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Freudenberg Sealing Technologies is developing Cell Caps 2, a new generation of battery cell caps for prismatic and cylindrical cells. The technology will be presented at Battery Show Europe in Stuttgart from 9 to 11 June 2026.
Battery cell caps are small components with a critical role in electric vehicle battery systems. They must seal the cell chemistry from the external environment, enable electrolyte filling, support mechanical integrity and contribute to safety functions in demanding operating conditions.
With Cell Caps 2, Freudenberg is working to reduce component complexity and improve battery packaging efficiency. The new development integrates the terminal in molded rubber into the base plate of the cell cap. Liquid elastomer is injected into the gap between the poles and the cap base plate, bonding the components together.
According to the company, this approach supports gas tightness, mechanical robustness and electrical insulation while reducing the number of parts and overall component mass. Depending on customer requirements, the second generation technology can reduce the height of the cell cap by up to 30%. This can free up space within the battery cell that can be used for additional energy capacity.
Freudenberg is currently working on mass production of a round cell cap using a manufacturing process based on technology already applied in high volume valve stem seal production.
The company is also expanding its battery safety portfolio with additional cell to cell barriers and venting foam mats. The barriers are available in different thicknesses and material variants, including multi layer structures with foam or elastomer compression layers and UL94 V0 certified heat shield options with adhesive tape.
These components can be adapted to different battery requirements, including thermal resistance, mechanical stability, cell swelling tolerance and compatibility with chemistries such as NMC, LFP and emerging formulations. Venting foam mats are positioned above the cells and are designed to help protect neighbouring cells in the event of thermal runaway.
Freudenberg will also present busbar seal demonstrators showing how sealing components can compensate for thermally induced movement while maintaining protection against media and the environment. In addition, the company will preview advanced battery cooling and heat pump components for electric vehicles.
For electric bus and commercial vehicle applications, developments in battery sealing, thermal barriers and battery thermal management are relevant because they influence pack safety, packaging efficiency and long term system reliability.
