Effective thermal management in battery-powered electric vehicles is essential for performance, reliability, and durability. These vehicles operate best at optimal temperatures—not too hot or cold—which are crucial for the battery pack, power electronic systems, and motor. Maintaining these temperatures preserves battery charge and capacity and ensures power systems and motors function efficiently.

Power electronic systems are responsible for controlling electric motors. Power electronic systems operate in line with the electric vehicle control system and drive the electric motor according to the control instructions. The power electronic system’s DC-DC converters, inverters, and control circuits are vulnerable to thermal effects. While working, the power electronic circuits generate heat loss, and proper thermal management is essential to release the heat from the circuit and associated systems. If the thermal management is insufficient, it can result in control glitches, and component failures. Usually, the power electronic system is connected to the electric vehicle’s cooling system to maintain optimal temperatures.

The industry is striving for higher power output, increased voltage, faster data transmission, lighter weight, and more compact sizes. To address these thermal management challenges, there is a need for thermally conductive yet electrically insulating thermal interface materials (TIMs) that feature high dielectric strength and low dielectric constant. While TIMs made from dielectric polymers are naturally insulative, incorporating ceramic fillers enhances their thermal conductivity while still maintaining electrical resistance. The exceptional thermal and dielectric properties of these ceramic thermal fillers are crucial for the effectiveness of thermal management materials.