Thermal - Adhesives, Epoxies, Greases, Pastes

Part Number	Description / PDF	Quantity
1333493 LOCTITE / Henkel	SILICONE GREASE TG100	0
1695226 LOCTITE / Henkel	TCP 4000 55CC EFD EN/CH	0
234476 LOCTITE / Henkel	3873 SELF SHIM HI COND THERM ADH	17
2055134 LOCTITE / Henkel	STYCAST 2850FT BK, 5 GAL PA	0
1188118 LOCTITE / Henkel	STYCAST 2850FT BLK 3# 1.36KG	5
1188124 LOCTITE / Henkel	STYCAST 2850FT BLU 3# INDIVIDUAL	10
1188125 LOCTITE / Henkel	STYCAST 2850FT BLU18#	0
2056963 LOCTITE / Henkel	STYCAST 2850FT BK 5GAL, 5 GAL PA	2
230178 LOCTITE / Henkel	7387 THERMAL ADHESIVE ACTIVATOR	0
1188134 LOCTITE / Henkel	STYCAST 2850KT BLU 3LB	28
1188135 LOCTITE / Henkel	STYCAST 2850KT BLU 20#	5
1586134 LOCTITE / Henkel	ECCOBOND 56C-CAT 9 KIT, 140.5GM	0
1188119 LOCTITE / Henkel	STYCAST 2850FT BLK18# 8.16KG	35
1188137 LOCTITE / Henkel	STYCAST 2850MT BLUE 18LB	0
1401008 LOCTITE / Henkel	2151 THERMALLY CONDUCTIVE ADH	0
1188112 LOCTITE / Henkel	LOCTITE ABLESTIK 285 BK	0
2056395 LOCTITE / Henkel	STYCAST 2850KT BL 5GAL PA	2
1188035 LOCTITE / Henkel	CATALYST 23LV CLR 1LB 0.454KG	0
1188099 LOCTITE / Henkel	STYCAST 2762FT BLK 3# INDIVIDUAL	27
1188100 LOCTITE / Henkel	STYCAST 2762FT (18LB),	0

Thermal - Adhesives, Epoxies, Greases, Pastes

1. Overview

Thermal interface materials (TIMs) are specialized substances designed to enhance heat transfer between mating surfaces. These materials fill microscopic air gaps and reduce thermal resistance in electronic, mechanical, and industrial systems. With increasing power densities in modern devices, effective thermal management has become critical for reliability, performance, and longevity.

2. Main Types & Functional Classification

Type	Functional Characteristics	Application Examples
Thermal Adhesives	Permanently bond surfaces while conducting heat. Available in conductive/dielectric variants.	CPU heatsink bonding, LED module assembly
Epoxy Systems	Two-part compounds with high structural strength and thermal conductivity.	Power module encapsulation, motor controller assembly
Thermal Greases	Non-curing compounds with optimal gap-filling properties.	GPU cooling, automotive sensor mounting
Phase Change Materials	Temperature-activated compounds that optimize interface at operational temperatures.	Server processors, high-frequency amplifiers

3. Structure & Composition

Typical formulations include:

Base Materials: Silicones, epoxies, polyurethanes, or acrylates
Fillers: Aluminum oxide, boron nitride, silver, or graphene for conductivity
Additives: Rheology modifiers, adhesion promoters, and antioxidants

Material microstructure is engineered to balance thermal performance with mechanical compliance.

4. Key Technical Specifications

Parameter	Significance	Typical Range
Thermal Conductivity	Primary measure of heat transfer efficiency	1-8 W/m K
Operating Temperature	Determines application environment suitability	-50 C to 200 C
Viscosity	Affects application method and gap coverage	500-500,000 cP
Dielectric Strength	Electrical insulation capability	5-30 kV/mm
Curing Time/Temperature	Production process compatibility	Room temp-150 C

5. Application Fields

Consumer Electronics: Mobile devices, gaming consoles
Automotive: EV battery packs, power electronics
Industrial: Power supplies, laser systems
LED Lighting: Heat spreader attachment
Aerospace: Avionics thermal management

6. Leading Manufacturers & Products

Manufacturer	Key Products	Specialty
3M	TC-2810 Adhesive	High-conductivity die attach
Dow	SYLGARD 8660	Low-outgassing space applications
Henkel	Berger TIM 880	Phase-change processor pads
Master Bond	EP42HT-2AO	Two-part conductive epoxy

7. Selection Guidelines

Key considerations:

Thermal requirements vs. operating conditions
Material compatibility with substrates
Production process integration (curing, dispensing)
Long-term stability under thermal cycling
Cost-performance tradeoff analysis

Case Study: A server manufacturer reduced CPU operating temperatures by 12 C by switching from standard grease to a phase-change material with optimized melt profile.

Industry Trends

Emerging developments include:

Nano-enhanced composites achieving >10 W/m K
UV-curable formulations for faster processing
Low-VOC water-based systems for environmental compliance
Smart materials with temperature-dependent conductivity
Increased demand from EV battery thermal management systems