Galvanic Corrosion: A Small Interface. A Big Impact.
Galvanic Decoupling for Demanding E-Mobility Applications
Different materials are indispensable in modern electric vehicles. Aluminum, steel, copper and other metallic materials are used wherever their specific properties are required. However, it is precisely at the interfaces between dissimilar metals that a challenge can arise: galvanic corrosion.
When different metallic materials are in electrically conductive contact and moisture or another electrolyte is present, a galvanic cell can form. As a result, the less noble material may experience accelerated corrosion.
Particularly in components that are expected to perform reliably over many years, even small interfaces can have a significant impact.
The solution: specifically decouple and protect dissimilar materials.
Material Expertise for Critical Interfaces in E-Mobility
The requirements for such a solution often extend far beyond simple electrical separation.
What mechanical loads need to be considered? How much compressibility is acceptable? What level of electrical resistance is required? Which media and temperatures will affect the component? And how can the solution be implemented reliably and economically in series production?
This is exactly where Frenzelit comes in.
With extensive expertise in fiber-based and sealing materials, Frenzelit develops material solutions tailored to the specific application. The starting point is not an existing standard product, but the specific technical challenge.
From the selection and development of the appropriate material to component geometry and production-ready design, the result is a solution tailored to the requirements of the application.
Material. Application. Manufacturing.
| Material Expertise Fiber composition, binders and other material constituents can be specifically designed to achieve the required performance characteristics. |
| Application Expertise Frenzelit does not focus solely on individual material properties. Instead, we consider the requirements of the specific installation situation and the interaction with adjacent components. |
| Manufacturing Expertise Future processing requirements are also taken into account. This enables a material solution to become a component that can be efficiently integrated into existing production processes. |
In Practice: Galvanic Decoupling with novaform®
An application in the field of e-mobility illustrates what this might look like in practice.
To provide galvanic decoupling between a high-voltage battery system and the vehicle body, Frenzelit developed custom rings made from novaform®.
For this application, the NBR-bonded fiber sealing material combines two key properties: low compressibility and high contact resistance.
The rings create a non-conductive separation layer between the components. This prevents a direct electrically conductive connection between the battery system and the vehicle body and helps reduce the risk of galvanic corrosion at this critical interface.
From Fiber to Ready-to-Install Component
What makes this special is not just the finished ring.
Frenzelit develops and produces the underlying novaform® materials in-house. Aramid fibers, filler and functional fibers, and the NBR binder are combined in such a way that the material properties required for the specific application can be achieved.
The customer-specific component is then manufactured from this material.
As a result, both material development and component design come from a single source.
novaform® gasket rings prevent corrosion
As the development partner, Frenzelit discovered the ideal fiber mixture, form and delivery method suitable for the customer’s assembly process
Engineered for the Application. Delivered for Manufacturing.
A technically sound solution must also be economically viable for integration into mass production.
That is why, at Frenzelit, development does not end with the individual component.
For the e-mobility application described, the novaform® rings are supplied pre-punched on a roll. This makes them easy to deploy and allows them to be integrated into the customer’s automated manufacturing processes.
This means:
- Customized component geometry tailored to the application
- Defined material properties for the specific application
- Pre-punched components supplied on rolls
- Easy handling within the production process
- Suitable for integration into automated manufacturing operations
This is how material expertise becomes a solution that performs not only in the vehicle, but already in production.
Practical experience: Decoupling of door hinges
Our novaform® 770 material makes an important contribution to high-quality acoustic design in the automotive industry.
Your Challenge. Our Solution: Material Expertise.
Galvanic decoupling is just one example of how targeted material development can solve the challenges of modern e-mobility applications.
Are you looking for a way to reliably separate different materials? Do you need a solution with specific electrical, mechanical, or thermal properties? Or a component solution that can be integrated directly into your production process?
Talk to our experts about your application.
Together, we will develop a material solution tailored to your technical requirements, your component and your manufacturing process.