Gaskets and sealing materials for electric vehiclesJohn Moot
Today there are more than 1.3 billion motor vehicles worldwide, of which one billion Car. That number is projected to rise to two billion by 2035. This is associated with major challenges not only for Germany, but for almost all industrialized and emerging countries: The traffic-related emissions of CO2, Air pollutants and noise are a headache, and dependency on oil imports continues to grow.
Electromobility is the key to climate-friendly mobility and innovation worldwide. The operation of electric vehicles generates significantly less CO2, especially in connection with electricity generated from renewable sources. In addition, electric vehicles with their energy storage devices will be able to compensate for fluctuations in wind and solar power in the future and thus support the expansion and market integration of these volatile energy sources.
In electric vehicles, seals are used in battery systems, which are developed by the Dr. Dietrich Müller GmbH. The battery packs in vehicles are located in panels that consist of an upper and a lower housing. Seals are used to separate these sections and prevent particles and liquids from entering these housing parts. They have a similar application in battery systems of hybrid vehicles, which are extremely sensitive to temperature changes.
Many automobile manufacturers have announced that they will electrify their vehicle platforms and portfolios in the coming years. With this development towards increased electrification, battery packs are becoming increasingly important as a central energy source for many types of vehicle.
The battery packs of most modern electric vehicles are quite different from those used in cell phones or other portable devices. Electric vehicle battery packs typically consist of hundreds or thousands of cells arranged in modules and typically surrounded by channels of liquid coolant to keep the battery in its desired temperature range. While lithium-ion batteries are the main source of power for most electric cars, automakers are moving towards solid-state batteries with the aim of bringing them to market at some point.
Electric vehicle battery packs: the role of seals
Heat and the ingress of moisture and other contaminants can seriously affect the performance of battery packs. Because of this, the seals used in the batteries must be able to withstand the effects of heat while protecting the battery from potential contaminants such as moisture and dirt.
In electric vehicles, the batteries are usually located in housings that consist of an upper and a lower part. Gaskets are used to separate these areas and prevent water, dust, moisture and salt from entering the battery pack. Should these elements penetrate a battery pack, the service life and performance of the battery can be significantly impaired.
In addition to sealing against environmental influences, the battery pack seals help control and regulate the heat generated by the battery pack, and they also prevent the volatile emission of gases and liquids. Finally, the seals of the battery pack of electric vehicles perform an important function in dampening noise and vibrations that could affect the battery pack or disturb the vehicle occupants.
In addition to the ability to seal the battery pack against temperature, air, dust and water, other factors that must be taken into account when purchasing seals for battery packs are fire resistance and compression set.
Battery pack seals from Dr. Müller
The Dr. Dietrich Müller GmbH produces and supplies battery pack seals for electric car applications. These seals are manufactured under strictly controlled conditions in our ISO 9001 certified factories using the latest CNC manufacturing technology by punching, water jet cutting and laser cutting.
Materials for battery seals
The Dr. Dietrich Müller GmbH manufactures battery seals from a range of elastomer and sponge / foam materials.
One of the materials we use for battery sealing applications is a specially formulated silicone foam. This material offers excellent sealing protection against weather influences, and its excellent compression set and closed cell structure ensure a reliable seal over a long service life. The silicone foam can withstand a range of extreme temperatures (-60 ° C to 230 ° C), making it an ideal material for vehicle applications where temperatures can fluctuate widely.
For battery applications, the silicone sponge is flame-retardant in accordance with UL94 V0 and has low-smoke and low-toxic properties, which improves the safety, reliability and service life of battery packs. The foam is available in different densities.
Selection and advice regarding the selection of the suitable sealing material
The application technology of Dr. Dietrich Müller GmbH advises on the selection of the suitable sealing material as well as the correct manufacturing process in order to provide the seals in accordance with the technical and logistical requirements of the manufacturers of battery systems. It is possible to produce single pieces, small series as well as mass stamped parts.
All manufacturing processes are at the Dr. Dietrich Müller GmbH available.