Freudenberg Sealing Technologies has developed an advanced sealing material for electric vehicle (EV) battery systems, offering a PFAS-free alternative to traditional thermoplastic and FKM seals. Designed for injection molding, the new elastomer-based material meets demanding environmental regulations while maintaining strong sealing performance and supporting extended battery life in EV applications.
In the fast-growing EV market, battery performance, thermal stability, and regulatory compliance are becoming increasingly critical. As OEMs across Europe and North America adapt to stricter environmental policies, materials that enable safety and durability are in high demand. This sealing solution addresses those needs, particularly by outperforming conventional thermoplastics in scenarios such as thermal runaway.
Unlike thermoplastics, which are prone to long-term plastic deformation under cyclical load, elastomers feature chemically cross-linked molecular chains that maintain their shape more reliably. This property is particularly important in EV batteries, where the cell “breathes” as it heats and cools during operation. Elastomer seals maintain integrity through these thermal cycles, helping to reduce leakage and protect internal battery chemistry.
The new material also supports sustainability goals by improving battery longevity and reducing failure risk. In customer applications, it has shown a tenfold improvement in leakage resistance compared to conventional thermoplastics. At the same time, manufacturing techniques have been refined to enable scalable production of these high-performance cell seals.
Battery cell electrochemistry is highly sensitive to contamination, making material purity critical. This new sealing compound was developed with strict controls to limit impurities and moisture infiltration—factors known to contribute to capacity degradation over time.
As global EV adoption accelerates, so too does the need for reliable battery components that can be produced at scale. Sealing materials like this one are essential for supporting longer battery lifecycles, minimizing safety risks, and helping manufacturers meet performance and regulatory targets in a highly competitive and rapidly evolving market.
Filed Under: Technology News