The news of Hutchinson Precision Sealing Systems

Hutchinson has developed an elastomer compound specially designed to meet the sealing needs of components used for heat pump applications in electric vehicles using the R744 refrigerant (valves, compressors, etc.).

Co-design and validation

The development of this innovative material was made possible thanks to the expertise of our teams in the formulation of elastomer materials and a close collaboration with the Volkswagen Group and a major thermal management equipment manufacturer. In addition to laboratory tests, functional validations were carried out with expert appraisal of the parts, confirming the technical solution with the EPDM 8EP3411 compound. Sealing solutions made with this EPDM are used in series production on vehicles equipped with the MEB platform, such as ID.3.

Thermal performance

Compared with traditional EPDM materials, this elastomer compound offers enhanced thermal performance with a temperature range from -40 to +165°C, corresponding to the optimum operating temperatures for heat pumps running on R744.

High-pressure resistance

A complete re-engineering of existing solutions enabled us to meet the new specifications. The 80 Shore A hardness makes it suitable for high-pressure applications of up to 130 bar. The seal environment still needs to be designed to limit extrusion gaps. The development teams are currently working on an elastomer with a hardness of 90 Shore A for the most extreme pressure conditions.

Resistance to Explosive Decompression (RGD – Rapid Gas Decompression)

Resistance to explosive decompression is a critical characteristic for elastomers to avoid physical degradation of seals (cracking, crazing, bubbles, etc.). Specific tests were carried out to reach the final formulation. 8EP3411 complies with the Norsok M710 standard: Rating 0, confirming the absence of defects after exposure.

A solution for the future

Already used in heat pump systems on buses and trains, and in industrial air conditioning systems such as supermarket refrigeration systems, environmental and now legislative constraints are likely to increase the use of R744 more widely in industrial applications such as residential heat pumps.

The planned end to the internal combustion engine vehicles in Europe in 2035, combined with environmental issues (PFAS, GWP, etc.), also make R744 a serious option for becoming the standard refrigerant for automotive applications in Europe.

Hutchinson, winner of the France 2030 ‘Hydrogen technology brick’ call for projects operated by ADEME, is launching the OBI-1 project to develop economical, high-performance bipolar plates for fuel cells.

Led by the Precision Sealing Systems activity and the Innovation & Research Center, this 43-months project aims to develop composite and metal plates with optimized sealing systems, which are essential for the efficiency and cost of fuel cells. The teams will focus on research into new materials, assembly technologies, and associated sealing systems, while improving transverse conductivity, enhancing corrosion resistance, and perfecting elastomeric sealing with low chemical release.

By 2028, Hutchinson will be able to offer bipolar plate solutions with integrated sealing systems:

• Increased compactness to create smaller stacks or generate more power for the same footprint, improved functional performance and simplified stack assembly.
• Large-scale production in France to maintain French leadership in H2 technology. 

Link to PR

Hutchinson has designed an innovative solution attenuating the sound vibrations emitted by E-compressors and E-Motors.

Our multi-material solution offers an excellent combination of vibration attenuation and absorption, especially in high frequencies (>1000 Hz) which is the range of E-Modules concerned.

Our Acoustic cover is thermoformed, lightweight and made of recyclable materials. It can provide rapid prototype solutions.

Numerical simulations and specific acoustic tests enable us to answer accurately to customers’ specific requirements.

Thanks to our material expertise, we improve E-compressor efficiency and the active cooling systems for E-motors with optimal thermal insulation properties.

This acoustic encapsulation solution has been validated and selected in 2023 by a major international OEM.