New-Energy Battery Packs
Inside a battery pack, tape does three jobs: it insulates, it fixes, and it protects edges. All three happen within millimetres of live conductors and within a few degrees of a thermal event, so the tolerances are tighter than in general electrical work.
The tapes that matter most here are high-temperature films and flame-retardant cloth grades.
What this application demands
Dielectric strength
The tape is part of the insulation system, so breakdown voltage has to be stated and stable across the temperature range.
Heat resistance
Cell and busbar temperatures, plus process heat from welding and curing, rule out low-temperature film tapes.
Flame retardancy
Self-extinguishing behaviour and low smoke are usually a pack-level requirement, not an option.
Clean removal
Tapes used as masking during assembly must come off without leaving adhesive that could trap contamination.
Recommended constructions
| Requirement | Recommended tape | Why |
|---|---|---|
| Busbar and cell insulation | PI5300 polyimide tape | Thin, tough polyimide film with silicone adhesive; the standard choice where space is tight and temperature is high. |
| General pack insulation | PT5200 PET high-temperature tape | 0.050 mm PET film, 5 kV breakdown voltage, heat resistance 180 °C. |
| Flame-retardant wrapping | B1300 / B1600 PET cloth tape | B-class self-extinguishing flame retardancy with class D abrasion resistance. |
| Edge protection and fixing | R1005 PET fleece tape, or X-1300A sleeve tape for cylindrical parts | Conformable fleece for irregular geometry; sleeve tape for rounded bundles. |
How to specify it
| Specification point | What to state on your enquiry |
|---|---|
| Insulation class | The voltage and insulation class the tape must support |
| Continuous temperature | Pack temperature plus process temperature, with duration |
| Flame requirement | The flame test standard and whether low smoke is required |
| Thickness budget | Maximum tape thickness that fits your gap |
| Adhesive compatibility | Any electrolyte, coolant or potting compound the tape will contact |
Common specification mistakes
Watch out for this: using a low-temperature film
Standard PVC or thin BOPP tapes deform or leave residue after pack-level thermal cycling.
Watch out for this: specifying thickness by feel
A 0.05 mm and a 0.08 mm film differ in dielectric strength and in how they sit in a tight gap — specify both.
Watch out for this: overlooking process heat
Laser welding and curing ovens can exceed the tape's short-term limit even when pack temperature is fine.
Talk to a tape engineer
Send us the application, the operating temperature and the base material you have in mind. We will come back with a recommended construction, a datasheet and a quotation within one working day.