Repair

Power electronics are found in nearly all industrial applications today. Their production is complex, energy-intensive, and relies on critical raw materials. For companies, this means that repair is not only ecologically and economically sensible but also strategically important—especially since supply chains are frequently unstable and outages can be costly.

The problem, however, is that existing rework guidelines and standards typically apply only to standard printed circuit boards. These specifications do not work for ceramic printed circuit boards used in power electronics. This is precisely where we at Fraunhofer IKTS come in: In recent years, we have been working intensively on repair concepts at the module level. For example, we can safely remove the silicone potting, selectively extract components, and then professionally reassemble and repot the modules. This opens up entirely new opportunities for service providers. They can expand their offerings and provide repairs cost-effectively. In addition, we can give companies specific guidance on which equipment and tools they need for such repairs.

© Fraunhofer IKTS
Assembly with silicone potting compound.
© Fraunhofer IKTS
Removed silicone potting compound.
© Fraunhofer IKTS
Desoldered components.
© Fraunhofer IKTS
Desoldered components.
© Fraunhofer IKTS
Cleaning processes.
© Fraunhofer IKTS
Deposited sintering/solder pastes for reassembly.

 

Another important factor is the so-called “state of health”—that is, the actual condition of a module. To address this, we are developing new methods that allow for a much more accurate assessment of this condition. These range from new material approaches to improved measurement and testing strategies. This will enable repair service providers to make much better decisions in the future about whether a repair is truly worthwhile—and which steps make the most sense for it.

However, there are also limitations. When it comes to hard potting compound materials, we are still in the early stages. These materials are very challenging, which is why we are currently working on new approaches in this area. In addition, we are expanding our repair concepts from the module level to include complete inverters. That is the next level of integration.

If you are a repair service provider or EMS provider considering expanding your offerings or tapping into new business areas in the field of sustainable power electronics, please get in touch with us. We would love to hear about the challenges you are facing, and which repair tasks remain unsolved today. 

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Some of the results were achieved as part of the flagship project “GANZ Power Electronics” funded by the BMWK (grant number: 75 LBR).