Inside the battery pack of a new energy vehicle,the high-voltage copper busbars act like the main arteries of the human body,carrying hundreds to thousands of volts of DC high voltage and peak currents at the kiloamp level.However,as battery energy density continues to rise and voltage platforms move toward 800V and beyond,the insulation and fire safety of busbars face unprecedented challenges.Traditional PVC or PET tapes have a temperature resistance of only 80–130°C and tend to soften and drip when exposed to fire.Mica tape,while fire-resistant,absorbs moisture,sheds powder,and is prone to delamination under prolonged vibration.Against this backdrop,ANDI ceramic silicone self-adhesive tape—with its unique properties of"soft and self-adhesive at room temperature,transforming into ceramic when exposed to fire"—is becoming the preferred solution for an increasing number of battery manufacturers and wiring harness factories.

 

　　ANDI Ceramic Silicone Tape uses ceramic silicone rubber as its base material.At room temperature,it is no different from ordinary silicone tape—only about 0.3 mm thick,soft and flexible,and can be wrapped manually or semi-automatically like everyday tape.Its volume resistivity is≥10¹⁴Ω·cm,dielectric strength≥25 kV/mm,and tensile strength≥60 N/10mm.In daily use,it reliably isolates copper busbars from adjacent aluminum busbars,sheet metal,and signal sampling wires,while resisting moisture and aging.It easily passes 1,200 hours of double 85(85°C/85%RH)testing without delamination.

 

　　What truly sets this product apart is its"transformative"ability under extreme high temperatures.When thermal runaway occurs in the battery pack and flame temperatures reach 300–500°C,the tape rapidly initiates a ceramic conversion reaction.At around 450°C,a dense ceramic hard shell forms on the surface.Even under direct flame impingement at 1000°C,it does not melt or drip.Its high-temperature insulation resistance remains above 500 MΩ,and dielectric strength exceeds 5 kV.This is equivalent to instantly generating an inorganic ceramic sleeve around the copper busbar,blocking direct flame exposure,preventing tracking and short circuits,and buying valuable time for the high-voltage relay to disconnect and for occupants to evacuate.

 

　　In actual vehicle applications,ANDI Ceramic Silicone Tape is mainly applied to high-voltage busbars between modules,copper-to-aluminum transition joints,parallel sections of main wiring harnesses inside the battery pack,and the roots of connectors.Installation is extremely simple:just degrease and clean the busbar surface,peel off the release film,stretch the tape by 5%–10%,wrap it in a half-lapped pattern,and press down the end.No heating or molding is required,making it more convenient than threading ceramic tubes and easier to repair than spray coatings.

 

　　Regarding selection and installation,the industry has established best practices:for high-voltage platforms above 800V,it is recommended to use double-sided ceramic silicone composite tape such as the Ceramic Silicone Tape series,with at least two layers in a single wrap.If the busbar has punched burrs,they should be polished smooth or a thin PET layer placed underneath to prevent puncturing the tape.On automatic wrapping lines,the stretch rate should be kept below 15%to avoid micro-cracks during high-temperature ceramic conversion.The product itself is halogen-free,low-smoke,with a flammability rating of FV-0,and certified to RoHS/REACH/ELV standards.At approximately 0.3 mm thick—more than half thinner than traditional mica tape—it saves space and does not shed powder,making it highly suitable for the compact layouts of CTP/CTC battery packs without modules.

 

　　In summary,the application of ANDI Ceramic Silicone Tape essentially upgrades the protection strategy for automotive copper busbars from"passive leakage prevention"to"active fire-triggered ceramic formation."It keeps the busbars thinly insulated during normal operation and instantly transforms into a hard ceramic armor in the event of extreme thermal runaway.As high-voltage fast charging and high-capacity batteries become mainstream in the industry,this material—which"stays invisible during normal use but reveals its true value in emergencies"—is gradually evolving from an optional add-on to a standard outer layer for high-voltage copper busbars.