In the electric mobility sector, thermal management is one of the most critical aspects to ensure the safety, performance, and durability of EV battery packs. The increasing energy density and the demands for long-term reliability have made thermally conductive gap fillers a key technology for battery and electronic module manufacturers.
Among the most advanced solutions, DOWSIL™ TC-5515 LT Low Density Thermally Conductive Gap Filler stands out for its unique balance of lightness, thermal conductivity, and high reliability, fully meeting the production needs of the automotive and energy management industries.
Technical properties and long-term reliability
Designed by Dow for applications where heat transfer is essential, DOWSIL™ TC-5515 LT offers:
- Thermal conductivity: 2.0 W/m·K, ideal for efficiently dissipating heat from battery modules, PCBs, and electronic control units.
- Low density: 1.95 g/cm³, which helps reduce the overall weight of the battery pack, a decisive advantage for electromobility.
- Wide operating range: from -45 °C to +150 °C, with resistance to thermal aging and thermal shock (-40 °C / +125 °C).
- UL94 V0 certification: ensures flame retardancy and greater safety against fire hazards.
- Stability under extreme conditions: tested to withstand high levels of temperature and humidity (85 °C / 85% RH).
These characteristics make the material a reliable choice for automotive applications, where charge-discharge cycles and environmental variations can compromise the performance of electronic systems.
Benefits in production processes
In addition to technical performance, DOWSIL™ TC-5515 LT has been developed to be compatible with the needs of automated industrial production:
- Efficient dispensing process: completely fills gaps and reduces thermal resistance.
- Soft and compressible material after curing, reducing mechanical stress on electronic components.
- Low abrasion on dispensing equipment, ensuring reduced maintenance of production lines.
- No post-curing required: the material is ready for immediate use after curing at room temperature.
- Reworkability: thanks to its slightly tacky surface once cured, it allows reworking and maintenance without compromising system integrity.
These properties translate into higher productivity, lower process costs, and greater reliability of final systems.
Main applications
DOWSIL™ TC-5515 LT is designed for sectors where advanced thermal management is an essential requirement:
- EV battery packs: efficient heat dissipation from cells, improving safety and durability.
- Electronic control units: protection of ECUs and power modules from thermal buildup.
- Other high-energy-density automotive systems, where thermal stability is critical.
Benefits for the automotive industry
The use of DOWSIL™ TC-5515 LT enables manufacturers to:
- Improve heat dissipation and operational safety.
- Reduce overall weight and maintenance costs.
- Integrate a reliable and certified material into automated production processes.
- Ensure consistent performance over time, even under extreme environmental conditions.
Conclusion
With the growing development of electric mobility, thermal interface materials are becoming increasingly strategic. DOWSIL™ TC-5515 LT represents a cutting-edge solution, capable of combining technical reliability, industrial productivity, and cost reduction, helping to enhance the safety and performance of EV systems. Contact our experts at MD Poland to find reliable solutions that meet the highest standards.
