We are demanding more and more from the batteries in our cars: fast charging, stable power supply and, above all, long range. Only cells with high energy density can achieve this.
If a battery is damaged, the consequences can be far-reaching. In particular, if objects penetrate the cells, a so-called "thermal runaway" can occur: a chemical reaction in which more and more heat is generated. The result is a fire or even an explosion. The power packs therefore need special protection - to protect the passengers.
Protection from below
The batteries of electric vehicles are usually mounted on the ground. What is good for the center of gravity is not unproblematic in terms of safety. This is because parts can be flung up while the vehicle is in motion, thereby endangering the battery. The solution is an intrusion protection plate, also called underrun protection. This cover secures the battery at the bottom.
Protective shield made of plastic
To prevent the protection from becoming ballast, however, we manufacture the intrusion protection plate from plastic. In this way, we replace solid steel and aluminum plates with a lighter, more cost-effective component. Corrosion is of course not an issue with this material. Thermal insulation is also better than with metal.
Safe like metal, sustainable like ... plastic!
Thanks to the use of fiber reinforcements, the polymer solution is just as safe as its predecessors: Röchling Automotive's plastic intrusion protection plate meets the important standards ECE R 100 and UL94-V0. We are currently researching special variants made of thermoplastic. These can be recycled after their use as intrusion protection plates. With these components at the latest, there are hardly any arguments left for the use of metal.
The most important highlights
Tailored material by using continuous and discontinuous reinforced materials
Flexible part design with high degree of function integration due to process combinations to meet the customer requirements
High damage tolerance at low energy impacts
Superior energy absorption level in the case of high-velocity crash
A thermoplastic material approach ensures good recyclability
Tailored intrusion management by additional structures within the survival space possible
State of the art V0 materials ensure the necessary thermal stability and flame resistance
Your customer benefit through our Intrusion Protection Plates
Full Solution Supplier
Ability to design, develop, produce and test the complete component tailored to customer requirements
Röchling is one of a few suppliers with compression and injection molding under one roof
Structural simulation in-house available
Simulation for processing compression molding in development
Validation from material up to product level
Long-term experience in End-of-Line testing (e.g. quality control)
Global footprint for prototyping and series application
Various press sizes and manufacturing methods available
Adhesive and mechanical fixation of additional components is state-of-the-art
Wall thickness tailored to application between 1,8 and > 5 mm
Continuous reinforced sandwich approach in combination with ribs and beads for increased bending stiffness
Hybrid design with local reinforcement by metal Potential Functional Integration
Integrated manufacturing clips and mounting points
Additional fire-resistant materials like ceramic sheets applicable
Management of fluid conduits, cables, etc.
Injection Molding PP-GF, PA-GF, etc.
Combined compression molding of sandwich structure:
Continuous reinforced PP/GF or PA/GF materials (e.g. Tapes)
Discontinuous reinforced PP/GF or PA/GF core material (e.g. D-LFT)
Wet compression molding of sandwich structures:
Continuous reinforced GF-Epoxy material in the face sheets
Discontinuous reinforced core material (e.g. LFI: PUR + GF)
In-house developed thermoplastic material compounds for injection molding and compression molding
Function integrated design decreases number of individual components and assembly steps