Innovation is key to growth at Deki Electronics. We develop new products, provide solutions to our customers and work not as mere manufacturers but as partners.
Here are some examples of our innovation in practice:
Requirement for lamp circuit capacitor in high wattage CFL
The critical section of a CFL is the lamp circuit since it has to withstand high voltage spikes with high frequency during the ignition phase of the CFL.
Polyester Inductive capacitors are generally used in low wattage CFL lamp circuits where the wattage is less than 24 watts. For high wattage CFL lamp circuits MPP/MPP capacitors are generally used as inductive capacitors cannot be used due to inherent design issues.
PET inductive capacitors have a film foil construction with aluminium foil as electrode and polyester (PET) film as dielectric. While the aluminum foil electrode thickness is 5-6 microns the dielectric film thickness depends upon the voltage rating of the capacitor. In this construction type, both the aluminium foils are parallel to each other and are separated by a dielectric. There is a probability of short circuit when high voltage spikes occur owing to the possibility of weak points in the dielectric.
At Deki, we have been successful in developing a unique capacitor that not only withstands the high voltage spike at ignition but also has self-healing properties. This self-healing inductive capacitor is an ideal choice for high wattage CFLs.
Some case studies:
Application - Suntanning capacitor
We were approached by a customer who had found significant failures in the design of the capacitors being supplied by the competition.
We found that there was high stress across this capacitor during working. Hoever, the solution that we developed was big in size and more expensive. Since size was a constraint for this application the customer's R&D department asked the Deki Technical Centre to look for an innovative solution.
Both teams decided to work together on this at Deki and a number of trials were conducted to zero in on the most optimum solution. After one week of rigorous working we were able to come out with a suntanning capacitor that answered all the requirement of the customer on performance and price. Today we are the sole supplier for this capacitor.
Application - Lighting (CFL)
Deki approached a global lighting manufacturer in Europe in 2000 to find that they were using expensive MKP and MKT non-inductive designs in their CFL products.
We had a detailed discussion with their R&D team after which they agreed to test the optimum solutions offered by us. Needless to say, our product met with approval as we were able to cut down the cost of their BOM by 40% thanks to our value engineering.
We have been exporting to the customer on a regular basis since then with the current level at 6 million pieces per month.
Application - Lighting (CFL)
Product - PEP Capacitor (mix dielectric)
Electronic ballast is the heart of any CFL and the striking capacitor in it plays a vital role in the performance of CFL. Manufacturing of CFL started with low wattage (8W, 11W, 14W, etc.) for which plain polypropylene was the ideal solution for this application.
As wattages later increased to 18W, 20W, 23W, 26W and beyond there was an increase in temperature within the capsule (> 100C). Though polypropylene is the ideal design for the application, it can withstand temperatures up to 100C only.
As a result, striking capacitors started failing when the temperature rose to over 100C . At Deki we saw this as an opportunity and developed the PEP capacitor.
The PEP capacitor is nothing but the combination of plain polyester and plain polypropylene. The PEP capacitor offers high stability in capacitance value up to 110C temperature and is being supplied to all leading CFL manufacturers in India and overseas.
Deki also won the ELCINA R&D award for the development of the PEP capacitor.