What is a gap filler?

A gap filler is a high-performance material designed to fill the spaces or gaps between components in battery packs. Often made of thermally conductive materials, gap fillers play a crucial role in improving heat dissipation and enhancing the overall thermal management of the battery system. These materials conform to irregular shapes and effectively reduce air gaps, ensuring that heat is efficiently transferred away from critical components, thus optimizing battery performance and safety. Gap fillers are essential for maintaining consistent temperature control, preventing overheating, and improving the lifespan and reliability of battery packs, especially in electric vehicles (EVs), energy storage systems, and data centers.

Why do batteries need silicone free gap fillers?

Batteries, especially in electric vehicles (EVs) and energy storage systems, require silicone-free gap fillers to ensure compatibility with sensitive electronic components. Silicone-based materials can sometimes release volatile compounds that may interfere with the performance or longevity of battery components. Silicone-free gap fillers eliminate this risk, providing a clean and stable solution that prevents potential contamination or degradation of the battery system. Additionally, these materials offer superior adhesion, ensuring effective heat management while providing structural strength. By using silicone-free gap fillers, manufacturers can enhance safety, improve performance, and maintain the long-term reliability of their battery packs.

How can gap fillers help for battery pack production efficiency?

Gap fillers play a critical role in improving production efficiencies for battery packs by simplifying the assembly process and reducing the need for additional components such as thermal gap pads. These materials are easy to apply robotically, conforming to complex shapes and irregular gaps, which streamlines the manufacturing process. By filling voids and ensuring uniform application, gap fillers minimize the risk of errors and rework, ultimately speeding up production times. With gap fillers, manufacturers can boost overall production efficiency while maintaining high-quality performance and safety standards in their battery systems.

What is a gap filler?

A gap filler is a high-performance material designed to fill the spaces or gaps between components in battery packs. Often made of thermally conductive materials, gap fillers play a crucial role in improving heat dissipation and enhancing the overall thermal management of the battery system. These materials conform to irregular shapes and effectively reduce air gaps, ensuring that heat is efficiently transferred away from critical components, thus optimizing battery performance and safety. Gap fillers are essential for maintaining consistent temperature control, preventing overheating, and improving the lifespan and reliability of battery packs, especially in electric vehicles (EVs), energy storage systems, and data centers.

Why do batteries need silicone free gap fillers?

Batteries, especially in electric vehicles (EVs) and energy storage systems, require silicone-free gap fillers to ensure compatibility with sensitive electronic components. Silicone-based materials can sometimes release volatile compounds that may interfere with the performance or longevity of battery components. Silicone-free gap fillers eliminate this risk, providing a clean and stable solution that prevents potential contamination or degradation of the battery system. Additionally, these materials offer superior adhesion, ensuring effective heat management while providing structural strength. By using silicone-free gap fillers, manufacturers can enhance safety, improve performance, and maintain the long-term reliability of their battery packs.

How can gap fillers help for battery pack production efficiency?

Gap fillers play a critical role in improving production efficiencies for battery packs by simplifying the assembly process and reducing the need for additional components such as thermal gap pads. These materials are easy to apply robotically, conforming to complex shapes and irregular gaps, which streamlines the manufacturing process. By filling voids and ensuring uniform application, gap fillers minimize the risk of errors and rework, ultimately speeding up production times. With gap fillers, manufacturers can boost overall production efficiency while maintaining high-quality performance and safety standards in their battery systems.

Optimize Battery Life and Safety with High-Performance Thermal Management Materials

H.B. Fuller® EV Therm thermally conductive adhesives and gap fillers are designed for energy dense battery packs. As energy density increases, so does the heat generated within the pack. These materials help extend longevity, increase performance and enhance safety.

Why use a thermally conductive material in your pack?

Help wick heat away from energy dense components
Increase battery life by maintaining optimal temperatures
Improve safety by eliminating excessive heat
Boost charging efficiency

H.B. Fuller EV Therm materials are designed to provide unparalleled reliability and performance in battery systems. By utilizing advanced formulations, these materials ensure that your batteries are equipped with superior heat dissipation and protection. With a focus on innovation and quality, our solutions help future-proof your battery designs, enabling them to meet the increasing demands of modern electric vehicles and energy storage applications. Trusting our team for your thermal management needs means investing in solutions that enhance overall efficiency, safety, and durability of your battery systems.

Interested in learning more about thermal management materials? Hear from Germaine on how our H.B. Fuller EV Therm materials help to extend battery longevity, boost performance, and enhance safety through superior thermal management.

Thermal Management Materials

Explore our comprehensive range of thermal management materials solutions and applications, including technical documentation.

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The Importance of Comprehensive Thermal Management in Electric Vehicle Battery Systems

Read our latest blog which is a guide to why batteries need thermal management, various types of heat management methods, and the role of these solutions for electric vehicle and energy storage systems.

Featured Product: EV Therm 441

EV Therm 441 is a modified, highly engineered structural acrylic adhesive designed to provide excellent thermal conductivity while maintaining superior strength and performance properties across a wide range of temperatures and substrates. EV Therm 441 has excellent flame retardancy with a UL 94 V-0 rating. EV Therm 441 with glass beads (EV Therm 441 GB) allows for control of the adhesive gap or bond line to a diameter of 0.25mm (0.01”).

Key Benefits:

–No surface prep required

–Meets UL 94 V-0

–Bonds to metals, e-coat, thermoplastics, thermosets and more

–Cures at room temperature

Working with H.B. Fuller’s Battery Team

H.B. Fuller leverages over 130+ years of material knowledge and expertise to support the clean energy market with advanced solutions tailored for battery, energy storage, wind & solar applications. Our specialized adhesives, sealants, and thermal management materials are engineered for the unique demands of these markets, including enhanced safety, durability, and stability.

With a comprehensive understanding of materials science and industry challenges, we offer products that improve performance, streamline manufacturing, and ensure long-term reliability. By partnering with H.B. Fuller, manufacturers gain access to cutting-edge materials and expert guidance for optimized, high-quality systems in a competitive market.

Strategic sourcing
A team of unified R&D experts
10,000+ adhesives in our portfolio
Formulated with variety of chemistries

H.B. Fuller’s clean energy team brings global expertise with a strong local focus, ensuring tailored support wherever you operate. Our network of experts understands regional market demands and compliance requirements, allowing us to deliver solutions that are both innovative and precisely adapted to local needs.

We collaborate closely with customers worldwide to provide on-the-ground insights and rapid responses, all backed by the extensive resources of a global leader. With a commitment to localized service and global knowledge, we empower our partners to succeed in diverse markets with materials that meet the highest standards of quality, safety, and performance.

H.B. Fuller offers robust technical support and testing capabilities to help customers achieve peak performance in their clean energy applications. Our dedicated technical team collaborates closely with you to understand specific challenges and optimize material solutions, ensuring they meet the highest standards.

With state-of-the-art testing partnerships and expertise in battery, energy storage, wind & solar applications, we provide insights that accelerate product development and enhance your designs. Our commitment to technical excellence means you can count on us for precise guidance and real-world testing to ensure every solution delivers exceptional results.

At H.B. Fuller, we don’t just offer off-the-shelf solutions—we take the time to understand your specific design requirements and formulate a tailored solution that precisely meets your needs. Our team collaborates closely with you, leveraging deep industry expertise and advanced R&D capabilities to create materials that enhance performance of your unique applications. From custom adhesives to specialized thermal management products, we’re committed to delivering innovative, fit-for-purpose solutions that empower you to succeed in a competitive market.

Frequently Asked Questions

What is a gap filler?

A gap filler is a high-performance material designed to fill the spaces or gaps between components in battery packs. Often made of thermally conductive materials, gap fillers play a crucial role in improving heat dissipation and enhancing the overall thermal management of the battery system. These materials conform to irregular shapes and effectively reduce air gaps, ensuring that heat is efficiently transferred away from critical components, thus optimizing battery performance and safety. Gap fillers are essential for maintaining consistent temperature control, preventing overheating, and improving the lifespan and reliability of battery packs, especially in electric vehicles (EVs), energy storage systems, and data centers.
Why do batteries need silicone free gap fillers?

Batteries, especially in electric vehicles (EVs) and energy storage systems, require silicone-free gap fillers to ensure compatibility with sensitive electronic components. Silicone-based materials can sometimes release volatile compounds that may interfere with the performance or longevity of battery components. Silicone-free gap fillers eliminate this risk, providing a clean and stable solution that prevents potential contamination or degradation of the battery system. Additionally, these materials offer superior adhesion, ensuring effective heat management while providing structural strength. By using silicone-free gap fillers, manufacturers can enhance safety, improve performance, and maintain the long-term reliability of their battery packs.
How can gap fillers help for battery pack production efficiency?

Gap fillers play a critical role in improving production efficiencies for battery packs by simplifying the assembly process and reducing the need for additional components such as thermal gap pads. These materials are easy to apply robotically, conforming to complex shapes and irregular gaps, which streamlines the manufacturing process. By filling voids and ensuring uniform application, gap fillers minimize the risk of errors and rework, ultimately speeding up production times. With gap fillers, manufacturers can boost overall production efficiency while maintaining high-quality performance and safety standards in their battery systems.

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Optimize Battery Life and Safety with High-Performance Thermal Management Materials

Why use a thermally conductive material in your pack?

Featured Product: EV Therm 441

Working with H.B. Fuller’s Battery Team

Frequently Asked Questions

Request A Quote For Your Next Project

You can also speak to one of our experts by calling +1(651)-236-5900

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