Protection tray
Rheinmetall has unveiled the Electric Mobility Vehicle (EMove), developed on the Fiat 500 platform, representing a pioneering concept in electric vehicle design. The EMove is anticipated to set a precedent for future electric and hybrid vehicles, which are expected to incorporate underfloor batteries.
The EMove demo vehicle highlights Rheinmetall’s commitment to e-mobility and showcases the company’s capabilities in the sector. Dr. Peter Seggewiß, Vice President of New Automotive Technologies, emphasized that underfloor batteries minimally affect load volume and do not raise the vehicle’s center of gravity. Additionally, these batteries can be integrated into the vehicle’s load-bearing structure.
While the design positions the energy storage units in a crash-safe area, the open nature of underbody batteries makes them vulnerable. Debris such as metallic objects on the road can pose a risk of damage. To mitigate this, Rheinmetall’s Automotive and Defence sectors collaborated to create a protective shell for the batteries.
The protection tray developed in partnership
This protective tray was jointly developed by Rheinmetall Automotive and Rheinmetall Chempro GmbH from the Defence sector, leveraging Chempro’s extensive expertise in ballistic vehicle protection and fiber composites. The innovative battery protection system earned third place in the Losgröße 1+ award by the ife Institut für Einzelfertiger, underscoring its advanced design.
About the battery protection tray
The battery protection tray consists of a fiber composite structure (CFRP/AFRP) optimized for load adaptation, successfully passing rigorous impact tests and numerical analyses. Weighing in at just 14 kilograms, this intrusion protection system is approximately 56 percent lighter than traditional aluminum counterparts. This weight reduction enables the tray to withstand impacts from blunt and sharp objects traveling at speeds of up to 150 km/h without compromising the battery’s integrity. Furthermore, it provides protection against static loads when the vehicle is stationary.
Additionally, the battery pack cover mirrors the protection tray’s fiber composite construction. In the event of a battery fire, this cover effectively shields the passenger compartment from high temperatures, ensuring a safe evacuation time of up to 15 minutes. The design incorporates materials with low thermal conductivity and a flame-retardant plastic matrix, along with an extra thermal protection layer, to meet stringent thermal safety requirements.
