Freudenberg Sealing Technologies is leading the way with state-of-the-art inventions meant to transform electric vehicle battery technology.
The nonwoven material-made battery cell envelope is one of the company’s outstanding innovations. These materials have a fibre network with a consistent pore structure and offer crucial safety and electrical insulation during the assembly process. Freudenberg claims that the electrolyte solution helps the fibres hold onto moisture, preventing gas bubbles from forming and preserving the ideal amounts of hydration in the cell stack.
Because Freudenberg’s nonwoven materials have better thermal conductivity than conventional foils, they also provide significant advantages in heat management. An important aspect of increasing safety and performance is the improved conductivity, which enables greater heat dissipation within the battery. These substances also act as an additional electrolyte reservoir, increasing battery efficiency all around.
The thicker nonwoven envelopes are designed to absorb the natural expansion of the cell stack, eliminating the need for excessive compression layers between cells. This design feature results in a more even load distribution within the battery, thereby reducing the risks of dendrite formation and lithium plating—two common issues that can compromise battery performance and safety.
In collaboration with cell manufacturers, Freudenberg has also developed custom cell caps that integrate essential safety features, such as rupture disks. These disks enable the safe dissipation of gases in the event of thermal runaway, a critical feature for preventing battery fires. The cell caps are engineered for long-term durability, offering high mechanical resistance to peak loads and fatigue over the battery’s lifetime.
“We combine state-of-the-art materials with intelligent design, merging our knowledge of sealing technology, engineering plastics, and stamping technology to set new standards for perfect sealing and long cycle life,” said Giulia Richard, Global Marketing Director at Freudenberg Sealing Technologies.
These cell caps are designed to remain gas-tight throughout the battery’s life, ensuring reliable performance across various conditions. Additionally, they are compatible with a range of electrolytes and coolants, further enhancing the flexibility and efficiency of EV battery systems.
“As the market leader in the technology, quality, and service segments for the automotive sector, we have all the expertise necessary to develop and manufacture innovative and leading-edge products for the mobility of the future,” said Ulrich Huth, President of Automotive Sales.
