Thermal Barriers: More Safety for Electric Cars – Now Also in 3D

Well over 100 million electric cars are expected to be on roads worldwide by 2030. To make electromobility more efficient in the future, many manufacturers are working on achieving higher ranges and shorter charging times. That is why high-performance batteries are one of the priorities in this development. But in lithium-ion batteries, higher energy density increases the risk of thermal runaway. For that technical environment, Freudenberg Sealing Technologies has developed thermal barriers. These slow down or even stop thermal runaway by increasing thermal propagation resistance.

“What is completely new is that the thermal barriers are now also available in customized, flexible 3D geometries, which makes it possible to use them in various positions within the battery and allows for integration of additional components,” says Andrew Espinoza, Global Vice President Technology of the Oil Seals Powertrain & Driveline Division at Freudenberg Sealing Technologies.

Thermal runaway, which is the ignition or explosion of a battery cell caused by a self-reinforcing heating process, is a significant safety problem. It can be caused by a range of internal and external factors, such as overcharging, excessive discharging, damage, or heating of the battery. Thermal runaway releases not only flames and hot gases but also electrically conductive particles. These in turn can cause thermal propagation in adjacent cells and lead to short circuits in the electrical system. Thermal barriers act as protective layers that slow down or even prevent the heat and flames from spreading in the battery, which significantly increases safety.