Thermal Pads | Insulation Fire Protection Gap Pads

Thermal Pads – Insulation & Gap Pads for EV and Industrial Applications

Q: What is the difference between Insulation Pads and Gap Pads?

Insulation Pads focus on blocking heat transfer and providing fire protection and energy efficiency. Gap Pads combine insulation with cushioning, filling small gaps between cells, modules, or components to enhance safety, vibration resistance, and assembly reliability.

Q: Where are Thermal Pads used apart from EV batteries?

Thermal Pads are used in industrial furnaces and kilns, pipes and ducts, fire doors and structural fire protection, cold chain pharma and food packaging, consumer appliances (ovens, boilers, HVAC), electronics and data centers, as well as aerospace, marine, rail, and defense.

Q: What temperature range can Wedge India Thermal Pads withstand?

Depending on the grade (Aerogel, Microporous, Ceramic), Wedge India pads operate from approximately −200 °C up to +1300 °C while maintaining excellent insulation performance.

Q: Are Wedge Thermal Pads fire resistant?

Yes. Most insulation pad grades are non-combustible (A1 class) and meet stringent flame-retardant standards (e.g., UL94 V-0), helping resist ignition and limit fire spread.

Q: Do you supply custom sizes and thicknesses?

Yes. We supply standard sheets and rolls, plus die-cut parts to customer drawings. Typical thicknesses range from 0.3 mm to 50 mm, with options like self-adhesive backings and foil or cloth laminations.

Q: How are Thermal Pads installed?

Pads can be cut, layered, or die-cut to fit. They are installed via pressure-sensitive adhesives, mechanical retention, lamination (foil/cloth), or direct placement between components—depending on temperature, environment, and assembly method.

Q: Can Thermal Pads be used for cold chain or pharma packaging?

Yes. Thermal Pads function as liners in cold boxes and shipping containers to help maintain 2–8 °C ranges for vaccines, pharmaceuticals, and perishable foods.

Q: What industries benefit most from Thermal Pads?

Automotive & EV, industrial manufacturing (steel, cement, petrochemicals, glass), cold chain logistics, construction & prefab, fire protection systems, aerospace, marine & defense, and electronics & data centers.

Q: How can I get prices or technical datasheets?

Fill the Get Price Enquiry Form at https://www.wedge-india.com/contact-get-price or email info@wedge-india.com. Our technical team will recommend the best grade and share datasheets, pricing, and delivery timelines.

Wedge India offers a complete range of Thermal Pads designed for heat insulation, fire protection, and gap filling across industries. Engineered with aerogel, microporous silica, and advanced composites, our Insulation Pads and Gap Pads deliver ultra-low thermal conductivity, fire resistance, and mechanical stability. In the fast-growing electric vehicle (EV) industry, battery performance, safety, and lifespan depend heavily on effective thermal management. At Wedge India, we deliver world-class EV battery insulation solutions that safeguard against thermal runaway, enhance efficiency, and ensure long-term reliability.

Why Choose Wedge India Thermal Pads?

Ultra-Low Thermal Conductivity – Keeps heat transfer to a minimum.
Wide Service Range – From -200 °C up to 1400 °C.
Fire Resistant & Non-Combustible (A1 Class) – Enhances safety.
Lightweight & Thin – Saves space without compromising performance.
Custom Sizes & Thicknesses (0.3 mm – 50 mm) – Sheets, rolls, or die-cut parts.
Self-Adhesive Options – Easy installation in compact assemblies.

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Thermal Pads

Why Thermal Management in EVs Matters

EV components like the battery pack, electric motor, power electronics, and climate control systems must operate within strict temperature ranges. For example, lithium-ion batteries perform best between 20°C–40°C. Without proper insulation and temperature control:

Overheating can cause thermal runaway and safety hazards.
Cold conditions can reduce range and charging performance.
Temperature fluctuations can shorten battery and component life.

Applications of Thermal Insulation Pads

Our Thermal Insulation Pads are widely used in:

EV Battery Packs – Cell-to-cell and module insulation; prevents thermal runaway.
Industrial Furnaces & Kilns – Backup insulation and fire barriers.
Pipes, Ducts & Turbines – High-temperature insulation in steel, cement, petrochemicals.
Cold Chain & Pharma Packaging – Thermal liners in shipping boxes and containers.
Fire Protection – Insulation pads in fire doors, lifts, safes, structural steel protection.
Consumer Appliances – Heat shields in ovens, boilers, HVAC & refrigerators.
Aerospace, Marine & Railways – Lightweight, fire-proof insulation solutions.

Applications of Gap Pads & Fillers

Our Gap Pads serve as thermal barriers + cushioning in compact assemblies:

Electronics & Semiconductors – IGBT modules, PCBs, power electronics.
Automotive Engines (Non-EV) – Under-hood insulation, exhaust shielding.
Telecom & Data Centers – UPS, battery backup, servers.
Industrial Machinery – Compressors, pumps, turbines.
Prefab & Construction – Fire-stop joint fillers in modular walls and panels.
Defense & Aerospace – High-temp insulation with vibration resistance.

Industries We Serve

Automotive & EV
Industrial Manufacturing (Steel, Cement, Petrochemicals, Glass)
Cold Chain & Pharmaceuticals
Construction & Prefabricated Buildings
Fire Protection Systems
Aerospace, Marine & Defense
Electronics & Data Centers

Our EV Battery Insulation Solutions

1. WedGel® Aerogel Thermal Pads

Ultra-low thermal conductivity for maximum heat protection.
Lightweight and thin – ideal for space-constrained battery modules.
Fire-resistant and non-combustible for enhanced safety.
Flexible and durable, withstanding daily mechanical and thermal stresses.

Applications:

Cell-to-cell insulation
Module-level gap fillers
Thermal barrier layers between battery sections

2. AlSi 250EV Fire Protection Pads

Engineered for high-temperature resistance in EV lithium-ion batteries.
Excellent vibration resistance for automotive environments.
Acts as both thermal and mechanical protection in battery packs.

Applications:

Thermal runaway containment
Sidewall and base protection in battery enclosures

3. Wedge FSMP® Microporous EV Battery Thermal Insulation Pads

Extremely low thermal conductivity – superior to many conventional insulations.
Microporous structure traps heat and prevents rapid transfer between cells.
Lightweight yet highly efficient for space-sensitive EV designs.
Stable under high temperatures, ensuring consistent performance during peak loads.

Applications:

Surrounding high-energy cells for runaway prevention
Heat shielding near high-voltage components

Integrated Thermal Management Benefits

Extended Range: Less energy wasted on heating/cooling.
Faster Charging: Maintains safe temperatures during rapid charge cycles.
Longer Lifespan: Reduces thermal stress on batteries and electronics.
Safety: Minimizes risk of fire and thermal runaway.

Industries & Vehicle Segments We Serve

Passenger EVs
Electric buses and commercial vehicles
Electric two-wheelers and three-wheelers
Energy storage systems (ESS)

Why Partner with Wedge India?

Global presence: UK | India | China | Hong Kong
Production & warehousing capacity in Faridabad, Mumbai & China
NABL-tested quality with certifications (ASTM, ISO, EN)
Fast shipping across India & worldwide

FAQs – Thermal Pads

Q1. What are Thermal Pads?
Thermal Pads are high-performance insulation and gap-filling materials made from aerogel, microporous silica, or composite fibers. They are designed to reduce heat transfer, prevent thermal runaway, and improve fire safety in EV batteries, industrial furnaces, cold chain packaging, electronics, and more.

Q2. What is the difference between Insulation Pads and Gap Pads?

Insulation Pads focus on blocking heat transfer, fire protection, and energy efficiency.
Gap Pads combine insulation with cushioning, filling small gaps between cells, modules, or components to improve safety, vibration resistance, and assembly reliability.

Q3. Where are Thermal Pads used apart from EV batteries?
Thermal Pads are widely used in:

Industrial furnaces, kilns, turbines, and ducts
Fire protection systems (doors, safes, lifts, structural steel)
Cold chain pharma & food packaging
Consumer appliances like ovens, boilers, HVAC units
Electronics, telecom & data centers
Aerospace, marine, and defense equipment

Q4. What temperature range can Wedge India Thermal Pads withstand?
Our pads cover a wide range from -200 °C up to +1300 °C, depending on the grade (Aerogel, Microporous, Ceramic). They maintain excellent insulation performance even under extreme conditions.

Q5. Are Wedge Thermal Pads fire resistant?
Yes. Most of our insulation pads are non-combustible (A1 Class) and UL94 V-0 flame retardant. They resist ignition, contain fire spread, and serve as effective thermal barriers.

Q6. Do you supply custom sizes and thicknesses?
Absolutely. We offer standard sheets, rolls, and die-cut shapes as per customer designs. Thickness options range from 0.3 mm to 50 mm, with self-adhesive or laminated coverings available.

Q7. How are Thermal Pads installed?
Thermal Pads can be easily cut, layered, or die-cut to fit specific designs. Depending on application, they can be fixed with adhesives, lamination (foil/cloth), or direct placement between components.

Q8. Can Thermal Pads be used for cold chain or pharma packaging?
Yes. Wedge Thermal Pads are ideal as liners in cold boxes and shipping containers, helping maintain 2–8 °C for pharma, vaccines, and perishable foods.

Q9. What industries benefit most from Thermal Pads?
Key industries include EV & automotive, industrial manufacturing, aerospace, defense, electronics & telecom, cold chain logistics, prefab construction, and fire safety systems.

Q10. How can I get prices or technical datasheets?
You can request a quotation and datasheet by filling out our Get Price Enquiry Form. Our technical team will suggest the most suitable grade for your application.

Q11: What is EV battery insulation and why is it important?
A: EV battery insulation is a specialized thermal barrier that regulates battery temperature, prevents thermal runaway, and enhances passenger safety. It is essential for maintaining performance, extending battery life, and meeting safety regulations.

Q12: What types of EV insulation products does Wedge India offer?
A: Wedge India offers WedGel Aerogel Thermal Insulation Pads for ultra-low thermal conductivity and AlSi 250EV Fire Protection Pads for advanced fire resistance and mechanical durability.

Q13: How does aerogel insulation benefit electric vehicle batteries?
A: Aerogel insulation provides exceptional thermal resistance in a thin, lightweight form, making it ideal for compact EV battery packs without compromising performance or safety.

Q14: Can Wedge India’s EV insulation withstand high temperatures?
A: Yes, both WedGel Aerogel and AlSi 250EV materials can handle extreme operating temperatures and provide reliable protection against heat transfer and fire.

Q15: Are these EV insulation solutions suitable for all types of electric vehicles?
A: Yes, Wedge India’s insulation products can be customized for passenger EVs, electric buses, two-wheelers, and commercial EV applications.

Q16: Does Wedge India offer custom sizes for EV battery insulation?
A: Absolutely. We supply insulation pads in custom sizes, shapes, and thicknesses to fit specific battery pack designs.

Q17: Do you export EV insulation products?
A: Yes, Wedge India supplies both domestically and internationally, ensuring compliance with global EV safety and performance standards.

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Thermal Management in Electric Vehicles (EVs)

In electric vehicles, thermal management is key to performance, safety, and battery life. Critical components such as the battery pack, electric motor, power electronics, and cabin climate control system must operate within optimal temperature ranges—typically 20°C to 40°C for batteries—to prevent overheating, energy loss, or reduced efficiency.

Key Focus Areas:

Battery Pack: Prevents thermal runaway and capacity loss in extreme temperatures.
Electric Motor: Maintains efficiency and avoids overheating under high loads.
Power Electronics: Keeps inverters and converters cool for reliable operation.
Cabin Climate Control: Balances comfort with minimal impact on driving range.

Thermal Management Solutions:

Cooling Systems: Liquid cooling for high efficiency; air cooling for lightweight designs.
Heating Systems: Energy-efficient heat pumps and resistive heaters for cold conditions.
Thermal Insulation: Advanced materials to limit heat transfer and maintain temperature stability.
Active Control: Sensors and smart algorithms to dynamically manage heat and cooling.
Battery Protection: Preconditioning, zonal cooling, and thermal barriers to prevent overheating.

Benefits of Effective Thermal Management:

Extends driving range.
Enables faster charging.
Increases component lifespan.
Enhances passenger safety.

At Wedge India, we deliver advanced thermal insulation and heat protection solutions—including aerogel-based EV battery pads and fire barriers—to help manufacturers achieve optimal temperature control in all operating conditions.