Freudenberg Sealing Technologies Develops the Next Generation of Battery Cell Caps: Cell Caps 2

As series production of the Cell Caps Generation 1 ramps up, the next evolution is already underway with Cell Caps 2. The core of the new development consists of integrating the terminal in molded rubber into the base plate of the cell cap:

To fix the terminals within the cell cap, liquid elastomer is injected into the gap between the poles and the cap base plate. The elastomer permanently bonds these components together, providing excellent gas tightness, mechanical robustness, and electrical insulation – all with a minimal number of parts and very low mass, which can significantly reduce the overall battery weight.

In addition to being less complex and more compact, Generation 2 technology can reduce the height of the cell cap by up to 30%, depending on customer requirements. An advantage that directly translates into higher energy capacity and, consequently, a longer operating time.

Freudenberg is currently working on the mass production of a round cell cap that fully leverages all the advantages of the next generation technology. In this context, the manufacturing process for these small components plays a particularly crucial role in optimizing production costs. The cell caps can be manufactured using the same technology as valve stem seals, which Freudenberg produces in the millions with high quality.