Investigating cracking phenomena in potting materials utilized in certain electronic devices and exploring alternative material solutions

Abstract

This master's thesis explores the issue of cracking in potting materials used for encapsulating converters in electric vehicles, with the aim of identifying root causes and proposing alternative materials to enhance performance and reliability. The research employs a multidisciplinary approach, integrating literature review, thermal testing, visual inspection, and simulation techniques to analyse failure modes and mechanisms. Results consistently reveal that thermal and mechanical stress incompatibilities among materials contribute significantly to cracking issues. The study underscores the importance of harmonizing material properties and behaviors to ensure the stability and durability of electronic converter assemblies. Recommendations for mitigating these challenges are proposed in the discussion and conclusion. This work provides valuable insights into optimizing material selection and product design for more reliable and robust encapsulation solutions in similar electric products and applications.