Case Study on Thermal Insulation Sealing of Control Box: Low Cost, High Performance Thermal Management Solution

📘 Case backgroundIn today’s rapidly developing era of intelligent manufacturing and industrial automation, electrical control boxes, as key electronic integration modules, are widely used in various fields such as rail transit, power systems, new energy equipment, industrial robots, etc. The control box integrates a large number of power modules, control chips, sensors, and power devices inside. These components will continue to generate heat during long-term operation, leading to module temperature rise and affecting its stability and service life. In order to ensure the long-term stable operation of the control box in harsh environments, sealing glue is often used to protect it. It not only plays a role in waterproofing, dust prevention, and shock resistance, but more importantly, it provides thermal management function to timely dissipate the heat generated during device operation, reduce thermal accumulation, and avoid device overheating and failure. In the client’s project, a control box for an industrial automation equipment needs to undergo thermal conductive sealing treatment. The main requirements of the customer for sealing materials are as follows:Thermal conductivity: 0.6~0.8 W/m · K, meeting the needs of daily industrial use;Moderate viscosity: has good fluidity and can fully fill the gaps inside the control box;Good electrical insulation: Ensure that it does not affect the operation of the circuit after encapsulation;After curing, it has a certain degree of flexibility: to avoid stress concentration caused by thermal expansion and contraction; The most important point is to control the cost within 20 yuan/kg and have the conditions for large-scale use. Control box thermal conductivity sealing ⚠️ Challenges FacedDuring the material selection process, customers faced the following challenges:one ️⃣ It is difficult to balance the thermal conductivity and cost of materialsTraditional high thermal conductivity sealing materials, such as silicone systems or epoxy systems with abundant fillers, although their thermal conductivity can reach…