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Explore our specialized portfolio of pre-cured, two-component dispensable gels, potting silicones, and chip-to-heatsink interface materials built for automotive-grade reliability.
As EV battery architecture evolves from conventional modular packs to Cell-to-Pack (CTP), Cell-to-Chassis (CTC), and 800V ultra-fast charging platforms, thermal interface materials are redefining volumetric energy density and lifecycle safety.
Electric vehicle lithium-ion battery packs operate under stringent thermodynamic boundaries. The ideal operating temperature range for high-energy nickel-manganese-cobalt (NMC) and lithium-iron-phosphate (LFP) cells is narrowly bounded between 15°C and 35°C. Operating above 45°C accelerates solid electrolyte interphase (SEI) degradation, induces capacity fade, and drastically escalates the catastrophic hazard of thermal runaway. Conversely, uneven temperature distributions across individual cells result in localized impedance imbalances, non-uniform state-of-charge (SOC) drift, and shortened pack longevity.
Dispensable thermal gels serve as the thermal conduit bridging the microscopic surface roughness and macroscopic mechanical tolerances between battery cells, module enclosures, and liquid cooling plates (chill plates). By eliminating microscopic air voids—which possess an extremely low thermal conductivity of approximately 0.026 W/m·K—thermal gel reduces bulk thermal contact resistance (Rth) to negligible levels. Unlike rigid adhesives or pre-formed thermal pads, dispensable two-component (2K) silicone gels provide zero-stress wetting over extensive, irregular surface topographies, absorbing continuous vibration, mechanical shock, and thermal expansion/contraction cycles without mechanical degradation or pump-out.
Ultra-low assembly compression modulus ensures fragile pouch and thin-walled prismatic battery cells remain completely free of mechanical deformation during high-speed pack mounting.
Formulated with multi-modal spherical aluminum oxide and aluminum nitride hybrid fillers to establish tightly packed thermal percolation networks for swift heat evacuation.
Optimized thixotropic index and shear-thinning rheology allow automated meter-mix-dispense (MMD) systems to achieve flow rates over 40-60 ml/s with zero vertical sagging or slumping.
Modern automotive thermal gels are engineered primarily around vinyl-terminated polydimethylsiloxane (PDMS) silicone resins or polyol-polyurethane prepolymers, compounded with specialized surface-treated ceramic fillers. Achieving high bulk thermal conductivity (e.g., 3.0 to 6.0 W/m·K) requires volumetric filler loadings exceeding 70-85 wt.%. Without precision surface coupling agents (such as organosilanes and titanates), such high filler contents cause abrasive wear on dispensing nozzles and severe viscosity escalation.
Songxi Technology utilizes proprietary particle grading technology, synthesizing a multi-modal distribution of sub-micron and micron-scale ceramic spheres. This particle packing morphology maximizes thermal contact points while preserving exceptional shear-thinning flow characteristics. In addition, our formulations exhibit virtually zero oil-bleeding, low volatile condensable material (CVCM < 0.1%), and meet stringent UL 94 V-0 flame retardance ratings, ensuring complete insulation reliability up to dielectric breakdown voltages exceeding 10 kV/mm.
| Engineering Parameter | Test Standard | Typical Value (Automotive Grade) | Operational Impact in EV Power Modules |
|---|---|---|---|
| Thermal Conductivity (W/m·K) | ASTM D5470 / Hot Disk | 2.0 – 6.5 W/m·K | Rapid extraction of Joule heat during 4C/6C high-rate fast charging. |
| Viscosity (Thixotropic, Pa·s) | DIN 53019 (Shear 10s⁻¹) | 120 – 350 Pa·s | Allows effortless low-pressure dispensing and prevents sagging on vertical cell walls. |
| Dielectric Breakdown (kV/mm) | ASTM D149 | > 12.0 kV/mm | Prevents high-voltage electrical arcing in 400V–800V EV battery architectures. |
| Volume Resistivity (Ω·cm) | ASTM D257 | ≥ 1.0 × 10¹⁴ Ω·cm | Guarantees electrical isolation between cell casings and aluminum cooling plates. |
| Flame Retardancy Rating | UL 94 | V-0 (0.8mm - 3.0mm) | Halts flame propagation during single-cell thermal failure events. |
| Operating Temperature Range | Continuous Aging | -50°C to +180°C | Resists freeze-thaw sub-zero winter drives and extreme engine bay / battery heat. |
From individual cell-to-cooling interfaces to Battery Management System (BMS) logic controllers, discover how thermal gel is applied across modern EV power platforms.
In modular and CTP pack structures, prismatic aluminum-cased cells are mounted directly onto extruded aluminum liquid cold plates. Dimensional tolerances, weld seams, and battery swelling create variable gap clearances ranging from 0.5 mm to 3.5 mm. Two-component dispensable thermal gel is applied robotically in serpentine or dot patterns before cell group insertion. The gel displaces air with minimal assembly force, achieving low interface thermal resistance and dampening road vibrations across the entire 8-year / 160,000 km battery warranty cycle.
High-density cylindrical battery arrays feature undulating micro-channel cooling ribbons (serpentine cooling tubes) woven between adjacent cell walls. Thermal pads cannot conform to cylindrical curvatures without excessive force. Low-viscosity two-component dispensable gel flows cleanly into radial crevices, locking the cells into thermal contact with the cooling ribbons, eliminating localized hot spots, and preventing domino-effect thermal runaway propagation between neighboring cells.
Pouch cells naturally experience dynamic volumetric breathing (swelling and contraction) during charge and discharge cycles. Rigid structural adhesives or stiff thermal pads generate severe stress concentrations that risk puncturing the aluminum laminated film packaging. Soft, low-modulus silicone thermal gel acts as a dynamic thermal cushion, sustaining uninterrupted thermal coupling while absorbing cyclic dimensional variations without delamination.
BMS master/slave boards, high-voltage contactors, and Power Distribution Units (PDUs) house high-heat microcontrollers, MOSFETs, and shunts. Dispensing thermal potting gel encapsulants protects delicate PCBA circuitry against moisture, condensation, salt spray, and vibration, while simultaneously sinking heat outward to the cast aluminum protection chassis.
Key technological and market drivers reshaping the demand for high-performance dispensable thermal materials in the global automotive sector.
In early EV battery manufacturing, pre-cut solid thermal pads were widely utilized. However, as Gigafactories scaled toward annual vehicle outputs exceeding hundreds of thousands of units, manual or robotic pick-and-place pad application revealed major operational limitations: high manual labor overhead, limited tolerance compensation, inventory management of dozens of pad SKU sizes, and high insertion pressure requirements. Dispensable thermal gels have emerged as the industry gold standard, enabling 100% automated high-speed dispensing, infinite geometric versatility, zero component stress, and significant total cost of ownership (TCO) reductions.
The global EV industry is aggressively migrating from 400V to 800V silicon carbide (SiC) architectures, unlocking 350 kW to 480 kW DC fast charging capabilities (adding 200 km range in under 5 minutes). High-rate charging generates extreme resistive heating ($I^2R$) within battery cells, demanding thermal interface materials with higher bulk thermal conductivity (> 4.5 W/m·K) and ultra-low interface thermal resistance to rapidly transfer heat spikes to the liquid cooling system.
In Cell-to-Chassis (CTC) and Cell-to-Body (CTB) designs, thermal interface materials frequently play a dual role: providing high heat dissipation while simultaneously contributing structural bonding strength (> 8-12 MPa shear strength) to reinforce pack rigidity. Songxi Technology offers both high-adhesion structural polyurethane/epoxy thermal adhesives and low-stress, reworkable two-component silicone thermal gels, catering to diverse mechanical and serviceability design philosophies.
Songxi Technology is a high-tech enterprise specializing in the R&D, production, and sales of electronic adhesives. Based on silicone, polyurethane, acrylic, and epoxy systems, we provide reliable bonding, sealing, and protection solutions for power electronics, optoelectronics, new energy, automotive, and aerospace industries.
We are committed to becoming a trusted provider of functional polymer material solutions for the electronics industry. Through continuous innovation and application development, we promote the localization of high-end electronic adhesives and help intelligent devices achieve greater stability and durability.
Led by a Ph.D. in Polymer Materials from Sichuan University, Songxi's R&D team brings nearly twenty years of silicone application expertise and has executed over 100 successful customized formulation projects.
Songxi's business covers three functional areas: adhesive & sealing, potting & protection, and thermal interface materials. Our portfolio includes PCBA fixing adhesives, UV adhesives, sealants, thermal conductive potting compounds, thermal greases, pads, two-component thermal gels, EMI shielding sealants, and reactive hot melt adhesives.
Our products serve power batteries, photovoltaic modules, drones, automotive electronics, 5G communications, and LED lighting. We provide both standard products and customized solutions for BMS conformal coating, IGBT thermal filling, and power battery structural bonding, supported by extensive technical application expertise.
We maintain deep collaborations with Chenguang Chemical Research Institute, Sichuan University, and Beijing Institute of Technology. Certified under ISO9001, our products fully comply with RoHS and REACH regulations, verified by SGS, and carry UL 94 V-0 flame retardant certification.
State-of-the-art planetary vacuum mixers, automated filling lines, and precision testing instruments ensuring flawless batch-to-batch consistency for automotive-grade thermal materials.
Key technical considerations when selecting and integrating dispensable thermal interface gels into EV battery design pipelines.
Q1: What distinguishes 2K two-component silicone thermal gel from 1K pre-cured thermal gel in automotive battery production?
Answer: 1K pre-cured thermal gels do not require chemical crosslinking after dispensing; they provide low contact resistance but can exhibit higher extrusion pressures during dispensing. 2K two-component gels are mixed via static mixer during dispensing and cure at room temperature or elevated temperatures into a soft, elastic elastomer (Shore 00 20-50). The 2K chemistry provides superior resistance to vibration-induced migration (pump-out), holds its shape across wide temperature extremes, and exhibits higher dispensing flow rates at lower line pressures.
Q2: How does dispensable thermal gel prevent pump-out under continuous vehicular vibration?
Answer: Pump-out occurs when thermal greases or poorly cross-linked gels experience cyclic mechanical vibration and thermal expansion mismatches between the cell casing and cold plate. Songxi’s two-component thermal gels develop a three-dimensional elastomeric polymer network upon curing. This crosslinked matrix retains filler particles permanently within the silicone backbone, preventing oil bleeding, phase separation, or displacement over severe automotive vibration profiles (per ISO 16750-3 testing).
Q3: How to choose between Silicone-based and Non-Silicone (Polyurethane/Epoxy) Thermal Gels?
Answer: Silicone thermal gels provide the widest continuous operating temperature window (-50°C to +180°C), superior flame resistance, and the lowest compression modulus, making them ideal for prismatic and pouch cell interfaces. Polyurethane thermal gap fillers are favored in applications where strict zero-silicone outgassing is mandated (e.g., optical sensors or relay switch contacts) and where higher structural lap shear adhesion is required to mechanically bond cells to structural trays.
Q4: What dispensing parameters should be considered for high-volume Gigafactories?
Answer: Key parameters include filler abrasiveness (to avoid premature valve wear), thixotropic index (ensuring the bead does not slump before module placement), package de-aeration (vacuum degassing to prevent dispensing air voids), and pot life / working time (typically tailored between 30 to 180 minutes to accommodate planned line stoppages).
Songxi adheres to integrity and quality throughout material selection, production, and delivery, turning reliability into a competitive advantage and earning long-term customer trust through professional service and continuous improvement across global markets. Contact our technical team for custom thermal conductivity, viscosity customization, and sampling.
