Freudenberg Sealing Technologies has developed innovative 3D thermal barriers for lithium-ion batteries, reducing the risk of thermal overheating.
These customized barriers can be flexibly positioned at various points within the battery and are already successfully deployed in series production.
They slow down the spread of heat and flames within the battery, enhancing the safety of electric vehicles and marking a significant advancement towards more efficient electromobility solutions.
Freudenberg Sealing Technologies Introduces Customized 3D Safety Components for Batteries.
3D thermal barriers for lithium-ion batteries. Image source: Freudenberg Sealing Technologies
Freudenberg Sealing Technologies has achieved a remarkable advancement in developing thermal barriers for lithium-ion batteries. These barriers play a vital role in mitigating the risk of thermal runaway by resisting heat propagation. The newly introduced customized 3D thermal barriers can be strategically positioned within batteries and have already demonstrated reliability in initial series production.
With the anticipated surge of over 100 million electric cars on the roads by 2030, manufacturers are striving to enhance the efficiency of electromobility through extended ranges and shorter charging times. High-performance batteries are a pivotal focus in this pursuit. However, the heightened energy density in lithium-ion batteries elevates the potential for thermal runaway.
What sets this innovation apart is the availability of thermal barriers in customized, flexible 3D geometries. This adaptability allows for their integration at various points within the battery and facilitates the incorporation of supplementary components.
Thermal runaway, the ignition or explosion of a battery cell due to a self-reinforcing heating process, poses significant safety concerns. It can be triggered by a range of internal and external factors such as overcharging, excessive discharging, damage, or elevated battery temperature.
Thermal runaway releases flames, hot gases, and electrically conductive particles, which can lead to thermal propagation across adjacent cells and provoke short circuits in the electrical system. Thermal barriers serve as protective layers, slowing down or even preventing the spread of heat and flames within the battery, thereby substantially enhancing safety.
Beyond the existing two-dimensional barriers like flat mats and thermal blankets, the introduction of a 3D variant presents a plethora of new opportunities. Tailored, three-dimensional geometries can be manufactured using various high and low-volume production techniques, such as injection molding and continuous extrusion.
Products in current production include profile seals, module separators, covers for bus bars, cooling lines, and electrical components. The intricately manufactured 3D geometries are lightweight and minimally impact the overall battery weight.
To address these specific requirements, material experts at Freudenberg Sealing Technologies have formulated heat-resistant, electrically insulating, and thermally insulating materials.
Rigorous in-house testing has demonstrated that these materials can safely withstand temperatures of up to 1,200°C. Their unique composition grants these compounded polymers exceptional heat resistance.
This also renders them resistant to particle impacts, as observed during cell venting. The 3D thermal barriers employ elastomer solutions in solid or foam form, in addition to plastic components such as Quantix Ultra, enabling intricate geometries.
The three-dimensional thermal barriers and their associated materials have undergone comprehensive testing surpassing the stipulated standards. Bench tests and battery system evaluations have affirmed their exceptional performance and reliability. These products adhere to the highest quality benchmarks, are UL 94 V-0 certified, and are already successfully employed in initial series production within the automotive industry.
