High-performance materials for battery systems

From thermal safety and electrical insulation to structural bonding: our solutions for battery systems offer maximum performance combined with maximum sustainability.

Whether material selection, system consulting or security of supply - we support you along the entire value chain with suitable solutions for your battery applications.

Thermal management

Thermal Runaway Propagation Protection
Thermal runaway remains one of the most critical risks in battery systems. Our high-temperature-resistant flame barrier materials provide effective protection against the propagation of thermal events:

  • FiberCork - a sustainable multilayer material certified according to UL 2596 Torch & Grit Test. Lightweight, robust, and ideal for battery storage applications. More about FiberCork
  • Flame retardant and technical films & tapes - versatile solutions for thermal protection and electrical insulation, customisable.


Thermal Interface Materials - managing heat effectively
Thermally conductive gap fillers, pads and pastes ensure efficient heat transfer between the cell module and the cooling structure. In our overview table you will find solutions for a wide range of requirements in terms of conductivity, mouldability, compressibility and type of application.

Material for thermal propagation protection
product Breakdown voltage [KV] Thickness [mm] Protection level [°C] Thermal conductivity [W/mK] CTI Flame class
FiberCork 5-15 1.4-5 700-1,200 °C
(>10 min, torch test)
0.118 - UL 2596 TaG
FiberCork+ 5-15 1.8-5 700-1,200 °C
(>10 min, torch test)
0.092 - UL 2596 TaG
Calin 142 - 1.8-10 1,000 °C 0,08 - -
3M FRB NT 1.1-8 0.076-0.381 IEC 60695-2-1
Glow wire flammability index
(GWFI) 960°C
0.15-0.25 600 UL 94 V-0.5VA
Wevosil 22027 FL -   1,000 °C short term 0.2 - UL 94 V-1

 

Materials for thermal interfaces
Product Thermal conductivity [W/mK] Type Shore hardness Viscosity [mPa*s] Temperature [°C] Flame class Hardening time [h]
Wevosil 26040 Fl 4.0 Silicone Shore 00 60-80 100,000 - 150,000 -60°C to +200 UL 94 V-0 4
tesa® 58326 2.0 Acrylic thermal tape
1.2mm, 15KV
Shore 00 87STK -, solid tape -40 to +100 - -
tesa® 58395 0.6 Acrylic thermal tape
0.25mm, 4KV
Shore 00 70
STK
-, solid tape -40 to +125
(+150 short term)
- -

 

High-voltage insulation & busbar protection
Electrical insulation

For high-voltage applications, we offer electrical insulation materials with excellent dielectric strength, partial discharge resistance and mechanical robustness. Whether as flexible insulating film, customised precistion die-cut parts or as protective busbar sleeves - our solutions safeguard your systems on all levels.

Materials for electrical insulation
Product Material Breakdown voltage [KV] Thickness [mm] Temperature [°C] CTI (V) Flame class UL file
Hostaphan® PET film 4.5-30 0.019-0.500 -70 to 150 - - E53895
Melinex® 238 PET film 16-26 0.125-350 -70 to 150 ≥ 600 VTM-2 E93687
Mylar® A PET film 6.1-21 0.019-0.350 -70 to 150 400-599 VTM-2 E93687
SynTherm® P PET film 4.5-26 0.023-0.350 -40 to 140 - - -
Nomex® 410 Aramid paper 0.9-20 0.05-0.760 -190 to 180 175-249 UL 94 V-0 E34739
SynTherm® YT510 Aramid paper 0.65-14.4 0.05-0.760 -190 to 180 400-599 UL 94 V-0 / VTM-0 E358562
Kapton® HN PI film (polyimide) 7.5-19.25 0.025-0.125 -190 to 240 100-175 UL 94 V-0 E39505
SynTherm® H PI film (polyimide) 3.75-22 0.025-0.200 -190 to 240 100-175 UL 94 V-0 E358562
Formex GK PP film (polypropylene) 11-41 0.127-1.57 up to 115 ≥600 UL 94 V-0 / VTM-0 E121855
SynTherm® HV-D ETFE film (ethylene tetrafluoroethylene) 17-29 0.1-0.25 -40 to 150 ≥600 VTM-0 -
Teonex® Q5100 PEN film (polyethylene naphthalate) 9.6-28.7 0.012-0.250 -40 to 160 175-249 UL 94 VTM-2 E51743
Lexan FR700 PC (polycarbonate) 14-44 0.250-0.750 -40 to 150 - UL 94 V-0 E121562, E207780, E45329

 

Electrical insulating tape (adhesive on one side)
Product Film material Adhesive Film thickness/
total thickness [mm]
Breakdown
voltage [KV]
Tempera-
ture [°C]
Flame class UL file
DuPont Kapton® polyimide film (Intertape® 4118) Polyimide tape / Kapton® silicone 0.025 / 0.067 7 -60 to +260 UL 510 E20780
SynTape® H/560 Polyimide tape / Kapton® silicone 0.025 / 0.060 6 up to +180 UL 510 -
SynTape® H/660 Polyimide tape / Kapton® silicone 0.050 / 0.065 10 up to +180 UL 510 -
Isotape® 4419PV3 Polyimide tape / Kapton® silicone 0.050 / 0.090 8 -73 to +260 - -
Intertape® 4616 Glass fabric rubber 0.127 / 0.178 2.5 up to +155 BU 2 E20780
Intertape® 4617 Glass fabric acrylic 0.127 / 0.178 3 up to +155 BU 2 E20780
Intertape® 4618 Glass fabric silicone 0.127 / 0.178 2.5 up to +200 BU 1 E20780
Isotape® 4637PV3 Glass fabric acrylic 0.145 / 0.180 2.5 up to +155 - E315249
Isotape® 4638PV3 Glass fabric silicone 0.125 / 0.190 4 up to +200 - E315249
SynTape® B 616/ GL.95 Glass fabric rubber 0.120 / 0.170 2.5 up to +130 - E178430
SynTape® F 562/ GL.94 Glass fabric acrylic 0.120 / 0.165 2.5 up to +155 - E178430
SynTape® H 618/ GL.96 Glass fabric silicone 0.120 / 0.170 2.5 up to +180 UL 510 E178430
SynTape® X50

Aramid / Nomex®
Aramid + polyimide

acrylic 0.050 / 0.100 2.5 up to +155 - E178430
SynTape® X80

Aramid / Nomex®
Aramid + polyimide

acrylic 0.080 / 0.120 3.8 up to +155 - -
SynTape® 6455

Aramid / Nomex®
Aramid + polyimide

rubber 0.080 / 0.135 7 - - -
Bonding, sealing, damping
Structural adhesives

Structural adhesives do more than just bond components: they seal, compensate for mechanical stresses, and reduce vibration. Our materials are engineered to meet the dynamic requirements of battery modules – from cell to spacer to module frame.

Materials for bonding and sealing
Material Carrier Adhesive Backing thickness /
Total thickness [mm]
Breakdown
voltage [KV]
Adhesion to steel [N/cm] Temperature °C Flame class
SynTape® S2 AG100 none (transfer tape) acrylic 0 / 0.100 - 10 after 24 h -40 to +200 -
SynTape® S20011 none (transfer tape) acrylic 0 / 0.50 - 8 after 24 h -40 to +180 -
SynTape® A16-320 PET fleece, 12 g/m² acrylic 0.100 / 0.100 - 6.4 -40 to +100 -
3M no. 4646F none (transfer tape) acrylic 0 /0.6 - 25 -35 to +150 -
H220 H-Old Kapton® silicone 0.025 / 0.100 7 2.7 +180, short-term + 260 UL 510
ATP S- 4610 FR PES/PVA fabric acrylic 0.09 / 0.100 - 6 after 24h -40 to +140 VTM-0
tesa® 58374 PET acrylic 0.069 / 0.100 6 8.2 / 9.2 after 14 d +125 short term +200 UL94 VTM-0
tesa® ACXplus 76730
Box Seal
Acrylic foam acrylic 2.8 - 5 1,050 (5 minutes) -
Materials for cell wrapping (cell insulation)
Product Film material Adhesive Film Thickness /
Total Thickness
[mm]
Breakdownvoltage*
[KV]
Adhesion to
steel
[N/cm]
CTI [V] UL file
tesa® 58352 Cell
Wrapping
PET tape Acrylic 0.023/0.085 7 4.5 400 backing /
600 adhesive
-