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Submitted 04/2026
Dielectric Insulation Tapes for Battery Systems
ES 1421 · FT 0031
Industrial Scale
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Short Description
Avery Dennison Performance Tapes' dielectric insulation tapes are single-coated pressure-sensitive adhesive solutions engineered for high-voltage electrical isolation in EV battery modules and packs. The portfolio includes a high-shear PET tape for flat and rigid surfaces and a proprietary stretchable polyolefin tape for complex geometries that undergo metal forming. Both provide thin-profile dielectric barriers compatible with high-speed automated assembly.
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Technical Parameters
High-voltage dielectric insulation — provides electrical isolation between battery cells, busbars, cooling plates, and metallic enclosure components in battery modules and packs.
- Applied to prismatic cell wraps, busbar insulation, cooling plate surfaces, cell-to-cell connection systems, and module housing components.
- Bonds to metallic (aluminium, stainless steel) and polymer substrates.
Electrical isolation in battery module design, busbar insulation, enclosure dielectric protection, and cooling plate insulation.
Product Information in Detail
Electrical isolation is a non-negotiable requirement in high-voltage EV battery modules and packs. Dielectric tapes provide a thin-profile alternative to moulded insulators, liquid coatings, and mechanical spacers — reducing stack height, simplifying assembly, and enabling automated application at production speeds.
Avery Dennison dielectric insulation portfolio addresses two distinct but complementary application scenarios.
- The ES 1421 is designed for flat and rigid substrate surfaces including prismatic cell wraps, busbars, cooling plates, and cell connection systems. Its 85 µm total caliper delivers a dielectric breakdown voltage exceeding 8 kV while adding minimal thickness to the module stack. The advanced acrylic adhesive provides high shear performance (2.0–4.0 MPa lap shear) and proven compatibility with multiple structural adhesives and thermal interface materials, making it suitable for laminated multi-layer assemblies where the dielectric tape must maintain position under secondary bonding loads. The adhesive’s shear adhesion failure temperature (SAFT) exceeds 200 °C, providing a margin above typical battery operating conditions.
- The FT 0031, part of the Volt Tough™ EV Battery Portfolio, addresses geometries where standard tapes fail. Its proprietary stretchable polyolefin carrier achieves over 300% elongation, allowing the tape to survive aggressive metal forming operations while maintaining a dielectric strength of >10kV (AC). This enables a manufacturing sequence change: the tape can be applied to flat stock before forming, maintaining dielectric integrity through bending, drawing, and stamping processes. For battery pack components with complex or unique geometries — formed aluminium housings, bent busbars, contoured cooling plates — this eliminates the need for post-forming insulation application in tight spaces.
Both variants are single-coated, optimized for high-speed die-cutting and automated tape-laying. The ES 1421 features high initial tack for reduced dwell time requirements, while the FT 0031 uses a pure acrylic adhesive formulated for strong adhesion to metallic battery pack components.
Features & USPs
High-Voltage Protection at Minimal Thickness
ES 1421 delivers >8 kV breakdown voltage at only 85 µm total caliper. FT 0031 provides 11.22 kV (AC) at 104 µm. Both enable tighter cell packing without sacrificing dielectric safety margins.
TIM and Structural Adhesive Compatibility
ES 1421 achieves 2.0–4.0 MPa lap shear with various thermal interface materials and structural adhesives, ensuring the dielectric layer remains stable in laminated assemblies.
Forming Survivability
FT 0031’s >300% elongation allows dielectric protection to survive metal forming operations, enabling pre-forming tape application and simplifying the assembly sequence.
Reduced Fossil Material Usage
ES 1421 uses 52% less fossil-derived material, 35% less net energy consumption, and 29% less greenhouse gas emissions versus alternative solutions.
Type of Solution
Standard Materials
Both variants are supplied in roll form, compatible with automated die-cutting and high-precision tape-laying machinery. Global availability through Avery Dennison manufacturing hubs in North America (Ohio), Europe, South America, and Asia Pacific.
Ideal Customer
Design & Electrical Engineers
Design engineers and electrical engineers responsible for high-voltage isolation in EV battery packs and modules. Process engineers at prismatic cell manufacturers requiring cell wrap insulation. Manufacturers integrating formed metallic components (housings, cooling plates, busbars) that require dielectric protection through forming operations.
Industry Challenges & Innovations
Challenge
Achieving consistent dielectric insulation on complex or formed metallic surfaces in battery packs. Standard tapes crack, lift, or lose dielectric integrity when substrates are bent or formed after application.
Innovation
The FT 0031 proprietary stretch film allows dielectric protection to remain intact during aggressive metal forming operations — a critical advancement for battery pack structural integration. The ES 1421 high-shear adhesive is globally producible and compatible with multiple TIMs, enabling standardised dielectric solutions across multi-regional manufacturing.