Intrusion Protection Plate

Safe maximum performance

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.

Thermal runaway

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

Design Freedom

• 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
• Gasket IP-69k
• Integrated manufacturing clips and mounting points
• Additional fire-resistant materials like ceramic sheets applicable
• Management of fluid conduits, cables, etc.

Material Overview

Thermpolastic solutions

• 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)

Thermoset solutions

• Wet compression molding of sandwich structures:
  • Continuous reinforced GF-Epoxy material in the face sheets
  • Discontinuous reinforced core material (e.g. LFI: PUR + GF)

Cost Reduction

• In-house developed thermoplastic material compounds for injection molding and compression molding
• Function integrated design decreases number of individual components and assembly steps
• Additional corrosion protection is not necessary