Several new chapters are being written in the success story of the pressure equalization element DIAvent: New major contracts are quadrupling the production capacity for the component and propelling it onto the international stage.
Daniel Uhl, Marketing Manager, Lead Center Diaphragms & Boots, is excited: “At a time when getting new business is a struggle, we have succeeded in winning important large orders for the DIAvent product family.” DIAvent is a multifunctional pressure equalization component from Freudenberg Sealing Technologies (FST) for car batteries. The heart and soul of the innovation can be found at the Reichelsheim plant, not far from Weinheim, Germany.
The exeptional performance of the DIAvent HighFlow element is attracting considerable interest from customers. In early 2023, the first completely automated, high-tech production cell for the product went into operation. It is a prime example of state-of-the-art automated and digitalized production technology. In December, an identical twin followed in the same hall, just a few meters away from the original. It can produce both the first generation of DIAvent and the newer DIAvent HighFlow.
The cause for celebration is mainly a major contract from automaker Hyundai, which is already using the DIAvent pressure equalization element from Reichelsheim in Europe and Asia and is massively increasing the order volume for it. “In one fell swoop, we doubled our capacity. The production capacity of the second installation is already sold out in large measure,” Uhl said.
Standardization Pays Off
Since the facility is short on space, a third DIAvent production line will go into operation this spring at the Lead Center Diaphragms & Boots facility in Berlin, Germany. It’s worth noting that the Lead Center will soon be ordering a second DIAvent HighFlow production line for Berlin (status as of the end of 2023).
That’s not all: In early 2025, the Lead Center will launch a production line in North America, at the company’s Shelbyville plant in Indiana. The components will fill a major order from the automotive giant Stellantis – which has the Chrysler, Jeep, Fiat, Peugeot and Opel brands, plus a few more. Stellantis is already a DIAvent customer in Europe. The company is now turning to the patented FST innovation for its crucial electric-mobility program. Next to Hyundai, it is the largest DIAvent series production order in the component’s young history.
The latest launch in Reichelsheim went quite smoothly. “We were able to incorporate the insights gained during the first installation,” said Uhl. Here, the standardization of the production technology is paying off. The experts handling the industrialization of DIAvent in Reichelsheim are working closely with coworkers at other facilities, transferring knowledge and sharing expertise. The thoroughly tested production technology is coming to Berlin and Shelbyville in exactly the same form, so the DIAvent team isn’t worried about the construction and launch of the new installations.
Laser Engraving as Seal of Approval
Each of the facilities turns out a finished component every few seconds. The high quality of each individual DIAvent is especially sought-after and appreciated. This has required the incorporation of a whole series of checks into the production processes. For example, the opening pressure and the density of the umbrella membrane – which is responsible for the emergency degassing – are tested automatically. Is the air throughput rate at the right level for the e-PTFE nonwoven disk to ventilate properly? It ensures that the battery can “breathe” during normal operation. Is the disc waterproof?
Without exception, each part must undergo these kinds of tests, along with 360-degree camera inspections, to ultimately receive a laser engraving as a seal of approval. It documents the components’ proper functioning and makes it possible to trace each pressure equalization element back to its point of manufacturing origin.
“Our customers in the auto industry are thankful that they can rely on FST as a trusted partner even in the new business field of electric mobility,” Uhl said. The fact that Freudenberg has the financial strength to invest in modern production technology should not be underestimated. It can adjust its manufacturing capacity at a fast pace to meet rapidly rising customer demand. FST can also meet this demand with local production from its global network in Europe, the Americas and elsewhere.
Business with DIAvent Light also Growing
The business is also making progress with the smallest member of the family, DIAvent light, Technically known as a “derivation,” DIAvent light is focused solely on pressure equalization in electric drivetrain components such as power electronics housings, inverters and dry-running electric motors. Its series production began in Reichelsheim in 2022, with state-of-the-art production technology similar to the systems for DIAvent HighFlow and from the same manufacturer. The next production cell, with the same fully automated approach, will be in place by midyear in Reichelsheim. At that point, existing customer projects will be pushing up against the limits of the manufacturing capacity for the product.
FST continues to invest in the further development of the DIAvent product family. Based on the DIAvent HighFlow’s technology, for example, it is developing customer-specific modifications to the fastening system on battery housings. It is still important for even these special models to be produced with standardized production technology – economically and with reliable processes.
