Key Takeaways
- Mactac has launched CleanTape® FR, a new series of non-halogenated flame-retardant adhesive tapes designed to enhance safety in electric vehicle (EV) batteries and energy storage systems.
- These advanced tapes are engineered to mitigate fire risks within battery packs, a critical concern as EV adoption rapidly increases globally.
- The CleanTape® FR portfolio also addresses significant engineering and assembly challenges faced by manufacturers in EV production.
- A dedicated webinar on September 17, 2026, will delve into EV battery fire risks, key safety standards, tape applications, and the unique performance advantages of CleanTape® FR.
- This presentation is part of the larger Virtual Conference on EV Engineering, broadcast live from September 14 to 17, 2026, covering the entire EV engineering supply chain.
As the global automotive industry rapidly shifts towards electrification, the widespread adoption of electric vehicles (EVs) has placed unprecedented emphasis on battery safety. Ensuring the integrity and thermal stability of EV battery packs is paramount, driving innovation in materials science and engineering across the supply chain.
In response to this critical need, Mactac, a leading adhesive solutions provider, has unveiled its latest innovation: CleanTape® FR. This new portfolio of non-halogenated flame-retardant adhesive tapes is specifically engineered to bolster battery pack safety while simultaneously resolving complex engineering and assembly hurdles faced by EV and energy storage manufacturers.
Addressing the Imperative of EV Battery Safety
The acceleration of EV integration into mainstream transportation underscores a fundamental challenge: managing the inherent risks associated with high-energy battery systems. Lithium-ion batteries, while powerful and efficient, pose potential fire hazards, particularly in scenarios involving thermal runaway. Thermal runaway is a critical condition where an increase in temperature causes a further increase in temperature, leading to a cascading failure that can result in fire or explosion.
Mitigating these risks requires a multi-faceted approach, integrating advanced cell chemistry, robust battery management systems (BMS), sophisticated thermal management solutions, and the strategic use of passive safety components. Among these, specialized adhesive solutions, particularly those offering flame-retardant properties, play an indispensable role in preventing or containing thermal events within battery packs.
Understanding Fire Risks in Battery Packs
EV battery packs are complex assemblies comprising thousands of individual cells, modules, intricate wiring, and cooling systems. A localized thermal event, such as an internal short circuit or external impact, can trigger thermal runaway in one cell. Without adequate protective measures, this event can propagate rapidly to adjacent cells and modules, leading to a catastrophic battery fire.
Materials used within the battery pack construction must therefore exhibit exceptional fire resistance and thermal stability. This includes everything from cell separators and module housings to the adhesives that bond various components, highlighting the critical function of robust flame-retardant tapes in enhancing overall system safety.
Introducing CleanTape® FR: A New Standard for Protection
Mactac’s CleanTape® FR represents a significant advancement in material science for EV applications. The term ‘non-halogenated’ is crucial here, indicating that these tapes achieve their flame-retardant properties without the use of halogen-containing compounds like bromine or chlorine. Traditional halogenated flame retardants, while effective, can release toxic and corrosive gases when burned, posing environmental and health concerns.
By opting for a non-halogenated formulation, CleanTape® FR offers a safer and more sustainable solution, aligning with stringent environmental regulations and the automotive industry’s growing commitment to greener manufacturing practices. These advanced flame-retardant tapes are designed to provide a protective barrier, slowing down or preventing fire propagation within the battery pack.
Performance Advantages and Engineering Solutions
Beyond their superior fire resistance, the CleanTape® FR portfolio is engineered to tackle specific engineering and assembly challenges inherent in EV battery manufacturing. Modern battery packs demand precise component placement, reliable adhesion in demanding thermal cycling conditions, and efficient production processes.
These flame-retardant tapes are formulated to offer excellent adhesion to a variety of substrates commonly found in battery packs, including plastics, metals, and composite materials. Their design facilitates efficient application, contributing to streamlined assembly lines and improved manufacturing throughput. The unique performance advantages of CleanTape® FR differentiate it in a competitive market, providing manufacturers with a reliable and compliant solution.
Applications Across EV and Energy Storage Systems
The versatility of CleanTape® FR extends its utility across numerous critical applications within both electric vehicle battery packs and stationary energy storage systems:
- Cell and Module Insulation: Providing electrical isolation and thermal management around individual battery cells and modules.
- Thermal Management Component Attachment: Securing components of the cooling system, such as cooling plates or tubes, to ensure optimal heat dissipation.
- Wiring Harness Protection: Wrapping and protecting delicate wiring harnesses within the battery pack, preventing short circuits and offering fire resistance.
- Structural Bonding: Contributing to the overall structural integrity of the battery pack, particularly in areas requiring enhanced fire protection.
- Ventilation and Pressure Relief Systems: Sealing and protecting critical pathways for gas release during off-gassing events, while maintaining flame resistance.
The robust design of these flame-retardant tapes ensures long-term performance and reliability in the harsh operational environments of EVs and energy storage facilities, where extreme temperatures, vibrations, and chemical exposures are common.
Navigating Key Safety Standards and Regulations
The development of flame-retardant tapes like CleanTape® FR is intrinsically linked to evolving global safety standards for EV batteries. Regulatory bodies worldwide, including those issuing UN 38.3, ECE R100, and various UL standards, continually refine requirements for battery safety, focusing on preventing thermal runaway propagation, electrical safety, and fire containment.
Manufacturers are under increasing pressure to design and produce battery systems that not only meet these rigorous standards but also exceed them, building consumer confidence and ensuring passenger safety. Materials like Mactac’s non-halogenated flame-retardant tapes play a pivotal role in enabling battery designers to achieve compliance and enhance the inherent safety of their designs, contributing significantly to the trustworthiness and market acceptance of new EV models.
Deep Dive into Solutions at the Virtual Conference on EV Engineering
Industry professionals seeking an in-depth understanding of these advancements are invited to a special webinar presentation on Thursday, September 17, 2026, at 11:00 am EDT. This session will provide comprehensive insights into EV battery fire risks, the current landscape of key safety standards, practical applications of flame-retardant tapes, and the distinct advantages offered by Mactac’s CleanTape® FR.
Registration for this informative session is free and highly recommended for engineers, designers, and manufacturers engaged in EV and energy storage development.
This webinar is a key highlight of the broader Virtual Conference on EV Engineering, an extensive digital event broadcast live from September 14 to 17, 2026. The conference offers a holistic view of the entire EV engineering supply chain and ecosystem. Attendees can explore a wide array of topics, including:
- Motor and power electronics design and manufacturing
- Advanced cell development and battery systems
- Comprehensive EV testing and measurement
- Powertrain optimization
- Innovative thermal management solutions
- Circuit protection strategies
- Wire and cable technologies
- EMI/EMC mitigation techniques
The conference also features numerous other sessions, offering valuable insights into crucial aspects of EV development, such as:
- Advancing Battery Safety Through Early Thermal Runaway Detection With Infineon Sensors
- Scalable And Cost-Efficient Testing Of State-of-the-Art Battery Management Systems
- CoolGaN™ Automotive Bidirectional Switch: Shaping Single-Stage On-Board Chargers
- Microseconds Matter: High-Fidelity FPGA Motor Models For Real-Time HIL Validation
- Simplifying Commercial EV Power Distribution With Integrated Off-the-Shelf Solutions
- From Lab To Vehicle: Driving Reliable Insulation Systems For E-mobility Innovation
- Driving Efficiency In EV Manufacturing: Ultrasonic Solutions For Critical Connections
- How To Test For Anti-Islanding In EV Chargers, OBCs, And V2G Systems
- Multiphysics Modeling Of Transport Phenomena In Cells With Gas Diffusion Electrodes
- Optimizing HV/LV Power Conversion For Next-Generation xEV Architectures
- Beyond Sealing: Extrusion And Co-Extrusion For Thermal, Electrical, And Sensing Applications
The Future of EV Battery Innovation
The introduction of solutions like Mactac CleanTape® FR underscores the continuous evolution in materials science dedicated to enhancing EV safety and performance. As the demand for electric vehicles continues its upward trajectory, the integration of advanced, environmentally conscious, and highly effective flame-retardant tapes will be indispensable for building safer, more reliable, and sustainable battery systems.
Innovations that address both safety and manufacturing efficiency are crucial for accelerating the transition to a fully electrified future. The upcoming webinar and the Virtual Conference on EV Engineering serve as vital platforms for industry leaders to share knowledge and explore the cutting-edge solutions driving this transformation.
Frequently Asked Questions (FAQ)
What is Mactac CleanTape® FR?
CleanTape® FR is a new series of non-halogenated flame-retardant adhesive tapes developed by Mactac. These tapes are specifically designed to enhance the safety of battery packs in electric vehicles and energy storage applications by mitigating fire risks, particularly those related to thermal runaway.
Why are flame-retardant tapes important for EV batteries?
As EV adoption grows, battery safety is paramount. Flame-retardant tapes serve as a crucial passive safety component within battery packs, helping to prevent or slow down the propagation of fire in the event of a thermal incident, thereby reducing the risk of catastrophic battery fires.
What does ‘non-halogenated’ mean in this context?
Non-halogenated refers to the absence of halogen-containing compounds (like bromine or chlorine) in the flame-retardant formulation. This makes CleanTape® FR a safer and more environmentally friendly option, as it avoids the release of toxic and corrosive gases typically associated with halogenated flame retardants during combustion.
Where are CleanTape® FR tapes applied within EV battery packs?
These tapes can be used in various critical areas, including cell and module insulation, securing thermal management components, protecting wiring harnesses, structural bonding within the pack, and sealing ventilation or pressure relief systems, all while providing enhanced fire resistance.
What engineering challenges do these tapes address?
Beyond fire safety, CleanTape® FR helps manufacturers overcome challenges such as achieving reliable adhesion across diverse materials, ensuring precise component placement, and supporting efficient, high-volume assembly processes that are essential for modern EV battery production lines.
How can I learn more about CleanTape® FR?
Mactac is hosting a free webinar on September 17, 2026, at 11:00 am EDT. This session will provide detailed information on EV battery fire risks, safety standards, applications, and the unique performance advantages of CleanTape® FR. Registration is available through the Virtual Conference on EV Engineering platform.