Battery Thermal Runaway Mitigation Tapes

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.