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Question:

Does the initial charge current affect the durability of capacitors?

Most capacitors have a very low ESR, a fraction of an ohm normally. This would mean that if I were to charge it up to say 10V, a very high current would initially flow, tens of amps perhaps, of course diminishing a fraction of a second later. However, most capacitors are only rated for say 1.5A of AC ripple current. Does this rating apply to the initial, non repetitive charge current as well? Would it significantly increase the lifespan of my capacitors if I were to throttle this current to within the AC ripple rating, even if the repetitive ripple current after that is only a few milliamps?

Answer:

All electrolytic capacitors are simply two sheets of aluminum attached to the terminals, separated by an electrolyte and rolled up to fit in a metal can. Thin film capacitors use a plastic sheet and spray a very thin layer of aluminum onto each side. The trick is attaching the terminals to the sheets. You can't just connect to the end of the sheets, or middle. That would cause all the current to pass through the thin material, increasing the resistance, inductance and current carrying capacity. So, as they wrap the capacitor, one electrode sticks up, the other down. That way they connect to the sheet throughout the roll. Still, these connections and the sheet is only capable of a limited current before it burns the foil or the connection. Most power sources are not zero impedance devices where the voltage is instantly applied at full potential. Everything has resistance; the transformer, the diodes, cabling and so forth. The voltage is rarely applied at the maximum potential because of the sinusoidal waveform. The voltage only peaks for a short period, lowering the effective current. Once the capacitor begins to charge, the AC ripple voltage is determined by how much the load draws the voltage down between charging peaks. This determines how much current the capacitor must supply between charging peaks and how much it must store during those peaks. Like a simple fuse, they can withstand maximum current forever but they will blow almost instantly with a high overload. The time to melt the wire is determined by the current and the duty cycle. The same is true for the capacitors. I have seen low ESR capacitors destroyed by shorting the terminals of a fully-charged cap with a copper bar. But it is unlikely that you can generate that kind of current in most power supplies. Although, theoretically it is possible. Especially in line-powered supplies.
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