Providing efficient heat dissipation, electrical insulation, and anti-breakdown protection for automotive transmission capacitor modules and EV power electronics.
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Automotive transmission systems generate significant heat during high-speed operation, especially in electric vehicles and intelligent driving systems. Our thermal conductive pads are designed to provide efficient heat transfer between electronic control modules, heat sinks, and metal housings.

With excellent thermal conductivity, compressibility, and vibration resistance, the material helps maintain stable operating temperatures and improves long-term reliability. Widely used in gearbox control units, power modules, and automotive ECUs, the solution supports high-performance thermal management in demanding automotive environments.

Project Background

As electric vehicles continue evolving toward higher power density and integrated electronic architectures, automotive transmission capacitor modules are exposed to increasingly demanding thermal and electrical conditions.

During continuous operation, capacitor modules inside the transmission control system generate substantial heat while simultaneously operating under high-voltage conditions. Conventional thermal interface materials often struggle to provide both efficient heat transfer and reliable electrical insulation.

To address these challenges, our 3W/mk PI-coated thermal conductive pad solution was adopted for automotive transmission capacitor modules. The PI film layer enhances dielectric strength and anti-breakdown performance while maintaining excellent thermal conductivity and mechanical stability.

The solution effectively improves heat dissipation, electrical safety, and long-term reliability in harsh automotive environments.

Customer Challenges

1.Heat Accumulation Inside Compact Transmission Modules

The transmission control unit (TCU) and integrated power modules operate continuously under elevated temperatures. Traditional interface materials were unable to maintain efficient heat transfer between the PCB, aluminum housing, and heat sink surfaces.

2. Vibration and Mechanical Stress

Automotive transmission systems are exposed to:

Continuous vibration
Mechanical shock
Thermal expansion
Long-term compression cycling

3. Complex Surface Gap Filling

The uneven surfaces between:

ECU housing
Power semiconductor devices
Heat spreaders
Aluminum casings

Required a soft and highly compressible thermal interface material capable of maintaining full surface contact.

Solution

Thermal Pad with PI Film Solution

Our PI-coated thermal conductive pad was specifically developed for automotive capacitor modules requiring both thermal management and electrical insulation protection.

High thermal conductivity
Excellent compressibility
Electrical insulation
Long-term reliability
Low thermal resistance

The material was installed between:

TCU module and aluminum housing
Power devices and cooling plates
PCB hot spots and heat sinks PCB

The integrated PI film layer provides enhanced dielectric strength and anti-breakdown capability, helping protect high-voltage capacitor modules from electrical leakage and insulation failure under demanding operating conditions.

In addition to excellent thermal conductivity, the material also offers:

Electrical insulation
High-voltage resistance
Stable compression performance
Vibration resistance
Long-term automotive reliability

To create an efficient thermal transfer path.

Product Features

Property	Performance
Thermal Conductivity	3.0 W/mK
Operating Temperature	-40°C to 180°C
Electrical Insulation	Excellent
Compressibility	High
Flame Rating	UL94 V-0
Vibration Resistance	Excellent
Automotive Reliability	Long-Term Stable

Results & Benefits

Improved Heat Dissipation Efficiency：The thermal conductive pad significantly reduced thermal resistance between heat-generating components and the transmission housing, improving overall heat dissipation performance.

Electrical Safety Improvement：The PI film layer significantly enhanced insulation reliability and anti-breakdown capability inside the high-voltage capacitor module, helping improve operational safety in EV transmission systems.