As electric vehicles push power electronics to new limits, materials are under pressure like never before. Higher power densities, rising heat losses and tighter installation spaces are forcing manufacturers to rethink how they protect and stabilise critical components.
Now, German giant WEVO-CHEMIE GmbH has unveiled a solution engineered for exactly these demands: the WEVOSIL 2210x FL range of 2K silicone potting compounds, purpose-built for next-generation EV power electronics.
Modern DC/DC converters, inverters and inductive components must endure continuous high currents, extreme temperatures and constant mechanical stress — all within increasingly compact assemblies. The new RTV silicones are designed to deliver precise thermal management, reliable electrical insulation and long-term mechanical stability in these high-load environments, as per the company.
As electrification accelerates, integration inside power electronics assemblies is intensifying. Inverters, converters and inductive components are packed closer together, while heat output continues to climb.
The WEVOSIL 2210x FL materials are formulated to secure sensitive components, improve heat dissipation and strengthen long-term reliability under these compounded stresses.
Similarly, DC/DC converters play a central role in high-voltage and onboard EV architectures — transmitting substantial power within confined designs.
WEVOSIL 22102 FL delivers thermal conductivity of 1.0 W/m·K, combining efficient heat dissipation with moderate density and strong mechanical decoupling. This makes it suitable for applications prioritising either weight reduction or enhanced thermal performance — especially where components must operate reliably under high continuous currents, elevated ambient temperatures or limited cooling surfaces.
The hydrophobic silicone potting compounds also protect densely assembled components, windings, transformers and sensitive capacitors by preventing moisture ingress, condensation and corrosion, the company says.
Inverters — core elements of the electric drivetrain — face sustained thermal loads. The potting material must fully wet tightly packed power modules, even across minimal gaps.
WEVOSIL 22105 FL combines very low viscosity with high thermal conductivity of 1.5 W/m·K. Designed for continuous operating temperatures of up to 200 °C, the silicone features a supersoft hardness of around 60 Shore 00 and adhesion bonding properties. The result: reduced stress on solder joints, substrates and sensitive semiconductors — critical to the durability of modern electric axles.
Ferrite cores are brittle and highly sensitive to mechanical stress, yet must maintain electromagnetic stability.
The RTV silicones provide vibration damping, crack protection and reduced acoustic effects. With standard viscosities below 5,000 mPa·s, they can be processed using conventional mixing and dosing equipment while minimising air pockets — supporting improved EMC stability in potted assemblies. The materials are also suited to demanding inductive applications such as chokes used in EV systems.
With its application-focused WEVOSIL 2210x FL portfolio, Wevo positions itself as a development partner for OEMs and suppliers working on cutting-edge EV power electronics.
