A leading inverter air conditioner manufacturer experienced intermittent failures in outdoor controller boards during production and field operation.
After investigation, the failures were traced to mechanical stress on electrolytic capacitor leads in both the switching power supply and communication circuits. Because high-capacitance electrolytic capacitors had relatively tall packages, external forces during assembly, connector insertion, and board handling caused internal lead damage, resulting in unstable electrical performance.
Challenges the client faced:
Intermittent power supply failures
Communication instability
Increased field returns
Reduced product reliability
JEC Solution
Without changing the original circuit design, JEC developed a series of low-profile electrolytic capacitors that maintained the same electrical performance while significantly reducing component height:
Lower package height to reduce mechanical stress
Improved assembly reliability
Direct replacement without PCB redesign
Available in 220μF, 470μF, and 1000μF versions
The Result
After implementing the low-profile capacitor solution:
Capacitor lead failures were eliminated
Production yield improved
Field failure rates decreased significantly
The solution was successfully adopted across multiple HVAC controller platforms.
At JEC (Dongguan Zhixu Electronics), we help clients solve reliability challenges through customized capacitor solutions, failure analysis, and engineering support.
Experiencing capacitor reliability issues in your industrial or HVAC applications? Contact JEC for free samples and one-on-one technical support.
Post time: Jul-02-2026