Innovations in all aspects of modern electromobility
Requirements due to electromobility
Electromobility is currently one of the four megatrends in the automotive world. Reduction of emissions such as CO2, NOX and particulate matter are on everyone’s lips. Far-reaching changes in mobility behavior present vehicle manufacturers in particular, but also automotive suppliers such as HEYCO, with new challenges every day.
We at HEYCO were quick to adapt to this and are therefore working closely with our customers on the mobility concepts of the future. This involves both specific components that are used exclusively in electromobility, but of course also components that have been adopted from classic vehicle construction.
These can be components around the battery, the core component of electromobility, but also adjacent components that protect the relevant installation spaces from external influences. These multi-component covers and structural elements generally integrate several functions and primarily serve the functional safety of the vehicle as a whole and the protection of passengers in the event of a crash or fire.
Thanks to its broad positioning, the HEYCO Group is predestined to manufacture hybrid and cross-functional components made of metal, plastic and technical textiles that meet the highest standards of automotive safety. We are just as familiar with all common automotive requirements as we are with agile simultaneous engineering projects – an asset that is particularly important in this rapidly developing technology.
Battery
The central elements of the battery system are the individual battery cells, which essentially occur in the vehicle in three formats. Both the round cells, which are reminiscent of conventional batteries, and the flat pouch cells or prismatic cells offer a high energy density and are selected accordingly depending on the vehicle architecture.
The HEYCO Group has been involved in joint development projects directly with its customers for many years and already has numerous battery-related components in production. In addition to the actual cell frames for holding round cells and their central supply with cooling media, HEYCO’s core competencies include fire protection and crash safety.
Cell frame (HEYCO) equipped with 40 round cells. The different materials (black/hard and yellow/soft) and the overmoulded metal inserts are clearly visible. (Source: AMG)
Cell frame
The cell frame is the central component in the battery box and is used to hold and cool the round cells. The high level of complexity is due to a structure with several materials in 2-component injection molding with simultaneous overmolding of metal inserts made of a special alloy.
The hard component of the injection-molded materials ensures dimensional stability and guarantees geometrically precise mounting of the round cells, while the soft component ensures the tightness of the system through which the cooling medium flows.
The metal inserts are used to contact the round cells and ensure the high energy density of the overall system by interconnecting them.
In addition to the multi-component injection molding mentioned above, the complex and fully automated production process for the battery cell frames includes numerous other operations such as laser welding, laser marking, high-voltage testing and bending of the contact lugs.
Fully automatic multi-component injection molding machine with rotary table
(Source: HEYCO)
Special machine for bending the overmolded metal inserts into contact lugs
(Source: HEYCO)
Laser welding machine for joining the various battery components
(Source: HEYCO)
Flame and fire protection equipment
According to the latest findings, electric cars do not have a higher fire risk than conventional cars with combustion engines. Electric vehicles can also be extinguished by firefighters, although firefighting may be more complex.
Nevertheless, the issue of fire protection in connection with electric vehicles is of particular importance. While conventional body shapes, in which the combustion engine has been replaced by the battery system, have been the main focus to date, other vehicle architectures will be used in the new and future car models.
Some of the battery systems are integrated into the body as load-bearing elements. As the batteries are therefore in the immediate vicinity of the passenger cabin, occupant protection is particularly important in the event of an accident.
The HEYCO Group and its subsidiary CARL STEINMANN Kunststoffverarbeitung GmbH offer a wide range of solutions that prevent the spread of fire long enough to allow all occupants to escape the danger zone.
Arrangement of the battery modules in the VW ID.3
(Source: Volkswagen)
Hybrid components made of plastic and fire protection materials
Recent ADAC tests have shown that vehicle fires do not occur more frequently in electric vehicles than in conventional combustion vehicles. However, in the unlikely event of an uncontrolled battery fire, known as a “thermal runaway”, external fire protection must be used to ensure that the occupants can leave the vehicle safely.
For this purpose, protective elements made of special fire retardants and applied fire protection materials are positioned over the relevant parts of the battery system. In addition to a correspondingly high dielectric strength, these have above all a high heat resistance over a defined period of time.
Fire protection material (type CS-TL 0005) from CARL STEINMANN Kunststoffverarbeitung GmbH applied to an aluminum panel.
Advantages of the material:
- Flexible in original condition
- Very low thickness
- Highest heat resistance
- Low weight
The HEYCO Group already supplies appropriate fire protection materials for high-voltage battery systems in series production.
This material group can be flexibly modified for the respective application depending on the requirements and is characterized by its excellent fire protection properties combined with low weight and thickness. The STEINMANN material withstands direct exposure to flames of 1400°C for more than 10 minutes and also meets all the other requirements specified by car manufacturers for occupant safety. The material is also particularly tear- and cut-resistant, clean and easy to work with.
Cooperation between HEYCO and STEINMANN development experts has made it possible to develop and test innovative hybrid components. For this purpose, corresponding covers and frame parts were fitted with STEINMANN material and successfully subjected to the usual tests. The result: depending on the application and positioning in the vehicle, the fire protection material can either be overmolded with special plastic materials or ultrasonically welded onto them.
These results open up a wide range of solutions for lightweight and form-fitting plastic covers that are also equipped with fire protection material. Such components are also more cost-effective than alternative aluminum panels.
Possible applications include covers and fire bulkheads in batteries with round, pouch or prismatic cells. It is also possible to integrate additional functions such as cooling or to install other assemblies.
Example of a frame part made of injection-molded plastic (blue) with suitably applied fire protection material.
(Source: HEYCO)
Mica components
Another group of fire protection components from Carl Steinmann are prefabricated panels made of mica material. Mica or mica are layered silicates from the group of mica minerals, which can be pressed with synthetic resin into sheets of varying thickness. Low electrical conductivity combined with maximum temperature resistance make the mica material a suitable fire protection material for use in vehicles.
STEINMANN uses laser cutting systems to cut mica panels in such a way that they can be fitted exactly above the battery systems and prevent flames from penetrating into the passenger compartment for a sufficiently long time.
The advantages of prefabricated mica panels are their excellent electrical insulation and thermal conductivity properties. Likewise the very good comparative tracking index and dielectric strength. (Source: HEYCO)
Forged battery reinforcements in the event of a crash
The greatest risk of a vehicle fire in an electric vehicle is damage caused by deformation following an accident. This can lead to direct deformation of the battery unit as a trigger for an uncontrolled fire or to the battery system being torn out of its anchoring points on the bodywork.
The HEYCO Group provides solutions for both cases. HEYCO manufactures forged and finished components such as structural elements, edge reinforcements, center bulkheads and fastening anchors. The high-strength and stable construction components prevent the battery box from deforming in the event of a crash and damaging the battery cells. They also hold the battery system firmly in place by compensating for the impact energy without tearing out of the anchorage.
Battery box reinforcement
Electric gearbox holding device
