Lightweight special: The underbody

For the automotive industry, lightweight construction is clearly the way of the future. Motivated by ever stricter emissions standards in many international car markets, manufacturers must make their products leaner. At the same time, the electrification of vehicles is quietly progressing forward. And since range is king in electric vehicles—which is also true here—lighter is better. Freudenberg Performance Materials (FPM) offers innovative lightweight solutions for both developments. A perfect example is the underbody systems made of polyester. Besides its low weight, it offers a number of other advantages.

Cutting weight is not useful everywhere on a vehicle. Too little weight in some locations can impact the driving performance. The underbody, however, is a prime target for weight reduction. Here, manufacturers like to achieve two fuel-saving measures in one go. Firstly, with good aerodynamics. Secondly, by making the part low in weight.

But how much mass can be eliminated here? On average, the underbody systems from FPM are 700 grams per square meter lighter than an injection-molded part. In comparison with glass fiber-reinforced textiles, one saves about 400 grams. Extrapolated to an entire production series, that would amount to several tons of CO₂. “No one is lighter today—especially not with this cost-performance ratio,” explains Dr. Alen Nosic, Global Strategic Business Unit Manager Automotive.

Underbodyshield

Ideal Layering

This is made possible thanks to a combination of one needle-punched nonwoven layer and two spunbond layers. These are arranged according to the sandwich layer principle, with the needle-punched layer in the middle. The ideal ratio of the layers as well as the individual layers themselves can be adapted to the specific application, such as to achieve even greater stiffness.

Testing, Testing, Testing

The light weight has definitely already proven itself in one of the core purposes, protection against stone impacts: To be entirely certain, the material experts at FPM fired nails and stones at the underbody. The results were gratifying. The nonwoven layers had no problem withstanding the test series.

Effective Handling

Additional advantages can be seen in further processing: The material is easy to shape and does not tear at the mounting points. For the workers at the car manufacturer’s assembly line, this means: “They need fewer screws to fasten the underbody, which in turn saves time and money,” says Nosic. Moreover, the nonwoven mixture poses no health risks, in contrast to glass fiber-reinforced materials. In other words, working with the material does not result in risks from fine dust or skin-irritating chips. The best part: The material is recyclable, which opens up new possibilities for sustainable production.

The Underbody Paneling

Six Reasons to Choose the FPM Underbody Paneling

Excellent cost-benefit ratio
Lowest weight for underbody solutions
Tensile strength and crack propagation resistance
Sound-absorbing properties
Secure against stone impacts and fire
Completely recyclable

Bonus Effect

From the perspective of the car owner, it is also worthwhile to have an underbody made of PET on the car. The material has an absorbing effect that reduces the generation of noise in the car interior. Alen Nosic explains: “Sound waves do not penetrate the structures. They are converted into thermal energy instead.”

Stable, quiet, easy to install: Important arguments for a lightweight part in the automotive sector. And the material competence that lies within the underbody paneling also makes possible alternatives to typical materials in other areas.

Read more about Freudenbergs Cargo Covers and invisible noise suppressors.

Further Topics in the Lightweight Special

Lightweight special: Everything covered

Eliminating a few kilograms in the right places can mean big CO₂ savings for car manufacturers. And if a lightweight part can also offer additional advantages beyond its low weight, even better!

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