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<\/figure>\n<\/div>\n\n\n\u201cWe anticipate future trends systematically and try to actively develop \u00adcomponents in line with them wherever we can build on existing knowledge, and they are good strategic fit for us. We increasingly find ourselves on a path, taking us from the individual seal to complete modules. We are working to acquire the necessary design and production expertise for this.\u201d<\/p>\nJens Trabert\u2002|\u2002Lead Function, Technology & Innovation at FST<\/cite><\/blockquote>\n\n\n The lithium ion batteries are the centerpiece of electric vehicles and e-mobility. Cells are the smallest units of these energy storage systems. When there is a short circuit, energy is abruptly released as heat and pressure. The electrolyte turns into gas and the cell ruptures. This can trigger a disastrous chain reaction from cell to cell and cause a fire that spreads through the entire battery. FST has developed solutions that prevent this uncontrolled cell-to-cell spillover \u2013 or at least slow the process long enough for occupants to \u00adescape the vehicle.<\/p>\n\n\n\n \u2026 from FST create barriers between the individual cells. \u201cWe are now developing the second generation of our heatshields. These are extremely compact, elastic mats made of a mix of materials in a multi-element structure. This makes it possible for the heatshield to withstand higher temperatures for a significantly longer period of time. Here our material expertise and our \u201cInnovating \u00adTogether\u201d with Freudenberg Performance Materials have come into play,\u201d Trabert said.<\/p>\n\n\n\n \u2026 perform the same tasks as heatshields, only at another point in the battery housing. These three-dimensional profiles prevent flames around the heatshields from spreading across the upper ends of the cells. FST manufactures these 3D thermal barriers with an injection-molding process using a special silicone-based material developed in-house. In parallel, FST is developing new materials for flat, two-dimensional thermal barriers, that is, sheet products that can be used as flame protection around the battery housing.<\/p>\n\n\n\n \u2026 is the name of FST\u2019s patented pressure equalization element that combines two functions in a single part. In normal operation, it enables an electric-car battery to \u201cbreathe.\u201d The technical term is \u201cbidirectional pressure equalization.\u201d It also draws off the overpressure that occurs quickly during thermal runaway \u2013 thanks to its high degassing rate. There are also different versions of the innovation. During emergency degassing, the flow rate of the HighFlow model is four times as high as that of the standard \u00adversion. DIAvent Light only provides pressure equalization during normal operation. Other \u00advariations are \u00adconceivable, potentially for \u00adbattery-powered \u00adtwo-wheeled vehicles.<\/p>\n\n\n\n \u2026 are power rails. In lithium ion batteries, electricity flows from cell to cell through power rails made of copper, not wires or cables. They also require the maximum protection against flames, whether they are straight, meter-long rails, wound molded parts or threaded elements. Busbars are either coated with flame-retarding, electrically insulating materials or encased in elastomers to prevent the short-circuits and fires that can result from overheating. The jobs of coating and encasing metals fall squarely into FST\u2019s core expertise. \u201cIt is obvious, even if it often requires explanation, why Freudenberg is offering products such as busbars. But as we collaborate with customers, we realize again and again how much our experience and our development expertise are in demand in these new businesses, which are still marked by uncertainty,\u201d Trabert said.<\/p>\n\n\n Cell caps play an important role in power transmission in lithium ion batteries. They are also a safety measure preventing cell chemicals and vapors from reaching the environment, sealing the two poles of the cell and insulating them from one another. The caps contain a range of parts. \u201cYears ago, we developed media-resistant sealing materials that \u201ccan live\u201d with cell chemicals. Since we also understand metal processing, whether for Simmerrings\u00ae or valve stem cells, it made sense to manufacture and offer the entire cell. The major advantage to the customer: They don\u2019t need to assemble individual parts from the anode to the integrated rupture element on their own. We provide them with the total module as a finished assembly,\u201d \u00adTrabert said.<\/p>\n\n\n Consider sensor, camera and radar systems: These electronic vehicle components give off electromagnetic radiation and can disrupt one another. The technical term is electromagnetic interference, or EMI. That means they must be shielded from one another, either with housings made of a conductive metal, usually aluminum, that is comparatively expensive and heavy, or with housings made of plastic, on which a seal can be directly injection-molded to permanently \u00adattach it.<\/p>\n\n\n\n For EMI shielding, however, the plastic must be made electrically conductive. FST has developed several ways to do this. One is known as \u201cEMI coating,\u201d the application of a conductive coating onto the surface of the plastic part. FST is working with BASF to \u00adoptimize the process.<\/p>\n\n\n With a\u00a0systematic process, FST is taking its sealing expertise to a\u00a0new level for electric powertrains. Its eCON products are an example. These low-friction radial shaft seals have a\u00a0\u201cbuilt-in lightning rod,\u201d or integrated grounding. The multifunctional seals dissipate harmful currents in the engine mount, preventing bearing damage that electric erosion can cause.<\/p>\n\n\n \u201cOur goal is to participate in a megatrend: the use of hydrogen as a future energy source,\u201d Trabert said. Electrolyzers uses electrical energy to produce hydrogen. They function much like a fuel cell \u2013 but in reverse. Like those in fuel cells, electrolyzer stacks have to be sealed. FST already provides flat seals and O-rings that are resistant to electrochemical media. \u201cThe major challenge with electrolyzers and fuel cells is reducing costs with automated production. Our concept is to connect our seals directly to the frame or the bipolar plate with an automated process as part of the vertical integration of our seals, and then deliver the unit to the customer as a finished module. This saves the customer several production steps,\u201d Trabert said.<\/p>\n\n\n Product innovations often go hand-in-hand with material and process innovations \u2013 or even presume they can be made available. That was the case with thermal interface materials (TIM). FST has had a thermally conductive and electrically insulating silicone material in its product line for a few years. FST now has developed it further \u2013 in two ways. First of all, the material can now also be processed into complex three-dimensional geometries using injection molding \u2013 an entirely new approach. Secondly, the material can become an integral element of two-component parts. It can be directly sprayed on, and it adheres to plastic, aluminum or copper. A two-component part with a thermoplastic main body has been in series production for some time for charging ports on electric cars. Its specific contribution is to make charging vehicles safer and more efficient: FST\u2019s product \u201cfeeds\u201d sensors with thermal information. The charging process can be continually monitored and controlled on this basis.<\/p>\n![\"\"](\"https:\/\/sw.fst.com\/magazine\/wp-content\/uploads\/2023\/05\/fst-sw-2023_3-1200sq_0000_arrows.png\")
<\/figure>\n<\/div>\n\n\nThe Centerpiece: A Safe Battery<\/h2>\n\n\n\n
Heatshields \u2026<\/h3>\n\n\n\n
Thermal barriers \u2026<\/h3>\n\n\n\n
DIAvent \u2026<\/h3>\n\n\n\n
Busbars \u2026<\/h3>\n\n\n\n
<\/figure>\n<\/div>\n\n\nPrismatic Cell Caps: Puttng A Lid On It<\/h2>\n\n\n\n
<\/figure>\n<\/div>\n\n\nEMI Shielding: \u00ad Teaching Plastic To Shield<\/h2>\n\n\n\n
<\/figure>\n<\/div>\n\n\neCON: Seals With A \u201cBuilt-In Lightning Rod\u201d<\/h2>\n\n\n\n
<\/figure>\n<\/div>\n\n\nElectrolyzers: \u00adHydrogen For Fuel Cells<\/h2>\n\n\n\n
<\/figure>\n<\/div>\n\n\nInnovative Materials And Processes<\/h2>\n\n\n\n