Freudenberg’s New Thermoplastic For EVs Withstands 1,200°C Without Melting

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Quantix ULTRA, according to the company, can withstand temperatures up to 1,200°C without melting. It’s currently being used as a fire protection barrier in an electric vehicle’s lithium-ion battery cooling system components, marking its first series application.

Freudenberg Sealing Technologies has developed a novel thermoplastic capable of enduring extreme temperatures up to 1,200°C without melting. This breakthrough is set to enhance fire safety in electric vehicle drives.

Named ‘Quantix ULTRA’, this thermoplastic is not only resistant to high temperatures but also offers advantages in injection moulding. Its lower density, compared to metallic materials, aligns well with the lightweight construction needs of modern vehicles. Its inaugural application is as a flame-resistant barrier in the cooling systems of electric car lithium-ion batteries.

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Electric vehicles, particularly those with lithium-ion batteries, require robust safety measures to prevent or delay thermal runaways. Quantix ULTRA stands out in this regard, demonstrating remarkable resistance to high temperatures and flame without melting or igniting. In tests, a two-millimeter sample of this material withstood a 1,200°C flame for over 25 minutes.

Further testing showed Quantix ULTRA’s resilience against high-pressure hot particle emissions, a potential hazard in battery cells. It outperformed a similar aluminium sample significantly in stress tests.

Kira Truxius, a Thermoplastics Material Expert at Freudenberg, highlights that Quantix ULTRA behaves elastically at high temperatures, maintaining its rigidity and flame resistance longer than other plastics. Its glass transition temperature is notably higher, adding to its protective qualities.

This innovative material is now being used in the production of flame barriers for lithium-ion battery cooling systems in cars, with its first commercial use in a series of production vehicles starting in February 2024.

Quantix ULTRA is versatile and applicable in numerous high-fire protection and lightweight construction scenarios. Its adaptability extends beyond specific shapes, allowing for varied implementations such as films in battery-electric drives, power supply unit enclosures, cable insulation, and more.

Freudenberg’s patented technology enhances Quantix ULTRA by carefully adding fillers like glass or carbon fibres and cross-linking plastic molecular chains. This technique, developed through collaborative efforts led by Dr. Björn Hellbach, ensures stability and shape retention under extreme conditions, with tailored properties for specific applications.

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