Thermal Interface Materials for EV/Hybrid DC/DC Power Converter Modules - Chomerics Division | Parker US
How to Ground Electronics

A global manufacturer of power control modules for EVs needed a fully cured dispensable thermal gel with excellent heat dissipation for their EV DC/DC converter control module.

Thermal Interface Material Challenges for DC/DC Power Control Modules

As the demand increases for electric vehicles (EVs) and hybrid electric vehicles (HEVs) worldwide, manufacturers must also cope with the increase in 12V or 24V accessories that traditionally have been powered by an alternator. In EVs and HEVs, this alternator is replaced with a DC/DC converter which can transfer the energy between the power source and on board accessories.

The amount of heat dissipated is dependent on the output load and converter efficiency. The control and evacuation of this heat is called thermal management. Prudent thermal management will result in long term reliable operation and allow maximum power utilization in a minimum amount of space.

Thermal Interface Material Design Requirements for DC/DC Power Modules

  • Thermal interface material is easy to dispense by robotic systems
  • Lower deflection force
  • Small assembly gap
  • Good heat transfer from components to heat sink
  • Verified performance of vertical gap slump application
  • Good dielectric strength to avoid breakdowns

Key Customer Requirements for Materials

  • Converter structure has to be reliable and lightweight
  • High efficiency, low electromagnetic interference and low current/voltage ripple
  • Heat that is generated from the converter must be adequately dissipated through the housing
Parker Image

Get a Quote Now

Tell us a little bit about your problem and we'll do our best to come up with a cost effective, timely quote to help you get started.

Solution

The recommended solution for this automotive component manufacturer was to dispense Parker Chomerics THERM-A-GAP® GEL 30 in various patterns onto the heatsink.  

A 300cc cartridge solution was implemented and will eventually convert to high volume manufacturing using a 1 gallon pump unit (1 GPU) and valve dispensing system.

This gave the customer a lower deflection force, excellent thermal performance, all in a solution that was easier to dispense with an overall competitive total value to thermal pads or thermal grease.

Conclusion

Parker Chomerics THERM-A-GAP® GEL 30 fit the needs and the specifications of the automotive component manufacturer’s requirements. High volume dispensed thermal interface materials are ideal for automotive applications where cost, time, and efficiency are of the utmost importance.

Need Help Finding the Right Solution? Talk to an Expert Engineer Now.

If you need assistance identifying the most suitable product for your application,  speak with one of our expert engineers. Our team is ready to help.

Learn more about high-performing EMI shielding solutions.

THERM-A-GAP PAD 30

Parker Chomerics THERM-A-GAP PAD 30 Thermally Conductive Gap Filler Pads provide a soft (34 Shore 00) solution with 3.2 W/m-K of thermal conductivity.

How to Choose the Right Plastic

Automotive Innovative Solutions That Matter

Our global customers rely on us to provide innovative ideas and material solutions. We work with OEMs and Tier automotive suppliers to solve complex electronics and design challenges.

We have an extensive range of products that are used for advanced driver assistance systems (ADAS), electrification cooling systems, metal to plastic light weighting and electrical grounding. Our automotive team has been involved in the design and development of many products including electronics packaging, chassis & body systems, suspension components and engine components. We also offer a range of solutions for internal combustion engines, electric motors, generators and battery packs.

red car driving on paved road

Access Port Covers for EV Cooling Systems

Plastic components provide a low-cost, space-saving solution, enabling Original Equipment Manufacturers (OEMs) to meet the integrated cooling requirements of high-torque electric motors. These products are backed by machine-based process monitoring, ensuring each manufacturing and assembly step is completed thoroughly and correctly.     

Access Port Covers for EV Cooling Systems

Our products are used in a wide range of industries.


 

Thermal Interface Materials & EMI Shielding Solutions

With more than 60 years of experience, we have the technical know-how to meet the rapidly increasing needs of engineers.

Can't find what you're looking for? Talk to one of our experts.