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48 DESIGN007 MAGAZINE I SEPTEMBER 2025 • Specialty solutions: To further mitigate out- gassing and contamination, specialty solutions are available that absorb and trap residual volatiles over time within sealed environments. These materials complement low-outgassing TIMs and enhance long-term reliability in high- vacuum and precision electronic assemblies. Compliance with IPC, UL, and JEDEC standards ensures that TIM2 materials meet both thermal and electrical requirements for demanding applications. Thermal Cycling and Long-term Reliability Cured 2K silicone gap fillers deliver outstanding long-term reliability, maintaining elasticity and con- tact at the interface even after thousands of thermal cycles. Key characteristics contribute to this durability: • Low modulus: Their inherent softness absorbs stresses caused by coefficient of thermal expansion (CTE) mismatches during thermal cycling, protecting delicate components from damage. • Pump-out resistance: Unlike thermal greases, cured silicone gap fillers remain securely in place throughout thermal cycling, preventing the mess and thermal performance issues associated with pump-out. Long-term performance is validated through accelerated aging tests, including thermal cycling from -40°C to 150°C, high-temperature storage, and humidity resistance testing. TIM2 in Automotive Applications The automotive sector places unique demands on TIM2 materials. Advanced driver assistance systems (ADAS), for instance, must meet strict automotive industry standards for performance, safety, and durability, ensuring long-term reliable performance under challenging and dynamic operating conditions. Key requirements include: • Thermal cycling: Automotive electronics face extreme temperature fluctuations, from -40°C cold starts to 150°C under-the-hood conditions. TIM2 materials must resist cracking, shrinkage, and delamination over thousands of thermal cycles. • Long-term reliability: Designed for 10- to 15- years of service, automotive electronics require TIMs to maintain elasticity and thermal con- ductivity under continuous exposure to thermal and mechanical stresses. • Vibration and shock: TIM2 materials, particu- larly gap fillers, must remain compliant and securely in place despite exposure to ongo- ing shock and vibration. • Electrical safety: With high-voltage components alongside sensitive mixed-signal circuits, electri- cally insulating TIMs are critical for preventing short circuits and ensuring functional safety. • Outgassing and cleanliness: Volatile emissions can impair optical components in cameras and LiDAR. Low-outgassing formulations that meet VOC standards are essential for pre- serving optical clarity and reliability. • Manufacturability and tolerance compensation: Assembly variability can create uneven gaps. 2K silicone gap fillers are ideal for this task, flowing into irregular gap geom- etries and curing in place. By meeting these demanding requirements, 2K silicone gap fillers have become a preferred solu- tion across a range of applications. Beyond ADAS modules, battery control units, radar systems, and camera electronics in modern vehicles, they are also used to enhance reliability in sectors such as high-performance computing, telecom, aerospace, defense, and green energy. Closing the Gap With Advanced TIM Solutions Looking ahead, ongoing innovation in rheology, filler architecture, and material chemistry will continue to