Thermally conductive gap filling materials

Dr. Mukesh Kumar Madhup

Amatech Innovation, Ahmedabad

Thermally conductive gap filling materials are crucial for many industries where heat dissipation is a concern. In battery applications, these materials are especially important as they help to improve the efficiency and performance of batteries, while also prolonging their lifespan.

Gap fillers are materials that are used to fill the gaps between two surfaces to improve heat transfer. These surfaces may be the battery cells themselves or the housing that contains the cells. Without thermally conductive gap filler, heat generated by the battery cells can build up and lead to thermal runaway, which can cause permanent damage to the battery or even a fire.

There are two main types of thermally conductive gap fillers: silicone gap fillers and non-silicone gap fillers. Silicone gap fillers are the most commonly used in battery applications due to their high thermal conductivity and excellent thermal stability. They can be further categorized as either single-part gap fillers or two-part gap fillers.

1. Single Part

Single-part gap fillers are pre-cured, ready-to-use materials that can be dispensed directly onto the battery cells or housing. They are typically cured at room temperature, which makes them easy to use in the field. However, their thermal conductivity is often lower than two-part gap fillers.

2. Two Parts

Two-part gap fillers consist of a base and a curing agent that are mixed together before application. Once the two parts are mixed, the material is dispensed onto the battery cells or housing and then cured at room temperature or through a heat cure process. Two-part gap fillers often have higher thermal conductivity than single-part gap fillers, but they require more preparation before use.

Non-silicone gap fillers are made from other materials such as epoxy or polyurethane. These materials may have higher thermal conductivity than silicone gap fillers, but they are often more difficult to work with and may not be as stable at high temperatures.

In addition to their use in battery applications, thermally conductive gap fillers have a wide range of other applications. They are commonly used in the electronics industry to dissipate heat from power supplies, LED lighting, and other electronic components. They are also used in automotive and aerospace applications to improve the thermal management of engines and electronic systems.

In conclusion, thermally conductive gap filling materials are an important component in battery applications. Silicone gap fillers are the most commonly used due to their high thermal conductivity and thermal stability. They can be further categorized as either single-part or two-part gap fillers. Non-silicone gap fillers are also available, but they may not be as easy to use or as stable at high temperatures. With the increasing demand for high-performance batteries, the importance of thermally conductive gap fillers will only continue to grow in the future.

Amatech has series of gap filling materials in the Amatech TCG AB series with various conductivities.

For further information – contact info@amatechinnovation.com