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Preventing Failures in High-Voltage Electronic Systems
High-voltage electronics are critical to many advanced technologies, including electric vehicles, industrial automation, renewable energy systems and aerospace components. However, these systems face extreme electrical stress and are highly vulnerable to environmental contaminants such as moisture, dust and chemicals. To ensure their performance and longevity, conformal coatings have become an essential line of defense.
Conformal coatings are thin, protective films that are often applied to printed circuit boards (PCBs) and electronic assemblies. Unlike bulky enclosures, these coatings conform to the surface contours of components, offering seamless protection without adding significant weight or bulk. This makes them ideal for compact, high-performance electronics and weight-sensitive applications.
The primary function of conformal coatings in high-voltage electronics applications is to prevent arcing, corona discharge and electrical leakage. At elevated voltages, even a small contaminant, such as a drop of water, can create a path for current to jump, potentially leading to catastrophic failure. A properly applied conformal coating serves as a reliable insulating barrier, significantly minimizing the risk of possible issues.
Each conformal coating type offers unique properties and benefits. Silicone coatings excel in high-temperature and high-humidity environments, making them a great choice for outdoor and industrial settings. For critical high-voltage applications, such as EV onboard charging, power conversion systems (PCS), electrical power controllers and variable speed drives, ultra-thin Parylene conformal coatings are ideal due to their unmatched uniformity and dielectric strength.
Conformal coating application techniques vary and include brushing, spraying, dipping and vapor deposition, depending on the material and end-use requirements. Regardless of the method, maintaining high-quality coating application standards is critical in high-voltage electronic systems, as even the slightest bubble or pinhole can lead to component damage.
As the demands on high-voltage electronic systems increase, ensuring their reliability and longevity is more important than ever. Conformal coatings play a key role in safeguarding these systems, offering enhanced protection against environmental and operational stressors. For engineers designing advanced power electronics, choosing the right coating early in the design process is essential for building safer, more durable and longer-lasting systems.
To learn how conformal coatings can enhance the performance and reliability of high-voltage electronics, contact SCS.
Global Coverage Issue 102, Spring 2025
