Thermal gap pads fill the gaps between heat-generating electronic components (heat sources) and heat-dissipating surfaces (heat sinks).
Heat is the enemy of reliable electronics, and thermal gap pads move more heat than the air that would otherwise fill these gaps.
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The ISP Advantage: Our Process and Capabilities
We source thermal gap pad materials from industry-leading suppliers like Polymer Science and Henkel Adhesive Technologies, and convert them into thermal gap pads that arrive ready to install. Depending on the volumes you need and the required tolerances, ISP uses digital knife cutting or precision die cutting to turn sheets of thermal interface materials (TIMs) into custom gap pads.
Proper packaging is a key component in the processing of thermal gap pads. Because thermal interface materials are not particularly stable, transportation can damage gap fillers that are not packaged correctly. ISP is experienced in converting thermal gap pads, and subsequently focuses on precise and protective packaging solutions for your shipments.
ISP is More Than Just a Die Cutter and Fabricator
At ISP, we provide engineering support and prototyping, with the flexibility to adapt to your specific process needs . For example, we can help you to select the right materials and in the most cost-effective quantities. We can also store and convert proprietary customer supplied materials.
With our ISO 9001:2015 and ISO 13485:2016 certifications, we’re also firmly committed to quality assurance. Your thermal gap pads will meet all your specifications and our Made in USA facility can help you to mitigate supply chain risks.
From prototyping to production to packaging, ISP is an extension of your engineering team
To discuss your thermal management application, contact us online or call (800) 984-1811.
Learn More About Thermal Gap Pads
What are Thermal Gap Pads?
Thermal gap pads move potentially damaging heat away from sensitive electronics. Sometimes, the movement of this heat is described as transfer or dissipation instead. Heat is the enemy of reliable electronics because it causes the materials in components and devices to degrade more rapidly. This can result in shorter lifespans, unexpected repairs, and premature device failure.
Thermal gap pads consist of a polymer matrix that contains thermally conductive filler particles. Most polymers are thermally insulating rather than thermally conductive, but the addition of specialized fillers creates a heat-transferring network within the pad. Because thermal gap pads are relatively soft, they can be precision die cut or digitally knife cutting to exacting tolerances.
Most thermal gap pads are square or rectangular in shape, but they can also have intricate designs with holes, chamfers, or other features to accommodate fasteners or other printed circuit board (PCB) components. Digital knife cutting supports intricate part designs, and with speed, precision, and accuracy.
Other names for thermal gap pads include:
- thermal pads
- thermal interface pads
- thermal gap fillers
- thermally conductive pads
- thermal gel pads
- heat transfer pads
Advantages of Thermal Gap Pads
There are many thermal management products, but thermal gap pads have important advantages over liquids, pastes, and greases. For example, die cut gap pads support dimensionally consistent and cost-effective fabrication at higher volumes. Thermal pads are also easier to apply, and they’re not messy. Plus, they remain in place and won’t slump or flow-out of position.
Because they are conformable and compressible, thermal gap pads also fill irregular voids and maintain surface contact with rough or uneven substrates. Maximum contact is necessary for optimal heat transfer, therefore thermal gap pads are available in a range of thicknesses to fill larger or smaller gaps and can come with adhesives or reinforcements.
Key Advantages
Thermal Gap Pad Tips: Selection and Installation
When selecting and installing thermal gap pads, keep these tips in mind.
Thickness: Thinner pads are better at transferring heat than thicker pads. Therefore, make the thermal interface line between the heat source and heat sink as thin as possible.
Compression: Most thermal gap pads are designed to be compressed by as much as 40%. The weight on top of the pad, such as from a metal heat sink, may be sufficient for compression; however, clips and screws are sometimes used.
Cost vs. Conductivity: Die cut thermal gap pads that transfer more heat contain more expensive filler materials. These fillers increase the total cost of the pad, so you may need to balance this against your performance requirements.
