Detailed mechanism of electric corrosion and countermeasures against it/Design considering electric corrosion
In the previous column, we explained our policy on electric corrosion.
In this column, we describe the detailed mechanism of electric corrosion and the points that should be noted when designing.
The contents described here are excerpts from the reports and lecture materials of the Japan Electronics and Information Technology Industries Association (JEITA).
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Electric corrosion is generally considered to be an electrochemical reaction that proceeds by the following mechanism.
(1) Moisture penetrates the protective coating of the resistor and reaches the resistive film under a high temperature/humidity atmosphere or due to dew condensation.
(2) When electricity is applied while moisture(water) is adhered to the resistive film, the water is electrolyzed.
(3) At this time, if any ionic impurities exist, electrolysis of water is accelerated.
(4) Hydroxide (-) ions generated by electrolysis of water move to the anode (+) and chemically react with the resistive film.
(5) The components of the resistive film change in quality and the physical properties change.
(6) Conductivity changes due to the changes in physical properties, causing an increase in resistance.
The above mechanism is expressed by a chemical formula as follows:
・For carbon film resistors
・For metal film resistors (nichrome type)
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In the unlikely event that electric corrosion occurs, the resistance value of the resistor will change significantly.
In such a case, the failure mode is “open” mode, so it is recommended to use a fail-safe design that ensures safety even when the resistor opens, assuming the worst case. For example, it is important not to design as in the examples below.
(Example 1)
Do not use resistors that are easily electrolytically corroded (such as carbon film resistors with the resistance of 100 kΩ or more) for the voltage dividing resistance of series electrolytic capacitors.
In the unlikely event of electric corrosion, the resistors will fail in open mode.
As a result, the shared voltage of the electrolytic capacitor collapses, and overvoltage or reverse voltage may damage the electrolytic capacitors, leading to smoke and ignition.
(Example 2)
Do not use resistors that are easily electrolytically corroded (such as carbon film resistors with resistance of 100 kΩ or more) as discharge resistors of power supply circuits.
In the unlikely event of electric corrosion, the resistors will fail in open mode.
As a result, when the power is turned off, the electricity charged in the capacitor may not be discharged.
If anyone touches the outlet plug in that state, the person will get an electric shock.
There are many other circuits that can cause problems with open mode failures.
In such circuits, it is important not to use resistors that are prone to electric corrosion as much as possible.
If you have any problems, please feel free to contact us.
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What is electric corrosion? – Our efforts