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Battery Energy Storage System (BESS) Sealing and Safety Solutions
Powering the Future of Energy Storage
Battery energy storage systems are becoming essential for renewable energy integration, grid reliability, and backup power in high-demand environments. In markets like data centers, uninterruptible power supply (UPS) systems use the same underlying battery technologies to help maintain power continuity and protect critical infrastructure during electrical disturbances. As data processing, cloud services, and electrification continue to increase energy demand, BESS and UPS manufacturers need components that support safe operation, protect against demanding environmental conditions, and help manage heat, pressure, and long-term system performance.
Freudenberg Sealing Technologies helps battery and system manufacturers address demanding BESS conditions with advanced sealing, thermal protection, and pressure management solutions. From cell-level components to system-level safety technologies, our solutions support performance, durability, and operational safety.
Designed for Critical BESS Applications
Battery energy storage systems rely on numerous safety-relevant components to manage temperature, pressure, environmental exposure, and long-term reliability. Freudenberg solutions support applications from individual battery cells to complete energy storage enclosures.
Key application areas include:
- Battery cell sealing and protection
- Cell-to-cell thermal propagation control
- Module-level thermal insulation
- Battery enclosure sealing
- Pressure equalization and emergency venting
- Electrical connection and feedthrough sealing
Why Safety Matters in BESS
As battery energy density continues to increase, thermal runaway remains one of the industry's most significant safety challenges. A single cell failure can generate temperatures exceeding 1,200°C, creating the potential for thermal propagation throughout a module or system. Effective sealing, thermal barriers, heat shields, and pressure management solutions help reduce risk and support overall battery system safety.
Products in Detail
Battery Cell Caps
Battery Cell Caps securely seal and electrically isolate battery cells while supporting pressure management and long-term reliability throughout battery life. Designed for demanding battery environments, they combine robust sealing performance with integrated safety functionality.
Benefits
- Gas-tight sealing performance
- Controlled pressure relief
- Electrolyte-compatible materials
- Enhanced cell safety and reliability
Battery Cell Envelopes
Battery Cell Envelopes protect and electrically insulate the cell stack while helping improve electrolyte wetting, thermal behavior, and manufacturing consistency. Their nonwoven design supports long-term battery performance and energy density improvements.
Benefits
- Electrical insulation
- Improved thermal management
- Enhanced electrolyte distribution
- Supports higher energy density
Thermal Barriers
Thermal barriers help slow or stop thermal runaway propagation by increasing thermal resistance between battery cells and critical components. Available in customized geometries, these solutions help improve battery safety while minimizing weight and packaging impact.
Benefits
- Thermal runaway protection
- High-temperature resistance up to 1,200°C
- Flexible and customizable designs
- Electrical and thermal insulation
Heat Shields
Heat shields are designed to reduce heat transfer between adjacent battery cells and help prevent thermal propagation. Their lightweight design enables improved battery safety with minimal impact on available installation space.
Benefits
- Cell-to-cell thermal protection
- Lightweight construction
- Reduced heat transfer
- Supports thermal runaway mitigation
Gaskets
Battery housing gaskets provide reliable sealing against dust, dirt, water, and other environmental contaminants. Designed for long service life and manufacturability, these solutions help protect critical battery systems throughout their operating lifecycle.
Benefits
- Environmental protection
- Long-term sealing performance
- Simplified assembly
- Designed for battery housings and enclosures
DIAvent®
DIAvent® combines pressure equalization and emergency degassing within a single solution. It supports normal battery operation while helping safely manage pressure build-up during abnormal operating conditions.
Benefits
- Controlled pressure equalization
- Emergency degassing capability
- Resealing functionality
- Supports battery safety and reliability
Plug & Seal
Plug & Seal solutions create reliable connections between housings, pipes, and assemblies. By combining multiple functions into a single component, they help simplify assembly while providing dependable sealing performance.
Benefits
- Moisture and contaminant protection
- Compensates for installation tolerances
- Simplified assembly
- Durable sealing performance
Connector Seals
Connector seals combine electrical connectivity and advanced sealing technology into a single, fully integrated component. By bonding rubber directly to the connector using FACT dry-bonding technology, they deliver superior sealing performance, enhanced electrical conductivity, and greater design flexibility, enabling next-generation system simplification, improved reliability, and increased cost efficiency.
Benefits
- Sealing and Electrical Connectivity in One Component
- Engineered to Enhance Battery Performance
- Reduced System Costs Through Functional Integration
- Accelerated Success Through Customer-Centric Co-Engineering
Busbar Sealings
Busbar Sealings provide reliable sealing and electrical insulation where busbars pass through housings, batteries, inverters, compressors, and other electrified systems. Designed for demanding operating conditions, they accommodate thermal expansion, manufacturing tolerances, and dynamic movements while ensuring long-term sealing performance and system reliability.
Benefits
- Thermal elongation and expansion compensation
- Tolerance and gap compensation
- Helps prevent microcracks caused by thermal and mechanical stresses
- Resistance to multiple fluids, including coolants, oils, and electrolytes
- Enhanced durability and lifetime performance
Materials Engineered for BESS Environments
Battery energy storage systems require materials capable of withstanding demanding thermal, chemical, and environmental conditions over operational lifetimes that can exceed 20 years. EPDM and FKM materials are commonly used within BESS applications because of their durability, chemical resistance, and temperature stability. Quantix® Ultra 94-2 further supports thermal protection applications with advanced fire-resistant performance.
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