electric vehicle charging
In February, I took possession of an electric vehicle. It got me thinking: electric vehicles use a lot of thermal interface materials—and not just in the car itself.
Batteries are the lifeblood of electric vehicles. They control everything: propulsion, climate control, heated seats, infotainment, and all auxiliary systems. Most modern EVs rely on battery modules—hundreds or thousands of individual cells packaged together to deliver massive amounts of energy. Because of this, the integrity of the battery pack is one of the most critical factors in EV performance, longevity, and safety.
But the vehicle is only part of the equation.
As charging speeds increase and power densities climb, electric vehicle chargers—both onboard and external—have become equally dependent on effective thermal management.
Integrity of the Battery Pack and Charging Systems
Maintaining thermal integrity means controlling heat at every stage:
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During vehicle operation
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During AC charging
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During high-power DC fast charging
This is where thermal interface materials (TIMs) play a central role.
Inside the vehicle, TIMs are used throughout:
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Battery modules and packs
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Power electronics and inverters
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On-board chargers (OBCs)
Outside the vehicle, EV charging equipment itself generates significant heat, especially in:
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DC fast chargers
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Power modules, and rectifiers
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Transformers and bus bars
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Control electronics, and cooling plates
Common thermal management solutions include thermal gap filler pads, thermally conductive elastomers, and liquid-cooled interfaces. Thermal pads are especially valuable because they can be compliant, filling gaps between uneven surfaces while maintaining consistent thermal conductivity. That compliance also helps manage vibration, shock, and mechanical tolerance stack-ups—critical in both automotive and charging environments.
When charging or discharging at high rates, unmanaged heat can lead to:
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Reduced efficiency
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Accelerated component aging
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Performance throttling
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In extreme cases, thermal runaway
Effective thermal design is no longer optional—it’s a requirement.
electric charger
electric charger
Advantages of Thermal Pads in EVs and Chargers
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Absorb vibration and mechanical stress common in automotive and outdoor charging environments
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Transfer heat efficiently to maintain safe operating temperatures
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Electrically insulating, helping isolate sensitive electronics
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Gap-filling and compliant, accommodating surface irregularities and tolerance variations
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Easy to handle and assemble, supporting high-volume manufacturing
Some Suggestions of Thermal Gap Filler Pads
TFLEX SF7 from QNity Electronics – 7 W/ m-K , Silicone-Free
Gap Pad 5000S35 by Henkel/Bergquist – 5 W/m-K, High Compliance
TFLEX HD300 from Qnity Electronics- 3 W/m-K, High Compliance, Good Mix
Gap Pad 6000ULM from Henkel/Bergquist- 6 W/m-K, High Compliance, High Performance
More Information on EV Chargers
NEDC die-cuts and converts thermal interface materials into custom sizes and shapes for use in electric vehicles, battery systems, power electronics, and EV charging equipment.
If you have an application involving batteries, chargers, or high-power electronics that could benefit from a thermal interface solution, contact