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This paper describes a unique multiphysics simulation tool allowing one to analyze and optimize reactive molding process used for the production of electrical insulation (in the form of epoxy resin embedding) in many power products. The presented methodology differs from the standard approach, since it excludes the requirement for high end-user's knowledge and experience in the area of CFD (Computational Fluid Dynamics) and mechanical simulations. The role of the tool user is limited only to the definition of CAD geometry and process parameters via user-friendly Website. The remaining operations involved in numerical computations, including CAD geometry analysis and discretization, solving and postprocessing, are executed automatically and the simulation results are published online. In this way the presented tool gives engineers an opportunity to verify the product/mold design and manufacturing process prior to the production launching or to improve the existing solutions without time-consuming and expensive experimental trials. In addition, the time needed to perform simulation (especially to prepare numerical mesh) is significantly shortened.

This paper reports on analyses and testing of sensitive power electronics components encapsulation concept, enabling operation in harsh, especially high pressure environments. The paper describes development of the concept of epoxy modules that can be used for protecting of the power electronics components against harsh environmental conditions. It covers modeling of the protective capsules using a simple analytical approach and Finite Element Method (FEM) models and validation of the developed models with the high pressure tests on samples fabricated. The analyses covered two types of the epoxy modules: of sphere-and elongated-shape, both with electrical penetrators that enable electrical connection of the encapsulated components with external power sources as well as other power modules and components. The tests were conducted in a pressure chamber, with a maximum applied pressure of 310 bars, for which online strain measurements have been conducted. The experimental results were compared with the simulation results obtained with analytical and FEM models, providing validation of the models employed. The experimental part of this work was conducted in collaboration with Polish Naval Academy in Gdynia.

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