Are you seeking suitable thermal management solutions for your electronic devices, automotive components, communications equipment, and other products? You may have found that thermal pads are an excellent and widely used thermal interface material. However, you remain uncertain whether thermal pads are appropriate for your specific application or use. This article will provide further details regarding the applications and advantages of thermal pads. Continue reading to make a more informed choice.
What is the Thermal Pad？
Thermal pads are materials inserted between heat-generating components and heat sinks (or casings) within equipment to enhance thermal efficiency. They come in various types, such as silicone thermal pads, silicone-free thermal pads, graphene thermal pads, and carbon fiber thermal pads, and meet your various needs for electronics, automotive, industrial equipment, and more. Owing to their ease of installation, diverse selection, high thermal conductivity, and extended service life, they deliver outstanding performance across different applications.
Main Applications of Thermal Pads
Mobile Electronic Devices
Thermal pads may be utilised in electronic devices such as tablets, cameras, mobile phones, and computers. Offering high thermal conductivity, these pads are exceptionally lightweight and compact. They facilitate the efficient transfer of heat generated by CPUs, VRM, and GPUs, etc., within electronic equipment to heat sinks, thereby preventing performance degradation or damage caused by overheating.
#1 Chips (CPU, GPU, SoC)
Thermal pads can be affixed between the chip and heat sink, filling surface irregularities caused by small components on the chip. This facilitates the transfer of heat generated during chip operation to the heat sink, offering efficient cooling.
#2 Motherboard Power Supply Circuit (VRM)
Voltage regulation modules within electronic devices generate significant heat during operation, potentially causing system throttling. Using thicker, insulated thermal pads ensures their safe and stable functioning.
#3 Memory (RAM) and Solid-State Drives (SSD)
Thermal pads are also utilised in the memory and SSDs of high-performance electronic devices to prevent performance degradation during high-speed read/write operations.
#4 Portable Devices
Thermal pads are not only lightweight but also boast extended service life. Beyond computers and gaming consoles, portable devices such as smartphones, smartwatches, and tablets incorporate thermal pads beneath heat spreaders and chips. Their resilience additionally provides cushioning and protection for the devices.
Automotive Industry
You can use thermal pads in automotive modules such as power supplies, electronic controls, and battery packs. On the one hand, they assist these components in maintaining optimal temperature ranges during prolonged operation, thereby preventing components from operational failures and damage. On the other hand, thermal pads are resilient and elastic, effectively mitigating vibrations and impacts experienced by vehicles during operation. This offers an enhanced experience for your customers while also conferring greater durability upon the vehicle.
#5 Battery Management System (BMS)
Thermal pads have many functions, including heat dissipation and protection, ensuring both the safety of battery components and extending their operational lifespan. Firstly, the high thermal conductivity of thermal pads facilitates the transfer and dissipation of heat generated during battery charging, maintaining temperatures within optimal operating ranges. Secondly, whilst possessing excellent thermal conductivity (excluding special conductive types), thermal pads exhibit insulating properties. This prevents battery damage from short circuits whilst safeguarding the integrity of the device’s electrical systems.
#6 Intelligent Driving Modules and Electronic Control Units (ECUs)
You can apply thermal pads between sensors, AI chip components, and heat sinks within automotive intelligent driving systems to get stable performance during operation, preventing slowdowns or malfunctions. Within control units for engines, transmissions, and other systems, thermal pads help maintain ECUs at optimal operating temperatures, enhancing vehicle reliability during prolonged use.
#7 Vehicle Chargers
Thermal pads reduce heat generated during charging for more stable operation. They also optimise energy efficiency, enhancing the charging efficiency of onboard chargers.
#8 In-Car Entertainment Systems
Thermal pads applied to audio playback devices and screens within entertainment systems deliver smoother, clearer experiences for your customers.
#9 LED Light
High-power LED lights generate significant amounts of heat and are susceptible to thermal degradation, which can lead to reduced brightness or even failure. Utilising thermal pads can effectively minimise such occurrences for you. They facilitate the dissipation of heat produced by the LED lights, thereby ensuring stable and sustained brightness while optimising energy efficiency.
#10 Power System
In electrical systems, thermal pads within equipment such as transformers and inverters not only facilitate heat dissipation to ensure the smooth and continuous operation of power supply and distribution, but also enhance the efficiency of electrical power transmission and conversion.
Industrial Equipment
For processing machinery, robotic systems, and similar equipment within industrial settings, thermal interface materials can be selected to achieve superior heat dissipation efficiency. Furthermore, you can opt for thermally conductive pads with electromagnetic interference suppression capabilities to ensure operational safety within large-scale equipment installations.
#11 Industrial Automation Equipment and Robotics
Thermal pads are required for CPUs/MPUs, IGBT/MOSFET power modules, and power management ICs within industrial automation equipment and robotics. This enables more stable operation during round-the-clock industrial production, preventing productivity losses or additional maintenance costs arising from shutdowns due to overheating.
#12 Communication and Computing
Thermal pads installed on processors, FPGAs, and RF power amplifier chips enable stable transmission during high-load operation, reducing interruptions and frequency throttling.
#13 Measuring Instruments and Sensors
The flexibility and conformability of silicone-free thermal pads provide excellent protection for chips within industrial sensors and precision measuring equipment, thereby enhancing accuracy.
Household Appliances
Thermal pads are utilised in medium-sized appliances such as air conditioners, televisions, and washing machines. They maintain optimal operating temperatures, thus improving performance and reliability during prolonged use. Furthermore, they contribute to noise reduction within household appliances.
#15 Air Conditioners and Refrigerators
Heat generated within the variable frequency components of air conditioners during operation can be transferred more rapidly to the refrigerant via thermal pads, enhancing heat dissipation efficiency and thereby improving energy performance. You can also use thermal pads within the cooling fins and evaporator piping of refrigerators to boost cooling efficiency.
#16 Televisions
Thermal pads are highly suitable for use within set-top boxes and power supply systems. They enable efficient heat dissipation for continuously operating televisions, preventing overheating. For components like television displays, thermal pads similarly facilitate heat release, ensuring stable picture quality.
#17 Washing Machines/Dryers
Thermal pads primarily serve an insulating function in washing machines and dryers, preventing heat generated during operation from transferring to the outer casing. This not only extends the equipment’s service life but also enhances user safety.
#18 Microwave Ovens/Induction Hobs
You will find thermal pads used in heating appliances like microwave ovens and induction hobs, where they ensure the stable operation of heating elements. For these applications, select thermal pads with a higher operating temperature range.
Medical Precision Equipment
Precision measuring instruments, imaging equipment, and monitoring devices used in healthcare are highly sensitive to temperature, and you must implement effective heat dissipation measures to prevent temperature fluctuations. Furthermore, compared to thermal paste, thermal pads do not easily dry out or pump out under recommended operating temperature conditions. They offer superior cleanliness and hygiene standards for you compared to thermal paste, making them more suitable for such precision equipment.
#19 Medical Imaging Equipment
Image processors and circuitry within devices such as CT scanners, ultrasound machines, X-ray units, and MRI systems can use thermal pads to achieve superior temperature control, thereby ensuring image clarity. Silicone-free thermal pads are the ideal heat dissipation material for such equipment, effectively managing heat while preventing contamination.
#20 Life-support Equipment
You can also apply thermal pads within the power modules and chips of devices such as ventilators and patient monitors to enhance the reliability of continuous operation.
#21 Diagnostic Equipment
Thermal pads provide heating components in PCR machines, blood analysers with optimal temperature control capabilities, reducing inaccuracies caused by overheating and preventing more severe consequences.
Why Use Thermal Pads for Your Applications?
Easy to Apply
Suppliers typically pre-form thermal pads and process them into sheets of different thicknesses. You can cut them to size and shape before installing them directly. This minimises installation steps and eliminates the need for additional tools. Particularly in high-volume processing, it integrates well with automated equipment, optimising production processes and enhancing efficiency, thus significantly reducing production costs.
Wide Applicability
- Multiple Thermal Conductivity Options: On the one hand, thermal pads offer various thermal conductivities ranging from 1 W/m·K to 20 W/m·K, allowing you to select based on specific heat dissipation requirements. Some models, for example, graphite thermal pads, can even offer thermal conductivities as high as 1950 W/m·K.
- Multiple Thickness Options: On the other hand, thermal pads are available in thicknesses ranging from 0.2mm to 20mm to accommodate the gap between your components and heat sinks.
- Multiple Types Available: Additionally, options include silicone-free thermal padsfor enhanced performance on silicone-sensitive projects, and ultra-soft thermal pads for rough surfaces. Should you require it, conductive thermal pads with electrical conductivity are also available.
- Customisable: Custom designs can also be developed to achieve the optimal thermal pad for your specific product requirements.
Long Service Life
Different types of thermal pads may have different service lives, but generally speaking, under normal usage, thermal pads can last between 2 and 10 years, depending on the operating environment and temperature. They remain effective without drying out, deteriorating, or experiencing significant performance degradation under high temperatures, high frequencies, and continuous operation. Compared to thermal paste, which requires replacement every 12 months, thermal pads not only reduce maintenance requirements but also enhance the reliability of your products.
Reusability
If your thermal pad has no visible damage or deformation, and it still maintains good elasticity and excellent thermal conductivity, it may be reused. This can reduce material wastage and save costs. You may also apply an adhesive layer to the thermal pad for improved stability during installation. However, thermal pads with an adhesive layer must not be reused to prevent increased thermal resistance or inadequate contact resulting from adhesive failure.
How to Choose Thermal Pads for Your Application
Determining the Thermal Conductivity of Thermal Pads
Before selecting a thermal pad, you must first ascertain your cooling requirements and match the thermal conductivity to your heat dissipation load. Thermal conductivity is typically measured in watts per meter-kelvin (W/m·K). Thermal interface materials with higher thermal conductivity offer lower thermal resistance and greater heat transfer efficiency, enabling their use in applications with higher thermal loads. Selecting a thermal conductivity that is too low will subject the thermal interface material to excessive loads, reducing its service life and making it difficult to achieve satisfactory temperature control. Choosing an excessively high thermal conductivity will result in unnecessary expenditure. Some suppliers can provide thermal simulation services to help customers determine the thermal conductivity required for their products.
Operating Environment
The operating environment is another important factor to consider during selection. Firstly, different thermal pads have distinct optimal operating temperatures. You must choose the appropriate one for your application to ensure the thermal pad remains stable during use and has a long service life. Secondly, multiple types of thermal pads cater to different equipment. Should you require thermal pads for silicone-sensitive projects, silicone-free variants can dissipate heat while minimising component damage. For applications subject to vibration and impact (such as automotive systems), you may select thermally conductive pads with mechanical strength and toughness.
Thermal Pad Thickness
You can trim the thermal pad to the required size and shape according to your component, but its thickness must be pre-machined by the supplier. A pad that is too thin will fail to fill the gap effectively, while one that is too thick will increase thermal resistance. Furthermore, these pads must not be stacked for use. Thicknesses ranging from 0.2 to 20mm are available, so you should select the most suitable option based on the gap between the heat sink and your component. Should no exact match be available, customisation is also possible.
Thermal Pad Insulation and Electromagnetic Interference Resistance
Most thermal pads are insulating to maintain the stability and safety of your equipment’s circuits. However, electrically conductive thermal pads are also available. These offer an electrical conductivity of approximately 20,000 S/cm. Additionally, certain thermal pads—such as carbon fibre thermal pads—possess electromagnetic interference resistance, enhancing the operational reliability of your equipment.
FAQs
Can I Reuse Thermal Pads?
This depends on whether your thermal pads have an adhesive layer. Thermal pads with an adhesive layer must not be reused. Thermal pads without an adhesive layer may be reused provided they remain undistorted and undamaged, and their thermal conductivity continues to meet your requirements.
What is the Difference between Silicone Thermal Pads and Non-Silicone Thermal Pads?
Their compositions differ, with non-silicone thermal pads not utilising silicone as their base material. As they do not produce silicone oil or emit volatile silicone vapour, they may be used in silicone-sensitive products to prevent component damage.
Can I Stack Thermal Pads to Fill Thicker Gaps?
You cannot stack thermal pads for use. Stacking would result in higher porosity, adversely affecting thermal resistance. You may opt for thicker thermal pads or consider alternative thermal interface materials.
How to Store Thermal Pads？
Unused thermal pads should be returned to their original packaging and stored in a dry location at 8–28°C, protected from ultraviolet light. Furthermore, thermal pads may expire if left unused for extended periods, leading to performance degradation or failure of the adhesive layer. It is advisable to utilise them before this occurs.
Are There Other Thermal Interface Materials that Can Replace Thermal Pads?
Apart from thermal pads, you may also opt for thermal paste, thermal tape, thermal grease, and so forth.
How to Extend the Service Life of Thermal Pads?
You’d better select a thermal pad capable of handling your heat dissipation load. If your product experiences significant fluctuations in thermal requirements, it is advisable to choose based on the maximum value. Furthermore, you should operate the thermal pad within the temperature range specified in the instruction manual.
Final Thoughts
Based on information regarding thermal pad applications, advantages, and selection criteria, you can better determine whether thermal pads are suitable for your product. GALLOP INNOTEK not only provides high-quality thermal pads but also offers other types of thermal interface materials and customised solutions(such as thermal simulation services、rapid prototyping & small-batch support). You are welcome to contact us at any time.
