DOWSIL™ TC-5533 Gap Filler
Harmonization Code : 3910.00.00.90 | Silicones in Primary Forms; Others
Main features
- Designed specifically for EV battery module
- Controlled siloxane volatility
- Vertical Stability
Product Description
DOWSIL™ TC-5533 Thermally Conductive Gap Filler is a two-part, room-temperature-curing silicone thermal interface material specifically engineered for electric vehicle (EV) battery thermal management applications. Featuring 3.0 W/m·K thermal conductivity, controlled siloxane volatility, and a soft, compliant cured elastomer, TC-5533 efficiently transfers heat from battery modules and electronic components to cooling plates, cold plates, or thermal management units while minimizing assembly stress. Designed for automated dispensing and high-volume manufacturing, the material remains stable on vertical surfaces, exhibits low abrasion to dispensing equipment, and delivers long-term reliability under temperature and humidity cycling conditions. Its combination of thermal performance, dielectric insulation, flame resistance, and processability makes TC-5533 an excellent solution for EV battery packs, energy storage systems, power electronics, and automotive control modules.
Key Features
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3.0 W/m·K thermal conductivity for efficient heat dissipation.
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Designed specifically for EV battery module thermal management.
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Controlled siloxane volatility for improved long-term reliability.
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Soft, compliant cured elastomer for vibration damping and stress relief.
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Low assembly force requirements to protect sensitive battery cells and electronics.
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Excellent stability during temperature and humidity cycling.
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Vertical stability in both uncured and cured conditions.
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Two-part 1:1 mix ratio by weight or volume.
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Automated dispensing compatible with low-abrasion filler technology.
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UL 94 V-0 flame classification for enhanced safety compliance.
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Dielectric strength of 11 kV/mm for electrical insulation.
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Operating temperature range of -45°C to 125°C, with short-term exposure up to 200°C.
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Suitable for EV battery modules, battery cooling plates, energy storage systems, power electronics, onboard chargers, DC-DC converters, and automotive electronic control units.
DOWSIL TC-5533
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Technical Specifications
General Properties
Physical Properties
Thermal Properties
Electrical Properties
Additional Information
DOWSIL™ TC-5533: Thermally Conductive Gap Filler for EV Battery Modules
DOWSIL™ TC-5533 Thermally Conductive Gap Filler is a two-part, room-temperature-curing silicone gap filler designed for effective thermal management of EV battery modules and other heat-generating electronic assemblies. With 3.0 W/m·K thermal conductivity, controlled siloxane volatility, low assembly forces, and long-term stability during temperature and humidity cycling, TC-5533 helps transfer heat from battery modules to cooling units while providing a soft, compliant thermal interface.
EV battery thermal gap filling with controlled volatility — TC-5533 combines 3.0 W/m·K thermal conductivity, low assembly force, vertical stability, and dispensing-friendly processing for battery module cooling.
Once cured, the silicone gap filler forms a soft elastomer that supports dielectric insulation, environmental protection, and stress relief against vibration, shock, and thermal expansion mismatch in EV battery systems.
Designed for EV battery cooling units — suitable for transferring heat from battery modules or other heat-generating components to cooling plates, housings, or thermal management units.
TC-5533 stays in place after dispensing, supports low assembly force, and is designed for automated dispensing with low abrasion and a wide application process range.
3.0 W/m·K Thermal Conductivity • EV Battery Modules • Controlled Volatility • UL 94 V-0
Features & Benefits
- 3.0 W/m·K thermal conductivity — supports efficient battery module heat transfer.
- Room-temperature cure — cures at 25 °C with optional heat acceleration.
- Controlled siloxane volatility — supports long-term electronic reliability.
- Low assembly forces — helps protect sensitive battery and electronic components.
- Stays in place — holds vertical position in cured and uncured states.
- Temperature and humidity cycling stability — designed for EV battery environments.
- Dispensing equipment friendly — low abrasion and wide application process range.
- UL 94 V-0 flame classification — suitable for flame-rated battery and electronics assemblies.
Typical Applications
- EV battery module thermal management.
- Battery module-to-cooling unit interfaces.
- Battery cooling plates and trays.
- Energy storage modules.
- Power electronics thermal gap filling.
- Automotive electronics and control modules.
- Automated dispensing applications.
Thermal Challenges in EV Battery Modules
EV battery systems require thermal materials that can efficiently dissipate heat while accommodating module tolerances, assembly pressure limits, vibration, and long-term environmental exposure. DOWSIL™ TC-5533 helps address these challenges with a soft, compliant silicone gap filler that transfers heat from battery modules to cooling units while maintaining reliable performance during temperature and humidity cycling.
Engineering Data for DOWSIL™ TC-5533
| Property | DOWSIL™ TC-5533 | Condition / Note |
|---|---|---|
| Type | Two-part silicone gap filler | Room-temperature curing |
| Mix Ratio | 1:1 | By weight or volume |
| Color | Part A: White Part B: Blue |
Typical appearance |
| Mixed Viscosity | 50 Pa·s | At 10 s-1 |
| Thixotropic Index | 5–6 | 1 s-1 / 10 s-1 |
| Working Time | 60 minutes | At 25 °C |
| Density, Cured | 2.6 | At 25 °C |
| Thermal Conductivity | 3.0 W/m·K | ASTM D5470 |
| Cure Time at 25 °C | 24 hours | Vertical stability for thin bondlines; full cure may take up to 7 days |
| Hardness | Shore 00 65 | Soft compliant material |
| Dielectric Strength | 11 kV/mm | Cured material |
| UL Flame Classification | UL 94 V-0 | Flame classification |
| Operating Temperature | -45 °C to 125 °C | After cure completion |
| Short-Term High Temperature Exposure | Up to 200 °C | Short periods only |
| Shelf Life | 6 months | At 25 °C |
*Typical properties are not intended for specification writing. Verify performance under actual application, substrate, assembly, compression, cure, and reliability conditions.
Where DOWSIL™ TC-5533 Fits
- Battery modules
- Cooling plates
- Battery trays
- ESS modules
- Battery packs
- Thermal management units
- Meter-mix dispensing
- Vertical placement
- Wide process window
Mixing, Dispensing & Cure
Mixing
Mix Part A and Part B at a 1:1 ratio by weight or volume. Static mixing is recommended for manual and automated mixing.
Dispensing
Automated airless dispense equipment can reduce voids and avoid de-airing. Purge trapped air or clear fluid during material change-over.
Curing
Cures at room temperature or with heat acceleration. Thin bondlines can achieve vertical stability in 24 hours at 25 °C; full cure may take up to 7 days.
How TC-5533 Supports EV Battery Module Design
| Design Challenge | DOWSIL™ TC-5533 Benefit |
|---|---|
| EV battery modules require efficient heat removal. | 3.0 W/m·K thermal conductivity supports heat transfer to cooling units. |
| Battery cells and electronics can be sensitive to high assembly pressure. | Low assembly forces help protect sensitive components. |
| Dispensed material must stay in place during pack assembly. | Thixotropic behavior supports vertical stability in cured and uncured states. |
| High-volume production requires equipment-friendly material flow. | Low-abrasion ceramic fillers support dispensing equipment life and process flexibility. |
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