Precondition

The rapid growth of electric vehicle production and sales has driven the development of the entire industry chain, particularly in the electric vehicle charging market, which is experiencing strong momentum for growth due to both policy incentives and market forces.

The foundation of electric vehicle charging operations lies in the reliable operation of charging equipment, and the normal operation of charging equipment relies on the efficient, stable, and safe guarantee provided by its core component – the charging module. Therefore, the charging module is a key and core hardware for charging operations and serves as a crucial product that helps charging operators achieve long-term profitability

Specific Analysis

Instability

Due to the crucial role of the charging module, downstream production and operation companies have high requirements for its reliability, often demanding a failure rate below 1% within three years. However, in actual usage of charging stations, the frequent occurrence of failures in the charging module often becomes one of the main factors affecting station operations. This directly impacts the profitability of charging operators and the user experience for vehicle owners.

The high failure rate of charging modules is primarily due to the current mainstream air-cooled modules on the market, which adopt a direct airflow design. These traditional modules intake air from the front panel and exhaust it from the rear, effectively dissipating heat from radiators and heating components.

However, since charging stations are typically located in outdoor environments where dust, salt mist, and moisture are present in the air, these particles tend to accumulate on internal components. This accumulation of dust can lead to poor insulation, reduced heat dissipation efficiency, lower charging efficiency, and ultimately decrease equipment lifespan.

Additionally, during rainy seasons or humid conditions, accumulated dust may absorb water leading to mold growth as well as corrosion of components. These factors can result in short circuits causing module and equipment failures.

Technological innovation

Due to the limited adaptability of traditional air-cooled modules, it is necessary to improve and optimize the method of air cooling heat dissipation. The solution of glue-sealed power module has attracted attention from various enterprises. A glue-sealed power module refers to covering all electronic components inside the power module with sealing glue.

When these electronic components are no longer affected by environmental factors, the failure rate of EV chargers will decrease significantly, avoiding unnecessary maintenance costs for upstream and downstream companies. This enables car charging stations to be deployed in places with poor air cooling conditions such as coastal areas, mining areas, and construction sites.

Especially in the current global trade and high-power trend, low-quality charging modules will pose significant problems during the subsequent operation of charging stations, increasing maintenance costs for station enterprises and operators.

Surveys have shown that both the cost and failure rate of products cannot be ignored, with the failure rate being an important assessment indicator. After-sales costs account for 20-30% of the entire lifecycle cost of charging stations.

The excellent performance of glue-sealed power modules will undoubtedly help station enterprises reduce costs, improve efficiency, and provide reliable technical support for after-sales service and operational maintenance.