Cooling systems for power electronics are becoming increasingly important as digitalization advances. Whether it’s system networking, Industry 4.0, artificial intelligence, or electrification, these developments demand more advanced electronic systems or the optimization of existing ones in terms of power density, efficiency, and sustainability.

Since every technical system has a certain efficiency level, components generate heat due to power losses. The efficiency ratio represents the usable power compared to the applied power. Although electronics are becoming more efficient, the need for cooling continues to rise as higher power outputs are required in the same or even smaller spaces.

Due to the high power density of modern systems, natural convection cooling is no longer sufficient to keep electronic components adequately cooled. Consequently, active cooling has become essential. While electronics cooling was often an afterthought in the past, thermal management is now crucial for the long-term performance of power electronics and the overall system. Particularly, component lifespan has become a top priority across almost all applications.

 

What Are the Consequences of Poor Cooling?

The operating temperature has the most significant impact on the lifespan of electronic components. A general rule is that for every 10 Kelvin increase in temperature, the lifespan of an electronic component is reduced by half. This means that inadequate cooling can result in a component designed to last decades failing within just a few years or even months. Every degree counts.

Moreover, even if your components continue functioning within their specified maximum temperature limits, the lifespan is still reduced due to this exponential relationship between temperature and longevity.

 

Unpredictable Costs Due to Production Downtime

A common question is: “What is the worst-case scenario of insufficient cooling?” The answer can vary widely but often involves critical electronic components unexpectedly failing. Whether it’s the server processing all your data, the electronics controlling your production line, or the power electronics converting energy in a wind turbine—overheating can lead to unexpected shutdowns.

Sourcing replacement parts is becoming increasingly challenging and time-consuming. Direct costs arise from spare parts procurement and installation, but the most significant impact often comes from operational downtime and its associated consequences.

 

How Can I Extend the Lifespan of My Electronic Components?

Improving the efficiency of electronic components is one option. However, the constant demand for increased performance often counterbalances these improvements. Therefore, effective thermal management remains critical.

In most cases, cooling solutions for power electronics are custom-developed for specific systems. This approach ensures optimal performance. Modern CAE methods, like those used at Cool Tec Electronic, enable faster, iterative virtual design processes through thermal simulations, reducing both time and costs. The need for multiple physical prototypes is often eliminated.

For existing systems already in series production, further development or redesign can be effectively supported by thermal simulations. This allows the assessment and improvement of heat management, ultimately enhancing the lifespan of electronic components.