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Federal-Mogul has announced its contribution to the 2011 Chevrolet Volt electric vehicle.

Federal-Mogul innovations include protective coverings from the company’s Systems Protection group for the lithium-ion battery-pack cooling system, braking system and high-voltage electrical system, as well as a number of powertrain and other electrical components.

The liquid-cooling system for the Volt’s lithium-ion battery pack uses Federal-Mogul’s Flexfit and Flexguard hose coverings for abrasion protection, while Twisttube 2420 – a product pioneered for the protection of complex electrical systems – protects the vehicle’s high-voltage cable system against abrasion.

The self-locating Shrinkgard covering completes the array of Federal-Mogul’s System Protection products by providing additional abrasion protection to the brake lines.

Federal-Mogul’s comprehensive range of Systems Protection products, which also are sold under the Bentley-Harris brand, includes solutions for electromagnetic shielding, electrical and mechanical protection, and thermal management.

The Flexfit and Flexguard protective coverings used on the Volt are expandable tubular sleeves that provide flexible protection against abrasion.

Both Flexfit and Flexguard are designed to conform to the routing contours of hoses and lines.

The products are used on the Volt’s coolant hoses and supporting components for the vehicle’s liquid-cooling system, which maintains a consistent temperature for the lithium-ion battery pack.

Flexfit and Flexguard products also protect components of the Volt’s HVAC system.

The Shrinkgard conforms to the Volt’s metal brake line tubes when heated and provides abrasion resistance for wear against other components.

Because of its conformability and tight fit, Shrinkgard can help optimise the component design, location and protection.

Federal-Mogul’s textile-based Twisttube 2420 provides abrasion resistance.

Twisttube was originally developed to provide a wraparound, abrasion-resistant covering with high conformability to bends.

Federal-Mogul System Protection now has developed this material to meet the industry’s high-voltage colour standards.

Twisttube is also available in a version that protects against electromagnetic interference (EMI).

Twisttube is manufactured with a proprietary material technology that can be easily installed on existing electrical/electronic architecture used in instrument panels, engine compartments, vehicle interior systems or other electrical and electronic devices.

The sleeving is available in tubular and self-wrapping varieties.

The material technology of Twisttube achieves a balance of low- and high-frequency shielding because its metal strands are twisted together with filler materials, resulting in a high-strength material.

When woven or braided into sleeves, the materials achieve an optimised blend of metal content and coverage that is lightweight, flexible and durable.

Federal-Mogul’s polyester and metal wrap solutions are said to offer nearly 30 per cent of weight savings over metal over braids, an approximately 40 per cent decrease in bundle diameter and a 55 per cent increase in overall flexibility.


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