How We Solved the Problem of Electronic Component Overheating Due to Inappropriate Insulation Materials: A Practical Guide

Photo: Albert Stoynov / Unsplash

A manufacturer of industrial control systems faced repeated failures of electronic components due to overheating. After a thorough analysis, we discovered that the cause was neither a design flaw in the printed circuit board nor insufficient cooling, but rather unsuitable insulating materials. While these materials met the basic requirements for electrical insulation, their thermal conductivity and resistance to high temperatures were inadequate. In this article, we describe how we approached diagnosing the problem and what steps led to its permanent solution.

Problem identification: When insulating materials fail

In the electrical engineering industry, the selection of insulating materials plays a key role in ensuring the safety and service life of equipment. In our case, the customer faced repeated overheating of electronic components in control units, leading to production downtime and increased maintenance costs. Initial analysis showed that the cause was not the failure of the components themselves, but the degradation of insulating materials due to temperature and chemical incompatibility.

The problem was particularly evident in equipment operating in environments with high humidity and temperature fluctuations. Standard insulating materials based on epoxy resins or polyesters lost their dielectric properties after just a few months of operation. Measurements showed that temperatures in critical areas reached up to 120 °C, significantly exceeding the recommended limits for the materials used. Additionally, it was found that some additives in the insulating compounds reacted with surrounding plastic components, accelerating degradation.

Analysis and Selection of Suitable Alternatives

After identifying the problem, we initiated a systematic analysis of available insulating materials, focusing on thermal resistance and chemical stability. We concentrated on materials with a high temperature class (minimum 155 °C) and low thermal conductivity, which could effectively dissipate heat from sensitive components. The options considered included silicone resins, polyimide films, and special epoxy compounds with inorganic fillers.

A key criterion was also compatibility with surrounding materials. We conducted a series of laboratory tests in which we simulated operating conditions—cyclic temperature changes, humidity, and mechanical stress. Special attention was paid to additives that could cause undesirable reactions. The result was the elimination of materials containing phthalates and certain halogenated compounds, which could corrode metal parts or degrade plastics.

Photo: Ludovico Ceroseis / Unsplash

Implementation of the solution and process optimization

Based on the analysis, we recommended switching to a silicone insulating resin with temperature resistance up to 200 °C and excellent dielectric properties. This material also exhibited low thermal expansion, which minimized the risk of mechanical stress during temperature fluctuations. For the application, we adjusted the manufacturing process – we introduced precise resin dosing and viscosity control to ensure uniform coverage of all critical components.

An important step was also the adjustment of the drying and curing technological parameters. We optimized the temperature profile to prevent local overheating during processing. We implemented a real-time continuous temperature monitoring system, which allowed for immediate response to any deviations. After implementing the new material and process, we conducted a series of stress tests that confirmed a significant improvement in the thermal stability of the equipment.

Results and Long-Term Benefits for the Customer

After six months of operation with the new insulating material, there was a significant reduction in failures caused by overheating. Measurements showed that the temperature in critical areas dropped by 25–30 °C, which extended the lifespan of electronic components by more than 40%. Additionally, the customer recorded cost savings on maintenance and a reduction in production downtime, which positively impacted the overall efficiency of operations.

We have long evaluated additional benefits with the customer – for example, improved resistance of equipment to moisture and chemical influences. The new insulating material also met the requirements for halogen-free composition, which was important for meeting environmental standards and certifications. This project demonstrated how crucial a systematic approach to material selection is and how properly chosen raw materials can bring measurable savings and increase the reliability of production processes.

Photo: Albert Stoynov / Unsplash

Impact of Thermal Conductivity and Electrical Properties of Insulating Materials on Electronic Performance

The problem of overheating electronic components is often linked to the inappropriate choice of insulating materials, which must meet conflicting requirements: high electrical insulation and, at the same time, effective heat dissipation. Standard insulating materials, such as epoxy resins or polyimides, provide excellent dielectric properties, but their thermal conductivity is usually low – often below 0.3 W/(m·K). This leads to heat accumulation in critical areas, such as power transistors or power modules, where temperatures can easily exceed 100 °C during operation.

The solution lies in using materials with optimised thermal conductivity, such as ceramic fillers (aluminium oxide, boron nitride) or special polymers with added carbon nanotubes. These materials achieve thermal conductivity of up to 5 W/(m·K) while maintaining insulating properties. It is also important to consider the coefficient of thermal expansion (CTE) to avoid mechanical stress on joints during temperature fluctuations. When selecting materials, it is necessary to test them according to standard methods for measuring thermal conductivity and dielectric strength.

Practical testing and validation of new insulating materials under real-world conditions

Before deploying new insulating materials in serial production, it is essential to conduct comprehensive testing under conditions corresponding to real-world operation. In our case, we selected a procedure involving thermal analysis (e.g., DSC or TGA), dielectric strength measurement, and long-term load tests at elevated temperatures. A key step was verifying material stability under cyclic loading – components were subjected to repeated thermal shocks ranging from -40 °C to +125 °C for 1,000 cycles.

For validation, we used thermal imaging cameras to monitor the temperature distribution on the surface of components and compared the results with the original materials. It was also important to verify compatibility with surrounding materials, such as solders or adhesives, to prevent chemical reactions or degradation of properties. Test results showed that the new materials reduced the maximum operating temperature by 20–30 °C, significantly extending the lifespan of the electronics and reducing the risk of sudden failures.

Optimization of the Manufacturing Process and Training of Technical Staff

The introduction of new insulating materials requires adjustments to the manufacturing process, particularly in terms of application and processing. For example, ceramic-filled resins have higher viscosity and require precise dosing and homogenization of the mixture. In our case, we had to adjust the mixing and application parameters to prevent the formation of air bubbles or uneven distribution of the filler. It was also important to optimize the temperature profile during curing to avoid material degradation or the creation of internal stress.

Equally important was the training of technical staff, who had to master new procedures and understand the critical process parameters. We implemented internal training focused on proper material handling, quality control, and identification of potential defects. Additionally, we created detailed process documentation, including checklists and standard operating procedures (SOPs), to ensure consistency and repeatability in production. This step was crucial for minimizing errors and ensuring the long-term reliability of the final products.

Do you need to optimize materials for your production?

Every application requires an individual approach. GCG Group provides complete technical documentation, including safety data sheets, for selected raw materials and advises on the selection of materials that meet your specific requirements for thermal resistance, electrical insulation, and long-term stability. Contact us – or browse our catalogue of over 1,300 products right away.