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Why P-THERM® Gap Fillers Are Essential for EV Battery Design

Posted by Ben Hvidston

November 1, 2023 8:45 AM

Electric Vehicle Battery Design

The rapid advancement of the electric vehicle (EV) market is no secret, and to keep pace with this progress, OEMs seek cutting-edge thermal management solutions that perform well and come at a reasonable cost.

Among essential materials used for heat management in EV batteries, thermal gap fillers play a crucial role. Marian collaborates with suppliers like Polymer Science, whose partnership allows for development of high-quality gap filler materials along with various other essential materials for managing heat in electric vehicles.

We sat down with John Biddle, Vice President of Product Development at Polymer Science for a Q&A session where we delved into their contributions to the production of thermal management material and the benefits they bring to the EV world.

Q&A With John Biddle - VP of Product Development at Polymer Science

Q: What makes thermal gap fillers essential to an EV battery and what solutions do they provide for design engineers?

A: Thermal gap filler materials are designed to keep components at optimized operating temperatures. Gap filler pads are easy to manage and make no mess when applied. They can also be customized to different shapes & sizes and are repositionable during assembly.

Q: How do P-THERM® Gap Fillers reduce the risk of thermal runaway and make EVs safer?

A: Gap pads are essential for maintaining optimal operating temperature of the system as they effectively transfer heat from cells to the cooling plate. Gap fillers also play a crucial role in compressing the cluster of cells and module housing, effectively damping vibrations caused by external forces and ensuring safety of the battery.

Q: How can a P-THERM® Gap Filler contribute to the weight reduction of an electric vehicle and enhance its efficiency?

A: Studies have shown that for every 7 kgs of weight reduction in an EV, an additional mile of range can be achieved, emphasizing the importance of weight reduction in all aspects of EV design. This plays a vital role in enhancing overall technology and efficiency of electric vehicles.

At Polymer Science, we provide durable solid gap fillers that can be precisely cut by expert die cutters like Marian, allowing for perfect placement of gap fillers in specific designs for OEMs and ensuring optimal performance and efficiency.


Q: What are some successful examples of P-THERM® Gap Fillers in battery applications?

A: I'd like to highlight two thermal gap fillers: PS-1543 and PS-2643. These have been used in applications with Marian and are highly successful in the market.

  • In a recent application, Marian's engineering team incorporated PS-1543 into a thermal multi-layer lamination for the customer's battery application. This innovative solution included an additional layer of fortified polyimide reinforcement added by Marian, further enhancing the performance and durability of the battery.
  • Our newly released PS-2643 showcases state-of-the-art advancements within the latest product line. This lower-cost 3 W/m K pad not only delivers outstanding performance but also offers a remarkable cost reduction for battery OEMs.

Both gap filler pads have proven effectiveness when applied between battery cooling plates and cells, ensuring optimal heat management in EVs.

Q: What distinguishes Polymer Science from competitors?

A: At Polymer Science, we differentiate ourselves with our innovative five-step methodology. This enables development of tailor-made material solutions that bring customer projects from concept to market quickly and efficiently.

We also prioritize customer satisfaction by offering custom roll-widths that minimize waste, maximizing yield for our customers. With our solid gap fillers and other materials produced in roll format, Polymer Science facilitates rapid and high-volume converting processes. Located in the heart of the midwestern United States, our global headquarters ensures competitive pricing for North American battery manufacturers. 

Q: What are the essential characteristics that define Polymer Science's P-THERM® Gap Filler product line?

A: P-THERM® Gap Fillers are available in varying constructions, including silicone and non-silicone versions that are supplied on rolls or sheets.

There are also a number of other important considerations when choosing the appropriate thermal management solution including:

  • Thermal conductivities: range from 1 - 5 W/m K
  • Typical thicknesses: range from 0.10mm - 5.0mm
  • Durometer range (Shore 00): 5 - 80 based on product type
  • Various colors available
  • UL V-0 rated
  • RoHS and HF compliant
  • Good surface wetting
  • Conformable

Q: Why is Marian the best converter for EV manufacturers looking to incorporate Polymer Science's P-THERM® Gap Fillers into their battery applications?

A: With over two decades of experience in product development at Polymer Science, I've had the privilege of collaborating with Marian. Marian distinguishes themselves by offering unparalleled support to OEM and tier customers in the industry. They go above and beyond to deliver exceptional service and quality engineered parts through various means like:

  • Offering guidance to customers in material selection, including access to top global manufacturers, such as our team at Polymer Science.
  • Providing rapid prototyping services to actively involve customers in the material selection process.
  • Engaging in conversations with experienced Process Engineers to facilitate design for manufacturing
  • Exploring automation possibilities
  • Demonstrating their expertise in intricate converting techniques for large-scale manufacturing

Q: What other solutions does Polymer Science offer that contribute to the advancement of EVs?

A: In addition to our extensive selection of P-THERM® Gap Filler pads and two-part dispensable thermal gap fillers, we also offer a wide range of innovative materials that significantly enhance performance and efficiency of EVs including:

  • Cutting-edge phase change materials that enable efficient heat transfer and temperature regulation
  • Advanced heat spreaders that efficiently dissipate heat and maintain optimal operating temperatures.
  • Innovative electronic control interfaces that enhance the functionality and reliability of EV systems
  • Reliable adhesives that ensure secure bonding and sealing of components

We also provide top-notch EMI shielding and grounding materials through our P-SHIELD® product line, which offers a wide array of options including fabric tapes, film tapes, foil tapes, foam tapes, and adhesives.

With these state-of-the-art materials, Polymer Science is at the forefront of driving advancements in EV technology.

"We are committed to providing solutions that improve the overall performance, durability, and sustainability of evs."

Q: Where can people learn more about Polymer Science, Inc.?

A: For more information on material solutions offered by Polymer Science, visit our website at www.polymerscience.com or join us on LinkedIn. Discover how our innovative products are shaping the future of EVs.

Work with Marian for Your EV Thermal Management Applications

Marian, Inc. is proud of our continued collaboration with Polymer Science along with several other renowned global materials suppliers. These partnerships greatly enhance our ability to provide exceptional die-cut thermal management solutions to our customers who are leaders in EV battery manufacturing. Reach out to us today and discover the capabilities of Marian's custom-engineered die-cut solutions. 

Experience the full range of solutions we offer for the EV Battery market by watching our EV battery solutions video above.

Marian Brochure: Die-Cut Solutions for Transportation Electrification

transportation electrification

Marian specializes in manufacturing custom die-cut components for various areas of the battery from the individual cell to the module and pack.


Transportation Electrification Brochure



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Topics: Thermal Management, EV, battery, Material selection, thermal interface material, Electric Vehicle, Thermal Gap Filler Pads, Automotive, Polymer Science