Freudenberg Unveils High-Heat Resistant Plastics for Electric Vehicles

Freudenberg Sealing Technologies is at the forefront of enhancing fire protection in electric vehicle drives across the world by introducing a groundbreaking class of materials, exemplified by "Quantix ULTRA." This material demonstrates exceptional resilience, resisting melting even at extreme temperatures reaching up to 1,200 degrees Celsius, and it boasts versatile and cost-effective processing through injection molding.

The imperative for safety in electric vehicles with lithium-ion batteries, ensuring everyday-use range coupled with high safety standards, has prompted the implementation of various protective measures. However, traditional plastic components employed for this purpose often fell short of meeting the rigorous test standards set by the automotive industry for electric drives. Quantix ULTRA from Freudenberg Sealing Technologies stands out in this regard, demonstrating an ability to withstand exceedingly high temperatures without melting or igniting.

Freudenberg Sealing Technologies leverages Quantix ULTRA to manufacture flame protection barriers for the cooling systems of lithium-ion batteries. These barriers are set to debut in series production vehicles by a car manufacturer as of February 2024, marking a significant milestone in the material's practical application.

Quantix ULTRA's versatility extends to various applications with high demands for both fire protection and lightweight construction. It transcends limitations related to specific geometric shapes, allowing it to be processed into films suitable for integration into battery-electric drives. Its potential applications encompass enclosures for power supply units, media-carrying lines, cable insulation, battery housing covers, and components for electric motors.

A distinguishing feature of Quantix ULTRA is its temperature resistance, a critical factor for engineering plastics. Unlike currently utilized polymers, Quantix ULTRA exhibits elastic behavior akin to elastomers at high temperatures, retaining rigidity and flame protection over an extended period. Its glass transition temperature surpasses that of existing materials by 53 Kelvin, ensuring sustained performance under demanding conditions.

The foundation of Quantix ULTRA is a temperature-resistant thermoplastic, enhanced by precisely adding fillers such as glass or carbon fibers to reinforce mechanical stability even in extreme heat. The additional cross-linking of plastic molecular chains further contributes to maintaining the component's shape under severe conditions, with the flexibility to tailor material properties for specific applications.

The patented know-how behind Quantix ULTRA involves the precise addition of suitable materials that create bridges between molecular chains. Dr. Björn Hellbach, a material expert at Freudenberg Sealing Technologies, highlights that the patents are the result of successful teamwork. The material's ease of processing through injection molding, coupled with the economical production facilitated by patented cross-linking, positions Quantix ULTRA as a versatile and groundbreaking solution for advancing fire protection in electric vehicles. This development showcases Freudenberg Sealing Technologies' commitment to innovation and addressing the evolving needs of the automotive industry.