Enhancing Automotive Electronics with Advanced Conformal Coating and Potting Materials

Author: Scott Stephan, Director- Electronic Business Line

As the automotive industry undergoes a seismic shift from internal combustion engines (ICE) to electric vehicles (EVs), the demands placed on electronic components have intensified. With the growing complexity of automotive electronics, ensuring their protection and reliability has become paramount. According to Research and Market, in the Global Automotive Conformal Coatings Market Report, the conformal coatings market will grow from $2B USD in 2024 to $3.5B in 2030 or a 10% CAGR. This growth does not include similar increases of respective potting materials. The increased growth of printed circuit board protection can be attributed to the increase of electronics designed into not only electric vehicles, but also traditional internal combustion engine vehicles. To meet these evolving needs, conformal coating and potting material formulators are specifically developing solutions to provide unmatched protection in critical applications such as power management, safety, crash-avoidance and in-cabin sensors.

The Critical Role of Conformal Coatings and Potting Materials

In modern vehicles, electronic systems are the backbone of performance, safety, and comfort. From power management units to a myriad of sensors that monitor and control various vehicle functions, these electronics must operate flawlessly under challenging conditions. However, exposure to environmental factors such as moisture, temperature extremes, vibration, and chemical contaminants can severely compromise their performance.

This is where our advanced conformal coating and potting materials come into play. Designed to offer superior protection, these materials form a resilient barrier that shields sensitive components from potential damage. Our formulations are meticulously crafted to ensure that they adhere uniformly, providing consistent coverage even in complex geometries and intricate electronic assemblies.

Meeting the Demands of Electric Vehicles

The transition to electric vehicles introduces additional challenges for automotive electronics. EVs typically operate at higher voltages and generate more heat than traditional internal combustion engine vehicles. Consequently, the electronic components in EVs are subjected to greater thermal and electrical stresses. Our conformal coatings and potting materials are engineered to excel under these conditions, offering enhanced thermal management and dielectric properties.

For power management systems, which are critical to the operation and safety of EVs, our potting materials provide robust encapsulation that safeguards against thermal cycling, vibration, and electrical interference. This ensures long-term reliability, even in the harshest operational environments. Similarly, our conformal coatings for in-cabin sensors protect against humidity, dust, and potential corrosive elements, ensuring accurate sensor performance over the vehicle’s lifespan.

Tailored Solutions for Automotive Applications

Recognizing the diverse requirements of automotive electronics, we offer a range of customizable conformal coatings and potting materials tailored to specific applications. Whether it is a high-flexibility coating for delicate sensor assemblies or a high-thermal conductivity potting compound for power electronics, our solutions are designed to meet the stringent standards of the automotive industry.

Moreover, our materials are developed with sustainability in mind, aligning with the broader industry push towards environmentally responsible practices. By reducing the need for rework and prolonging the lifespan of electronic components, our conformal coatings and potting materials contribute to the overall reduction of electronic waste.

Partnering for the Future of Automotive Innovation

As the automotive industry continues to evolve, so too must the materials that protect and enhance its electronic systems. Our commitment to innovation ensures that our conformal coating and potting solutions will continue to meet the ever-increasing demands of automotive electronics, driving performance and reliability in the next generation of vehicles.

Whether an OEM or a supplier in the automotive sector, our advanced materials can elevate manufactured products and meet the challenges of today’s dynamic automotive landscape. Together, we can drive forward the future of automotive technology, ensuring that the vehicles of tomorrow are safer, more reliable, and more efficient than ever before.

Advanced conformal coatings and potting materials play an essential role in protecting automotive electronics, particularly as the industry transitions to electric vehicles. The unique challenges posed by EVs and the tailored solutions our materials provide highlight the importance of these products in ensuring the long-term reliability and safety of automotive electronics.

ELANTAS conformal coating and potting materials create a solid, long-lasting layer of protection that offers the best defense against corrosion, heat, moisture, and dust. Automotive manufacturers and Tier 1 suppliers have found that using coatings or potting on the printed circuit board for safety sensors, crash-avoidance sensors, and power electronics in harsh conditions will provide a higher level of protection to the equipment. Our conformal coating and potting materials, such as the ELAN-Tron^® U 549 FR & UH 510S, Synthite^® AC-46-1, and Conathane^® CE-1170, are available to protect the investment and help provide longevity.

ELANTAS PDG, Inc., based in St. Louis, Missouri, is a premier global supplier of specialty resins for applications in the electrical and electronic industries. Over the years, ELANTAS has developed and acquired additional products and chemistries to service these industries.