Month: April 2025

Applications of Pressure-Sensitive Adhesive Solutions for Batteries

Pressure-sensitive adhesives (PSAs) have long provided a reliable and affordable way to assemble cartons and seal packages and bags. More recently, they have become indispensable for high-capacity battery applications, such as EVs, due to several unique characteristics. For example, PSAs are flexible, lightweight, quick to apply and form a bond, not vulnerable to vibrations or impact, and can be formulated for high heat resistance. They are also versatile and can be applied as transfer tape, single- or double-coated with a carrier, and with or without liners.

As vehicle powertrain electrification continues to grow and EV demand increases, the need for adhesive-for-battery materials is also expanding. PSAs have a range of uses including dielectric insulation, flame retardance, mounting and spacing, thermal management, and more. What’s more, these advanced adhesive materials are compatible with automated manufacturing processes and equipment.

TPC Converting is a leading supplier for the EV industry. We offer a variety of options for tapes and die-cut products that can be used to adhere and seal battery cell and system components.

Here, we’ll look at what makes EV battery tapes and other PSAs powerful tools in battery pack technology, and some common ways they are used.

Thermal Management

EV battery packs contain thermal interface materials that dissipate heat and maintain safe operating temperatures. Materials like ceramic and mica help control excess heat propagation, while graphite heat spreader sheets dissipate heat within cells. These materials can be adhered with PSA tape for a permanent, lightweight bond.

Flame retardant adhesives help prevent thermal runaway and fire within battery systems. Certain adhesives can also be used to laminate or encapsulate thermal management materials to keep them free from dust and lint, further reducing the risk of fire.

TPC’s selection of thermal management PSA materials includes:

Electrical Insulation

EV batteries have specific breakdown voltage requirements that call for adequate electrical insulation. PSA tapes with facestock and filmic carriers have high dielectric strength and offer excellent insulation with both steel and aluminum components and busbars.

Flexible PET carrier material makes it possible to fully wrap components for secure protection, and they are compatible with automated manufacturing processes, including vision inspection cameras.

These products feature:

Mounting, Spacing, and Sealing

Pressure-sensitive adhesives for EV battery packs must firmly secure a wide range of components in place inside and between cells, including flame barriers and insulation sheets, heat spreader plates, spacers, gaskets and seals, and battery enclosure components. Cables and wires can also be wrapped or secured with adhesive tapes to organize them and protect them from abrasions.

The advantages of using PSA materials for mounting and securing components include:

Grounding and EMI Shielding

PSAs are used to adhere conductive foams that ground battery systems by isolating them from the vehicle chassis. Foams also provide protection from electromagnetic interference (EMI) from nearby electronics by blocking or filtering EM radiation or filling any tiny gaps between components that can occur even with the tightest tolerances and excellent part fit.

Unlike glue, adhesive tapes stay where they are applied for precise placement of these critical materials without leakage or runout. They are also flexible and adjust to contours, corners, and other profiles.

Contact TPC Converting for PSAs for EV Battery Applications

Effective thermal management, electrical insulation, and component mounting are essential to keeping battery cells and packs safe and functional during operation. TPC Converting supplies a range of EV tape materials and custom die cut product capabilities for EV and other automotive applications.

Contact us to learn about our products and services, or to discuss your EV battery or e-mobility application.