How Do Thermal Pads Work in Automotive & Battery Applications?

Thermal Materials in the Automotive Industry

Thermal management is a critical component in the automotive sector, particularly with the rise of electric vehicles (EVs) and advanced battery systems. Of the many types of thermal interface materials available, thermal pads (aka thermal gap pads) stand out as the ideal choice for automotive and battery applications due to their efficiency, scalability, and ease of use. Let’s explore why thermal pads are indispensable in this evolving industry.

What Do Thermal Pads Do in Automotive Systems?

Thermal pads bridge heat-generating components—such as battery cells, power electronics, or motor control units—and heat sinks, helping dissipate heat efficiently and prevent overheating. This ensures the safety, reliability, and performance of the entire system.

In automotive applications, thermal pads:

• Fill microscopic air gaps between components (known as wet-out) to ensure maximum heat transfer.
• Provide high thermal conductivity, measured in Watts per meter-Kelvin (W/mK). The higher the W/mK, the better the heat dissipation.
• Offer a long-lasting and low-maintenance solution for thermal management, which is crucial in vehicles designed for durability.

Key Materials for Automotive Thermal Pads

Silicone Thermal Pads

Silicone is an exceptional choice for automotive thermal pads due to its flexibility, durability, and electrical insulation properties. Its ability to conform to uneven surfaces makes it ideal for components like:

• Battery modules
• Power inverters
• Electric motor control units

Sur-Seal’s Sur-Cool silicone thermal pads can be customized in various thicknesses and compression levels to meet the unique requirements of automotive applications.

Graphite Thermal Pads

Graphite thermal pads are favored for their high thermal conductivity and thin construction, making them a great fit for applications requiring optimal heat transfer in tight spaces. They are commonly used in:

• High-performance EV batteries
• Compact power electronics

However, graphite pads work best on smooth and parallel surfaces to maximize thermal performance.

Alternative Materials

Alternative materials such as acrylic, polyester, aluminum, or fiberglass may be used in some automotive designs. These materials cater to niche applications with specific thermal or structural requirements.

Thermal Pads vs. Thermal Paste in Automotive Applications

Thermal Pads

• Scalability: Pads are ideal for mass production and can be cut precisely for easy placement during assembly.
• Durability: Unlike thermal paste, pads maintain their performance over time, resisting degradation from factors like vibration and thermal cycling.
• Cleanliness: They eliminate the mess associated with paste, making them easier to handle in high-volume manufacturing environments.

Thermal Paste

• It provides excellent wet-out and performance in low-cost, small-scale applications but often requires precision application equipment, making it less practical for the automotive industry.

Why Choose Sur-Seal for Automotive Thermal Pads?

Sur-Seal’s Sur-Cool® line of thermal pads offers the versatility and reliability needed for cutting-edge automotive applications. Our thermal pads are engineered to:

• Handle the demanding thermal loads of EV batteries and power electronics.
• Conform to the unique shapes and sizes of automotive components.
• Provide a scalable and cost-effective solution for manufacturers.

Beyond our patented thermal management solutions, we have access to a diverse array of materials to meet any need, thanks in part to our trusted supplier partnerships. Sur-Seal also holds the IATF-16949 certification, making us one of the few North American converters with comprehensive certifications across the automotive, healthcare, and aerospace sectors.

With decades of experience and a commitment to innovation, Sur-Seal is the partner of choice for thermal management solutions in the automotive and battery industries.

Ready to Optimize Your Automotive Thermal Systems?

Sur-Seal delivers industry-leading thermal pads that keep your components cool and efficient. Contact us today to learn how our Sur-Cool thermal pads can enhance your automotive or battery application.