the situation were reversed and the negative terminal suddenly had a higher voltage than the positive terminal (which is also referred to as reversing the voltage polarity), the aluminum material that is used as the dielectric could short circuit and become damaged. It could also overheat, which could cause a substantial leak. 

The capacitor could also vaporize, which could cause the entire enclosure to burst under the right circumstances. It is important to note, however, that this phenomenon is very rare.

To convert your concepts in to reality in Magnetic Components. Exxelia SVM can play a significant role in your Product Design where Magnetics is a vital component; in simple words Exxelia SVM can be your Strategic Solution Provider for your Special Magnetic components.

Exxelia SVM Design and Technology group works as an extended arm of customers Innovation Team in understanding the Specification, Criticality and the time lines of the Project implementation.

Design Organization

• Electrical, Electronics, Mechanical (Bobbin, Clamps and brackets)
• Design and simulation Capability for Inductors, Transformers, Hall Effect Current Transformers, Actuators, Solenoids.
• Power Converters, Stabilizer for Medical Equipment’s.
• Design and Development for Molded , Laminated , Epoxy powder coated , Nickel& Golde plated, Silver Plated , Brazing&Tin Plated , Flexible busbars and other Press Components.

Knowledge, Expertise & Techniques

• The Team at Exxelia SVM can Engineer your ideas and convert them into End use Components
• MATLAB, FEMM Modelling and Thermal Simulation of Magnetic components
• Reliability of components evaluated using Thermal Cycle, Random Vibration Test and Packaging Drop Test for Shipping and Handling
• Load Test for High Current Inductors and Linear Power transformers to check the temperature rise at actual loading pattern

Support for End use and Application

• The Team at Exxelia SVM Interact with Customers and provide solutions for End use and Application

Functional test set up developed for Variable Frequency High power test bench to test the transformers and inductors
Topologies – Full Bridge, Half Bridge, Push-Pull, Forward with loading facility.

Flyback Transformer Testing Set up

• Frequency – Up to 133 kHz
• Rating - Up to 250VA

High frequency Transformer Testing set up

• Frequency – Up to 100 kHz
• Rating - Up to 25kVA

Waveforms:

Lab Facility as per UL Safety Requirements

• Partial Discharge Test up to 100kV AC
• Impulse Testing Facility upto 100kV DC (Both Lighting and Switching Impulse)
• Load Test up to 50kVA (50HZ operating frequency)
• Dielectric Strength Test both AC and DC
• Precision LCR Magnetic Analyzer for measuring Inductance, Capacitance and Resistance
• DC Bias Test up for Inductors
• Temperature Data Logger

Magnetics Manufacturing Facility

• Multi spindle CNC Winding Machines
• Automatic Test equipment’s (ATE)
• Copper Foil Winding Machines
• Vacuum Impregnation plant

Busbar Manufacturing Facility

• Automatic Pressure Gelation Machine ( Resin Cast)
• Amada CNC Turret Punching Machine
• Amada CNC Bending Machine
• AIDA Pneumatic Press for Blanking and forming
• CNC PET Film Cutting Machine
• Hot Press for Lamination
• Powder Coating Plant
• Plating Plant
• Resistance Brazing and Pressure Welding Setup
• PEM Nut and Stud insertion Machine.

Backward Integration

• Round Litz Wire up to 350A Current Rating
• Rectangular Type 8 Litz wire up to 350A Current Rating
• Press Components
• Bobbin manufacturing both Thermoset and Thermoplastic
• Sophisticated Tool room
• Lamination Stamping Facility
• Thermoforming Packaging Trays

Special Purpose Machines (SPM)
Builds special jigs, Fixtures, Machines to bring out Customized Products