Hot topic: Freudenberg Sealing's new lab tests thermal runaway in EVs

PLYMOUTH, Mich.—There is no question that the transition to electric vehicles will reap critical environmental benefits, as carbon neutrality is sought by suppliers, OEMs and just about everybody in between on the supply chain.

The onset of EVs also brings new, previously unconsidered risks, such as thermal runaway, a phenomenon that causes EV batteries to overheat and combust.

As such, Freudenberg Sealing Technologies, a division of Freudenberg Group that makes seals and components for the EV industry (among many other applications), has installed an advanced battery test lab at its North American headquarters in Plymouth.

The "multi-million dollar" state-of-the-art battery testing lab was added as part of the company's research and development space.

"Freudenberg Sealing Technologies leverages its experience in sealing, material design, component design and manufacturing to provide solutions across all of the industries it serves," said Chad Bauer, senior vice president of technology and innovation for the company. "This battery laboratory will help provide valuable insight and the data needed to design solutions for EV products.

"Our material development experience with fire and thermal applications began more than 20 years ago with our aerospace products and we continue to build upon this knowledge for EV applications."

The battery testing space will be able to simulate thermal runaway in an 8-foot-by-8-foot-by-8-foot containment area designed by explosive experts.

The steel-welded containment space can withstand heat and explosions equivalent to the explosive power of several pounds of dynamite, or about 25 kWh, Freudenberg said.

The sealing company put in 9-volt, 100-amp low voltage charging, as well as 800-volt, 600-amp, high-voltage charging capabilities in the test room.

The test area also has video cameras and a "sophisticated data acquisition system" that operates with over 100 input channels and captures the data in excess of 60Hz, or 60 data points per second.

In keeping with its focus on sustainability, Freudenberg also has installed an exhaust system for the fumes from the battery event tests.

A "quencher" helps lower the temperature on gases and removes particulates, and a two-phase scrubber stack and rooftop charcoal filtration system help ensure that exhaust from the testing procedures is filtered and safe before being exhausted.

"Simulation tests that replicate battery cycling scenarios are also possible in the new laboratory," Freudenberg said in a news release. "Freudenberg Sealing Technologies' new laboratory will allow engineers to observe thermal runaway and other operations, as they take place and incorporate data generated during these tests into their research and development activities."

In every sense, according to Freudenberg, the battery testing space was developed with safety in mind.

The company put in steel-reinforced concrete walls at the back of the laboratory and explosion pressure vents within the exhaust system to maintain safety both in and out of the laboratory and building.

Sensors are everywhere to monitor pressure, flow and gases, and a sprinkler system and CO2-dampening gases have been put in the new battery lab.

Personal protection equipment also is readily available in the lab, Freudenberg said.

"We are working with heat, pressure, gases and fire in this laboratory," said Heather Shuman, mechanical laboratory manager for Freudenberg Sealing Technologies in the Americas. "We have placed high emphasis on establishing and continuously reviewing safety protocols and emergency protection plans. An important aspect of how we conduct battery testing is how safely we do it.

"Battery events can be dangerous, but we are equipped so we can conduct this research safely and responsibly."

The new lab works in concert with other EV-related testing capabilities for Freudenberg, including its H2 electrolyzer and fuel cell testing services.

So what does this mean for Freudenberg customers?

A shorter development cycle, for one, based on the enormity of the testing parameters and data that can be gleaned from the battery tests.

Freudenberg Sealing is one of the first component suppliers to install battery testing along with thermal runaway capability in North America, Bauer said.

"Our new lab enables us to conduct testing of different cell chemistries, cell types, battery configurations," said Bauer. "This allows us to learn and gather data to use with the development of our products and materials—materials that can benefit many industries and many applications. Going forward, we will better understand what the customer needs and where we can offer more support with an evolving market and product portfolio."