Power Conversion Systems

Power Conversion Systems

Chargers, Converters, Inventers


DC/DC Converter

DC/DC converter converts higher-voltage DC power from the traction battery pack to the lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary battery.

DC to DC converters are a type of electrical device that enables the conversion of a DC voltage level to another DC voltage level. These devices are critical in a range of applications, including power supplies, electric vehicles, and renewable energy systems.  In this application page, we will provide a technical overview of DC to DC converters and the materials used in their construction.

The construction of DC to DC converters involves multiple components such as the transformer, inductor, diodes, capacitors, and semiconductors. These components need to be appropriately connected to perform the required electrical functions. In the assembly process, adhesives are used to secure the components to the printed circuit board (PCB) to ensure that they remain in place during operation. The adhesives used in the assembly process must provide a reliable and robust bond while maintaining the electrical performance of the circuit.

Chemical substances such as flux and solder paste are also used in the construction of DC to DC converters. The flux is used to remove any impurities or oxidation from the solder surfaces before soldering, enabling a strong bond between the components and PCB. The solder paste is used to join the components to the PCB and is heated to create a strong bond.

To ensure the long-term reliability of DC to DC converters, the selection of materials is critical. The devices need to withstand extreme environmental conditions such as high temperatures and vibrations without degrading the performance of the circuit. Chemicals such as epoxy resin, silicone, and polyurethane adhesives are used to protect the circuit from environmental factors and ensure that the device remains operational.

dc dc converter - courtesy of Bosch

Assembly adhesives

Epoxy resin is a common adhesive used in DC to DC converter construction because of its high strength and resistance to thermal and mechanical stress. Silicon adhesives are also used due to their excellent flexibility and electrical insulation properties. Polyurethane adhesives are used to protect circuits from harsh chemicals and extreme temperature environments.

DC to DC converters are a critical component in a range of electrical applications. The construction of these devices involves the use of adhesives, solder paste, and flux to connect the components to the PCB. To ensure long-term reliability, materials such as epoxy resin, silicon, and polyurethane adhesives are used to protect the circuit from environmental factors. The selection of materials and chemicals used in the construction of DC to DC converters is essential for maintaining the operational integrity of the device.


Thermal interface materials

Thermal interface materials (TIMs) are also an important consideration in the construction of DC to DC converters. These materials are used to improve the heat dissipation from the converter components, such as the power semiconductors and inductors, to the heat sink or PCB. This is important because excessive heat can lead to the failure of the device, decrease its performance, or even shorten its lifespan.

There are several types of TIMs that can be used in DC to DC converters, including thermal greases, gap fillers, and phase-change materials. Thermal greases are composed of a silicone oil base with added filler particles, which help to improve thermal conductivity between the surfaces. Gap fillers are soft materials that can conform to irregular surfaces to fill any gaps, providing a more complete contact between the heat sink and the component. Phase-change materials are solid at room temperature but become liquid when exposed to heat, enabling them to flow and fill in any gaps, providing better thermal contact.

The selection of the appropriate TIMs depends on several factors, including the application, component size, and the heat sink's size and shape. Some TIMs may require additional curing time or special handling procedures. Careful consideration of the TIMs used in the construction of DC to DC converters is essential to ensure that the device can withstand high temperatures, maintain optimal thermal performance, and avoid overheating.

In summary, the use of thermal interface materials is crucial in DC to DC converter construction to improve heat dissipation and prevent device failure. Various TIMs can be used, including thermal greases, gap fillers, and phase-change materials. Proper consideration of the TIMs selected, including their thermal conductivity, viscosity, and curing time, is necessary to ensure optimal thermal performance and device reliability.