Getting heat out of an EV battery pack depends on the thermal interface between the cells and the cooling plate. Two options dominate: pre-cut thermal gap pads, and liquid-dispensed thermal gap fillers. For volume battery production the liquid gap filler is winning — and it needs a two-component dispensing machine to apply it.
| Factor | Liquid Gap Filler (2K) | Gap Pad |
|---|---|---|
| Surface contact / wet-out | Flows into micro-gaps, no voids | Traps air pockets |
| Heat transfer | Higher (better contact) | Lower |
| Automation | Robot dispense, fast | Manual placement, slow |
| Material waste | Applied as needed, minimal | Die-cut scrap |
| Thickness/shape | Any gap, tunable | Fixed sizes |
Why Liquid PU Gap Fillers Win for Volume
Liquid gap fillers flow into the microscopic valleys of cell and plate surfaces, eliminating the air pockets that limit gap-pad performance. They are dispensed by a metered two-component machine, so they suit automated battery lines and produce almost no scrap. PU-based (silicone-free) systems are increasingly chosen to avoid siloxane contamination of electronics.
The Machine That Applies It
Thermal gap fillers are applied on a two-component metering-mixing-dispensing machine. Because the fillers carry abrasive thermally conductive fillers, wear-resistant metering pumps and mixing heads keep accuracy over long runs. See our PU machines for EV battery thermal management and PU dispensing machine.
FAQ
Is a gap filler better than a gap pad?
Can your machine dispense abrasive thermal gap fillers?
Do you supply the gap filler material?
Tell us your gap filler and output — we will propose the right dispensing machine and quote.