Avery Dennison tape solutions for battery energy storage systems include adhesives engineered for thermal runaway protection, high-voltage insulation and no-cure assembly. U.S.-manufactured to meet UL® test standards.
A battery energy storage system stores electrical energy in rechargeable batteries and releases it when the grid or a facility needs it. Most large systems use lithium iron phosphate (LFP) cells grouped into modules, packs and containerized units, from grid-scale installations down to commercial sites. Inside each unit, adhesive tapes bond and insulate the cells, barriers and connections that keep the system safe and stable.
Our functional tape portfolio addresses the three core material challenges in BESS design, assembly and performance.
Acrylic- and rubber-based adhesives with Flame Tough™ flame-retardant adhesive properties allow composites and materials to meet UL®94 V-0 and other flame requirements.
Single-coated Volt Tough™ tapes and double-coated tapes which incorporate dielectric films. Our materials and adhesives are tested for breakdown voltage and dielectric strength requirements using GB/T 1408.1-2016 and ASTM D3755 test methods.
Functional tapes can replace liquid adhesives and mechanical fastening methods while offering a thinner profile, lighter weight, repositionability and instant bond.
Battery energy storage systems (BESS) face a critical challenge: thermal runaway propagation between cells can cascade through entire modules in seconds. Thermal barriers, mica sheets, aerogel pads and ceramic paper are the proven solution, but these materials are fragile, shed fibers or crumble during handling and assembly.
Unlike liquid adhesives that require mixing, dispensing equipment, and cure time, PSA tapes deliver instant bonding for automated assembly lines. Die-cut precision eliminates waste and enables camera/vision system detection with colored variants.
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
Automated assembly compatibility
Dimensional precision for tight tolerances
No volatile emissions or mixing equipment
Supply chain simplification
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
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
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
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
Our applications engineering team provides material selection guidance, die-cut design optimization and testing support for BESS applications.
Product specifications and test data for thermal, electrical and mechanical properties
Die-cutting and converting partner network for prototype and production volumes
Thermal runaway barrier encapsulation design guide
Whether you're designing next-generation utility-scale storage or optimizing existing battery pack assembly processes, our team can help you select the right PSA tape solutions.
Request technical consultation:
Thermal barrier bonding and encapsulation solutions
Dielectric tape selection for high-voltage insulation
Die cut component design for automated assembly
Domestic content verification for IRA compliance
Custom product development for specialized BESS applications
2 mil clear biaxially oriented polyethylene terephthalate (BOPET) with blue pigmented acrylic adhesive. The adhesive provides electrolyte resistance/compatibility. This product is intended as electrical insulation for prismatic and cylindrical cell wrapping for energy storage and electric vehicles.
2 mil clear biaxially oriented polyethylene terephthalate (BOPET) with yellow pigmented acrylic adhesive. The adhesive provides electrolyte resistance/compatibility. This product is intended as electrical insulation for prismatic and cylindrical cell wrapping for energy storage and electric vehicles.
Specially designed, high-quality PET material with good fire resistance and insulation properties. Features a permanent, acrylic-based adhesive.
FBA 8960 is a 4.0 mil double-coated polyester with a modified acrylic adhesive. It bonds well to low surface energy materials and has good foam bonding properties.
FM 2333 is a 36 mil double-coated white polyethylene foam with a modified acrylic adhesive. Bonds well to low surface energy materials and can fill gaps. Commonly used in general industrial foam applications.
Yes. Our pressure-sensitive adhesive tapes are formulated to maintain adhesion and dimensional stability across the full BESS operating range of -40°C to +150°C. High-temperature grades are rated to 220°C for applications near cell venting zones or thermal management components subject to repeated cycling.
Outdoor and containerized installations introduce moisture, condensation and temperature swings that can degrade standard adhesives over time. Our closed-cell foam tapes and weather-resistant constructions are selected specifically for module-to-housing sealing in these environments, providing long-term adhesion without corrosion risk or seal degradation.
The majority of our BESS tape solutions are U.S.-manufactured, which can support your compliance documentation for domestic content verification. Our applications engineering team can provide the relevant country-of-origin documentation needed for project-level compliance reporting.