Thermal management materials are used to manage the heat generated by electronics, batteries, motors and other devices.
By regulating temperature, they promote safety, reliability, and performance and can extend the life of components and systems that are susceptible to damage from high heat.
We proudly work with many material partners, such as:
Main Types of Thermal Management Materials
Thermal Insulation
Thermal insulation materials slow or stop the spread of heat, such as between the adjacent battery cells in an electric vehicle (EV). They have a high thermal resistance.
Thermal Interface
Thermal interface materials (TIMs) transfer heat, such as from an integrated circuit (IC) or chip to a heat sink. They have a high thermal conductivity
ISP Works With Both Types of Materials
We source sheets or rolls from material partners and use digital knife cutting and precision die cutting processing to produce thermal insulation or TIM components at our US-based manufacturing facility. In addition to the thermal management materials listed below, ISP also works with customer supplied materials and offers value added services including slitting and laminating.
From prototyping through production, ISP is an extension of your engineering team
To discuss your thermal management application,
contact us online or call (800) 984-1811.
Thermal Resistance vs. Thermal Conductivity
Thermal insulation materials have a relatively high thermal resistance, an expression of a material’s ability to stop or slow the flow of heat.
Typically, the unit of measure is kelvins per watt (K/W) or degrees Celsius per watt (°C/W). This represents the temperature difference that’s required to transfer one watt (W) of heat through the material.
On some data sheets, thermal insulation lists the R-value instead. This is the temperature difference per unit of heat flux that’s needed to sustain one unit of heat flux between a warmer surface and a colder surface.
Denser and thicker thermal insulation tends to have higher R-values, which means that they have greater resistance to heat flow.
Thermal conductivity is the opposite of thermal resistance. It’s abbreviated as TC and often measured in watts per meter kelvin. (W/mK).
Thermal conductivity quantifies the rate at which heat energy flows through a material when there is a temperature difference across it. A higher TC indicates that a material is a better conductor of heat.
Air has relatively low thermal conductivity and does not transfer the flow of heat very effectively. That’s why thermal interface materials, with their higher thermal conductivity, are used to fill the air gaps between hotter and colder surfaces.
Thermal Insulation Materials
Solid polymers provide a measure of thermal insulation, but foam and sponge materials are better thermal insulators because of their cellular structure. Closed-cell foam and sponge materials are especially effective because the trapped air in enclosed cells or pockets is an effective thermal insulator.
ISP converts three main types of thermal insulation materials. Our experts can help you with material selection and recommend the right thermal barrier for your application.
Closed Cell EPDM Foam
- combines thermal insulation with resistance to weather, water, moisture, ozone, and sunlight.
- often used in outdoor applications.
Although closed cell EPDM cannot match the high-temperature resistance of polyimide foam or silicone thermal insulation, its superior weather resistance and durability are distinct advantages.
Polyimide Foam
- provides high-temperature insulation
- lightweight, fire resistant, and low outgassing.
- can provide acoustic insulation
Polyimide foam resists higher temperatures than silicone thermal insulation and has a broader temperature range than closed cell EPDM foam. Often, polyimide foam is in high heat applications that require long-term performance.
Silicone Thermal Insulation
- maintains its properties over a wide temperature range
- lower temperature resistance than polyimide foam
- valued for its flexibility and elasticity.
With its low compression set, silicone thermal insulation resists permanent deformation under pressure.
Thermal Interface Materials
Normally, the polymers that are used in TIMs are thermally insulating. To impart thermal conductivity, specialized fillers such as aluminum oxide or boron nitride are added. The polymer also provides its own properties, such as EPDM’s tensile strength or silicone’s thermal stability.
ISP converts two main types of thermal interface materials. Our experts can help you with material selection.
Thermal Gap Pad Materials
- combine thermal conductivity with performance properties from the polymer and other additives, such as flame retardants
- silicone based gap pads are compressible with low contact resistance to conform to irregular surfaces
- acrylics, polyimide, and polyester are typically used in silicone-free environments
Thermally Conductive Tapes
- used in applications that require both thermal management and mechanical attachment
- can replace screws, clips or fasteners in sensitive electronics
- can be kiss-cut so that they are easier to peel