LORD Corporation

With more than 3,100 employees in 26 countries, 19 manufacturing facilities and 10 R&D centers worldwide, we're there for our customers.

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CoolTherm gap filler dispensed by meter mix dispense equipment

Gap Fillers

Our liquid-dispense, cure-in-place gap fillers provide low stress on components and improve thermal resistance when compared to thermal pads. As batteries for electric vehicles become smaller and higher performing, they produce more heat which must be dissipated safely. Our gap fillers combine high thermal conductivity and low viscosity with the ability to maintain insulating properties.

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Liquid-Dispense Cure in Place Gap Fillers Up-Close

Liquid-dispense gap fillers can be applied in a variety of patterns to achieve your most challenging electric vehicle designs. Watch our video of them being dispensed through MMD equipment.

Battery Packs

As battery technology evolves towards increased energy density, the ability to manage heat during charge and discharge cycles is crucial for optimizing performance. Our CoolTherm thermal management materials are fully customizable and compatible with cylindrical, pouch and prismatic battery cells. Our dedicated application engineers will work with you to ensure your project’s specific performance requirements, cost targets and deadlines are met quickly.

Charging Systems

CoolTherm solutions improve proper heat flow in inductors and transformers, optimize performance during charging and discharging, and increase product longevity. Since these products have a low viscosity, they flow easily into the tiniest crevices, enabling better impregnation of irregularly-shaped magnetic components and helping to reduce inductor hum. We can help you select the correct material and optimize your process to improve performance and lower costs.

Power Electronics

Protect components and improve stability - in order to extend the life of your power electronics, you need to maintain low thermal resistance and protect components from shock, moisture and debris. CoolTherm products are robust thermal interface materials that protect delicate electrical components, and provide excellent isolatation and vibration dampening.

Featured Whitepaper: The Right Amount of Stress

Interested in learning how different properties impact the ability to remove, recycle and repair gap fillers in electric vehicle battery packs? Read our latest white paper which explores the influence of  surface and material properties on gap filler reworkability.

Reworkability of Gap Fillers for Battery Packs

Infotainment Devices

Infotainment devices are the main source of information for EV drivers when it comes to entertainment, navigation, feedback from the vehicle, cabin comfort and more. Since there are so many small electronics housed behind one screen, it's important these circuit boards stay cool, especially when packed into a tight space. 

Experts in Gap Filler Technology

Our thermal management portfolio allows us to make huge contributions in mass market adoption of electric vehicles by allowing batteries to run cooler, which in turn allows them to drive longer range and reduces the need for more frequent charges. We prides ourselves on being one of the best value, highly efficient thermal management material offerings on the market.


What is a gap filler (thermal paste)?

Gap fillers are thermally conductive liquid-dispensed thermal interface materials and are often applied by meter-mixing a two-part system. When cured, the material forms a solid, but compliant interface that dissipates heat away from components, leading to extended lifetime and higher performance. They are often used as a replacement to thermal gap pads since they achieve lower thermal impedance and offer design flexibility. They are also well suited for high volume production of electronic components such as batteries, inverters/converters, motors, and power electronics.

What’s the difference between gap fillers and thermal gap pads?

Gap fillers are often applied by meter-mixing a two-part system, dispensing on one of the two substrates, and pressing the two substrates together to reach a specified thickness. The material is then allowed to form a solid, but compliant interface. Thermal pads, on the other hand, are pre-cut to a desired shape, applied to one substrate, compressed down to set thickness, and fixed in place.

The applied compressive load forces the solid, yet compliant, pad to make intimate contact with the rough surfaces.   Also, gap fillers, unlike solid thermal pads, flow into the small valleys, and create more intimate contact with the surface. This allows a more efficient transfer of heat between the upper and lower substrates.

When comparing the key attributes of the two types, the relative cost for using thermal pads is high due to the costly scrap that results. Air entrapment is more frequent with thermal pads since they can’t reach those tiny spaces that result from the surface roughness. Gap fillers are the answer for design flexibility since the hardness and working time can be adjusted using the mix ratio of the gap filler’s two parts. And lastly, when it comes to applying the product, the large form factor thermal pads can be difficult to apply without trapping air and automation is difficult. On the other hand, gap fillers are well-suited for high volume production.

How do you increase cure speed of a gap filler?

To increase the cure speed of most gap fillers, potting materials, and/or adhesives, increase the temperature of the part to which the materials are applied. This can be done using an oven, a heat lamp, or induction heating. Parts can be pre-heated to the desired temperature, or material can be dispensed first and then the part can be heated. It is a general rule of thumb that the cure speed will approximately double for every 10 degree Celsius increase in temperature. It is worth noting that, for rigid materials, increasing cure speed can increase the risk of generating a high internal stress in the material, which may degrade its mechanical strength and its ability to resist thermal and/or mechanical shock.