Acrylic Polyimide Tape for Cell Wrapping & Tab Fixation
Application Summary
Protecting battery cells and electrical interfaces in EV battery packs requires insulation materials that remain stable under high voltage, localized heat, electrolyte exposure, and long-term aging.
In cell wrapping and tab fixation processes, Acrylic Polyimide Tape is widely specified where electrical insulation, thermal stability, and chemical compatibility must be achieved without introducing silicone-related contamination risks.
While PET insulation tapes are commonly used for large-area cell wrapping driven by cost efficiency, Acrylic Polyimide Tape becomes critical at functional risk points, particularly around tab fixation, welding protection, and high-voltage interfaces, where thermal and electrical demands are significantly higher.
Common Problems (Failure Modes)
Edge Lift at High-Temperature Interfaces
During ultrasonic or laser welding near battery tabs, localized temperatures rise sharply.
Tapes with insufficient adhesive thermal resistance may experience edge lift, exposing conductive areas and compromising insulation integrity.
Adhesive Transfer & Contamination
Silicone-based adhesive systems may migrate or volatilize under heat, creating contamination risks inside battery modules.
Adhesive residue can interfere with downstream welding, sealing, or electrical contact reliability.
Moisture Sensitivity
Moisture ingress during cell wrapping or fixation can reduce adhesive performance and accelerate electrochemical degradation.
In high-humidity environments, unsuitable tapes may lose adhesion or contribute to corrosion at interfaces.
Electrolyte Compatibility
Battery electrolytes can chemically interact with certain adhesive systems.
Incompatible tapes may swell, soften, or lose adhesion during long-term exposure, leading to insulation failure inside the battery pack.
Ion Migration & Leakage Current
Excessive ionic content in adhesive systems increases the risk of ion migration under high voltage, potentially causing leakage current or localized electrochemical corrosion over extended service life.
Recommended Tape Types
Acrylic Polyimide Tape (Primary Recommendation)
Acrylic Polyimide Tape is specified for EV battery applications where thermal resistance, dielectric strength, and chemical stability must be balanced with silicone-free safety requirements.
Key characteristics:
Polyimide film backing ensures dimensional stability near welding zones
Acrylic adhesive system minimizes ionic contamination and silicone-related risks
Stable adhesion under localized heat and high-voltage stress
Compatible with electrolyte exposure when properly qualified
Typical uses:
Tab fixation and insulation
Welding protection near tabs (ultrasonic / laser)
High-voltage interface insulation
High-safety cell wrapping in premium or high-energy-density designs
PET Insulation Tape (Acrylic Adhesive)
PET insulation tape with acrylic adhesive is widely used for large-area cell wrapping, where temperature exposure is moderate and cost efficiency is a primary consideration.
Key characteristics:
Good dielectric insulation for bulk wrapping
Acrylic adhesive supports low ionic contamination requirements
Suitable for automated wrapping processes
Typical uses:
Large-area cell wrapping
General insulation inside battery modules
Applications without direct welding heat exposure
Selection Checklist
When selecting insulation tapes for EV battery applications, evaluate the following parameters:
Adhesive System: Acrylic adhesive preferred for silicone-free, low ionic risk environments
Dielectric Strength: Must meet high-voltage platform requirements (400V–800V systems)
Thermal Resistance: Required near tab welding and localized heat sources
Electrolyte Compatibility: No swelling, softening, or adhesion loss after electrolyte immersion
Moisture Resistance: Stable adhesion under humid conditions
Residue Control: Clean removal without adhesive transfer or contamination
Typical Tape Constructions
| Tape Type | Backing Material | Adhesive System | Typical Thickness | Dielectric Strength | Key Strengths | Typical Applications |
| Acrylic Polyimide Tape | Polyimide Film | Acrylic PSA | 0.05 mm | ≥ 5 kV | High thermal stability, low ionic risk, silicone-free | Tab fixation, welding protection, high-voltage insulation |
| PET Insulation Tape (Acrylic) | PET Film | Acrylic PSA | 0.06–0.10 mm | ≥ 4 kV | Cost-effective, good dielectric insulation | Cell wrapping, general module insulation |
Related Products
Acrylic Polyimide Tape Series
A full range of Acrylic Polyimide Tape designed specifically for EV battery insulation requirements.
Available options:
Multiple thicknesses and widths
Slit rolls for automated processes
Tight tolerance control for precision tab insulation
Commonly specified for:
Tab fixation and insulation
Welding protection zones
High-voltage battery interfaces
PET Insulation Tape (Acrylic Series)
PET-backed acrylic insulation tapes optimized for large-area wrapping and automated application.
Commonly specified for:
Cylindrical, prismatic, and pouch cell wrapping
Module-level insulation layers
Cost-sensitive production lines
Documents We Provide
TDS (Technical Data Sheet) and application Guidance
Evaluate Acrylic Polyimide Tape or PET Insulation Tape in your battery production line
Consult Our Engineers: Get application-specific recommendations for tab fixation and cell insulation design.
For battery insulation buyers comparing silicone and acrylic adhesive options, River Tape provides silicone and acrylic adhesive polyimide tape with custom width and bulk order support.