Submitted 04/2026
Directional Battery Cell Venting Tape
ES 3505
Industrial Scale
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Short Description
Avery Dennison Performance Tapes' directional cell venting tape is a single-coated pressure-sensitive adhesive solution engineered for controlled gas exhaust and environmental sealing in EV battery modules. Featuring a specialized blue PET carrier with anisotropic flame behavior, the tape acts as a reliable seal under normal operating conditions while providing a predictable, one-directional burst path during thermal runaway events. It serves as a functional safety component designed to integrate seamlessly into automated high-speed assembly lines.
Inputs
Outputs
Technical Parameters
Directional cell venting — seals gas channels during normal operation and provides controlled, anisotropic flame release during thermal runaway events
Applied at cell-to-cell or cell-to-module interfaces where gas venting channels are designed.
Bonds to mica sheets, metallic enclosures, and polymer substrates.
Product Information in Detail
The ES 3505 addresses a specific gap in battery module thermal management: the need for a material that functions both as a reliable seal during normal operation and as a controlled release mechanism during thermal events. Traditional insulation materials either remain intact (failing to vent) or degrade unpredictably. The ES 3505 is engineered for a defined failure mode.
The tape’s core innovation is its anisotropic flame behaviour. The blue PET facestock is designed so that the top surface bursts quickly when exposed to flame from a specific direction, while the adhesive side maintains significantly longer resistance. This directional response enables battery pack designers to create controlled exhaust paths that vent thermal runaway gases exactly where intended, rather than allowing pressure to build or escape at uncontrolled points.
Under normal conditions, the tape provides a high-tack bond (800 N/m initial loop tack) and a reliable environmental seal. Composites using the ES 3505 pass IP6X and IP7X ingress protection testing, confirming dust-tight and water-immersion resistance. The dielectric properties of the PET carrier provide additional electrical insulation between cells.
The 135 µm total caliper and clear polyester liner are optimised for high-speed die-cutting, supporting integration into automated battery module assembly lines. The permanent acrylic adhesive resists corrosion and maintains bond integrity across a continuous service range of −40 °C to 149 °C.
Features & USPs
Burst-on-Demand Venting
The PET facestock is engineered for anisotropic flame response — the top surface releases rapidly during thermal events while the adhesive side maintains its bond, creating a controlled exhaust path for thermal runaway gases.
Environmental Sealing
Composites pass IP6X and IP7X testing for dust-tight and water-immersion resistance, ensuring the battery remains sealed under normal driving conditions.
Dielectric and Fire Resistance
The high-quality PET carrier provides reliable electrical insulation and inherent fire-resistant properties, adding a secondary safety function beyond venting.
Thin-Profile Integration
At 135 µm total system caliper, the tape adds minimal thickness to the module stack while enabling venting functionality that would otherwise require additional mechanical components.
Type of Solution
Standard Material
The ES 3505 is supplied in roll form, compatible with high-speed die-cutting and automated tape-laying systems. Avery Dennison Performance Tapes provides global availability through manufacturing and support hubs in North America (Ohio, USA), Europe (Turnhout, Belgium), South America (Vinhedo, Brazil), and Asia Pacific (Kunshan, China).
Ideal Customer
Battery Pack Designers & Thermal Management Engineers
Battery pack designers and thermal management engineers developing cell venting and exhaust strategies where specific, directional flame-burst behaviour is required for safety. Relevant for module-level thermal runaway mitigation design in automotive and industrial EV applications.
Industry Challenges & Innovations
Challenge
Bond strength is dependent on surface contact, which is influenced by the specific pressure, time, and temperature applied to various rigid or film surfaces.
Innovation
The development of burst-on-demand facestock technology allows engineers to create controlled exhaust paths during thermal events, significantly improving battery pack safety by converting a passive insulation layer into a functional safety component.