Today’s power electronics devices require improved thermal management due to higher voltages, higher operating temperatures, faster switching and smaller designs. Battery packs must deliver more power and extended range through better thermal control. Advanced thermal interface materials (TIMs) are critical for effiiciently dissipating heat, increasing power density and boosting reliability in power modules and batteries.
Choosing the Right TIM for Optimal Performance
Choosing the right thermally conductive gap filler for batteries or gel for inverters, converters, onboard chargers and electronic control units depends not only on performance but also on ease of dispensing. Consistent, reliable dispensing with minimal equipment maintenance helps ensure high quality and reduced system costs.
Traditional TIMs can cause dispensing challenges, including:
• Maintenance downtime to replace the dispensing extrusion head due to excessive abrasion from the TIM.
• Phase separation over time that can cause pumping problems and affect mixing ratios.
• Quality issues that arise when the TIM is not tailored to the equipment and end-use application.
Dow’s silicone-based thermal management materials address all these dispensing issues. The company’s formulation success is based on close collaborations between Dow experts and leading equipment vendors to tailor material properties for consistent, reliable, fast and easy dispensing. High or low flow may be required depending on the type of equipment and the end application. Formulation optimizations may be needed to minimize abrasion and prevent phase separation over time, which avoids the need for re-mixing.
Effective Dissipation and Reliability for Power-Dense Semiconductors
In addition to working with equipment manufacturers, Dow operates in-house labs equipped with popular dispensing systems, enabling its scientists and researchers to adjust and validate their formulations.
The most power-dense semiconductors require efficient dissipation of heat and improved reliability. Dow’s thermally conductive silicones can be applied in thin layers or formulated with low viscosity to completely fill oddly shaped gaps. They can also generate large contact areas for maximum heat transfer.
The following TIMs are well suited for power modules and batteries. Dowsil 4060 GB250 Thermal Gel and Dowsil TC-4525 CV Thermally Conductive Gap Filler for electric vehicle (EV) inverters, converters and onboard chargers provide high temperature resistance and vibration damping. Dowsil 4060 GB250 Thermal Gel features excellent dispensing performance at a fast rate (1.0 ml/sec) to reduce cycle time. Dowsil TC-4525 CV Gap Filler is specifically designed for a smooth assembly process and is ideal for automated dispensing with meter mix equipment.
Dowsil TC-5533 Gap Filler for battery assembly features excellent flowability during dispensing and low abrasion, making it well suited for dispensing equipment across a wide application process range. This two-part, soft, thermally conductive silicone product dissipates heat and relieves stress between the battery modules and the cooling plate.
Partnering for Thermal Management Success
To help battery and power electronics customers achieve their thermal management goals, Dow is partnering with them throughout the application lifecycle.
From the selection of the appropriate TIM at the design step to the optimization of production, Dow’s experts consider the customer’s dispensing equipment and make formulation adjustments to ensure high throughput, minimal downtime and consistent quality. Testing and validation of the solution are performed to ensure top thermal management performance during application usage. This collaboration includes strategies to facilitate disassembly, reuse and recycling at the end of life, matching customers’ sustainability expectations.
Dow supplies a variety of advanced silicone solutions and support services to optimize thermal management performance, streamline dispensing and address application requirements.
