New energy vehicle solutions

chace | 2025-10-29
 

Advanced driving assistance systems (headlights, radar, display screen)

In order to improve driving convenience and safety, the assisted driving and autonomous driving functions of automobiles are rapidly being introduced. All automotive ADAS functions require high-quality, comprehensive sensor kits and their data processing to provide superior performance. Each vehicle has a large number of sensors, which are designed to be aesthetically pleasing in smaller sizes, leading to densification of components and posing challenges in thermal management. In addition, ADAS also needs to face harsh vehicle application environments such as vibration and impact, so the anti vibration and impact performance of thermal interface materials must also be met. There are many chips for detection modules and other modules, and the computing power and power consumption of chips are constantly increasing, so there is a better demand for heat dissipation of processing chips.

Thermal pads are easy to use by hand; Easy to process, can be cut into various shapes; Good repairability and easy disassembly and assembly; Flexible design; The back can be glued or not, and can be backed with silicone tape/PI film. Can be used between modules and casings, among which low volatility series and silicon free series gaskets can be used for applications in car lights or cameras.
Thermal conductive silicone grease has high thermal conductivity, high reliability, high cost-effectiveness, good wettability, extremely low thermal resistance, low volatility, no corrosion to the substrate, good heat dissipation surface wettability, and can achieve extremely low thermal resistance.
Thermal conductive gel is a new type of  thermal conductive material, which has the characteristics of low thermal resistance, high reliability, low required working pressure, strong adhesion, simple operation, low requirements for interface geometry, and excellent design flexibility.
 

Charging station

The development speed of the new energy electric vehicle (EV) market is accelerating under the global efforts to reduce emissions, which also indicates a significant demand for charging infrastructure equipment. Not only does it require an increase in the number of charging stations, but safe and fast charging is also crucial for use. The charging power level ranges from ordinary household 110V to ultra fast commercial 800V or even higher, from household AC to fast charging DC, where components such as inductance modules and power modules generate heat quickly and in large quantities. So, to meet the market demand for fast charging in a safe and sustainable way, and to improve the reliability and durability of equipment.

Thermal conductive silicone grease is used to fill the gaps between heat source devices (CPU, GPU, IGBT, etc.) and heat sinks. It can fill tiny gaps as low as 10 μ m, with good thermal conductivity and insulation properties, high temperature resistance, and good reliability. It is the best choice for chip thermal conductivity of various components of charging piles.
Thermal conductive silicone gasket can quickly transfer heat to the aluminum casing of the power supply; Alternatively, the heat from low-power devices can be conducted to the water-cooled plate through a heat sink, utilizing the high elasticity of the thermal pad to provide shock absorption and shock absorption.
High thermal conductivity two-component flexible silicone, mixed 1:1 during use, can be cured at room temperature or accelerated by heating without any gas release. It is commonly used to fill gaps between heating components and eliminate assembly tolerances after curing. Automatic dispensing design improves work efficiency, enabling automated assembly and highly adaptable thermal conductive materials.

When renovating or assembling charging stations, the use of insulating thermal conductive sealing adhesive can protect the sealing protection of power modules and other electronic components with waterproof, dustproof, and high and low temperature resistance properties, and more importantly, improve their safety and service life. At the same time, room temperature curing sealant can be used for bonding inserts or sealing components.
  

Vehicle power control system

Due to high-power charging and discharging, electronic components, chips, MOSFETs, etc. that generate a large amount of heat inside the housing of the car charger need to conduct the heat out in a timely manner, otherwise it will greatly reduce the lifespan and performance of the internal components. Thermal interface materials (thermal conductive gasket, thermal conductive insulating film, thermal conductive gel, thermal conductive potting adhesive, etc.) can not only provide excellent thermal conductivity, but also effectively fill the uneven gap between the device and the radiator surface to remove air and establish an effective thermal conduction path.

The thermal conductive insulation film based on glass fiber and polyimide film is applied between power tubes and heat sinks. This thermal conductive material achieves insulation, voltage resistance, tear resistance and other functions.
Thermal pads are mainly used for large interface gaps; Absorb stress under relatively large tolerances; Assembly components that experience frequent vibrations during the application process; Suitable for assembling thermal conductive materials and the whole machine in different places.
Thermal conductive gel not only has good thermal conductivity, but also has insulation and operability, which can realize large-scale
automatic production. High thixotropy, effectively filling uneven gaps, with shock-absorbing effect, can ensure the system operates in a stable structure, while also conducting heat out in a timely manner.

Thermal conductive sealing adhesive can effectively fix small electronic components, prevent damage caused by collisions, fill the gaps between irregular heat sources and heat sinks, protect the stability of internal structures, and has characteristics such as low viscosity, accelerated curing at room or high temperatures, high thermal conductivity, high temperature resistance, and flame retardancy.
  

Vehicle Drive System

Pure electric vehicles are powered by the onboard battery pack, and their range is affected by the efficiency of the motor. Due to the high power density requirements of electric vehicle motors, heat dissipation is also the primary solution for designers. A large amount of heat is generated during the operation of the motor, and the heat in the stator is conducted from the iron core to the casing by the thermal conductive material. The casing dissipates the heat to the environment through water-cooled water channels or surface fins.

 

Fill the gap between the winding at the end of the motor and the casing with thermal conductive sealant, and maintain a solid state after heating and curing, with good thermal conductivity and insulation properties.
The thermal pad is in direct contact with the cooling plate, and the heat is dissipated through the cooling plate and cooling disk, achieving good heat dissipation effect.

Battery Pack

As manufacturers strive to increase the range of new energy vehicles, cars need to design as many battery cells as possible within a certain space. Many battery packs composed of independent battery modules will generate heat during vehicle operation and accumulate in relatively small spaces. Due to the dense stacking of battery cells inside the battery pack, it also makes it relatively difficult to dissipate heat in the middle area, exacerbating the temperature inconsistency between the cells. As a result, it will reduce the charging and discharging efficiency of the battery and affect its power; In severe cases, it can also lead to thermal runaway, affecting the safety and lifespan of the system. Thermal management materials can quickly transfer the heat generated by charging and discharging to the heat dissipation components, and the materials can comprehensively protect the battery from damage caused by liquids, harsh environments, vibrations, and thermal shocks.

 
Thermal pads are used to fill gaps and conduct heat between the casing and PCB components. Thermal pads improve thermal performance and reliability by eliminating air and reducing interface thermal resistance.