Flipped Capacitors

Different Capacitor Shapes

Most electronic design engineers know SMD capacitor parts come in the “standard” sizes of let’s say 1206, 0805, 0603,0402, 0201 etc. The common element of these parts is that their size is longer along terminals(between 2 pads you actually solder) than along the width of the part. Most times width of the part is half the length. There is a different class of capacitors which are wider than long. These are called flipped or reverse geometry capacitors. So the sizes will be 0612, 0508, 0306, 0204 etc. (To be honest, you might not find a flipped capacitor for every “standard” size capacitor though)

Why do we want to use a flipped capacitor? In one of my older posts, I explained that a capacitor in real life is not a capacitor by itself. It has an equivalent series resistance(ESR) and inductance(ESL). For an ideal capacitor, we would want to have ESRs and ESLs to be zero. Since there is an ESL in a capacitor, you usually see a V-shaped impedance curve with frequency in capacitor datasheets. The impedance value keeps getting low till a point and then it increases due to ESL. Here is where flipped capacitors come into the picture. Flipped capacitors are designed specifically to reduce ESL. When you flip the width and length dimensions of a capacitor, it reduces the soldering pad distances(or the length). Lower travel length means lower inductance and lower conductor length(Not to complicate it more, loop area also reduces, which is a good thing). So current needs to travel a shorter distance. A wider flipped capacitor effectively can have an impedance curve which is similar to 3-4 same standard-size capacitors. That means overall lower BOM count and layout space is lesser. For these reasons, these wider capacitors are starting to gain acceptance in the PCB design space.

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Wireless Headphones and Batteries

Personally, I am not a fan of wireless headphones. There is a myriad of reasons for it but the primary one is its battery life. I hate having to recharge the headphones time and time again. This week, I came to know from our friends at iFixit that there is a new headphone in the market which can do 300hrs+ of active playback on a single charge. It’s the Cloud Alpha Wireless from HyperX. That’s a mind-boggling number, if you are a heavy headphone user, using it for 10hrs a day, headphones would still have juice in them at the end of the month.

Headphone Teardown
Headphone Teardown

If you check their teardown video, you will see them trying to figure out the reason behind this insane battery life. If you analyse the PCB, they just have standard components designed for low power usage, like an ultra-low power 24bit audio codec driver, DA7212, from Dialog or NXP M0+ controller with 46 μA/MHz power consumption. But these are kind of a norm in today’s consumer tech devices and it’s not something that’s out of the ordinary. Personally what sets it apart is its massive battery. Let’s talk about that.

These headphones come with a 1500mAh(5.5Wh) battery which weighs around 25g and fits snugly in ONE of the 2 earpieces with room to spare. A larger battery means a larger playback time(Duh!). Herein lies my problem with major wireless headphone manufacturers out there. Let’s take Apple’s premium Airpods Max(approx runtime of 20hrs), which weighs in at 385g(Compared to 337g of HyperX), costs $550 and has 2 batteries totally 664mAh(2.53Wh). Why on earth do you not add larger batteries to your headphones? It cant be due to lack of space since you have 2 massive areas around the ear where you fit it. It cant be due to price, a larger battery will only increase your BOM by a max of $1. It cant be due to the weight, as larger batteries will add a max of around 15g to the device. So, all I can think of is that it’s by choice.

It’s not just Apple, take any major company out there. Playtime numbers are similar around 30-40hrs. If a company can make leaps in terms of longevity by a simple design choice, as a consumer, I am all for it. Granted that HyperX doesn’t have active noise cancellation which is a power guzzler because of the real-time signal processing involved. But it’s really making a statement that something like this can be built. I am hoping other companies do take note and start to follow suit.

PS: Teardown pics are from the iFixit video https://youtu.be/5t0Jyzh0veo. Do check it out.

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