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“At a time when suppliers are fiercely competing for every order, we have successfully secured this and other major orders for our DIAvent product family. We are particularly thrilled about a series production order from the USA, which is unprecedented in DIAvent’s brief history,” says Ralf Schmid, Senior Vice President Special Sealing Division at Freudenberg Sealing Technologies. “In order to meet this huge demand, we have rapidly tripled our production capacities,” Schmid continues.

The first fully automated high-tech production cell for DIAvent HighFlow was launched in Reichelsheim, Germany, at the beginning of 2023. A structurally identical twin followed in December, just a few meters away in the same production hall. Due to space constraints in the location, a third DIAvent production line will be operational at the Berlin facility, also in Germany, in the first half of 2024. But that isn’t all. Freudenberg Sealing Technologies will start up at least one additional production line in early 2025 at its North American site in Shelbyville, Indiana, to fulfill the large US order. This exemplifies how Freudenberg Sealing Technologies is dynamically adjusting its capacity to meet the rapidly growing demand. Additionally, Freudenberg can cater to this demand through its global production network spanning Europe, America, and beyond.

DIAvent HighFlow unlike anything else in the industry

Since 2017, Freudenberg Sealing Technologies has been developing the DIAvent family, an array of intelligent pressure compensation elements that merge pressure equalization and emergency degassing into a single unit, thereby enhancing electric vehicle battery safety. The range extends from the basic DIAvent light ventilation element to the DIAvent HighFlow, which integrates bidirectional pressure compensation with an emergency degassing function in one component.

DIAvent HighFlow is the only product of its kind in the industry. Freudenberg engineers developed it to balance air pressure variations within the battery housing of an electric vehicle and to provide emergency degassing in case of thermal runaway. The component occupies 50 to 70 percent less space than similar solutions and is lighter due to its innovative UL94-V0-compliant plastic housing. This not only makes it more cost-effective than two separate units but also simplifies installation and reduces supply chain complexity. Moreover, it supports the use of batteries with higher power density, fulfilling the demands for range, performance, and safety in battery-powered vehicles.

“Our intelligent pressure compensation elements offer car manufacturers an efficient way to enhance the safety of electric vehicles,” explains Ulrich Huth, President Automotive Sales at Freudenberg Sealing Technologies. “The product we offer them with DIAvent HighFlow is unparalleled in the industry. Its robust sales growth reflects its outstanding market reception.”

Quality that impresses the automotive industry

The consistent high quality of each DIAvent unit is highly valued and sought after in the automotive industry. The production process encompasses various controls to maintain this standard. For instance, the opening pressure and tightness of the diaphragm responsible for emergency degassing are automatically tested. The system also verifies the correct air flow rate of the breathable and waterproof e-PTFE fleece disk, ensuring proper ventilation of the battery during regular operation.

Without exception, each part must undergo these kinds of tests and various 360-degree camera inspections in order to receive a laser engraving as a seal of quality at the end. This documents the functionality and at the same time makes it possible to trace each individual pressure compensation element.

“Our clients in the automotive industry appreciate the reliability and trust they can place in Freudenberg Sealing Technologies as their partner in the emerging field of electromobility,” says Schmid.

Investing in the future

Freudenberg Sealing Technologies is also investing in the continued development of the DIAvent product family. For example, customized modifications to the battery housing’s fastening mechanism are being developed based on the technical foundation of the DIAvent HighFlow. It remains crucial that these kinds of special models can also be produced economically and reliably using standardized production technology.