Avery Dennison Powers the Next Generation of EV Battery Innovation

As electric vehicle battery systems evolve toward higher voltages, greater energy density, and more compact architectures, advanced adhesive technologies are becoming critical enablers of safety, efficiency, and manufacturability. In this exclusive interview, Max VanRaaphorst discusses how Avery Dennison is developing next-generation pressure-sensitive adhesive tape solutions for cell connection systems (CCS). From vibration damping and flame retardancy to lightweight assembly and 1000V dielectric protection, VanRaaphorst explains how innovative tape technologies are helping OEMs and suppliers accelerate EV battery performance, reliability, and production efficiency.

Automotive Industries: Hi Max, As EV battery architectures become more complex, how are Avery Dennison’s new pressure-sensitive adhesive tapes helping engineers simplify cell connection system design while improving overall safety and performance?

VanRaaphorst: Our tapes can be used to make single-sided, laminated cell connection systems, which eliminates an intricate step of applying a second layer within tolerances. Our solutions enable our customers to produce these systems more rapidly than many other options in the marketplace. Our tapes help remove time-consuming steps, steps prone to rework, offering customers a cost-effective assembly solution.

Automotive Industries: Flame retardancy and high-temperature resistance are becoming essential for next-generation EV batteries — what key innovations in your new CCS tape portfolio address these evolving safety requirements?

VanRaaphorst: We’re constantly evaluating and developing new materials to improve heat resistance and/or flame retardancy. Finding the balance between properties is a critical challenge, but we enjoy working with our customers and suppliers to optimize for each application.

Automotive Industries: Vibration and mechanical stress can affect battery sensing accuracy and longevity — how do Avery Dennison’s tapes help mitigate these challenges in real-world EV operating conditions?

VanRaaphorst: We have a long legacy in vibration damping and are utilizing our expertise to address these critical challenges. PSA tapes are viscoelastic and tend to absorb vibrations in general. We take it a step further and help identify the key frequencies and temperatures the components will encounter, then we design our adhesive solutions to maximize vibration absorption in that window. This reduces stress accumulation on those delicate parts and improves their longevity and reliability.

Automotive Industries: The ability to eliminate components such as topsheets could significantly streamline manufacturing — how are your novel tape construction approaches enabling lighter, more efficient battery assembly?

VanRaaphorst: Design for manufacturing is the cultural waystone for our group. We’re always thinking of creative ways to enable our customers to reduce the number of steps and complexity involved in producing their parts. When we can do that it is a win for us, our customers and ultimately consumers who get better and less expensive products.

Automotive Industries: With OEMs and tier suppliers pursuing different battery chemistries and designs, how important is customization, and how does Avery Dennison collaborate with customers to develop tailored CCS tape solutions?

VanRaaphorst: Being flexible and able to iterate and quickly customize is crucial. Each design has different considerations, and yes the different battery chemistries can play a major role in the design. Other factors like cell type (pouch, prismatic or cylinder cells) all make it one of the most exciting and dynamic marketplaces to work in.

Automotive Industries: Looking ahead, what emerging trends in EV battery design and energy storage systems will drive the next wave of adhesive tape innovation from Avery Dennison?

VanRaaphorst: High-voltage architecture will demand higher CTI values for dielectric protection materials. We’re already developing new tapes that have passed 1000V—the industry norm and max was 600V just a few years ago. Cell- to-pack and Cell-to-chassis pack designs will predominate, and holistically enabling that work is highly critical and a major focus for Avery Dennison.