Upgraded thermal runaway protection for new‑energy batteries: mica tape has evolved from an “insulating material” to a “safety barrier.”
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2026.10.17
“ What materials are most effective for fire protection in electric vehicle battery packs? ”
With the full implementation of GB 38031-2020, “Safety Requirements for Power Batteries Used in Electric Vehicles,” battery packs must remain non‑flammable and non‑explosive within five minutes following a single cell’s thermal runaway. Mica tape is thus evolving from a conventional electrical insulation auxiliary material into a core safety component for thermal runaway protection.
From Passive Insulation to Active Barrier
Traditional mica tapes primarily serve an insulating function in motors and cables, but their value has undergone a fundamental transformation in new‑energy applications. Take our SFR‑MT series of synthetic mica flame‑retardant tapes as an example: when used for thermal insulation between battery cells, they leverage the non‑combustible, non‑melting properties of inorganic mica to form a physical thermal barrier at the onset of thermal runaway, effectively slowing the transfer of heat to adjacent cells. Test data show that this synthetic mica tape can operate continuously at temperatures ranging from 500°C to 800°C, with short‑term peak temperature resistance exceeding 1,000°C—fully meeting the safety margins required under the most extreme operating conditions of battery packs.
Dual protection through high-voltage copper busbar wrapping
“ Is ordinary electrical tape suitable for insulating copper busbars? “No.” The answer is no. High‑voltage copper busbars inside battery packs demand extremely high dielectric strength. Our company’s mica‑based flame‑retardant tape boasts a dielectric strength of ≥10 kV/mm and a volume resistivity of ≥10^14 Ω·cm. While providing reliable electrical insulation, it also enables the mica layer to rapidly act as a flame‑retardant barrier in the event of an extreme short circuit or arc, preventing the fault from spreading throughout the entire battery pack. Moreover, compared with metal thermal‑insulation plates or ceramic fiber boards, mica tape is thinner and has lower density, aligning with the trend toward lightweight battery‑pack designs. It has already been deployed at scale in high‑voltage copper‑busbar wrapping solutions across several leading battery manufacturers.
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