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Opportunities and Challenges for Polymeric Insulation Materials in Electric Vehicles Powertrains
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DOI：10.1016/j.etran.2026.100590.png)
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Abstract
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• The paper presents a comprehensive review of polymeric insulation materials in electric vehicle (EV) powertrains, emphasizing their critical role in ensuring safety, efficiency, and durability across batteries, electric motors (EMs), and power electronics. With the ongoing transition to EVs driven by decarbonization goals, these materials face increasing thermal, electrical, mechanical, and environmental stresses. • Battery insulation, particularly for lithium-ion (LIBs) and sodium-ion batteries (SIBs), relies heavily on polymer-based separators to prevent internal short circuits. While polyolefins like PE and PP are widely used due to cost-effectiveness and mechanical strength, their thermal instability and poor electrolyte wettability have led to innovations in composite materials. Enhanced separators now incorporate polymers like PVDF, PI, PAN, and PEEK, often modified with ceramic or nanofillers (e.g., TiO2, SiO2, BaTiO3) to improve ionic conductivity, thermal resistance, and dendrite suppression. Techniques such as surface coating, electrospinning, and multilayer designs further address performance limitations. • In electric motors, insulation systems (EIS) face intensified stresses due to high-speed, high-voltage operation, and advanced inverter technologies (e.g., PWM, SVM). The paper categorizes insulation into primary (e.g., enamel or PEEK-coated magnet wires) and secondary (e.g., slot liners, resins, separators) systems. Innovations focus on enhancing dielectric strength, thermal endurance, and partial discharge resistance. Emerging solutions include nanodielectric coatings, advanced varnishes, and hybrid laminates that integrate mechanical, thermal, and electrical protection. • The paper highlights T.E.A.M. (Thermal, Electrical, Ambient, Mechanical) degradation mechanisms, emphasizing the need for robust materials that withstand combined stressors. Partial discharge, corona erosion, and treeing are identified as critical failure modes, especially with rising voltage levels (e.g., 800V platforms) and faster switching rates. • Looking ahead, we, the authors, advocate for multifunctional, scalable, and sustainable insulation materials that support the growing power density and efficiency demands of EVs. Materials like polyimide/PEEK-based nanocomposites and MOF-enhanced membranes exemplify promising directions. In summary, the paper underscores the pivotal role of polymeric insulation in advancing EV reliability and performance, calling for interdisciplinary efforts to develop next-generation materials tailored for extreme EV environments.
Keywords:
Polymeric insulation
Electric vehicle powertrains
Battery separators
Electric motor insulation
Multifunctional materials
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