Thermal Management in Electric Vehicles: China’s Carbon Materials Driving Efficiency

Introduction

As electric vehicles (EVs) rapidly gain global traction, thermal management emerges as a critical bottleneck in performance, safety, and battery longevity. Whether it’s managing battery pack temperature, motor heat dissipation, or interior climate control, effective thermal regulation defines the lifespan and reliability of an EV.

In this landscape, carbon-based materials—especially graphite, graphene, and carbon nanotubes (CNTs)—are proving indispensable. China, with its maturing EV industry and robust carbon material supply chain, is already commercializing carbon-enabled thermal solutions across multiple vehicle subsystems.

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This article explores how Chinese companies are using carbon materials for thermal pads, phase change materials, coatings, and heat-dissipating structures in production-ready EVs.

1. The Thermal Challenges in EVs

EVs present unique thermal issues:

• Battery Packs: Require cooling between 20–40°C to avoid thermal runaway and capacity fade

• Power Electronics: Inverters and onboard chargers generate high localized heat

• Motors and Gearboxes: Continuous mechanical operation leads to temperature spikes

• Cabin Comfort: No combustion heat means more demand on electric HVAC systems

Traditional metal-based heat sinks are often heavy and rigid. Polymer composites can’t conduct heat well. This gap has been increasingly filled by carbon-based thermal interface materials (TIMs).

2. Carbon Materials and Their Roles

3. Chinese EV Manufacturers Adopting Carbon-Based TIMs

A. BYD (比亚迪)

• Uses graphite-based heat spreading sheets in its blade battery pack.

• Partners with thermal material firms to ensure tight thermal tolerance in high-voltage modules.

B. NIO (蔚来)

• Adopts CNT-enhanced phase change materials (PCMs) in its power electronics.

• Uses flexible graphene pads for motor control units.

C. XPeng Motors (小鹏)

• Integrates graphite composite foils in battery trays.

• Involved in R&D collaboration for graphene epoxy composites for in-cabin electronics.

D. CATL (宁德时代)

• Supplies batteries with custom graphite and graphene heat dissipation layers.

• Cooperates with materials firms to localize mass-producible graphene-enhanced coatings.

4. Representative Chinese Suppliers and Materials

5. Application Scenarios and Product Forms

A. Thermal Interface Pads

• Made with graphite or graphene composites

• Laminated between heat-generating parts and metal chassis

• Flexible, ultrathin (<100 µm), and customized for each car model

B. Phase Change Materials (PCMs)

• Blended with CNTs to improve thermal conductivity

• Absorb heat during acceleration, release it during idle

• Used in battery modules and power electronics housings

C. Heat-Dissipating Adhesives & Pastes

• Include carbon black + CNT + graphene nanoplatelets

• Applied between MOSFETs, capacitors, and heatsinks

• Ensures stable thermal conductivity over the life cycle

D. Spray Coatings

• Graphene-oxide-based sprays applied to battery compartments

• Improves heat dispersion and fire resistance

• Some coatings are also electrically insulating

6. Manufacturing Techniques in China

Key advancements enabling mass production include:

• Roll-to-roll production of graphite films

• CNT and graphene dispersion systems with stable thermal performance

• Low-temperature curing carbon pastes for sensitive EV electronics

• Scalable coating methods for battery pack assembly lines

With cost control and local supply, Chinese thermal materials firms are increasingly integrated into OEM and Tier 1 supplier ecosystems.

7. Government Policy and Standards Support

• National policies like 《新能源汽车产业发展规划（2021-2035）》 prioritize safe and efficient EVs

• R&D funding for advanced thermal management under “New Materials” key projects

• Safety standards (GB/T 31467, GB/T 38775) indirectly drive adoption of non-metal thermal solutions

As a result, carbon-based materials are increasingly viewed not as niche but as strategic enablers of safe, efficient, and long-range EVs.

8. Outlook: Toward Integrated Thermal Systems

Future EVs will likely adopt:

• Co-engineered thermal + electrical conductive materials

• Carbon fiber-based structural heat spreaders

• Integrated battery and motor cooling plates using graphene films

• AI-controlled thermal systems to optimize energy use dynamically

China’s vertically integrated carbon industry—from graphene producers to OEMs—puts it in a strong position to lead next-generation EV thermal innovation.

Conclusion

Carbon materials have evolved from lab-scale promise to factory-floor productivity. In China, these materials are already helping cool the batteries, stabilize the motors, and extend the range of electric vehicles on the road today.

For EV makers and materials firms alike, this is not just about performance — it’s about shaping the future of mobility through advanced material science.