SONGXI Launches Next-Generation Thermal Conductive Silicone Pads for Battery Modules and Power Electronics

SONGXI is expanding its materials portfolio with the launch of the DR8561 series thermal conductive silicone pads. The new thermal gap pad combines high thermal conductivity with excellent compressibility and long-term compression-set resistance — properties that are increasingly critical for electric vehicle battery packs, power electronics, and high-density computing hardware. The result is a material that lets manufacturers manage heat with precision while simplifying assembly compared with liquid gap fillers or thermal pastes.

SONGXI's DR8561 series delivers fast, clean assembly with consistent thermal performance across large surface areas.

As battery packs and power modules pack more energy and switching capacity into ever-smaller volumes, thermal interface materials must do more than simply conduct heat: they need to absorb tolerance stack-up, resist aging, and endure years of thermal cycling without degrading. SONGXI developed and validated the new DR8561 pad together with automotive and electronics customers to meet exactly these demands. Key technical properties at a glance:

• Thermal conductivity: 0 W/m·K (measured per ASTM D5470) — enables efficient heat transfer even under high power density
• Wide operating temperature range: stable from −50 °C to 200 °C — ensures reliable performance across extreme automotive and industrial environments
• Softness and conformability: Shore 00-35 hardness with low compression force — conforms to uneven surfaces and minimizes stress on delicate components
• Compression set resistance: less than 10% compression set after 1,000 hours at 150 °C — maintains consistent thermal contact over the product lifetime
• Electrical insulation: volume resistivity >10¹³ Ω·cm, dielectric breakdown voltage >6 kV/mm — safe for use near high-voltage circuitry
• Easy application: die-cut or roll formats with optional adhesive backing on one or both sides — supports fully automated pick-and-place assembly
• Flame retardancy: UL 94 V-0 rated — meets fire-safety requirements for automotive and electronics enclosures

Thermal Interface Material for EV Battery Packs

In electric vehicles, battery modules sit tightly against cooling plates, busbars, and enclosure walls, leaving little room for error in thermal management. With its low compression force and wide hardness range, DR8561 conforms to natural variation in cell and module dimensions without imposing excessive mechanical stress — a common failure point for stiffer interface materials. At the same time, its high thermal conductivity ensures efficient heat transfer from cells to the cooling system, helping to prevent thermal runaway and extend battery life.

The pad's resistance to compression set means it continues to deliver reliable thermal contact even after years of vibration and thermal cycling under real-world driving conditions. Because the pads are supplied pre-cut to size, they also eliminate the mess and cure-time delays associated with liquid dispensed gap fillers, enabling faster, more consistent assembly on high-volume production lines.

Reliable Cooling for Power Electronics

Power modules, inverters, and onboard chargers generate concentrated heat loads that must be carried away from sensitive semiconductors quickly and evenly. Rigid thermal solutions or thin thermal greases often struggle to maintain consistent contact across uneven heatsink and housing surfaces, leading to hot spots and premature component failure. SONGXI's DR8561 bridges this gap by combining high thermal conductivity with the mechanical compliance needed to fill air gaps completely, without additional fasteners or pressure plates — reducing both assembly complexity and long-term failure risk.

Silicone Pads Built for Technological Progress

With the DR8561 series, SONGXI reinforces its focus on developing tailored thermal interface materials that support the pace of innovation across industries such as electric mobility, renewable energy, and power electronics.

Key Takeaways: SONGXI DR8561 Thermal Conductive Silicone Pads

• New thermal gap pad — DR8561 — designed for EV battery packs and power electronics
• High thermal conductivity: 6.0 W/m·K — suited to high power density applications
• Mechanical properties: Shore 00-35, <10% compression set after 1,000 h at 150 °C — long-term reliable contact
• Process advantages: die-cut/roll formats, optional adhesive backing, UL 94 V-0 flame rating — supports fast, automated assembly

thermal pads for module-level uneven gaps