FFD IM - Freudenberg Forschungsdienste SE & Co. KG

Issue 2_2012 

FFD IM 

DIALOG 

More information under www.forschungsdienste.info 

Innovative lithium ion battery separators 

Freudenberg 

Forschungsdienste KG 

u Batteries at FFD – under scrutiny

Table of contents 

2 Table of contents 

1. Editorial P. 3 

2. Innovative lithium ion battery separators P. 4 

3. RFID P. 9 

4. RSSR tribometer P. 14 

5. News from the Senior Scientists P. 17 

6. Seminars P. 20 

CT cut-away view of a winding cell (recorded at FFD Microscopy)

Editorial 

Dear Business Partners, 

To the great surprise of its competitors, BMW succeeded in driving 

home a victory already in the second race after joining in the German 

Touring Car Championship again. This permits a number of conclusions 

as regards the success factors in this fiercely contested race: 

To enter a new field of work, it is imperative to have a high level 

of knowledge and quality for known components. 

In the face of changed underlying conditions, it is decisive to 

adjust to them as quickly as possible. 

Innovative approaches, possibly merely innovative details, are 

instrumental in gaining a leading edge over competitors. 

Thanks to a capable, experienced and committed team, a product 

can rapidly become a success – whether in the preparatory 

phase, in the pits or in the race for victory. 

Some of these factors are repeatedly encountered at Freudenberg. 

For FFD, we will be presenting a number of examples in this issue 

of “FFD Dialogue”. 

The process of generating and saving energy will be one of the 

continuing challenges of the future. With its newly developed battery 

components, Freudenberg can play a very important role on 

the market (page 4). The use of what is, to all intents and purposes, 

known technology in other applications helps to save both 

costs and development time. FFD has applied RFID technology to 

safe work on rotating machinery (page 9). A high-speed method 

for selecting suitable materials and mating materials enables the 

developer to achieve products with a high level of operational stability 

within a relatively short time (page 14). Our committed team 

of experienced experts (page 17) and well trained organisers, 

engineers and scientists (page 20) ensures long-term success. 

I trust that you will find reading this issue both exciting and stimulating. 

Yours sincerely, 

Dr. Gerd Eßwein 

Editorial 

3

Batteries at FFD – under scrutiny 

InnOvAtIve LIthIuM IOn 

bAttery sepArAtOrs 

4 


Introduction 

Battery separators are porous surface-type components which 

prevent electrical contact between the positive and negative elec- 

trodes of a battery cell yet, at the same time permit an unobstructed 

transport of ions between the electrodes. Ideally, separators are 

not involved in electrochemical reactions inside a battery, although 

they influence battery properties such as energy density, power 

density, lifetime and operational reliability to a very considerable 

extent. In the case of lithium ion batteries for classic applications 

in the 4C market (computers, cameras, cellular phones, cordless 

tools), separators are primarily microporous polyolefin-based 

(PP and / or PE) membranes. The ten largest lithium ion battery 

manufacturers alone need more than 450 million m 2 of separators 

per year (2011), with growth rates of more than 10%. The 

advantages of microporous membranes are their thickness (25 µm 

or less) and their small pore sizes (< 1 µm). The disadvantages of 

these membranes are their low melting point (approx. 120°C for 

PE and 160°C for PP), their high shrinkage rate and, in particular, 

their low puncture resistance with regard to electrode particles, for 

example. In 2011, on behalf of the French Ministry of the Environment, 

the French institute INERIS established that conductive particles 

which force their way through a separator have been one of

the main causes for internal short-circuits of lithium ion batteries. 

This has resulted in very cost-intensive recall campaigns by battery 

manufacturers. Since conventional polyolefin-based separators 

have the weaknesses described above, FFD, in cooperation with 

Freudenberg Vliesstoffe KG, has since 2007 been developing separators, 

particularly for large-volume lithium ion batteries. Due to 

their high energy content, these impose totally new requirements 

on the safety of batteries and thus also of separators. 

Freudenberg’s technology 

With Freudenberg’s approach (see Figure 1), an ultra-thin 

temperature-stable PET wet nonwoven is coated with anorganic 

particles and an organic bonding agent. The anorganic particles 

ensure excellent temperature stability and the organic bonding 

agents create a level of flexibility which, despite the anorganic 

particles, does not make the materials brittle but highly flexible. 

Figure 1: Coating of a nonwoven 

Due to temperature stability, the separators developed by Freudenberg 

feature a very low shrinkage rate. Figure 2 depicts a comparison 

between a Freudenberg separator and commercial PO membranes 

after a storage period of one hour at 160°C. What can be 

clearly seen is the shrinkage rate of the wet membrane (1, PE) and 

the unidirectionally stretched dry membranes (2, PP and 3, PE / PP 

multilayer). In both cases, the stress levels of the membranes which 

are frozen at room temperature are increasingly released, resulting in 

shrinkage and thus in a high safety risk. In contrast to conventional PO 

separators, Freudenberg’s products do not show any detectable shrinkage, 

a fact which predestines them for safety-related applications. 

Figure 2: Comparison of the shrinkage rates of different lithium ion separators 

puncture resistance of separators – resistance desired 

In order to be able to determine and assess the relevant safety 

properties of separators, the Physical Testing Department has, over 

the last few years, developed and improved a series of specific test 

methods, including the mixed penetration test (see Figure 3), with 

which the puncture resistance of a separator can be determined. 


5

Figure 3: Mixed penetration test 


6 Innovative lithium ion battery separators 

In this test, the separator is located 

between the anode and 

the cathode in order to better 

simulate the set-up of a battery. 

A voltage is applied at the electrodes 

and then a mandrel with a 

semi-spherical tip is used to exert 

pressure on the battery component 

with force being continuously 

increased until a short-circuit 

results, the separator is thus damaged 

and the anode and the 

cathode come into direct contact 

with each other. The relevant 

force is measured at which the electrical resistance very suddenly 

falls from “infinite” to less than 100 kΩ. Figure 4 shows the results 

of the mixed penetration test as an example using two Freudenberg 

samples (FV-1 and FV-2) and two conventional commercially 

available PO separators. 

Cyclical lifetime – batteries under scrutiny 

For purposes of everyday suitability, lithium ion batteries need not 

only the above-referenced safety-related properties but also a long 

Figure 4: Comparison of the puncture resistance of different separators

cyclical lifetime and a high current-carrying capacity. The Applied 

Physics Department has developed test methods for investigating 

the cyclical lifetime and the current-carrying capacity and provides 

the necessary measuring systems. For this purpose, FFD has 

a multi-channel battery test system which enables the characterisation 

of separators in battery cells of different designs and sizes. 

Due to programmable application software for automated test 

procedures and data evaluation, measurements can be efficiently 

performed at the battery test bay. In addition to the standardised 

test processes from the available test catalogue, customer-specific 

test requirements, e.g. battery tests in climatic chambers, are also 

taken into consideration. 

A large number of factors determine whether the nominal cyclical 

lifetime is reached. The temperature and discharge current (also 

referred to as “C rate”) apply as the most important contributory 

parameters. The C rate specifies the electrical load relative to nominal 

capacitance. At a C rate of 0.5, a rechargeable battery with 

a nominal capacitance of 2000 mAh is discharged at a current of 

1000 mA. Under ideal conditions (temperature of 20°C, current 

of 1C nominal ), commercially available series cells should have at 

least 75% of their initial capacitance after more than 500 complete 

charging / discharging cycles. Figure 5 shows the cyclical 

lifetime of type 18650 winding cells with Freudenberg separators. 

Figure 5: Determination of cyclical lifetime 

To ensure effective usage of the overall capacitance of a rechargeable 

battery, battery manufacturers recommend a defined 

electrical load at approx. one fifth of the nominal current, i.e. at 

approx. 0.2 C. When increasing the current load to many times the 

nominal capacitance, the actually usable capacitance decreases 

significantly, this being due to the load-dependent increase in 

internal battery resistance. Due to its material properties and 

coating topology, the separator in use makes a by no means 

negligible contribution to a cell’s internal resistance. 

Figure 6 shows the load-dependent capacitance of lithium ion 

batteries with identical electrodes but different separators which 

means that differences in capacitance are attributable to the se- 


7

Figure 6: Comparison of discharge rate-dependent capacitance of different 

lithium ion batteries 


8 


parator. The influence of the separator 

on capacitance is easily 

discernible, with FV2A being the 

first developed separator and 

FV2B, FV2B2 and FV1C the separators 

which have been optimised 

in terms of internal resistance. 

Comparison of the capacitances 

shows that, due to a continuous 

improvement in coating recipes 

for separators, the actually usable 

battery capacitance has 

been increased. 

Conclusion 

It has been shown that innovative lithium ion battery separators 

have been developed featuring not only good electrochemical behaviour 

but also, in particular, considerably improved safety properties 

which distinguish them from conventional PO separators. 

In addition to their very low shrinkage rate, these separators have 

a very high puncture resistance which particularly recommends 

them for large-surface, safety-related lithium ion cells in both 

stationary and mobile applications. Alongside separator development, 

over the last few years an almost complete test catalogue 

for the characterisation of separators and lithium ion batteries 

has been put together at FFD. In 2011, the market for lithium ion 

separators was more than 450 million m 2 with a continued high 

growth rate in which Freudenberg wishes to participate. 

your contacts: 

Marina Senina 

Physical Testing 

Tel.: +49 (0)6201 - 80 38 27 

Fax: +49 (0)6201 - 80 38 27 

marina.senina@ 

freudenberg.de 

Süleyman Altuncu 

Tel.: +49 (0)6201 - 80 49 55 

Fax: +49 (0)6201 - 80 30 63 

sueleyman.altuncu@ 


Dr. Michael Roth 

Tel.: +49 (0)6201 - 80 52 60 

Fax: +49 (0)6201 - 80 52 60 

michael.rath@freudenberg.de

As non-contact machine guards 

rFID 

Introduction: 

In many processes, it is still imperative to move items to be processed 

to the processing point by hand. Classic examples to this 

effect may be found in mechanical workshops. Circular and band 

saws, chamfering benches and sheet-metal bending machines 

may be primarily referred to as examples. However, in typical processes 

at Freudenberg, such as the mixing and rolling of rubber 

compounds or foularding, manual handling is required in some 

cases. In all these specified processes, staff are inevitably exposed 

to a potential hazard. 

As conventional protection of staff in danger zones, three possibilities 

are available, although they are subject to restrictions: 

Permanent separating machine guards. In this case, production 

items cannot be moved to the processing point by hand. 

Movable separating machine guards. If a guard door is used, 

the machine is emergency-stopped. Movable machine guards 

with an approach function generally have recesses through 

which the production item can pass. If the guard is moved by 

part of the operator’s body, an emergency stop is triggered. The 

disadvantage is that, for many production items, the recess has 

RFID 

9

RFID 

10 RFID 

to be so large that the operator’s arm, for example, can also 

access the danger zone or the recess has to be dimensioned 

sufficiently small so that an emergency stop is triggered by a 

production item when passed through. 

Non-contact machine guards. Such available guards, such as 

light curtains, cannot distinguish between a production item and 

part of an operator’s body. 

For some applications, RFID (radio-frequency identification) technology 

is suitable for the installation of a machine guard. RFID 

uses electromagnetic waves for identification purposes. 

This technology is actually familiar to everyone as it is used in antitheft 

tagging systems in department stores. Articles of clothing are 

often fitted with a transponder (or radio tag). Devices which create 

an electrical field are positioned at the entrances to department 

stores. The transponder detects the electrical field on approaching 

it and sends a signal to an evaluation unit which generates an 

acoustic signal prompting the customer with an unpaid-for item to 

think twice before leaving the premises and to pay for the article 

in question. 

This principle can also be used on a machine guard. 

Function and elements of an rFID machine guard 

For the reasons outlined above, FFD decided in 2010 to introduce 

a RFID machine guard on a laboratory roller mill. This system comprises 

a limited number of components. The antenna is the core 

element of the system. It generates the electrical field (protective 

field) and consists of an extended conductor through which a current 

flows. Using a low-frequency AC current (9 kHz), a cylindrical 

magnetic field is generated which has a very high level of penetration 

through almost all materials. The antenna is positioned in 

parallel to the roller clearance above the rollers. 

To protect the operator’s hands, two transponders have to be worn 

on his or her wrists. Each transponder detects the field and sends 

a signal to the evaluation unit. In the X, Y and Z directions, the 

transponders are fitted with a coil which means that it is irrelevant 

how a transponder enters the field.

In our case, active transponders are used which draw the energy 

needed for signal transmission from a battery. 

The evaluation unit receives the signals sent by the transponders 

and the self-test module. These signals are redundantly processed 

by the control unit. The evaluation unit supplies the signal for triggering 

an emergency stop to the machine’s control unit. 

These imperative functional units are supplemented by different 

additional devices which are to ensure that functionality is permanently 

monitored. For visual display of the protective field boundary, 

a linear laser is used to project a mark on the roller. Since it is 

absolutely necessary for the machine guard to continuously check 

whether the protective field is available, a self-test module is used. 

This module is positioned in the protective field which it monitors. 

As soon as the protective field is no longer available, the self-test 

module sends a signal to the evaluation unit and the machine is 

emergency-stopped. This could, for example, be the case due to a 

broken cable or a power failure. 

To ensure that the transponders are applied, they have to be 

logged on at a log-on unit. It is only then that the system can be 

started. Successful log-on provides the operator with the information 

that the battery still has a lifetime of at least eight hours. In the 

case of our roller mill, log-on has to be repeated after a pre-set 

time in order to ensure that rolling is continuously monitored by a 

member of staff. The roller mill is then emergency-stopped upon 

expiry of this time. 

The objective was to achieve a finalised safety concept with a very 

high level of protection in the system. For this reason, traditional 

machine guards were also kept. FFD’s roller mill continues to be 

equipped with emergency stop pushbuttons, toggle triggers and 

a cut-off rocker. The rocker as a machine guard with an approach 

function has, however, been modified so that the roll of uncured 

rubber can be rolled and turned out and the additives dosed in 

an ergonomically favourable manner, providing optimum process 

possibilities. 

rFID workshop 

FFD invited colleagues interested in this subject to participate in 

the RFID workshop 

to present the mode of operation of an RFID machine guard 

to discuss the possibilities and limits of application 

to develop suitable decision-making aids for usage 

and thus to define underlying conditions for usage at Freudenberg 

At this workshop, RFID technology was presented by the manufacturer. 

During the talk given, if became clear that a wide range of 

different possible applications are conceivable. 

RFID 11

RFID 

12 RFID 

The theory block was rounded off by a close look at the laboratory 

roller mill in FFD’s Elastomers Pilot Plant . All participants had the 

possibility of seeing for themselves the different functional elements. 

They found it particularly interesting to talk with colleagues on site 

who already work with the RFID machine guard. It was in this connection 

that a specially positive aspect became clear. Although the 

machine guard is not mandatory since the transponders have to 

be worn by staff, a high level of motivation to do so is apparent 

since the RFID machine guard permits considerably more ergonomic 

work than was previously the case. The roll of uncured rubber is 

now rolled in an ergonomically more favourable working position 

and, in order to be turned out into the clearance between the rollers, 

it need not be lifted over a separating machine guard. 

Finally, there was an intensive discussion about which technical 

and organisational basic conditions have to exist for suitable 

usage of this technology. 

basic conditions for application of rFID technology as machine guards 

The relevant workplaces have to be continuously manned by a 

limited number of staff. Machinery which is used by many 

persons for brief activities is not suitable. For example, it is not 

very likely that staff who use a band saw in a workshop for short 

periods only always think of wearing the transponders. 

Only machinery should be considered on which process items 

are currently moved to the processing point by hand. Machinery 

on which a fixed or movably separating or non-contact machine 

guard is suitable without restricting the process possibilities is 

unsuitable for the use of RFID. Such examples include injection 

moulding machines and presses. 

The technology must be “just right”. For example, the switching 

times and the braking distances of the machine have to be 

designed in such a way as to permit safe braking before the 

hazard point can be reached.

examples of suitable machinery 

Old machinery, e.g. old roller mills which have not yet been 

fitted with machine guards or which are only protected by a 

Bowden cable emergency stop above the clearance between 

the rollers 

Bale openers, waste presses 

basic conditions for organisation 

Hazard evaluation with an analysis of the residual hazards 

Limitation of the number of staff to a minimum 

Operating instructions and briefing 

Regular adjusted checking of the emergency stop function 

Conclusion 

FFD’s experience shows that, under certain defined conditions and 

constraints, an RFID machine guard can make a very positive contribution 

to machine safety. A key factor is the readiness of staff 

to move over from a “visible” separating machine guard to an 

“invisible” one. Active staff involvement from the very beginning is 

a basic condition for the usage of such systems. 

your contact: 

Ulrich Freund 

Tel.: +49 (0)6201 - 80 42 74 

Fax: +49 (0)6201 - 80 30 63 

ulrich.freund@ 


RFID 13

Establishment of a test method… 

rssr trIbOMeter 

14 RSSR Tribometer 

… required for rapid assessment of elastomer / lubricant combinations 

Introduction 

For the design of dynamic seals with radial shaft sealing rings 

(RSSR), not only a large number of other influencing factors but 

also the selection of suitable elastomer / oil combinations plays 

a decisive role. At present, no standardised test method exists for 

the purpose of recording the wear and friction of simple material 

samples, taking into consideration operating conditions such as 

sealing geometry, contact force, circumferential speed and temperature. 

For investigations of elastomer / oil combinations on radial 

shaft sealing rings, it is, due to different shrinkage behaviour, 

frequently imperative to produce a separate sample tool for each 

elastomer compound. 

In order to exclude material combinations which are unsuitable at 

an early stage, the RSSR tribometer was developed and tested as 

a dynamic test method within the context of project 664 of DGMK 

(German Society for Petroleum and Coal Science and Technology), 

enabling a preselection of suitable materials on the basis of 

easy-to-manufacture elastomer samples. In order to establish this

test method as a standard, we are currently searching for partners 

who are interested in jointly implementing such a solution. 

Design and mode of operation 

The basic design of the RSSR 

tribometer is depicted in Figure 

1. A circular ring-shaped ela- 

stomer test specimen is pressed, 

at a defined force, against a 

truncated-cone shaft test specimen. 

The contact area between 

both test specimens represents 

the contact between the radial 

shaft sealing ring and the shaft 

itself. 

The shaft test specimen is dri- 

Figure 1: Mode of operation of the RSSR tribometer 

ven via a shaft and the moment 

transferred to the elastomer test 

specimen is recorded. The contact area is located in a container 

filled with the test oil. The area below the elastomer test specimen 

can be filled with air. 

In addition to selecting the 

materials for the elastomer test 

specimen, shaft test specimen 

and test oil, the parameters oil 

sump temperature, circumferential 

speed and contact force 

can be set. Figure 2 shows the 

course of the friction moment 

for different test oils when 

using a test specimen made 

of nitril butadiene rubber during 

the 20-day standard test 

Figure 2: Tests with RSSR and RSSR tribometer 

procedure. Furthermore, the 

influence of the three cycles 

(see Figure 2) in which the circumferential speed is varied can be 

clearly seen. 

results from investigations on radial shaft sealing rings and 

rssr tribometer in comparison 

The basic suitability of the RSSR tribometer is examined by investigations 

of a sample elastomer / oil combination of a nitril butadiene 

rubber with a conventional mineral oil, and the results of the 

RSSR tribometer are compared with those of radial shaft sealing 

rings of the same material. Figure 3 shows the influence of the parameters 

oil sump temperature and circumferential speed at the sti- 

RSSR Tribometer 15

Figure 3: Test procedure: a NBR with five oils in comparison 

RSSR Tribometer 

Figure 4: Comparison of wear sustained by the RSSR and the RSSR tribometer 

16 RSSR Tribometer 

realisation 

pulated linear load. In the case 

of the RSSR tribometer and the 

radial shaft sealing ring, the 

influence on wear (see Figure 

4) is comparable. Due to the 

radial force which, during the 

test, decreases in the case of 

the radial shaft sealing ring as 

a result of the change in temperature 

and wear, the RSSR 

tribometer, however, causes 

wear to increase at about 

twice the rate. 

The investigations show that 

testing with the RSSR tribometer 

is highly suitable for the 

purpose of comparing material 

combinations. Further standardisation 

of the test method is 

currently the subject of DGMK 

project 738. 

Investigations performed so far are taking place at ten prototype test 

bays of TUHH. Partners from the DGMK project have approached 

us in order to assume responsibility for the construction, sales and 

servicing of such dual test bays. 

At present, on the basis of these prototypes, marketable test bays 

are being realised in the form of dual test bays. In order to esta- 

blish the new method on as broad a basis as possible, we are currently 

searching for further partners and potential customers who 

wish to use such a method within the context of development and 

selection of elastomer seals and / or lubricants and participate in 

the realisation of test bays or who are interested in acquiring RSSR 

tribometer test bays. 

your contacts: 

Dr. Stefan Sindlinger 

Tel.: +49 (0)6201 - 80 36 90 

Fax: +49 (0)6201 - 80 36 90 

stefan.sindlinger@ 


Dr. Ravindrakumar Bactavatchalou 

Tel.: +49 (0)6201 - 80 24 36 

Fax: +49 (0)6201 - 88 51 91 

ravindrakumar.bactavatchalou@ 

freudenberg.de

News from the Senior Scientists 

Figure 1: Input of the major stretches in the “invariant” app 

Mobile engineering by “app” no longer a dream of the future 

… was the headline in the newspaper published by the Association 

of German Engineers “VDI-Nachrichten” in April 2011 and 

was repeated in a similar form in April 2012. FFD, too, is facing 

up to this challenge and is currently investigating possibilities of 

providing appropriate services for mobile technical applications. 

Within this context, Dr. Baaser has, together with two students 

from Bingen University of Applied Sciences, developed an app 

which maps his basic investigations for representing possible deformation 

modes of elastomers onto the plane of invariants. 

Figure 2: Graphic output of deformation on the plane of invariants I 1 -I 2 

The classic material models for 

elastomers are based on the 

deformation invariants; exten- 

sions of these models are at least 

based on these classic descriptions. 

This raises the question, 

also in discussions with customers, 

regarding a suitable visualisation 

of current deformations 

in rubber components. As early 

as in the mid-20th century, Prof. 

L.R.G. Treloar was concerned 

with this task and, to this effect, 

suggested the representation 

of all possible deformations of 

rubber materials on the plane 

of invariants. Thus, it is very 

impressively possible to classify 

all deformations between the 

uni-axial and bi-axial prototype 

modes. 

The assessment of these modes 

is a crucial aspect of [1] and 

[2] and aims later at lifetime 

estimation for elastomers. The 

Adjunct professor Dr.-Ing. habil. 

herbert baaser 

Senior Engineer for Physical 

Material Properties and Life 

Cycle 

Tel.: +49 (0)6201 - 80 68 82 

Fax: +49 (0)6201 - 88 30 84 

News from the Senior Scientists 17

Figure 3: LEVITEX crankshaft seal, 1999 – 

2003 

News from the Senior Scientists 

18 News from the Senior Scientists 

user interface of this app currently comprises two screens 

on a mobile device with Android or the Apple operating 

system. The first page (see Figure 1) is primarily for the 

purpose of entering two stretches of the material. This deformation 

is then visualised in the graphic output of the 

second page (Figure 2) on the plane of invariants for incompressible 

materials. 

If you have any suggestions or other ideas on this complex 

subject, please contact Dr. Baaser who would be delighted 

to provide you with this application as a “tool” and for 

demonstration purposes. 

FFD’s CAe supports LevIteX developments for Fst-Ape and burgmann- 

Automotive 

An idea and development of Burgmann Automotive 

for gas-lubricated crankshaft seals, now ten 

years old, have been picked up at FST again. 

This sealing concept is currently being refined at 

FST under the aspect of CO2 savings within the 

context of the LESS (Low Emissions Sealing Solution) 

package. A new approach in which an elastomer 

spring is to be used in combination with 

megaseries-suitable face geometries is shown 

as a cross-section in Figure 4. It is thus possible 

to reduce manufacturing costs to such an extent 

that cost-effective usage is directly worthwhile. In 

addition, benefits result due to the elastomer 

spring since the friction-prone ancillary seal , as 

used in conventional crankshaft seals, is no longer 

needed. The first few studies on this concept 

have evolved with Burgmann’s calculation program 

for crankshaft seals in cooperation with 

Dr. Klaus Lang of Burgmann (Wolfratshausen). 

Figure 4: Design and refinement of Burgmann’s LEVITEX 

The first design of the elastomer spring was re- 

seal 

alised using FFD’s WebFEM program. For complete 

optimisation of the functionality and harmonisation of the 

components, Burgmann’s calculation program is now being linked 

to Dr. Baaser’s developments. This enables a computer-aided structural 

optimisation of the overall concept. At this point, there is also

Figure 5: Axi-symmetrical FE model of an elastomer spring 

Figure 6: Axial stress in the cross-section of the elastomer spring 

close cooperation with Frank 

Schönberg who analyses such 

optimisation procedures within 

the context of robust design in 

cooperation between FST, FFD’s 

CAE and the University of Technology, 

Darmstadt. 

For structural optimisation of the 

elastomer spring, in this project, 

a special element formulation 

including material behaviour for 

elastomers has been implement- 

ed on the basis of a separate 

FEM program system DAEdalon 

which is freely available on the 

internet as open-source software 

under www.DAEdalon.org. The 

possibilities offered by such a 

software package have already 

been presented in a book (Figure 

7) authored by Dr. Baaser and 

have now been used for a development 

at FST for the first time. 

Figure 5 shows the axi-symmetrical 

model of the crankshaft seal’s 

elastomer spring; a calculation 

result obtained in the course of 

structural optimisation is specified 

in Figure 6. The resulting axial 

stress (in N/m²= Pa) is shown. 

(1) Baaser, H.: FEM-Simulation von Elastomerbauteilen. ATZ – Automobiltechnische 

Zeitschrift, April 5, 2010 

(2) Baaser, H., Schobel, A., Michaeli, M., Masberg, U.: Vergleich von äquibiaxia- 

len Prüfständen zur Kalibrierung von Werkstoffmodellen, Kautschuk Gummi Kunststoffe, 

May 2011 

(3) Baaser, H.: Development and Application of the Finite Element Method based 

on MatLab, Springer, 2010 

Contact: 

Adjunct Professor Dr.-Ing. habil. Herbert Baaser 

Senior Engineer for Physical Material Properties and Life Cycle 

Tel.: +49 (0)6201 - 80 68 82 

Fax: +49 (0)6201 - 88 30 84 

herbert.baaser@freudenberg.de 

Figure 7: Book on DAEdalon 

News from the Senior Scientists 19

to register, please contact: 

Ms. Ulrike Kast 

Tel.: +49 (0)6201 - 80 48 80 

Fax: +49 (0)6201 - 88 30 63 

ulrike.kast@freudenberg.de 

Seminars at Freudenberg Forschungsdienste KG 

Location: FFD, 

Höhnerweg 2–4, 

69465 Weinheim 

Fee: EUR 1,350 

plus VAT 

Date: 07. - 08.11.2012 

Location: FFD, 

Höhnerweg 2–4, 


Fee: EUR 1,050 

plus VAT 

Date: 20. - 21.11. 2012 

20 Seminars 

r&D Funding by the German state – 

non-repayable Grants for your Company 

Target group: This seminar is aimed at all project managers who 

wish to submit a funding application or who have already applied 

for/been granted funding for their R&D project. This is of relevance 

to anyone wishing to round off their knowledge about ruleconformant 

processes and requiring decision-making assistance. 

Contents: The participants find out how their company can profit 

from state R&D funding. Knowledge about formal processes from 

the preparation of an outline through to project close-out including 

price checking is provided. Important elements of the prescribed 

cooperation agreement, e.g. know-how protection, are presented. 

The experienced speakers provide tips from everyday administration 

practice in which they have successfully implemented numerous 

R&D funding projects. 

seminar on Failure Analysis in plastic Components 

Seminar management: Siljana Lietz, FFD / Dr.-Ing. habil. Sonja Pongratz, VW 

This seminar is aimed at engineers and technicians who wish to 

gain a thorough understanding of failure mechanisms in plastic 

components and become familiar with methods of systematic causal 

analysis. At this seminar, possible causes of failure in moulded 

parts and the methods of investigation used in failure analysis will 

be presented. The systematic processing of instances of failure will 

be demonstrated using a guideline. 

seminar on rubber / Metal bonding 

Seminar management: Dr. Michael Ballhorn 

This seminar is aimed at engineers, chemists, technicians and machine 

operators involved in the area of rubber / metal bonding. 

Contents: rubber: classes, processing and bonding capacity; metal: 

cleaning, pretreatment (mechanical, chemical, phosphating), 

wetting; bonding agents: composition and effects, application, 

adhesion mechanisms, rubber and surface analytics, approaches 

and remedial measures in cases of failure, practical demonstrations 

and exercises. 


Ms. Sonja Heinzelbecker, tel. +49 (0)6201 - 80 55 63, 

fax +49 (0)6201 - 88 55 63, sonja.heinzelbecker@freudenberg.de 

Location: Freudenberg, 

Building 23, 

Höhnerweg 2-4 

69469 Weinheim, 

Fee: EUR 500 plus 

VAT for 

Freudenberg staff, 

EUR 750 plus 

VAT for 

external participants 

Date: 15.11.2012, 

8.45 a.m. - 5 p.m.

Location: FST Academy 

Building 75 

Fee: Euro 690 plus VAT 

Date: 09./10.10.2012 


Building 75 


Date: 23./24.10.2012 


Building 75 


Date: 20./21.11.2012 


Building 75 


Date: 11./12.12.2012 

Location: FFD Building 32 


Date: 18./19.12.2012 



Date: 06./07.11.2012 

seminar series “elastomers processing at Freudenberg“ 

Seminar management: Dr.-Ing. Andreas Kammann 

The seminars are aimed principally at participants with a technical 

or scientific background and are especially suitable for those 

employees new to the company in the areas of production, development 

and marketing, etc. The aim of the seminars is to enable 

them to familiarise themselves quickly and in a targeted way with 

what for most is an unknown field. 

Module 1: Materials 1 

Principles of polymer chemistry; what is “rubber”? deterioration 

protection and fillers; plasticisers and auxiliary products; general- 

purpose rubber; high-performance rubbers and specialities; technical 

thermoplastics as metal substitutes; thermoplastic elastomers (TPE). 

In cooperation with the FDS Academy 

Module 2: Materials 2 

Dynamic-mechanical behaviour of polymers; bonding of rubber; 

practical; surface modification and tribology; liquid silicone rubber; 

REACH; threats and opportunities of nanotechnology; formula 

optimisation; technical thermoplastics as metal substitute; polyurethanes. 


Module 3: processes 1 

Technology of mixing; visit to the rubber mixing facility, mixing 

process in internal mixers, alternative mixing processes; development 

of the mixing process; principles of vulcanisation; vulcanisation 

process; special processes; TPE fabrication; moulding preparation; 

process data processing. 


Module 4: processes 2 

Processing following the internal mixer; scale-up; influence of the 

mixing process on constituent characteristics; approaches to mix- 

ing process optimisation; manufacture of natural rubber flooring; 

process optimisation in elastomers processing; finishing of mould- 

ed rubber parts; thorough examination of processing processes; 

rapid prototyping. 


Module 5: products 

In this seminar, the developers of various product areas deal with 

the basic physical properties of their product groups. The participants 

are given a broad outline of the entire range of products 

of Freudenberg Seals and Vibration Control Technology and of 

Vibracoustic. 

Module 6: Mould technology and Mould Cleaning 

Mould steel, cold runner technology, mould coatings, physicaltechnical 

principles of mould cleaning, microblasting, cleaning 

with dry ice (including practical demonstration), laser cleaning 

(including practical demonstration), ultrasonic cleaning, separa- 

Seminars 

21



Date: 16./17.10.2012 



Date: 19.10.2012 



Date: 22./23.01.2013 



Date: 06./07.12.2012 



Date: 16.11.2012 

22 Seminars 

ting agents for elastomers processing, fundamentals of mould technology, 

rapid tooling, design of injection molds, laser structuring. 

Module 7: test Methods and Analytics 

Static test methods, dynamic test methods, lifetime prediction, 

consistency tests, caloric properties, optical microscopy, scanning 

electron microscopy, elastomer analytics, failure analysis. 

seminars on Other subjects 

Seminar management: Dr.-Ing. Andreas Kammann 

From Caoutchouc to rubber – a starter seminar 

This seminar answers a number of basic questions on elastomer 

chemistry: What is rubber at all and what is caoutchouc? How is 

caoutchouc made into rubber? Why do so many different components 

become part of a rubber compound? What actually happens 

during moulding and vulcanisation? Why are there so many 

different types of caoutchouc? 

polyurethanes – Materials and processing 

Basics of polymer chemistry, raw materials for polyurethanes, 

processing methods (casting, RIM, injection moulding, extrusion, 

foaming, impregnation, etc.); mechanical and chemical properties; 

analytical investigations. 

practical seminar: Installation of an Injection-Moulding Machine and 

troubleshooting 

This seminar is aimed at all machine operators who have al- 

ready gained initial experience in the processing of elastomers and 

are, in future, to work more independently due to a more in-depth 

understanding of the process and assume tool setter duties. Content: 

basics of elastomer injection moulding, practical set-up of an 

injection-moulding machine, fault detection and remedial measures. 

Industrial property rights – patents, trademarks and Designs 

This seminar is aimed at anyone who is involved in the development 

and marketing of technical products (chemical engineers, 

chemists, engineers, technical specialists, material developers, 

purchasers, sales staff and commercial administrators). Content: 

patents, utility models, trademarks, designs, protective range of a 

patent or design, patent strategy. 

Further information 

on our range of seminars may be found at any time under: 

www.forschungsdienste.info 


Ms. Simone Horn, tel. +49 (0)6201 - 80 48 80, 

fax +49 (0)6201 - 88 30 63, simone.horn@freudenberg.de 

We reserve the right to reject requests for registration submitted by staff from 

the competitors of the Freudenberg Group.

Impressum 

Freudenberg 

Forschungsdienste KG 

Published by: Freudenberg Forschungsdienste KG, 


Germany 

Editor-in-Chief: Martin Gramlich 

Editorial Staff: Dr. Katharina Müller, Andrea Deis, 

Ulrike Kast, Sabrina Lemke, 

Dr. Christof Schmitz, 

Dr. Ulrike Herrlich, Dr. Franka Geiß 

Layout: Ehret Design, www.ehretdesign.de 

Freudenberg Forschungsdienste KG 

69465 Weinheim (an der Bergstraße) 

Telefon +49(0)6201 80-5123 

E-Mail ffd@freudenberg.de 

www.forschungsdienste.de 

23

FFD IM - Freudenberg Forschungsdienste SE & Co. KG

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