PC Film and Flame-Retardant Polycarbonate Thin Sheet for Battery Pack Insulation
Factory-direct PC film, black flame-retardant PC film and thin sheet component supply for energy storage battery modules, copper busbar insulation protection covers, spacer strips and hardware control cabinets. The main product shown is a black flame-retardant PC film and thin sheet component made by die-cutting, compression forming and flame-retardant PC material for battery module copper busbar insulation protection cover applications.
High-Performance Insulation & Safety
PC film and flame-retardant polycarbonate thin sheet are used where insulation, toughness, dimensional stability and fire safety must work together. Battery pack designers often need a formed cover or strip that protects copper busbar areas, avoids short-circuit risk, and stays stable during module assembly.
UL94 V-0 Fire Rating
Certified self-extinguishing performance with no flaming droplets—ensuring maximum safety.
Energy Storage Grade
Optimized for battery pack insulation, spacer strips, and hardware control cabinets.
Excellent Die-Cutting
Superior dimensional stability and elongation for precise component manufacturing.
Halogen-Free & Eco-Friendly
Compliant with strict environmental requirements (Low Br/Cl content).
★ Available in Transparent, Black Satin, and Opal Diffuser finishes.
Where PC Film and Thin Sheet Are Used in Energy Storage Battery Packs
The application map shows typical PC film and thin sheet positions inside an energy storage battery pack. The black formed part can be used as an insulation protection cover around copper busbar or conductive connection areas, while flat die-cut pieces can work as module cover, spacing strip, end plate insulation or protective separator.
- copper busbar insulation protection cover: formed black PC part around busbar or conductive zones to reduce short-circuit risk.
- module cover: flame-retardant sheet cover over cell groups or electrical connection areas.
- spacing strip: die-cut strip for separation, insulation and assembly positioning.
- pack-side insulation: thin sheet barrier for battery pack inner walls, hardware control areas and structural insulation components.
- cover plate and separator: shaped film/thin sheet pieces for local protection where metal, wiring and cells are close together.
Die-Cutting, Compression Forming and Component Requirements
For a battery module copper busbar insulation protection cover, the buyer should specify not only sheet thickness and color, but also forming height, bend radius, hole position, edge tolerance, flame rating and whether the finished part must resist assembly stress without cracking.
| Requirement | What to Specify | Why It Matters |
|---|---|---|
| Die-cut geometry | DXF/DWG drawing, hole size, slot location, edge tolerance | Controls fit around copper busbar, terminals and fasteners. |
| Compression forming | Forming depth, flange, corner radius, tool direction | Prevents cracking and keeps insulation cover shape stable. |
| Electrical insulation | Clearance, creepage, contact area and protected conductive zone | Reduces short-circuit and arcing risk in module assembly. |
| Flame retardancy | UL94 V-0 or V-2, thickness and test direction | Battery pack designs often need self-extinguishing materials. |
| Surface finish | Black satin, transparent, opal diffuser or custom finish | Affects appearance, light reflection, handling and inspection. |
Material Grades and Specification Range
The original product range covers black flame-retardant sheet, opal diffuser panel and transparent flame-retardant sheet. Dimensions and colors can be customized for large-scale industrial projects. All products are certified under IATF 16949 quality management systems.
| Grade / Type | Flame Retardant Rating | Standard Dimensions | Primary Application Fields | Service Life |
|---|---|---|---|---|
| PC Black Sheet (One-Side Satin Finish) | UL94: V-0 / V-2 | Width: ≤ 1300 mm Length: ≤ 6000 mm Thickness: 0.76 - 2.5 mm | Energy Storage Battery Insulation AI Hardware Control Cabinets Structural Insulation Components | 8 - 15 Years |
| PC Opal Diffuser Panel | UL94: V-2 | Width: ≤ 1300 mm Length: ≤ 6000 mm Thickness: 2.0 - 8.0 mm | Charging Pile Panels & Faceplates Firefighter Helmets & Visors Industrial Light Diffusers | Project dependent |
| PC Transparent Sheet | UL94: V-0 / V-2 | Width: ≤ 2100 mm Length: ≤ 6000 mm Thickness: 2.5 - 12.0 mm | High-Impact Security Glazing Electrical Equipment Shields Flame Retardant Vision Panels | Project dependent |
Flame Retardancy UL94 Review
Battery pack and control cabinet projects often require the material supplier to confirm the flame-retardant grade by thickness and application direction. Use the table below as the original product reference for UL94 V-0 behavior.
| Flame Retardancy UL94 | Standard Value (V-0) |
|---|---|
| Afterflame Time First Ignition (t1) | ≤ 10 Seconds No Flaming Droplets |
| Second Ignition (t2) | ≤ 10 Seconds No Flaming Droplets |
RFQ Checks for Faster Quotation
- Material type: PC film, black FR PC thin sheet, transparent FR sheet, opal diffuser panel or formed insulation component.
- Thickness, width, length, color, surface finish, UL94 rating and halogen-free requirement.
- Drawing: die-cut outline, holes, slots, compression forming height, bend radius and tolerance.
- Application: battery module copper busbar insulation protection cover, module cover, spacing strip, control cabinet insulation or charging pile faceplate.
- Electrical and assembly requirements: clearance, creepage, screw area, contact zone, forming stress and packing method.
- Related sourcing page: bulk polycarbonate sheets.
Get a Factory Quote
Send drawings, thickness, flame rating, forming details, quantity and battery pack application. Bakway will review it as a material or finished component project.