Case Study: Heat Dissipation for Hybrid Vehicle DC/DC Converter
The Challenge
The consumer demand for electric vehicles (EVs) and hybrid electric vehicles (HEVs) has skyrocketed over the past several years and can only be expected to continue to grow. As that demand increases, manufacturers must also consider the increased demand in 12V and 24V accessories which have traditionally been powered by an alternator. For EVs and HEVs, that alternator is replaced with a DC/DC converter such that energy is allowed to transfer between the power source and the on-board accessories.
Design Requirements
It’s important when considering the design of the DC/DC converter that the structure allows for minimal electromagnetic interference and current/voltage ripple. It should be reliable, lightweight and highly efficient. Any heat that is generated from the converter must be able to dissipate through the structure of the converter without compromising functionality.
Key Customer Requirements
- Easy to dispense
- 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
Conclusion
Parker Chomerics THERM-A-GAP® GEL 30 meets each of the requirements above, made with high volume dispensed thermal interface materials. These materials are the industry standard when cost, time and efficiency are of utmost importance.
The Solution
The solution for this automotive component manufacturer gave the client a lower deflection force and highly-improved thermal performance. How? By dispensing the Parker Chomerics THERM-A-GAP® GEL 30 onto the heatsink.
A 300cc cartridge solution was implemented and will eventually convert to high volume manufacturing using a 1 gallon pump unit (1GPU) and valve dispensing system.
The end result led to optimized, highly-efficient functionality all in a solution that was easier to dispense. With an overall competitive total value to thermal pads or thermal grease, the Parker Chomerics THERM-A-GAP® GEL 30 is the industry leader in thermal gel for automotive manufacturing.