Future of Automotive Electric Mobility, Metallized Films, Energy Efficiency, Infrared Reflective Films

The future of automotive electric mobility

A new concept vehicle that combines both companies' ideas for holistic electric mobility has been developed by Daimler and BASF. The resulting vehicle is the 'smart forvision', developed with a special emphasis on energy efficiency, temperature management and lightweight design. The clear objective of greatly increasing the zero-emission range resulted in completely new concepts and materials in the areas of insulation, reflection, lightweight design and energy management. In addition to transparent organic solar cells, transparent and energy-saving light-emitting diodes and infrared-reflective films and coatings, high-performance foams are used for insulation against cold and heat. smart is also setting new standards of lightweight design with the use of the first all-plastic wheels. This vehicle showcases technologies for sustainable and holistic electric mobility of the future. The researchers and designers intentionally realised a mixture of visionary materials and technologies in the concept vehicle: some of these are still at a laboratory stage, while others have a realistic chance of entering series production.
Energy efficiency: light and energy from above
The hexagonal transparent areas on the roof are an eye-catching feature - as the first light-transmitting roof that also generates energy. Transparent solar cells covering the entire roof surface are the technology used here. They are based on organic dyes embedded in a sandwich roof. The transparent dyes of the solar cells are light-activated. Even in diffused light and poor light conditions, they generate enough energy to power the multimedia components and the three fans that assist with climate management in the vehicle interior. If the vehicle is standing in the sun, the ventilation is permanently operated with the help of these solar cells, keeping the car cool. This new photovoltaic technology opens up further efficiency potential and the energy generated can be used for additional applications in the car. There is an additional new feature under the solar cells: transparent OLEDs (organic light-emitting diodes) that illuminate the vehicle interior when the door is opened or a button pressed. When switched off, they allow for a clear view outside. This results in a glass roof effect during the daytime, whilst the areas are pleasantly illuminated without any dazzle at night. Thanks to a free choice of colours the new OLEDs not only offer more design freedom, they also consume less than half as much energy as conventional energy-saving lamps.
Lightweight: different, better, stylish
A world first leads to a considerable weight reduction and a unique design: the first all-plastic wheel suitable for high-volume production. In its current development status, the wheel developed by BASF from a new high-performance material results in a considerable weight saving of 3 kgs per wheel. Unlike conventional polyamide composite materials, this new plastic has long reinforcing fibres which improve its mechanical properties. The result: excellent thermal and chemical stability, dynamic strength, toughness and good continuous operating characteristics. First intensive product tests at smart show the performance capability of the all-plastic wheel and confirm the potential for possible use in production vehicles. In addition to the tridion passenger cell, further components such as the doors are made of carbon-fiber-reinforced epoxy resin � a high-performance composite material. The use of such materials enables a weight saving of more than 50% to be achieved compared with steel or 30% compared with aluminium. Thanks to short hardening times the resin systems are also suitable for producing larger volumes.
Heating: close to the body and efficient
The multifunctional, comfortable and lightweight seats offer a unique combination of efficient temperature management and an energy-saving lightweight design. Here, several innovative products are combined with one another for the first time. A new, lightweight, self-supporting plastic seat shell forms the basis. Numerous studies have shown that the body only absorbs heat efficiently through certain contact points. This is why "e-textiles" - thin fabrics with custom-tailored conductive coatings - replace conventional seat heating in the smart forvision. With direct heating close to the body in the middle and lower back area of the seats they provide for a pleasant feeling of warmth. The energy, space and weight-saving e-textile technology is also found in the armrests of the doors and ensures that body contact points sensitive to the cold are also warmed in this area. The innovations continue with the seat foam, which provides for both comfort and weight savings. The material from BASF is around 10-20% lighter than other materials and enables different degrees of hardness to be realised in different areas of the upholstery in a single work operation � resulting in clear ergonomic advantages. Superabsorbent containing fleece fabric integrated in the seat greatly enhances seating comfort through its passive climate control. Compared with conventional climate-controlled seats the lightweight seat in the smart forvision does not have the complexity and energy requirement of mechanical ventilation.
Temperature management: heat stays outside
As a large amount of energy is needed to air-condition and heat a vehicle, temperature management was a key focus area. A whole package of measures has been implemented to ensure more efficient air conditioning of the vehicle. At the same time they make energy-intensive heating of the whole interior superfluous. A heat shield that has not been previously used for automotive applications consists of a new kind of infrared-reflective film from BASF, applied in the windscreen and side windows, protecting the car interior from heating up. Integrated between the panes of the safety glass the metal-free film ensures that the infrared rays are effectively reflected. Thanks to its high transparency in the visible range it can also be applied to tinted windows and guarantees an unprecedented level of reflection of sunlight and heat. Unlike metallized films, which are already used in some vehicles, the new film reflects only the infrared rays of the sun. Radio waves that are necessary to use GPS, Bluetooth, mobile phones or toll collection pass through the glass unhindered. The high-performance foams from BASF fitted in the body panels also provide for a pleasant climate inside the car. They keep the vehicle pleasantly cool in summer and also insulate it against the cold in winter. Thanks to their high efficiency even in a small width, they can be fitted everywhere in the vehicle. With this innovative insulation system, the two companies are breaking new ground in the automotive sector.
Cool coatings - cool interior
The infrared-reflective and extremely scratch-resistant coatings system covers two important aspects at once. Firstly, it supports the extensive temperature management system and, secondly, the brilliant and high-quality look of the coating underlines the unique design. The concept vehicle features a white special-effect coating with glass flakes that create a gleaming metallic look. An important side effect: the colour white reflects heat rays from sun and light particularly well. But even surfaces coated with dark colours stay much cooler thanks to special colour pigments from BASF. They ensure that heat radiation is reflected rather than absorbed. This leads to a temperature reduction of up to 20°C on the paint surface and of up to approximately four degrees in the vehicle interior.
Futuristic design trendsetter
Painted in pearl white and accentuated by the tridion safety cell coated with a copper-coloured liquid metal paint, there is a deliberate connection between the basic structure of the smart forvision and the design of the smart fortwo. Trendy yet high quality - the aluminium flakes in the liquid metal paintwork create a reflecting surface on the safety cell, changing between light and dark depending on the viewer's perspective. Both the panels and the cell are additionally painted with an extremely scratch-resistant clear coat. The faceted side doors with integrated door openers are a real eye-catcher. Here, plastic is presented in a new, expressive and three-dimensional form; a reinterpretation that is only possible at smart thanks to the consistent use of plastic. The precise facets give the area stability and enable a smaller material thickness to be used. Optimal use is made of the possibilities offered by plastic as a material. In contrast, the front and rear have a softer design with smooth transitions from the doors. Just as the integrated door handle does not need an additional component, the familiar smart air inlet is represented by small hexagons located right on the outer skin. The jet-like rear lights are reminiscent of small aircraft turbines and give the rear a futuristic and sporty look. Inside the lights, small propellers convey the air from the inside to the outside. In addition to all the light functions needed, transparent stacks in the form of rings around the lights also show the charge status of the battery during charging. The headlamps are emphasised by a ring comprising the daytime driving lights and indicator functions. The lights add to the likeable expression.
Doors open to the future
With a mix of polygonal surfaces and organic shapes the interior builds a bridge to the architectural design handwriting of the exterior. This also applies to the colour concept: a cool white dominates in the interior as well, accentuated by the inner part of the instrument panel in liquid copper. Hexagons in the form of white rubber nubs on a white floor are a reference to the design idiom of the overall vehicle, as is the tone-in-tone design of the seat upholstery. The faceted surface of the side doors is also found on their inside. The polygonal surfaces with integrated armrests and stowage compartments curve into the interior. They are painted in the body colour and feature coloured LEDs. These greet the driver with a light animation when the door is opened and closed with light running from the outside to the inside and also guide him out again. After closing the door the animation changes to unobtrusive ambient lighting. The elliptical user interface with a copper coloured frame - matching the lightweight tridion - is semi-transparent when switched off. When the vehicle is switched on all cockpit information is then projected onto the transparent surface. The driver uses a touchscreen to switch between operating menus. The white steering wheel that is reminiscent of an aircraft yoke gives the cockpit an additional futuristic look. Function buttons as well as the LED display for the battery charge status are found here.
Forward-looking technologies
The smart forvision not only shows that electric mobility can make emission-free driving possible. At the same time, it also paves the way for new technologies in the automotive sector. Many of these innovations are based on nano technology, the key to the development of sustainable solutions. Nano materials serve as drivers of innovation in the automotive industry, as they do in the fields of construction, energy, healthcare and electronics.The total of all technologies integrated in the concept vehicle make a perceptible contribution to increasing the range. This is always at the centre of discussions relating to battery-electric driven vehicles. With maximum energy efficiency, intelligent temperature management and consistent lightweight construction it is possible to increase the range by up to 20% - an additional bonus for electric mobility of the future.
Both Daimler and BASF are engaged in wide-ranging research and development work aimed at getting electric cars on the road and ensuring that electric mobility becomes part of everyday life as soon as possible. The two companies have combined their technological competencies for the first time, developing a forward-looking vehicle concept that offers decisive solutions to the challenges of the future. The new vehicle brings design, lifestyle and technology together to form a new functional whole.