Electrical insulation of EV batteries with adhesive tapes

      The Importance of Electrical Insulation for EV Batteries

Lithium-ion batteries are the heart of electric vehicles 🚗⚡.

However, without proper electrical insulation, they can become unstable and pose risks:

• Risk of short circuits between cells

• Overheating that can lead to thermal runaway

• Premature wear of internal components

Effective technical solutions exist to protect batteries and extend their lifespan:

• Ultra-resistant insulating adhesive tapes

• Vibration-absorbing foams that protect cells

• High-performance polymer films

These materials provide reliable electrical insulation in a lightweight form and are already adopted by leading battery manufacturers.

      Our Solutions for Effective Electrical Insulation

How to effectively protect an electric battery? Insulation is not just a simple coating. It needs to be applied at multiple levels:

1️⃣ Battery Cell Insulation

Each cell must be individually insulated to prevent any internal short circuits and ensure safe operation.

• High-temperature polyimide tapes ➝ Protect electrodes from stray discharges.

• High-voltage insulating films ➝ Limit electrical interference.

• Vibration-absorbing foams ➝ Reduce mechanical wear of cells.

📌 Example: A UL94 V0 polyimide tape placed around the cells prevents any unwanted contact between conductive components.

2️⃣ Insulation of Battery Modules and Packs 

Cells are grouped into modules, then assembled into battery packs. These modules require reinforced insulation to:

✔ Limit electrical interference between cells.

✔ Prevent the spread of thermal runaway.

✔ Ensure the stability of the electrical field in the battery pack.

• Polyester (PET) tapes to separate cells.

• Fire-resistant polymer films conforming to safety standards.

• Insulating and cushioning foams to reduce the impact of vibrations.

📌 Example: A UL94 V0 polymer film between modules prevents any electrical arcs and enhances the reliability of the battery pack.

3️⃣ Insulation of Bus Bars and Electrical Connections

Bus bars carry energy between modules and require effective insulation to:

✔ Reduce energy loss.

✔ Prevent uncontrolled electrical discharges.

✔ Improve the lifespan of electrical connections.

• High-performance PET tapes ➝ Optimal protection of connections.

• High-voltage polymer films ➝ Advanced dielectric insulation.

• Solutions conforming to UL94 V0 and IEC 62619 standards.

📌 Example: An insulating PET tape applied on a bus bar limits electrical losses and ensures a more stable energy transmission.

      What Materials for Which Battery?

🔎 Not sure which material to choose? Here is a quick guide based on the type of battery:

	Battery Type	Meilleures solutions d’isolation	Pourquoi ?
	Cylindrical EV Battery	Polyimide tapes + silicone foams	Enhanced thermal and electrical resistance
	Pouch Cells EV Battery	UL94 V0 tapes + PET films	Weight reduction and safety improvement
	Prismatic EV Battery	Fire-resistant tapes + cushioning foams	Increased stability and vibration reduction
	Solid Electrolyte EV Battery	Polymer films + high-strength tapes	Better insulation and improved longevity