Problems and Challenges of Power Electronics Cooling – And the Perfect Solution: NEOcore Cooling Technology

The Critical Role of Thermal Management in Power Electronics

Let’s face it: in power electronics, heat is the silent saboteur. Whether you’re designing in Helsinki or Houston, thermal management isn’t just a box to tick - it’s the difference between a product that dazzles and one that fizzles.

This article dives into the real-world problems of power electronics cooling, with a special focus on what happens when things get too hot to handle. Spoiler alert: overheating causes a whopping 55% of all electronics failures. That’s not just a statistic - it’s a wake-up call for power electronics designers. Should you pay more attention to it?

This Is Just the Beginning

This post kicks off our new blog series on NEOcore, game-changing power electronics cooling technology. 

In the coming weeks, we’ll dive deeper into the technological innovations, unique features, and practical customer benefits of NEOcore technology. You’ll get an inside look at real-world use cases - with actual, measured results from real power electronics projects.

Expect to see significant performance boosts, impressive energy savings, reduced device weight, improved end products, and even increased market share.

Stay tuned - your journey to smarter, cooler power electronics starts here!

Why Is Power Electronics Cooling So Challenging?

Power electronics design is evolving at warp speed, and so are its thermal headaches. Here’s why keeping your cool is harder than ever:

• Higher Power Levels & New Technologies: More powerful power electronics means more heat. With IGBT and SiC devices pushing the boundaries, advanced cooling is a must.
• Miniaturization & Power Density: As power electronics devices shrink, heat flux intensifies. Suddenly, traditional heat sinks are not able to handle it.
• Reliability & Lifetime: Poor thermal control shortens component lifespans. Think of it as premature aging for your power electronics.
• Cost & Space Constraints: Power electronics designers must juggle thermal performance with tight budgets and even tighter spaces.
• Complex Systems: Multi-component systems (like power inverters and converters) make efficient cooling a real puzzle.
• Thermal Limitations: Insufficient power electronics cooling means lower efficiency and performance. Nobody wants a high-performance inverter that’s always stuck in “eco mode” because you have to de-rate your electrical power.
• Regulatory Challenges: European Union’s F-Gas Regulation aims to phase out fluorinated greenhouse gases (F-gases) with high global warming potential, such as sulfur hexafluoride (SF), commonly used in cooling systems for power electronics. These restrictions compel industries like energy storage, EV chargers, and renewable energy to adopt sustainable alternatives.

The High Cost of Delayed Power Electronics Thermal Design

Addressing power electronics cooling early in the design process isn’t just smart - it’s essential. If you think you can “fix the cooling later”, think again. Secure long-term success by involving thermal management expertise early in your product design. Here are examples of problems you can avoid:

• Heat breeds more heat - a vicious cycle.
• Performance de-rating at high temperatures: Components run below their max to avoid overheating.
• Reduced system efficiency & system-level failures: One hot part can take down the whole system.
• Energy inefficiency = higher power losses: More resistance, less efficiency.
• Shortened product lifespan due to material degradation: Insulation, adhesives, and semiconductors wear out faster.
• Premature failures: Transistors, capacitors, and diodes can overheat, degrade, or fail.
• Painful redesigns when thermal issues pop up in testing and sacrifice the performance.
• Inefficient or oversized cooling solutions added as an afterthought: Poor design means bigger, more expensive power electronics cooling systems.
• Dry-out in copper heat pipes: Thermal issues can cause the working fluid to evaporate faster than it returns, reducing reliability and forcing components to run below capacity.
• Ballooning development and production costs.
• Delayed time-to-market (while your competitors are already selling).
• Safety hazards, as overheating components can ignite.

Business Problems: When Overheating Burns More Than Circuits

Thermal missteps don’t just fry components - they can roast your bottom line:

• Lost revenue: Product failures mean warranty claims, replacements, and refunds.
• Increased costs: More maintenance, repairs, and expensive recalls.
• Lost competitive edge: Slow launches and underperforming products let rivals steal your market share.
• Operational inefficiencies: Downtime and supply chain delays.
• Customer satisfaction & brand damage: Bad reviews, lost trust, and a reputation that’s hard to fix.
• Legal headaches from safety incidents and recalls.

The Solution? Lower Temperature, Higher Performance with NEOcore Technology

At CooliBlade, we know power electronics cooling inside and out. Our NEOcore technology isn’t just another heat sink - it’s a game-changer.

NEOcore is a groundbreaking advancement in heat dissipation that leverages an innovative design and extraordinary thermal conductivity. NEOcore’s revolutionary design is particularly beneficial for cooling IGBT (Insulated Gate Bipolar Transistors) and SiC (Silicon Carbide) power modules, where efficient heat management is critical.

Here are some examples of NEOcore’s technological features and customer benefits:

Where Advanced Cooling Matters Most

Examples of power electronics applications where NEOcore cooling technology excels:

• String and central inverters for utility-scale solar farms
• Hybrid inverters (PV + energy storage)
• Power optimizers and microinverters for rooftops
• EV charging infrastructure
• Battery energy storage systems (BESS)
• Smart grid and grid-forming inverters
• Wind power converters and application cooling

The Bottom Line: NEOcore Technology Is Your Best Power Electronics Cooling Partner

As electrification surges and power electronics take center stage, thermal management isn’t just a supporting act - it’s the headliner. From maximizing efficiency and lifespan to ensuring safety and compliance, advanced cooling solutions are the heroes of next-generation power electronics.

At CooliBlade, we’re not just keeping things cool - we’re powering the renewable energy revolution.

The story doesn’t end here. Stay tuned for the next post as we dive deeper into the innovations and real-world results of NEOcore technology. We’ll explore more technological breakthroughs, features, benefits, and customer success stories.

Stay Cool with CooliBlade!

Ready to keep your cool? Learn more how CooliBlade can help you design the future of power electronics - Contact our cooling experts

Learn more about NEOcore cooling technology