VDA-Wintermeeting 15 th February of 2007 Saalfelden, Austria. Sealing Solutions for CO 2 -HVAC Systems. Dr. Ulrich Frenzel

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1 VDA-Wintermeeting 15 th February of 2007 Saalfelden, Austria Sealing Solutions for CO 2 -HVAC Systems Dr. Ulrich Frenzel Freudenberg GmbH & Co. KG INNOVATIONCENTER, Weinheim

2 Freudenberg Group - Corporate Structure - Parent Company Freudenberg & Co. Business Area Seals and Vibration Control Technology Business Area Nonwovens Business Area Household Products Business Area Specialties and Others Business Groups Business Groups Business Groups Business Groups Seals and Vibration Control Technology Europe Seals and Vibration Control Technology North America Vibracoustic Nonwovens Freudenberg Politex Nonwovens Household Products Chemical Specialties Building Systems IT Services Divisions Research Service Service Support Burgmann Industries Freudenberg GmbH & Co. KG / 2

3 Freudenberg Group - Corporate Structure Africa / Australia 2 Germany 25 Asia 7 South/Central America 4 EU (excluding Germany) 33 North America 25 Other European countries 4 Freudenberg GmbH & Co. KG / 3

4 FDS Business Development turnover in m. employees in Europe : production locations: PLAN Freudenberg GmbH & Co. KG / 4

5 FDS organizational Structure Europe Management Freudenberg Möhlenkamp Dr. Barimani Preisler Simmerrings/ Damperseals Special Sealing Products O-Rings Merkel Freudenberg Fluidtechnic Industrial Vibration Control Flat Gaskets Brake Parts Autom. Public Relations Human Resources Simrit FPS QM & HSE Controlling Technology Corteco Innovation Center Business Area Sales Central Functions Elastomer Devl. Information Technology Corporate Procurement SCM Freudenberg GmbH & Co. KG / 5

6 Sales FDS by Business Areas in 2005 others 8 % Spare Parts (Corteco) 5 % Industrial Vibration Control 2 % O-Rings 6 % Flat Gaskets 7% Turnover 2005: Mio. Simmerrings Dampersealings and Valve Stem Seals 36% Brake Parts 9 % Merkel-Freudenberg Fluidtechnic Special Sealing Products 17% 10 % Freudenberg GmbH & Co. KG / 6

7 Sales FDS by Sectors in 2005 Mechanical Engineering 40% Agricultural- and Construction Machinery 13% Automotive 51% General Industry 39% Trade Railed Vehicles Power Train Engineering 11% 8% 7% Mountings 3% others 4% Automotive Spare Parts 5% Chemical Industry Electrical Engineering 3% 1% Other Industries 14% Freudenberg GmbH & Co. KG / 7

8 Complete Sealing - For Engine and Transmission - Valve cover Cylinder head cover gasket Intake elbow seal Valve stem seal Exhaust elbow seal Cylinder head Gasket Seal for warm water inlet/ outlet O-rings Simmerring for transmission Chain case seal Front crankshaft Simmerring Rear crankshaft Simmerring with Sensor Mechanical face seal for water pump Freudenberg GmbH & Co. KG / 8

Automotive Production Facilities in Europe New York Shock Absorber Remagen Accumulators Kerkrade Mechanical Face Seals

Hoses New York Cramlington Auray Nantiat Chamboret Parets del Vallès Montrond Burscheid Remagen Weinheim Langres Barcelona

Andrézieux Castelli Calepio Panissière Settimo Pinerolo Luserna Ceperka Kecskemét Ploiesti Weinheim Actuators, Transmission

9 Automotive Production Facilities in Europe New York Shock Absorber Remagen Accumulators Kerkrade Mechanical Face Seals Berlin Boots & Bellows, Dust Covers Langres Engine Oil Seals Frame Gaskets Nantiat Cylinder Head Gaskets Montrond Brake Hoses New York Cramlington Auray Nantiat Chamboret Parets del Vallès Montrond Burscheid Remagen Weinheim Langres Barcelona Kerkrade Mâcon Reichelsheim Rubber Moulded Parts Hamburg Velten Berlin Schwalmstadt Reichelsheim Öhringen Oberwihl Kufstein Andrézieux Castelli Calepio Panissière Settimo Pinerolo Luserna Ceperka Kecskemét Ploiesti Weinheim Actuators, Transmission & Axle Oil Seals Oberwihl O-Rings Andrézieux Brake Moulded Parts Pinerolo Valve Ste, Seals Beltan Freudenberg GmbH & Co. KG / 9

10 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 10

11 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 11

12 Technology - Alternative Refrigerants - R152a / GWP =120 Refrigerant is highly inflammable and is not allowed to be used in interior systems. Second heating circle necessary. Modifying of R134a-system required! Additional costs per HVAC system are between 50 to 150,- EUR (Source: Automobil Industrie 7-8/2006) Legislator will strengthen the limit values from 2011! EU-Commission has not decided yet! Goal GWP <50 Fluid H / GWP<10* DP1 / GWP=40* INEOS / GWP=low* * manufacturers instructions Declaration of producers: Not highly inflammable refrigerant, which can be used in common R134a-Systems. Expansion valve has to be modified and because of bad cooling power if applicable the circuit needs to be expanded. Overall view GWP: During the production of 1kg partial fluorescent hydrocarbon approx. 8kg CO 2 will be generated! R744 / GWP =1 R744 has a significant increased pressure and requires a new design of the whole systems. Freudenberg GmbH & Co. KG / 12

13 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 13

14 Optimized Materials for R134a and Drop-In Applications Permeation optimized material has been developed according to OEMspecifications (reduction of total leakage by 50% with R134a) Conform to VW TL concept O-Rings in Air Conditioning System - Material Requirements Auspicious to drop-in applications Selective permeation has no longer strong effects, if permeation in total is reduced factorized permeation violett EPDM optimized violett EPDM Freudenberg GmbH & Co. KG / 14

Optimized Materials for R134a and Drop-In Applications Development activities with Honeywell Fluid H shows selective permeation when elastomer

change of the refrigerant composition) Fluid H does not affect the elastomer Honeywell specifies oil which determines compability with elastomer

15 Optimized Materials for R134a and Drop-In Applications Development activities with Honeywell Fluid H shows selective permeation when elastomer materials are used Application of today s standard materials doubtful because of relative high permeation ratios (selective permeation leads to a change of the refrigerant composition) Fluid H does not affect the elastomer Honeywell specifies oil which determines compability with elastomer R744-material seems to be usable (tests scheduled) & So far not accessible Information about further development necessary Freudenberg GmbH & Co. KG / 15

16 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 16

17 Elastomer Sealing Solutions for R744 Oil Compatibility swelling mechanical properties R744 Permeation pressure temperature R744 Resistance leakage / idle time leakage / operating time swelling expl. decompression Freudenberg GmbH & Co. KG / 17

18 Elastomer Sealing Solutions for R744 Test condition: Stored for 336 hours at 150 C in Lubricant: a) EA 318/169 b) EA 318/183 Volume change [ ] Volume change [ % ] 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM EA 318 / 169 9,6 5,8 10,3 2,1 1,8 EA 318 / 169 9,6 5,8 10,3 2,1 1,8 EA 318 / ,5 16,7 15,4 2 1,6 EA 318 / ,5 16,7 15,4 2 1,6 Change in tensile strength [ ] Change in tensile strength [ % ] 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM EA 318 / EA 318 / EA 318 / EA 318 / Change in elongation at break [ ] Change in elongation at break [ % ] 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM 85 EPDM 85 HNBR 85 EPDM 85 FPM 85 FPM EA 318 / EA 318 / EA 318 / ,1-0,5 EA 318 / ,1-0,5 a) EA 318/169 POE polyolester all materials exhibit excellent resistance b) EA 318/183 Fuchs Reniso ACC64 PAG polyalkylene glycol FKM: very high resistance levels EPDM: moderate swelling, very good resistance, resistant at 180 C (1000h long-term test) HNBR: dramatic change in mechanical value level Freudenberg GmbH & Co. KG / 18

19 Elastomer Sealing Solutions for R744 Oil Compatibility swelling mechanical properties R744 Permeation pressure temperature R744 Resistance leakage / idle time leakage / operating time swelling expl. decompression Freudenberg GmbH & Co. KG / 19

20 Temperature [ C] Alternating Temperature Test at 100 bars and 120 C requirements with customer consultation Elastomer Sealing Solutions for R744 Tests for Explosive Decompression Time [h] grading quantity size < 3 mm > 3 mm x 0 2 >3 x (x) x 4 >3 (x) x 5 destroyed pressure release after 76h within 10 sec 85 HNBR EPDM EPDM FKM bubble grade swelling [%] 4,37 15,16 5,2 58,47 X = determinable 0 = not determinable moderate swelling The FREUDENBERG materials 85 HNBR and 85 EPDM are resistant against explosive decompression in alternating-temperature-tests. Freudenberg GmbH & Co. KG / 20

21 Elastomer Sealing Solutions for R744 Oil Compatibility swelling mechanical properties R744 Permeation pressure temperature R744 Resistance leakage / idle time leakage / operating time swelling expl. decompression Freudenberg GmbH & Co. KG / 21

22 Elastomer Sealing Solutions for R744 measured at R744 quick coupling with d 1 =8mm according to VDA complex of loads material: 85 HNBR factorized faktorisierte leakage Undichtigkeit [g/a] [g/a] O-ring standard design O-ring design Ax O-ring design Ay O-ring design Bx O-ring design By low pressure side high pressure side behind gas cooler high pressure side behind compressor limit of 0,5g per connection and year Freudenberg GmbH & Co. KG / 22

23 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 23

24 Sealing Competence of FREUDENBERG vaporizer expansions valve collector + inner heat exchanger (Behr-concept) connection elements compressor pressure sensor gas cooler service valves Freudenberg GmbH & Co. KG Source: Behr / 24

Sealing Solutions - Connection Elements - Material 85 HNBR 230861 85 EPDM 232444

Temperature range -40 to +180 C Coating requirements Pressure range up to 145 bars

25 Sealing Solutions - Connection Elements - Material 85 HNBR EPDM Solution O-ring Design Permeation ratio <0,5g/connection/year Explosive decompression Temperature range -40 to +180 C Coating requirements Pressure range up to 145 bars Groove Design Assembly forces <100 Nm Oil resistance Ageing Freudenberg GmbH & Co. KG / 25

26 Sealing Solutions - Compressor - O-rings Face seal Soft metals Frame gasket source: Volkswagen PTFE piston rings Freudenberg GmbH & Co. KG / 26

O-ring) Collector Protection Cover source:

27 Sealing Solutions - Components - Expansionvalve Pressure sensor O-rings, special design and bonded source: Volkswagen source: Volkswagen Service valve (Bonded or O-ring) Collector Protection Cover source: Ventrex Freudenberg GmbH & Co. KG source: Volkswagen / 27

28 Service valve - Micro Seal with Self-tighten-effect - Freudenberg GmbH & Co. KG source: Ventrex / 28

29 VDA-Wintermeeting 2007 Agenda 1 Technology Alternative Refrigerants 2 Optimized Materials for R134a and Drop-In Applications 3 Elastomer Sealing Solutions for R744 4 Sealing Competence of FREUDENBERG 5 Conclusion Freudenberg GmbH & Co. KG / 29

30 Conclusion - FREUDENBERG Sealing Solutions for all possible Scenarios - R134a / GWP =1300 Fluid H / GWP<10* (Honeywell) DP-1 (DuPont) / GWP=40* Modification of current material: New material developed with 50% less permeability according to VW TL concept Application of improved elastomer materials for R134a is under investigation INEOS / GWP=low* (INEOS Flour) * manufacturers instructions R744 / GWP=1 Novel materials: 85 HNBR and 85 EPDM New coatings (reduced assembly forces) Innovative O-ring designs Face seal substitutes lip seal Freudenberg GmbH & Co. KG / 30

31 Thank you for your attention! Freudenberg GmbH & Co. KG / 31

CERTIFICATE. Freudenberg Sealing Technologies GmbH & Co. KG. with the organizational units/sites as listed in the annex

CERTIFICATE. Freudenberg Sealing Technologies GmbH & Co. KG. with the organizational units/sites as listed in the annex CERTIFICATE This is to certify that with the organizational units/sites as listed in the annex has implemented and maintains an Occupational Health and Safety Management System. : Development, production