4 Ways Manufacturers Use Tape in Battery Thermal Management

As electric vehicles (EVs) and renewable energy solutions rise in prominence, the importance of efficient battery thermal management has become undeniable. One innovative and increasingly popular material aiding in this process is adhesive tape. Lightweight, flexible, and versatile, tape offers unique advantages over traditional solutions like screws, brackets, or liquid adhesives. Here are four ways manufacturers use tape to enhance battery thermal management:

1. Thermal Interface Materials (TIMs) for Heat Dissipation

Maintaining optimal temperature is critical for battery performance and longevity. TIMs facilitate heat transfer between the cold plate and battery module while minimizing the resistance of heat flow into, through, and out of an interface. Tape materials are sought after because of their unique design and flexibility that acts as effective thermal interface materials. These specialized tapes are designed specifically to keep batteries within their optimum temperature ranges, especially in unpredictable environments, TIMs reduce draw from battery power required for cooling and heating systems. 

• Advantages:
  • Lightweight, flexible  and easy to apply, eliminating the need for messy liquid adhesives.
  • Provides consistent thermal contact, improving heat dissipation.
• Top Recommendations:
  • Tesa 58326, 58327, 58328, 58394, 58395, 58399
  • 3M™ Thermally Conductive Acrylic Interface Pad 5571
  • 3M™ Thermally Conductive Tape 9890

2. Bonding and Sealing Battery Modules

Structural adhesive tapes are used to securely bond battery modules while providing a sealing function to prevent contaminants like dust or moisture from entering the assembly. Structural adhesive tapes provide flexibility and conformability which allows it to stick to a verity of substrate surfaces.

• Advantages:
  • Strong adhesion with flexibility to absorb vibrations during operation.
  • Helps create compact and lightweight battery designs by replacing bulky mechanical fasteners.

3. Electrical Insulation

Electrical insulation is a key requirement in battery pack design to prevent short circuits and ensure safety. Manufacturers use adhesive tapes with dielectric properties to insulate battery components while maintaining thermal performance.

• Advantages:
  • Acts as a dual-function material: thermal management and electrical insulation.
  • Reduces weight and complexity of the design compared to using separate insulating materials.
• Top Recommendations:
  • 3M™ Dielectric Tape 3514
  • Tesa 51407, 4163

4. Gap-Filling and Cushioning Solutions

High-performance tapes are also used to fill gaps between cells or modules in battery packs. These tapes can offer cushioning, thermal conductivity, and even flame-retardant properties, enhancing both safety and performance.

• Advantages:
  • Absorbs shocks and vibrations, protecting sensitive components.
  • Optimizes thermal distribution by ensuring consistent contact between cells.

Why Tape is a Game-Changer in Battery Thermal Management

The demand for safer, more efficient, and lightweight battery systems has driven manufacturers to explore innovative materials like adhesive tapes. Unlike traditional solutions, tapes streamline assembly processes, reduce overall weight, and offer multifunctional properties that improve both performance and safety.

As the battery industry continues to evolve, tape is proving to be a flexible, efficient, and sustainable option in thermal management—helping manufacturers meet the demands of a greener future.

Whether it’s cell-to-cell bonding, compression pads, or another electric vehicle or battery design you’re developing, Saunders’ team of engineers will help you get the job done.  

Fill out the form on this page and contact a Saunders converting specialist today.