Mica Tape Insulation: Safety Design & Application for Power Battery Electrical Protection
Electrical Protection of Power Batteries: Safety Design of Mica Tape Insulation
With the rapid development of new energy vehicles and energy storage systems, the electrical safety and thermal safety of power batteries have become core concerns in the industry. Featuring excellent electrical insulation, high temperature resistance, flame retardancy and stable chemical properties, mica tape has emerged as the preferred solution for insulation protection of high-voltage components, electrical bus bar, cells and modules in power batteries. It can effectively reduce the risks of short circuits, electric arcs and thermal runaway propagation, and improve the long-term reliability of battery systems.
Dense layout of high-voltage electrical bus bar, connectors and wiring harnesses leads to risks of creepage, arcing and short circuits.
Sustained heat generation during charge-discharge cycles, combined with rapid temperature rises under extreme operating conditions, easily causes aging, softening and failure of conventional insulation materials.
Vibration, extrusion, hot and humid environments can degrade the adhesion and integrity of insulation layers, creating long-term potential hazards.
New national standards impose stricter requirements on safety performance after thermal propagation, bottom impact and fast-charging cycles, demanding insulation materials that deliver both electrical insulation and thermal protection capabilities.

PART.02
High Dielectric Strength for Reliable Electrical Isolation
High Temperature Resistance & Flame Retardancy to Inhibit Thermal Runaway Propagation
Excellent Chemical Stability for Harsh Battery Environments
Flexible & Easy to Process for Complex Structures
Material Selection Matching Application Scenarios
- High-voltage electrical bus bar & power wiring harnesses: Select mica tape with high mechanical strength and stable high-temperature resistance, balancing insulation performance and vibration resistance.
- Thermal insulation between cells / modules: Use low thermal conductivity grade to enhance both thermal insulation and electrical isolation.
- High-temperature zones & fast-charging systems: Prioritize products with outstanding high-temperature resistance to adapt to temperature rise caused by high-frequency fast charging.
Structural and Process Design Specifications
- Lapping process: Control tension and overlap width to ensure tight lamination between layers, avoiding gaps, wrinkling and damage.
- Thickness matching with voltage: Determine insulation thickness based on system voltage level, creepage distance and safety margin; properly increase safety margin in high-temperature and vibration environments.
- Interface treatment: Ensure firm adhesion to metal conductors and structural parts, no delamination or displacement under high temperature and vibration, maintaining long-term insulation effectiveness.
Coordination with Thermal Management and Structural Protection
- The insulation layer shall not block normal heat dissipation paths; cooperate with thermal interface materials to optimize heat dissipation, balancing insulation and temperature control requirements.
- Cooperate with the casing and buffer structures to improve vibration and extrusion resistance, realizing multi-dimensional protection of electricity, heat and mechanics.
- Comply with relevant ISO, IEC and GB standards, and pass reliability verification such as voltage withstand, heat resistance, humidity-heat test and vibration test to ensure design compliance and safety.

PART.04
High-Voltage electrical bus bar Insulation
Wiring Harness & Connector Protection
Cell / Module Isolation
Energy Storage Battery Systems
Mica Insulation Design – Reliable Electrical Safety for Power Batteries


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