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Thermal Management in E-Mobility: Efficient Cooling for the Future of Driving.
Electric vehicles (EVs) offer environmentally friendly and powerful alternatives to conventional combustion engines.
Thermal management plays a crucial role in regulating the operating temperatures of power electronics, the battery, and various comfort and convenience functions such as air conditioning, display, infotainment, heating, and improving efficiency. The energy consumption of the power units and applications is a key aspect in EVs with direct impact on range, and lifetime. So every degree celsius counts.
THERMAL INTERFACE MATERIALS
Various types of thermally conductive materials are available for optimization. These include thermal pastes, thermal pads, gap fillers as pads or pastes and thermal foils. The selection of the appropriate thermal interface material depends on the specific requirements of the application and the operating temperatures.
Thermal Management Challenges in Electric Vehicles
In electric vehicles, efficient thermal management is not optional — it directly determines battery range, lifespan and safety. Power electronics including inverters, onboard chargers and DC/DC converters generate significant heat loads that must be dissipated reliably. Battery cells require precise temperature control within a narrow window to maximise cycle life and prevent thermal runaway. Every degree counts.
HALA TIM Solutions for E-Mobility Applications
Battery Thermal Management
Silicone-free gap fillers and silicone gap fillers are the primary TIMs for EV battery packs — filling the gap between cells and cooling plates, compensating for height tolerances and accommodating the mechanical expansion of battery cells during charge/discharge cycles. Silicone-free variants are essential where paint repellency or strict automotive silicone restrictions apply.
Power Electronics & Inverters
For MOSFETs, IGBTs and SiC power modules in inverters and onboard chargers, phase change materials deliver the lowest thermal resistance at the bonding interface. Thermally conductive silicone foils provide electrically insulating solutions for direct substrate-to-heatsink contact.
Heat Pipe Systems for EV Cooling
Heat pipe assemblies and vapour chambers enable decentralised cooling solutions for high heat flux applications — transporting heat from compact power modules to remote heat sinks with thermal conductivities of 5,000 to 20,000 W/mK.
Potting & Encapsulation
Thermally conductive potting gels encapsulate battery management systems and power electronics modules, providing thermal conductivity, electrical insulation and protection against vibration and moisture simultaneously.
HALA YOUR SPECIALIST
HALA specializes in thermal interface material (TIM) design-in and customized solutions. We believe that efficient thermal management further drives not only performance, but also sustainability of applications. Contact us to find out how we can improve your thermal management.
FAQ
EV battery packs primarily use gap fillers — either as pre-formed pads or dispensable 2K materials — to fill the gap between battery cells and cooling plates. Silicone-free gap fillers are increasingly specified in automotive battery applications to avoid siloxane contamination in painting and assembly processes.
Volatile siloxanes from standard silicone-based TIMs can cause paint repellency, contaminate electrical contacts and trigger warranty issues in automotive assembly. Silicone-free gap fillers eliminate this risk entirely — making them the preferred choice for EV battery manufacturers and Tier 1 automotive suppliers.
SiC and GaN power modules in EV inverters require the lowest possible thermal resistance at the die-to-substrate interface. Phase change materials are the preferred solution — process-safe, dry to handle before assembly and delivering near-paste-level thermal resistance after the first heat-up cycle. Thermally conductive insulating foils provide electrical isolation between power substrates and heat sinks.
During charging and discharging, battery cells expand and contract. Gap fillers — particularly highly elastic silicone variants — absorb this mechanical movement while maintaining continuous thermal contact with the cooling plate. HALA offers gap filler pads from 0.5 to 10 mm thickness to accommodate various cell formats and tolerance stacks.
Yes. HALA specializes in TIM design-in for specific applications — from material selection through prototype sampling to series supply of custom die-cut parts. Contact our experts for a free consultation and sample.
