In March/April 2019, a Chinese manufacturer of electric shared bicycles was working to develop a new e-bike design that would reduce manufacturing costs and weight while improving aesthetics and reliability. 

Customer Challenge

• Modern-day motor drives are integrating more complex power devices to manage growing energy efficiency requirements.  The customer’s next-generation motor controller required a thermal interface material (TIM) to manage new performance challenges and higher power densities. 
• As the IC power module is subjected to motor vibration, reliability and stability of the thermal interface material – with no material migration -- is critical to enable operational integrity.
• Any thermal material selected had to meet challenging metrics: Electrical isolation with high dielectric strength (>5000 Volts) and low thermal resistance are necessary to meet in-application conditions.

Paint and coatings expert Ulrich Dawidowski explains how more efficient and sustainable treatment processes for steel parts make customers smile.

6W/mK thermal gel with balance in dispensability and in-application stability address the demands of 5G telecom infrastructure systems.

Customer Challenges
Increased production demand for the customer’s low-voltage power distribution enclosure systems dictated a faster, more efficient gasketing approach. 

Customer Challenge

• The customer’s new design for a power supply used in a high-power industrial application incorporates several discrete packages, making traditional mechanical attachment processes inefficient.
• In addition, the system’s power levels, high breakdown voltage and heat generation suggested that use of conventional adhesives as a mechanical replacement could not deliver the thermal performance necessary. 
• The customer aimed to reduce overall manufacturing costs, while improving production efficiency, performance and yield. 

Our hot melt adhesive Technomelt Supra 7220 PS Easyflow^® sets new standards to make production processes for palletizing with adhesives more sustainable and efficient.

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Customer Challenge

• The customer’s new design for a DC-DC power converter required a more efficient, high-volume solution for the application of thermal management materials. 
  
  
• For previous-generation designs, silicone pads were applied in several locations between the DC-DC converter’s printed circuit board and metal housing. Use of the pads presented several inventory and production-related issues, including:
  
  - Operator handling difficulty of the thin sheets
  - Manual and time-consuming application process
  - Sourcing of silicone pads in many different sizes and thicknesses
  
  
• Any new material solution had to provide similar or better thermal performance as that achieved with the silicone pads.