Material innovations to mitigate thermal, mechanical, and environmental stresses in modern power electronics.
Global power demands are skyrocketing. New needs—driven by electric vehicles (EVs), data centers, and other critical applications—mandate innovations in power generation, conversion, storage, and end-use applications.
Consequently, power conversion in AC/DC power supplies, DC/DC power converters, inverters, and storage must increase in efficiency and deliver more energy, more reliably. To do so, electronics used in these devices are radically increasing in complexity, integration, and power density. While these changes help elevate power efficiency in the creation, conversion, and storage of energy, they introduce new challenges in electronic design and manufacture.
To keep powering ahead and meet growing demand, power systems are evolving in profound ways that generate novel needs. For example:
Higher power densities
in the electronics that comprise power supplies and converters, such as AC/DC, DC/DC, and uninterruptible power supplies (UPS), require more thermal management for operational integrity.
Power grid resiliency
is being bolstered with microgrids and grid decentralization, moving power generation closer to where it is used to gain efficiency, power quality, and sustainability.
EV charging infrastructure installations
are growing rapidly to support EV usage. Charging components must work reliably in harsh outdoor, highly variable environments—such as extreme temperatures, dirt, corrosive materials, and moisture.
Alternative energy sources
like wind and solar, are leveraging renewable energy to accelerate decarbonization and energy cost reductions, requiring new energy storage systems and solutions.
In power conversion systems, reliability is mission critical. Electronics must deliver fail-safe performance 24/7/365 while operating in harsh environmental conditions. One electronic malfunction can cause an entire power system to fail.
Here are some of the factors that can compromise electronic performance and longevity if not properly and proactively managed:
Too much heat
a characteristic of smaller, denser electronic designs, can wear out electronics and cause premature failures.
Contaminants in the environment
such as humidity, dust, chemicals, and corrosive gases, can produce corrosion and degradation, decreasing electronic performance and reliability.
Mechanical stresses
from thermal cycling, vibration, and shock, cause fatigue that can fracture solder joints and component connections.
Electrical stresses
stemming from electrostatic discharge, lightning, and power supply switching, can damage electronics. In addition, electromagnetic interference (EMI) can disrupt and degrade circuits, creating system-wide risks
These factors demand the use of advanced materials to mitigate risks in modern power systems and their electronics. Innovative materials can improve electronic performance and reliability in these ways:
Thermal management
Higher power densities, smaller footprints, and more integrated electronic designs increase heat — such as the adoption of wide bandgap semiconductors. Thermal interface materials such as gap pads, liquids, film, gels, adhesive solutions, and phase change materials help dissipate heat and extend the lifetime of critical electronic parts.
Protection
Moisture, dust, vibration, heat, corrosive gases, and shock (mechanical stresses) are some of the environmental stresses that degrade electronics. Advanced materials—such as conformal coatings, underfills, sealing/potting materials, and gasketing solutions—safeguard motors, drives, and controls to deliver longevity and peak performance.
Bonding
Bonding solutions—like threadlockers, assembly adhesives, and thermally conductive adhesives—can often eliminate the need for mechanical hardware, enhance electrical integrity, and allow for more design freedom.
Advanced materials must be designed with safety and sustainability at the forefront, driven by civic responsibility, customer demand, regulatory requirements, and emissions cost savings. Manufacturers are increasingly turning to renewable energy, equipment upgrades that cut greenhouse gas emissions, and processes like recycling cooling water to reduce resource consumption.
Collaborative innovations in sustainability not only advance environmental goals but also create competitive advantages, with solutions such as iso-free gasketing, conformal coatings, and solvent-free Sil Pads for thermal interface materials. However, true sustainability spans the entire value chain. Arbor estimates that 80% of a product’s environmental impact is determined before it is made, during the design and material sourcing phases. Careful vetting and selection of advanced materials at this stage maximizes sustainability across the product lifecycle, from sourcing and production to end-use, re-use, repair, and recycling.
A manufacturer of AC/DC power supply for Cloud and Hyperscale data centers needed a robust thermal management solution to work in a compact design with diverse topographies. The solution had to work with existing dispensing equipment and accelerate assembly for maximum cost efficiency and effective device attachment. The ultimate goal was to achieve consistent 24/7/365 power access in data centers throughout the life of the system.
BERGQUIST LIQUI BOND TLB SA2000 thermally conductive adhesive met the manufacturer’s production and end-use performance requirements. It eliminated the need for mechanical fasteners and improved productivity by 20-30%, while reducing manufacturing costs by 15-20%. The AC/DC power supply achieved a thermal conductivity of 2.0 W/m-K, ensuring high reliability and meeting the demands of data center power consumption.
As the world demands more power, managing energy efficiently and reliably is a mission-critical requirement. Advanced materials are providing next-level performance, reliability, and sustainability in the achievement of power’s new mandates.
Henkel, a leader in customized formulations engineered for customer needs and made sustainably, helps organizations power ahead. Let’s put your ideas in motion to advance power systems for a better tomorrow.
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