Thermally Conductive Tapes and Adhesives

Thermally conductive tapes, or thermal adhesive tapes, are used in applications that require both thermal management and mechanical attachment.

These thermal interface materials (TIMs) can replace screws, clips or fasteners in sensitive electronics. They can also be kiss-cut so that they are easier to peel.

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Converting Thermal Adhesive Tapes

ISP can die cut or kiss cut thermal adhesive tapes using materials from our partners or we can work with customer-supplied materials.

In addition to thermally conductive tapes and adhesives, ISP can also die cut thermal gap pad materials. These thermal interface materials are thicker than tapes but may also use acrylic PSAs.

From prototyping through production, ISP can be an extension of your engineering team

To discuss your thermal management application, contact us online or call (800) 984-1811.

Technical Specifications of Thermal Adhesive Tapes

Thermal adhesive tapes have at least two components: a thermally conductive adhesive layer and a release liner. They may also have a backing material that acts as a carrier for the adhesive and provides structural support for the tape. This backing, or carrier, can have the adhesive on one or both sides. If the adhesive is on both sides, a second release liner is used.

Unless otherwise noted, thermal tapes are electrically insulating instead of electrically conductive. If your application requires high voltage insulation, consider a tape’s dielectric strength: the maximum voltage that a material can withstand per unit thickness before it fails to insulate.

When identifying the best thermal adhesive tape for your application, the following specifications are top priorities to keep in mind:

Thermal Conductivity

Thermal conductivity (TC), a measure of the ability to move heat, is expressed in watts per meter Kelvin (W/mK). Most thermal tapes and adhesives have TC values just under 1 W/mK. By comparison, the TC of air at standard atmospheric pressure and room temperature is approximately 0.026 W/mK. Note that TC values decrease as temperatures increase.

Normally, the polymeric adhesives that are used with tapes are thermally insulating; however, they can be combined with specialized fillers that impart thermal conductivity. When comparing product specifications, consider whether the TC value that’s listed is only for the thermally conductive adhesive, or if it’s for the entire tape – including its non-conductive components.

Also, it’s important to note that thermal conductivity alone does not determine the thermal performance of these tapes. For optimal heat transfers, a thermally conductive adhesive needs to wet out the surface. Wetting out refers to how well the adhesive spreads and flows across the surface, including small voids. Good wetting out also promotes adhesive bond strength.

Continuous-Use Temperature

Continuous use temperature is the range of temperatures at which a thermally conductive tape can operate for an extended period without a significant degradation in properties. It is measured in degrees Celsius (°C) and given as a range. For some materials, a maximum intermittent usage temperature for a specific period is listed instead.

Flame Ratings

Flame ratings are flammability specifications. For example, the UL 94 V0 flame rating from Underwriters Laboratories (UL) applies to vertically oriented materials that stop burning within 10 seconds of each flame application, and without dripping flaming particles. Some thermally conductive tapes can meet this flammability specification, which is UL’s most stringent.

Environmental Resistance

Environmental resistance covers resistance to water, moisture, humidity, sunlight, and ozone.

Flame Ratings

Adhesive Type

Many of the tapes that ISP die cuts use a thermally conductive acrylic adhesive. Acrylic adhesives have strong initial tack, which means they stick well on initial contact. They also form long-term bonds and adhere well to metals, plastics, and glass. Typically, the temperature resistance of an acrylic adhesive ranges from -40°C to +120°C.

Thermally conductive silicone adhesives have lower initial tack but higher temperature resistance, generally up to ~200°C. They are better at withstanding outdoor environments but come with a higher cost. Some silicone adhesives do not bond well to low surface energy materials like polyethylene. ISP can source and die cut thermal tapes with non-acrylic adhesives if you need them.

There are also thermal adhesive tapes that use pressure-sensitive adhesives (PSAs). Among their advantages, PSAs support peel-and-stick insulation and require light pressure instead of heat to activate the adhesive.

Backing Material

Backing materials, or carrier types, for thermal adhesive tapes include polyester films, aluminum foils, silicone compounds, and fiberglass. When selecting a backing, consider application requirements such as puncture resistance (polyester films), electrical conductivity (aluminum foil), compression resistance (silicone compounds), and physical integrity (fiberglass).

Number of Sides

Thermal adhesive tapes are either one-sided or two-sided. One-sided tapes do not have a carrier; the tape consists of an adhesive layer and a release liner. One-sided tapes lack the dimensional stability of double-sided tapes, but conform and wet-out surfaces made of low surface energy materials. In the absence of a carrier, single-side tapes also tend to be thinner.

Double-sided tapes usually have a carrier. The products are designed to bond two surfaces together, such as the bottom of an electronic component and the top of heat sink. Among their advantages, double-sided tapes have greater dimensional stability and are generally easier to apply by hand because they are thicker.

Thickness

The thickness of thermally conductive tape is important because it affects performance, mechanical reliability, and ease of assembly. Generally, tape thickness is expressed in millimeters. It may be listed as a range or given in specific sizes. For best results, choose a thickness that fills surface irregularities but is not so thick that thermal performance suffers.

Thicker thermal adhesive tapes generally have greater thermal resistance: the opposite of thermal conductivity. However, thicker tapes can better conform to rough or uneven surfaces. They can also absorb greater shock and vibration. The disadvantages of thicker thermal adhesive tapes include their inability to fill small gaps and potential interference with tolerances.

Thinner tapes are well suited for flat, polished surfaces. They may have higher TC values because of the relative thinness of the low-TC carrier. However, thinner tapes may not provide sufficient thickness if there are high vibrations or flexing. In applications such as compact electronics or wearables, even a 0.1mm difference in tape thickness can make a difference.

Color

Thermally conductive tapes are also available in various colors. This may not be an important consideration if the tape is hidden from view, such as inside an electronic enclosure.

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Converting Thermal Adhesive Tapes

From prototyping through production, ISP can be an extension of your engineering team

Technical Specifications of Thermal Adhesive Tapes

Get a Quote for Converting Thermally Conductive Tape