Gap filler vs. Gap pad

Gap filler vs. gap pad

In a variety of applications, materials must be used to dissipate heat: New electronic devices and components, for example in the automotive industry or consumer electronics, are becoming smaller and smaller. At the same time, more and more functions are being realised in the smallest possible space.

Thermal management is the keyword for optimisation in this area. Thermal conductive materials can be found in household appliances as well as in commercially available smartphones and tablets or in LED lighting technology. Other areas of application are motor construction, power electronics applications or battery systems in hybrid and electric cars.

Attempts are always made to dissipate the heat from electrical components via improved contacts into a heat sink or into an assembly that functions as a heat sink.

In order to close larger gaps and thus improve heat dissipation, two products are available in principle: Gap fillers and gap pads

What is a gap filler?

Gap fillers are thermally conductive, liquid-applied materials. These thermally conductive gap fillers are often applied by metered mixing of a two-component system with a metering system. Silicone-based, polyurethane-based or acrylate-based systems are often used as a base. Silicone-free gap filler systems based on polyurethane or arcylate are increasingly being used.

Once these materials have been applied, the gap filler cures. Once cured, the material forms a solid but compliant interface that conducts heat away from the electronic components, resulting in longer life and higher performance.

They are often used as a replacement for thermal pads because they achieve lower thermal impedance and offer more design flexibility. Gap fillers are also well suited for high volume production of electronic components such as batteries, inverters/converters, motors and power electronics.

What is a gap pad?

Gap pads are soft, elastic, relatively thick mats with thermally conductive properties. Gap pads compensate for height differences between components through their material thickness and elasticity. Here, too, silicone-based, polyurethane-based or acrylate-based systems are often used as a basis. Silicone-free systems based on polyurethane or arcylate are increasingly being used.

The low self-adhesion of the gap pads, which can be achieved by special settings, enables simplified pre-assembly in many cases. Where stronger adhesive forces are required, self-adhesive versions of the Gappads can also be used. Here it is important to ensure that the adhesive matches the system, i.e. silicone-based, polyurethane-based or acrylate-based adhesive systems are used.

 

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