Thermally Conductive Silicone Sponge

Thermally Conductive Silicone Sponge

At NEDC, we are all about thermally conductive gap filling pads. A unique thermal gap filler that can double as a gasketing material is Thermacool R10404 Thermally Conductive Silicone Sponge. This closed-cell silicone sponge rubber gap filling material is not only electrically isolating but also ideal for thermal heat transfer applications. Its silicone base gives it its high temperature, and low compression set properties. As with other gap filling materials, good contact is everything. Below is a screenshot of the chart relating compression and thermal impedance. 

Thermally Conductive Chart

Thermally Conductive Chart (re-presented from datasheet below)

Properties of Thermacool R10404 Silicone Sponge

Thermacool R10404 Silicone Sponge is a unique solution as no other silicone sponge manufacturer (I know of) offers a thermally conductive expanded silicone sponge product. As with other silicone sponge gasketing materials it features a rigorous temperature range – performing across -80° to 400° degrees fahrenheit. Since it has a closed cell silicone sponge structure, it is reliable for gasketing solutions that other conventional silicone sponge products may be used in. Applications for R10404 Thermally Conductive Silicone Sponge include vibration dampening, gasketing, and gap filling in battery cells, and lithium ion battery packs. R10404 comes in a medium density at a 25% compression for 18 psi of pressure (CFD). 

Why Use Thermacool R10404 Silicone Sponge over a conventional Thermal Pad?

There are a few reasons for that:

-Its Repositionable, having no natural tack/adhesive

-Offers great sealing as gasketing

-Some thermal pads are not electrically isolating, however Thermacool R10404 is

-It is not prone to take a set due to its closed cell silicone sponge make-up

More Info on Cutting/Availability

NEDC die-cuts or waterjet cuts Thermacool R10404 Silicone Sponge. It is available with adhesive backing in either silicone/acrylic tape, and comes in a light green color. However, it is good to keep in mind that adhesive backing will increase thermal resistance of the product. Lastly it comes in thicknesses ranging from very thin 1/32’’ to a thicker ¼’’.  In addition, NEDC also cuts other thermally conductive products such as Thermacool materials. For more information on thermal gap filling materials, please contact

Datasheet Downloads

R10404 Thermacool Thermally Conductive Silicone Sponge Datasheet

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