Submitted 04/2026
Battery Thermal Runaway Mitigation Tapes
ES 3507 · FT 8065 · FM 2333 · FT 8383 EZ
Industrial Scale
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Short Description
Avery Dennison Performance Tapes' thermal runaway mitigation tapes are a family of pressure-sensitive adhesive solutions engineered for flame barrier, cell isolation, and thermal insulation applications in EV battery packs. The portfolio includes ceramic flame barrier tapes, flame-retardant double-coated bonding tapes, and mica-bonding foam tapes — designed as flexible, thin-profile alternatives to rigid insulation materials in thermal runaway mitigation systems.
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Technical Parameters
Thermal Runaway Mitigation — provides flame resistance, high-voltage dielectric isolation, and thermal insulation to prevent cell-to-cell propagation.
- Applied between cells, around modules, and at pack-level interfaces where flame barriers, dielectric insulation, and thermal isolation are required.
- Bonds to mica sheets, metallic enclosures, foam gaskets, and polymer substrates.
Thermal runaway mitigation design, cell-to-cell isolation, flame barrier assembly, mica sheet integration, pack sealing and gasketing.
Product Information in Detail
Thermal design and thermal runaway mitigation in EV battery packs requires multiple material functions: flame resistance at the cell interface, dielectric isolation to prevent arcing, and structural bonding to keep insulation layers in place under vibration, temperature cycling, and mechanical stress.
Traditionally, these functions have been addressed with rigid materials — primarily mica sheets — combined with mechanical fasteners or liquid adhesives. This approach introduces manufacturing complexity, limits design flexibility in tight geometries, and creates potential failure points where rigid materials fracture or delaminate.
Avery Dennison’s thermal runaway protection tape portfolio addresses these challenges with a series of pressure-sensitive adhesive technology that integrates flame barrier, dielectric, and bonding functions into thin, conformable tape formats.
- The ES 3507 uses a proprietary ceramic-filled rubber carrier that withstands temperatures up to approximately 800 °C, providing flame barrier performance comparable to mica in a flexible format. The ceramic-rubber construction conforms to curved and recessed geometries where rigid mica sheets fracture, lift, or delaminate.
- The FT 8065 adds flame-retardant and dielectric properties to bonded assemblies using Flame Tough™ technology. Both the polyester carrier and acrylic adhesive are engineered to meet UL 94 flammability requirements, providing a minimum 6.1 kV breakdown voltage. As a pressure-sensitive adhesive, it requires no cure time — providing immediate strength during high-speed assembly.
- The FM 2333 solves the specific problem of bonding rigid plate mica into battery packs. Its modified acrylic adhesive achieves peel adhesion on mica up to 10× higher than alternative tapes (288 N/m) and lap shear 2–5× higher (411 kPa). The release liner is specifically engineered so that removal does not pull the mica away from the bond — a common failure mode with standard tapes on frangible substrates.
- The FT 8383 EZ complements the portfolio as a high-tack foam bonding solution for gaskets and sealing components in thermal management assemblies. Its EZ densified kraft liner is designed for tear-free stripping of complex die-cut geometries.
Features & USPs
Flexible Flame Barrier
The ES 3507 ceramic-filled rubber carrier provides ~800 °C heat resistance in a conformable format, replacing rigid mica in geometries where traditional insulation fractures or delaminates.
Integrated Flame-Retardant Bonding
FT 8065 Flame Tough™ chemistry combines flame retardance (UL 94) and dielectric strength (6.1 kV) in a pressure-sensitive adhesive format that requires no cure time.
Manufacturing Efficiency
All variants are designed for high-speed die-cutting and automated assembly. Pressure-sensitive adhesive technology eliminates cure time, clamps, and secondary fasteners.
Type of Solution
Standard Materials
All 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
Battery pack thermal management engineers and module designers responsible for cell-to-cell thermal propagation prevention, flame barrier integration, and mica replacement strategies. Tier 1 suppliers and OEMs seeking flexible, thin-profile alternatives to rigid insulation materials in high-volume EV battery manufacturing.
Industry Challenges & Innovations
Challenge
Mica and other rigid flame barriers are frangible and difficult to integrate into battery packs. Standard tapes may delaminate mica when the release liner is removed, and mechanical fasteners or liquid adhesives can cause delamination under load.
Innovation
Flame Tough™ technology enables pressure-sensitive adhesives to provide functional flame barrier properties in compact battery designs. The FM 2333 combines optimised release liner technology with mechanical properties specifically tuned for mica bonding — solving the integration challenge at its