Power conversion system | E-Mobility

The three main power conversion systems, the on-board charger (OBC), the inverter, and the DC/DC converter each present a number of technical challenges.

Challenges for power electronics and EV conversion systems.

The three main power conversion systems, the on-board charger (OBC), the inverter, and the DC/DC converter each present a number of technical challenges. Reducing the size of these components, consolidating inverters/converters and on-board chargers, without compromising reliability and safe operation is key. Vehicle performance is addressed through shock and vibration stability, environmental suitability, and resistance to internal and external forces.

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Connector lubricants

Thermal potting
Gap filler
Thermal paste
Conformal coating
Gasketing

Thermal management

Industry trends toward combining electric motors with power conversion systems and increasing miniaturization of components allow manufacturers to save space and reduce weight. The result is both higher power density and higher risk of engine failure. In order to reduce these risks, electric motors require better thermal management materials, including resins with higher thermal conductivity.

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Reliability

Lifetime performance of EV e-drives is a significant challenge for manufacturers. Constant movement and the tendency to improve power density require stronger materials. Mascherpa’s thermal encapsulation and sealing technologies can help increase the reliability of electrical drive systems

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Conformal coating

A protective paint or conformal coating is a thin polymer film applied to a printed circuit board (PCB) in order to protect the board and its components from the environment and prevent corrosion.

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Gasketing

Electronic housing gasket technologies provide a reliable seal against automotive fluids and other external agents.

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Gap Filler

The material is first dispensed as a liquid onto the target surface, and then, when the components are assembled, the material wets onto adjacent surfaces, filling the smaller spaces and air gaps.

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Thermal potting

Encapsulants protect sensitive electronic components in the electric motor, preserving them from vibration, high temperatures, dust, corrosion and moisture.

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