Tapes for battery energy storage systems

BESS modules routinely exceed 1,000V DC, creating arcing risk between cells, busbars, cooling plates and module housings. Electrical insulation failures can trigger short circuits, thermal events and system shutdowns.

Volt Tough™ dielectric tape solutions provide high-voltage protection throughout battery energy storage systems:

• CTI 600V rating: Material Group I classification per IEC 60112 for compact BESS designs with minimal clearance distances

• Dielectric strength >200 kV/mm: Tested per ASTM D149 and GB/T 1408.1-2016 for global supply chain compliance

• Cell insulation: Can prevent shorts between prismatic LFP cells in high-density pack configurations

• Busbar and cell connection insulation: Insulates high-current connections in module and pack assemblies

• Cooling plate isolation: Electrically isolate conductive thermal management components from cell contact surfaces

• Temperature range -40°C to +150°C: Stable dielectric properties across BESS operating conditions

PET-based constructions provide the optimal balance of dielectric strength, dimensional stability, and cost-effectiveness for utility-scale installations. For applications requiring high-temperature performance and electrical insulation, we offer specialized constructions that address the CTI limitations of standard polyimide films.

BESS manufacturers face aggressive timelines, automation requirements and cost pressures. Material selection directly impacts throughput and total cost of ownership.

PSA tape vs. liquid adhesive vs. mechanical fasteners

Instant bonding with no cure time

• PSA tapes bond on contact with pressure activation
• Liquid adhesives require significant cure cycles before handling
• Mechanical fasteners add more mass, space and assembly steps

Automated assembly compatibility

• Die-cut tape components integrate directly into robotic pick-and-place systems
• Liquid dispensing requires dedicated equipment, mixing controls and quality checks
• Mechanical fasteners require tooling changes when the design is modified.

Dimensional precision for tight tolerances

• Laser die-cutting delivers ±0.1mm accuracy for cell wrapping and barrier placement
• Liquid adhesive beads vary in thickness and will ooze if sufficient material is applied
• Mechanical fasteners create stress concentration points

No volatile emissions or mixing equipment

• PSA tapes are ready-to-use, solvent-free solutions
• Two-part liquid adhesives require ratio control, pot life management and may require ventilation systems
• Mechanical assembly can create pinch points and may require multiple different parts

Supply chain simplification

• Single SKU per application with guaranteed shelf life
• Liquid systems require separate resin, hardener and dispensing consumables
• Fastener assembly requires matching hardware, washers and thread-locking compounds

BESS safety standards continue to tighten following high-profile thermal events. NFPA 855 now mandates Hazard Mitigation Analysis (HMA) for nearly all installations, while UL® 9540A has introduced stricter test requirements in its latest edition.

Our BESS tape solutions meet critical industry standards:

• Flame-retardant tapes help maintain flammability ratings for multi-material solutions

• UL® 9540A thermal runaway test method compliance can be unlocked by laminating multiple thermal barriers together to support system-level fire safety testing at cell, module, unit and installation scales

• NFPA 855 material selection requirements - Flame-retardant constructions that address prescriptive requirements for materials in direct contact with energized battery components

• IEC 60112 comparative tracking index (CTI) - Volt Tough™ tapes achieve Material Group I classification (CTI ≥600V) for high-voltage applications with minimal creepage distances

• ASTM D3755 dielectric breakdown voltage - Tested insulation performance for voltage ratings relevant to utility-scale BESS systems exceeding 1,000V DC

For thermal runaway protection:

• Cell-to-cell thermal barriers: Flame Tough™ acrylic PSA for aerogel encapsulation and thermal barrier bonding in prismatic LFP cell modules

• Inter-module fire barriers: High-temperature PSA with ceramic paper or intumescent materials for pack-level protection

• Vent path sealing: Flame-retardant tapes with pressure-sensitive adhesive for controlled thermal event gas management

For electrical insulation:

• High-voltage cell wrapping: Volt Tough™ PET film tape with acrylic adhesive, CTI 600V, dielectric strength >200 kV/mm

• Busbar and cell connection electrical insulation: Polyester film tape with rubber adhesive for irregular surfaces and high-temperature exposure

• Component isolation: Die-cut insulation pads for cooling plates, module frames, and conductive structural elements

For compression and gap filling:

• Cell swelling management: Flame-retardant polyurethane foam with acrylic PSA, multiple densities for pouch and prismatic cell formats

• Module-to-housing sealing: Closed-cell foam tape with weather-resistant adhesive for containerized outdoor BESS installations