Vehicles continue to gain mass, generation over generation, which is counterproductive to the drive to increase efficiency and reduce emissions, hybrid and battery electric vehicles are no exception. The battery pack is a significant contributor to the overall mass. Roechling Automotive has been focusing on reducing the mass of these heavy structures (85kg - 120kg). Lighter weight enclosures provide an opportunity for extending range on electric vehicles and by definition increase the energy density of the packs. Even with reduced mass, the battery enclosure can maintain or improve structural robustness, specifically in the areas of side impact and underside intrusion. Currently battery enclosures made out of stamped steel or sheet aluminum typically have thin cross-sections of 2-6mm thickness. During a side impact crash the thin material isn't able to absorb the impact energy due to high stress concentration. By utilizing Roechling's Statura™ Hybrid material the amount of energy that can be absorbed is increased by adding plastic material to the cross section while giving a lower area weight then metal alternatives. Additional functionality such as thermal and acoustic insulation, can be integrated when using a composite material solution.
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