Climate change, efficient use of limited (fossile) resources, the demand for cleaner traffic and the increasing awareness for environment protection to secure life quality leads to the focus on alternative ways to drive in modern societies. Being seen as a promising next technology the implementation of e-mobility cars capable of competitive ranges relies heavily on efficient battery concepts and the integration of high power / high capacity energy storing systems. While safety regulations must be met increasing the range for cars is mainly realised by two aspects: increasing the number and size of the batteries and investigate an efficient car concept focusing on efficiency and weight reduction. The integration of battery packs into the body in white comes with several conflicts: crash safety, driving-system integration, component cooling, air tightness, corrosion and electromagnetic shielding must be met and yield in the complex manufacturing in AlMg casting or deep drawing of steel in the state of the art.
The project Carbon SMC Battery Protection for e-Mobility Body-in-White will focus on the development of manufacturing technologies for this battery carrier in Carbon SMC technology and aims for:
- A weight reduction to aluminium casting by the factor 2 at competing strength
- Integrated manufacturing in one shot technology and reduction of assembly operations
- Recycling of primary scrap Prepreg / dry fibre material
The partners will develop C-SMC production concept for a modular approach on a versatile and flexible carrier concept scale-able for different platforms and applications from automotive to e-propulsion flight, boats, motorcycles and so on. As Carbon SMC and its life cycle assessment is not validated and researched for reliable prediction a holistic approach including the development of material data and performance prediction, engineering and design regulations and efficient, robust manufacturing routes will be investigated and validated in representative technology test samples.