Electromobility.

Battery Technology.Sustainable solutions fit for series production.

03

04 ElringKlinger worldwide

06 Focus on electromobility

08 Battery modules and energy storage units

10 System expertise with hofer powertrain

11 Battery components

11 Cell housings

12 Cell connectors

13 Cell contact systems

14 Module connectors

14 Plastic housings for energy storage units

15 Pressure equalizing elements

16 Development and testing

17 Electrical tests

17 Component validation

18 Prototyping and production

ADDITIONAL MATERIAL

Experience mobility – Drive the future.The ElringKlinger Group.

We are dedicated to developing cutting-edge solutions and new

technologies for current and future generations of vehicles. As

an expert development partner and approved OEM supplier, we

take an all-embracing approach and focus on the vehicle system

as a whole. Our particular strength is that we are one of the few

automotive suppliers capable of developing and manufacturing

technologically sophisticated components for all types of drive

system – based on either combustion engines or electric solutions.

Customized components from ElringKlinger for engine, transmis-

sion, exhaust gas system, underbody, chassis, and body are used

by virtually all vehicle and engine manufacturers and countless

automotive suppliers worldwide. Our product range includes gas-

kets, lightweight polymer components, shielding systems, battery

and fuel cell technology, transmission control plates, exhaust gas

purification systems, components made of high-performance

plastics, tooling technology, and development services. Building

on our innovative products, we set industry benchmarks and help

to achieve environmentally compatible mobility. We also supply

an extensive range of spare parts to the aftermarket sector in more

than 140 countries. In addition, ElringKlinger boasts a successful

track record in other branches of industry, e.g., with exhaust gas

purification systems, PTFE products, and fuel cells. These efforts

are supported by a dedicated workforce of more than 9,000 peo-

ple at 49 ElringKlinger Group locations around the globe.

CONTENTS

We have produced separate brochures with detailed information on our entire e-mobility range, our fuel cell solutions, and the products and services offered by our strategic partner hofer power train. Areas of application outside the automobile industry are described, for example, in our corporate brochure “The ElringKlinger Group” and in brochures published by our subsidiary new enerday GmbH.

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ElringKlinger worldwide.

Africa FRIK A

´

SOUTH AFRIC A

Johannesburg

North America

C ANADA

Leamington

USA

Plymouth

Southfi eld

Buford

Austin

Fremont

ME XICO

Toluca

South America

BR A ZIL

Piracicaba

Cylinder-head gaskets

Sealingsystems

Lightweight plastic components

Plastic modules

Thermal and acoustic shielding

systems

Exhaust after-treatment systems

Transmission control plates

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Asia

PR CHINA

Changchun

Suzhou

Qingdao

Chongqing

SOUTH KORE A

Gumi

Seoul

JAPAN

Tokyo

Saitama

Europe

GERMAN Y

Dettingen/Erms

Langenzenn

Runkel

Geretsried-Gelting

Thale

Lenningen

Bissingen/Teck

Bietigheim-Bissingen

Heidenheim

Mönchengladbach

Idstein

Rottenburg am Neckar

Magdeburg

Neubrandenburg

Nürtingen

SPAIN

Reus

ITALY

Settimo Torinese

Milan

HUNGARY

Kecskemét-Kádafalva

ROMANIA

Timisoara

TURKE Y

Bursa

GRE AT BRITAIN

Redcar

Gateshead

FR ANCE

Nantiat

Chamborêt

Poissy

SWIT ZERL AND

Sevelen

Elsau

NE THERL ANDS

Enschede

INDIA

Ranjangaon

INDONESIA

Karawang

THAIL AND

Bangkok

PTFE components

Engine development services

Tooling technology

PEM fuel cell stacks

Development services with hofer

powertrain

Battery technology

Electric Drive Unit

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0707

Electromobility. From future vision to reality.

The automotive industry is undergoing a period of transforma-

tion, the focus being on sustainable mobility and alternative

drive technologies. ElringKlinger has consistently been one

step ahead of these developments and so is actively helping to

shape the future of the automotive industry. Whether electric

motor, hybrid system, or combustion engine: we offer innova-

tive, tailor-made solutions for all types of drive technology.

Through our strategic partnership with hofer powertrain, an

engineering company in Nürtingen that specializes in electric

drive technology, we have significantly expanded our expertise

and range of products and services in the area of e-mobility.

Drawing on this know-how, we can therefore support our cus-

tomers at an even earlier stage and even more comprehensively

in the realization of future-oriented drive concepts.

BAT TERY AND FUEL CELL :

ELEC TRIF YING SOLUTIONS

An efficient energy storage unit is regarded as key technology

for future-proof electric vehicles. ElringKlinger already manu-

factures various components for lithium-ion batteries in highly

economical series production, e.g., cell contact systems and mod-

ule connectors. In addition, we also develop and manufacture

entire battery modules, battery systems, and integrated energy

storage units.

One of the key benefits of buses and passenger cars equipped

with fuel cell propulsion systems is their long range. Fuel cells

can also be used as range extenders for battery-operated vehi-

cles. Depending on system design, the electric drive can thus be

supplied with energy directly or the battery can be recharged.

In the field of fuel cell technology, the advantages offered by

ElringKlinger are its proprietary stacks, patented designs for

metal bipolar plates, and plastic media modules that allow

substantial simplification of the fuel cell system (see also our

specialized brochure “PEM fuel cells”).

As regards the automotive future, both concepts, the battery

and the fuel cell, are viable options on account of their specific

characteristics and benefits. In addition, they can display their

strengths in combination. Our mission is to drive innovations

forward, set standards, and play an active role in technological

change with highly competitive, top-quality product solutions.

For sustainable mobility – worldwide.

Battery modules and energy storage units. Pioneering, fl exible, reliable.

In the case of battery modules, the core competence of

ElringKlinger, i.e., bringing together a large number of differ-

ent components to make an assembly in a reliable process, is

proving to be a valuable asset. Voltage and temperature moni-

toring is already integrated in our cell contact system. Through

specifi c cell balancing the battery modules of ElringKlinger

achieve a long service life whereby our systems make a contri-

bution to the conservation of resources.

Our battery modules are structured in such a way that we can

provide a fl exible response to customers‘ needs. The basis is a

48 V module, which on account of its technical design can be

used for integrated systems up to 800 V. A modular approach

allows cost-effective series production. Furthermore, our bat-

tery systems can be used in fi elds of application beyond the

automotive industry. Via an interface, customer-specifi c bat-

tery management systems can be integrated. Alternatively, a

solution designed by ElringKlinger can be used.

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Performance of ElringKlinger battery modules

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1

2

36 48 60

EN

ER

GY

(kW

h)

7 98 10 11 12 13 14 15 16

MODULE LENGTH (mm)

VOLTAGE (V)

300 400 500

12s1p MODULE

7s1p MODULEMODULELENGTH

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1 Customer-specific modules with different capacities and voltages are available on request (max. 32 cells).2 Conditionally and in dependence of future cell development3 Depending on cell capacity

TECHNIC AL DATA 4 8 V MODULE

MODULE CONFIGURATION 1 12s1p

CELL TECHNOLOGY Lithium ion (NMC)

CELL TYPE Prismatic (PHEV2)

NOMINAL VOLTAGE (V) 43.8

NOMINAL CAPACITY (Ah) 2 ≥ 37

SPECIFIC ENERGY (kWh) 2 ≥ 1.6

MAX. CONTINUOUS CHARGE CURRENT (A) 3 148 / 4 C

MAX. CONTINUOUS DISCHARGE CURRENT (A) 3 259 / 8 C

MAX. PULSE DISCHARGE CURRENT (10 s) (A) 3 370 / 10 C

DIMENSIONS (mm) 370 x 157 x 125

WEIGHT (kg) 9.8

SAFETY FEATURES Integrated cell balancing; interface for optional BMS

LIFE TIME (UNTIL 80 % CAPACITY) 2,000-6,000 cycles (depending on application)

THERMAL MANAGEMENT Solutions for liquid and air cooling available on customer request

ENVIRONMENTAL TEMPERATURE (°C) Charge: 0-45 Discharge: -20-60Storage, transport: -40-45

MAX. SYSTEM VOLTAGE (V) 800

CONFORMITY UN 38.3, CE and on customer request

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Thanks to a strategic partnership with hofer powertrain, the

ElringKlinger Group has signifi cantly expanded its expertise

and range of products and services in the fi eld of electromobil-

ity. The engineering company hofer powertrain is regarded as

a specialist in electric drive technology; it has already amassed

ten years of series production experience in this fi eld. What is

crucial is the overall know-how: system integration, electric

machines, power electronics, automatic control software, trans-

missions, thermal management/cooling, and safety concepts

are an integral part of the portfolio.

The benefi t for ElringKlinger: working in close collaboration

with our customers, we can offer the very best in integrated

solutions tailored to their requirements. Our demonstrable

know-how in battery technology, processes, and production

methods in conjunction with pooled engineering expertise from

hofer powertrain provides the basis for achieving specifi ed

goals quickly and effi ciently. Building on our holistic view of

the entire chain of energy conversion in the vehicle, we are able

to leverage the full range of opportunities with regard to cost,

quality, and system performance.

System expertise with hofer powertrain.Implementing integrated solutions. Without fail.

know-how in battery technology, processes, and production

methods in conjunction with pooled engineering expertise from

hofer powertrain provides the basis for achieving specifi ed

goals quickly and effi ciently. Building on our holistic view of

the entire chain of energy conversion in the vehicle, we are able

to leverage the full range of opportunities with regard to cost,

EDU (Electric Drive Unit), consisting of a machine, an inverter, and a transmission based on the hofer powertrain platform.

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When it comes to the development and production of cell hous-

ings, we also benefi t from our expertise as a development partner

and series-production supplier to the international automotive

industry. In this sector ElringKlinger concentrates on the manu-

facture of prismatic hard-case housings. The outstanding relia-

bility of our products, despite the substantial volumes involved,

is based on our experience with regard to large production series

and our expert knowledge in the fi eld of sealing and forming

technology. High-current-capable joining processes and opti-

mized sealing concepts ensure that the cell has a long service

life. Highly effi cient safety systems for excess pressure, excess

current, or elevated temperatures enable a high degree of safety

even at cell level.

All components of the cell housing are from a single source and

are perfectly matched to each other – ensuring top quality and

functional reliability.

Battery components.Powerful, reliable, customized.

Cell housings.

Apart from lithium-ion battery modules for installation in inte-

grated storage systems, ElringKlinger, with its wide range of

battery components, is also ideally lined up for alternative drive

technologies. Our portfolio covers not only cell housings, cell

connectors, and cell contact systems but also module connec-

tors, plastic energy storage unit housings, and pressure equal-

izing elements.

On account of many years of experience in the fi elds of metal

forming, plastic injection-molding, joining and coating technol-

ogies, automated assembly processes, and an in-house tool-

making and mold-making facility, we can deliver customized,

mass-production-ready products for present and future electro-

mobility.

functional reliability.

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Cell connectors.

The conduction of current between the individual cells of a

module is handled by cell connectors. The latter have to be

as fl exible and thin as possible, on the one hand, in order to

compensate for tolerances between the cells; on the other hand,

they have to transmit very high currents, for which purpose a

large cross section is required. The specifi c, weight-optimized

connection solutions developed by ElringKlinger offer not only

the necessary fl exibility but also the matching cross sections for

the best current-carrying capacity possible. Due to extremely

high thermal and physical strength, temperature fl uctuations

between the cells are optimally compensated for at all times.

Compensation for forces results in a longer service life for

the cells.

Another benefi t: the surface of our cell connectors meets the

highest standards in terms of cleanliness, surface tension, rough-

ness, degree of refl ection, and fl atness, so it can be subjected

to automated laser welding. ElringKlinger offers solutions for

all types of cells, while various material combinations can be

adapted accordingly, including material transitions within the

cell connector – even in cost-effective series production.

In the case of ElringKlinger cell connectors, thermal expansion is optimally compensated for at all times, i.e., forces are restricted to the cell terminals.

DYNAMIC EXPANSION COMPENSATION ASSEMBLY TOLERANCE COMPENSATION

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Cell contact systems.

ElringKlinger cell contact systems for lithium-ion batteries in

various confi gurations are precisely matched to the customer‘s

particular specifi cations; they can be directly mounted on the

cell combination and welded together accordingly. The systems

are comprised of a plastic carrier frame that accommodates

the cell connectors and ensures installability in all tolerance

positions.

The required voltage and temperature sensors are already inte-

grated, while the electronic cell supervision circuit (CSC) can be

integrated by customers themselves. At the interfaces, approved

or even newly developed automotive connector systems are

used (Plug and Play). The cell connectors have a compensation

element to reduce forces acting on the cell terminals. Voltage

taps are used to monitor the cells and enable active/passive cell

balancing. For thermal monitoring of cells there are many differ-

ent types of temperature sensors in use – with an optimal heat

link to the cell connector.

Our cell contact systems are manufactured in fully automated

inline production; they undergo a 100% end-of-line inspection.

Development, validation, and release of the assemblies take

place according to the customer‘s requirements and in com-

pliance with automotive standards such as LV 124 or DIN EN

60068. ElringKlinger cell contact systems are ideal for use not

only in hybrid vehicles but also in full-electric vehicles.

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Module connectors.Plastic housings for energy storage units.

In order to create an energy storage unit, module connectors are

required as interfaces between the individual modules and the

cell contact systems. The modules are connected not only with

each other but also with the power electronics of the vehicle.

ElringKlinger module connectors can also be directly integrated

into the cell contact system as an optional feature. This means it

is possible to create extended, bolted solutions as well as combi-

nations of them. All approved contact systems can be used; alter-

natively, newly developed, requirement-compliant systems can

be implemented together with engineering partners if needed.

Flexible wiring with specifi c contact systems ensures optimal

adaptation of our module connectors to customer specifi cations.

At ElringKlinger, it can be taken for granted that development,

confi guration, and approval conform to the automotive stand-

ard LV 214.

The housing of a battery storage unit must meet numerous

requirements. For example, the installation footprint in the vehi-

cle has to be taken into account in the best possible way in

housing design. In addition, it must be possible to fi t additional

components, such as seals and electric terminals, at low cost.

When in operation, the housing is exposed to many mechanical

and thermal stresses.

ElringKlinger‘s solution: energy storage unit housings made

of plastic that are optimized for weight, are robust, and allow

the integration of additional functions; their design can be opti-

mally adapted to existing installation spaces. For this purpose,

we draw on our extensive knowledge in the fi eld of plastics pro-

cessing of large-format components and in sealing technology

and implement innovative solutions with injection-molding pro-

cesses, plus hybrid design. If necessary, areas can be strength-

ened via sandwich structures and an EMV shielding can be

implemented by using metallic foils.

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Pressure equalizing elements.

The energy storage unit housing must be able to compensate

for different pressures between the interior of the storage unit

and its environment. Such pressure differences arise, for exam-

ple, when driving uphill or downhill, if there are temperature

differences, or when transporting battery modules or electric

vehicles by air in freight chambers not equipped with pres-

sure equalization systems. ElringKlinger pressure equalizing

elements with an integrated safety function compensate for

such differences in pressure. On account of permeability to water

vapor, condensation in the energy storage unit is also reduced.

An emergency degassing function that is also integrated into

the pressure equalizing element opens up a port with a large

cross section in the event of gas emission from a battery cell;

this brings about controlled pressure equalization in the stor-

age unit housing as quickly as possible. Due to the use of a

porous PTFE membrane, we are also able to adapt air fl ows

to requirements in the best possible manner. In this context,

we benefi t from the PTFE material expertise of our subsidiary

ElringKlinger Kunststofftechnik GmbH. Depending on the cus-

tomer‘s request, compliance with all IP protection classes

specifi ed by DIN EN 60529 is possible (water column, splash-

ing water, pressure washer, etc.).

TECHNIC AL DATA PRESSURE EQUALIZING ELEMENT

HEIGHT 24.5 mm

MAX. WIDTH 91.2 mm

AIR EQUALIZATION CAPACITY [AT A DIFFERENTIAL PRESSURE OF 0.1 BAR] 25 l / min

DEGASSING CROSS SECTION 590 mm²

PRESSURE THRESHOLD FOR EMERGENCY DEGASSING 0.35 bar

IP PROTECTION CLASSES

(ON REQUEST) IP66, IP67, IPXXC (IP6K, IP9K)

FIRE RATING V0

OPERATING TEMPERATURE -25 to 80°C

INSTALLATION With a bolt fl ange; introduction of threads in the storage unit wallwith threaded holes or, for example, with inserts

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Development and testing.Electrifying solutions.

Short development cycles, complex interaction between the

individual components, and high demands with regard to cost

efficiency and sustainability can only be implemented by means

of an all-embracing approach. This is essential when it comes to

achieving smart solutions at the highest technological level pos-

sible. At our purpose-built E-Mobility Development Center all the

necessary test and validation facilities are brought together under

one roof. Be it a cell test, a module inspection, or a component

validation test – we handle all the various procedures. In taking

this approach, we can offer our customers the very best condi-

tions when it comes to pursuing new routes and achieving goals

sooner; this also applies to small batches and prototypes. Other

automotive suppliers also take advantage of our expertise and

have tests performed by us. Reliable, economical, comprehensive.

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Development and testing.Electrifying solutions.

When it comes to electrical and mechanical module design, it is

absolutely essential to have a thorough understanding of cell

behavior under various extraneous boundary conditions. For

example, the service life of battery cells is directly dependent

on temperature, the rate of charging and discharging, and the

mechanical environment. When cells are interconnected to cre-

ate a module there are also other effects that have to be taken

into account, such as mutual cell infl uence and an altered cool-

ing characteristic, which also depends on the location of the cell

in the module and hence a change in cell temperature. Further-

more, while cells are not identical, they are all exposed to the

same level of current in the module.

Using electrical cell and module test benches, we investigate

these and other effects in order to achieve the best possible con-

fi gurations for our modules. At these test stations it is possible

to rigorously check multiple cells and modules under various

climatic conditions in a single procedure. The various test spec-

imens can all run through one and the same electrical stress

profi le or be exposed to loads that are different from each other.

Simple charge/discharge cycles are possible, but also driving

profi les such as the Artemis cycle or the American FTP-75.

The components of an energy storage unit must – like all compo-

nents in the automotive sector – meet demanding requirements

in terms of ruggedness and durability. The focus of testing is

on the various connections between the components, which

have to be validated in specially adapted tests with regard to

their durability over the entire life of the vehicle. Here, too, we

can take advantage of the experience we have acquired over

decades.

Typical examples are mechanical tests such as peel tests, shear

tests, tensile tests, vibration tests, vibration resistance tests,

shock tests, electrical tests such as dielectric strength tests,

maximum continuous current tests, and short-circuit tests at

several thousand amps.

In addition, we conduct all standard environmental simulation

tests and battery-specifi c tests for chemical infl uences. Exam-

ples include climatic tests, thermal cycling tests, media resist-

ance tests such as salt spray tests, or the testing of various

materials for resistance to electrolytes.

Electrical tests on battery cells and modules.

Componentvalidation.

Cell and module test benches Testing of battery components

1818

Prototyping and production. Series-produced quality. Worldwide.

New types of products call for new, innovative manufacturing

concepts. ElringKlinger attaches great importance to its own

process development and the associated expansion of expertise

to meet the full range of quality requirements. All processes and

procedures necessary for the products are validated and con-

stantly refi ned. Thanks to the close interaction between develop-

ment, prototype construction, and product commercialization,

an optimum quality standard can be achieved from the very start

of production.

Within a short space of time and to a very high standard,

ElringKlinger produces samples and small batches at its in-house

prototyping facility, the equipment of which is very close to that

of full-scale production. We have resources available for all the

manufacturing processes that are also used in series production,

e.g., ultrasonic welding and laser welding systems. In this way,

we achieve continuity in all processes from prototyping to series

production – only the degree of automation has to be adjusted.

At an early stage, during prototype construction, it is possible

to ensure seamless 100% traceability, as in subsequent series

production.

ElringKlinger also operates high-performance production lines

for manufacturing the various components in series. Adapted to

specifi c customer requests and product requirements, we imple-

ment highly fl exible, scalable or fully automated production solu-

tions – integrated in a continuous quality concept. Our mission

is to achieve competitive series production geared to specifi c

product requirements. Effi ciently, safely, and reliably. Worldwide.

W W W.ELRINGKLINGER .COM

ElringKlinger AG

Max-Eyth-Straße 2

72581 Dettingen/Erms

Germany

Phone +49 7123 724-0

Fax +49 7123 724-9006

E-mail info@elringklinger.com

www.elringklinger.com 08/1

7

The information provided in this brochure is the result of technological analyses and may be subject to changes depending on the design of the system. We reserve the right to make technical changes and

improvements. The information is not binding and does not represent warranted characteristics. We do not recognize any claims for compensation based on this information. We accept no liability for printing errors.