Freudenberg Sealing Technologies has unveiled a breakthrough in battery cell technology with its latest prismatic battery cell solutions, promising enhanced reliability, extended cycle life, and increased design flexibility. This advancement positions the company at the forefront of the global transition to electric mobility.
The automotive industry anticipates that by 2030, over 100 million electric vehicles will be on the roads worldwide. To meet the growing demand for more efficient electromobility, manufacturers are focused on extending battery ranges and reducing charging times. High-performance batteries are critical to this evolution. Freudenberg Sealing Technologies is responding with solutions designed to boost cell reliability, offering products that enhance cycle life, design flexibility, and overall cell performance.
Among Freudenberg’s new offerings are advanced cell caps and nonwoven cell stack envelopes, both now ready for mass production. These products are set to transform battery design and performance.
Nonwoven Cell Envelopes: A Technological Leap
Freudenberg’s cell envelopes utilise cutting-edge nonwoven materials that encase the cell stack. Unlike traditional films, these nonwoven envelopes deliver superior protection during assembly and crucial electrical insulation. Their fibre network creates an ultra-homogeneous pore structure that enhances electrolyte wettability, reducing the likelihood of gas bubble entrapment and ensuring sustained cell stack hydration throughout the battery’s lifespan.
These nonwoven materials also improve thermal management within the cell due to their higher thermal conductivity.
The electrolyte absorbed by the nonwoven acts like a reservoir, releasing additional electrolyte during the cell’s ageing process when swelling occurs. This absorption mitigates the effects of cell stack growth and maintains an even load distribution, reducing risks such as dendrite formation and lithium-plating, and ultimately contributing to a longer cycle life.
Enhanced Safety with Custom Cell Caps
Freudenberg’s cell caps are designed with precision to enhance the safety and performance of electric vehicles. Developed in collaboration with cell manufacturers, these caps incorporate all essential features, including rupture disks to manage gases in the event of a thermal runaway. Produced locally to minimise carbon footprint and adhere to automotive standards such as IATF 16949, these cell caps set a new benchmark in sealing technology.
The cell caps are welded to the inner electrodes, providing robust gas-tight sealing and insulation throughout the battery’s life cycle. This ensures consistent performance across various operating conditions while minimising the risk of gas leakage. With exceptional resistance to mechanical stress and compatibility with various electrolytes and coolants, these caps are seamlessly integrated into different electric vehicle systems.
Giulia Richard, Global Marketing Director at Freudenberg Sealing Technologies, notes, “Our approach combines advanced materials with intelligent design. By leveraging our expertise in sealing technology, engineering plastics, and stamping technology, we are setting new standards for battery cell performance and longevity.”
Ulrich Huth, President of Automotive Sales at Freudenberg Sealing Technologies, adds, “As the mobility landscape evolves, Freudenberg Sealing Technologies remains at the forefront, equipped with the expertise to develop and manufacture innovative products that will drive the future of mobility.”
Freudenberg Sealing Technologies continues to lead the way in advancing battery technology, underscoring its commitment to supporting the industry’s shift towards sustainable, high-performance electromobility.
