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Reliable Thermal Management for EV On-Board Chargers in Southeast Asia

As electric vehicle adoption accelerates across Southeast Asia, on-board charger (OBC) manufacturers face a common engineering challenge: dissipating the heat generated by high-power conversion electronics while protecting sensitive components from humidity, vibration and relentless thermal cycling. This case study describes how a regional OBC module manufacturer standardized on the HN-8830A/B high thermal conductivity silicone potting compound (3.0 W/m·K) to raise thermal performance and long-term field reliability.

Client Background

The client is a Southeast Asian power-electronics manufacturer producing on-board chargers for passenger EVs, light commercial vehicles and two-wheelers. Its modules are potted to protect the power stage from moisture, dust, salt spray and vibration, and to conduct heat away from switching devices and magnetic components.

The Challenge

OBCs convert AC grid power into the DC electricity that charges a traction battery. Because they sit inside the vehicle, they must survive wide temperature swings, high humidity and constant vibration. The client’s previous potting material offered only modest heat transfer, creating hot spots on the power MOSFETs and magnetics that shortened service life and drove occasional field returns in hot, humid tropical conditions.

• Thermal conductivity too low to move heat away from high-power switching devices.
• Poor flow and voiding when potting densely populated OBC boards.
• Risk of cracking under repeated thermal cycling between charging sessions.
• Need for UL 94 V-0 flame retardancy and high electrical insulation.

The Solution

After evaluating several suppliers, the client selected Shenzhen Hanast’s HN-8830A/B, a two-component, addition-cure (platinum-catalysed) silicone potting compound. Its 1:1 mix ratio by weight and self-levelling flow make it easy to fill complex OBC housings with minimal air entrapment, while the cured elastomer stays rubber-elastic from −40 °C to 200 °C.

Application Process

1. Pre-mix: Component A stirred and Component B shaken to re-disperse fillers.
2. Weighing: Parts accurately weighed at a 1:1 ratio by weight on a precision scale.
3. Mixing & degassing: Blended until uniform colour, then vacuum-degassed for void-critical modules.
4. Potting: Poured within pot life (60–180 min at 25 °C) to fully encapsulate the power stage.
5. Curing: Two-stage cure — room temperature until tack-free, then 30 min at 80 °C.

Results

Why It Matters for the Region

With EV sales climbing across Vietnam, Thailand, Indonesia and Malaysia, OBC reliability directly affects warranty cost and brand trust. By adopting a 3.0 W/m·K silicone potting compound with UL 94 V-0 flame retardancy and a wide operating window, the client delivered chargers better suited to tropical duty cycles — and positioned itself for the next wave of regional EV growth.