Safety and Reliability for E-Bikes and E-Scooters

Well protected, minimal space requirement: Each battery for the E-Bike Powertube is individually packaged in a shock-resistant shell.

Pöppelmann K-TECH® has over a decade of experience in the e-mobility sector and is familiar with all common battery cell concepts. The division of the Pöppelmann Group from Lohne develops highly precise plastic parts from materials that withstand the special requirements of electric drives. Here, thermal conductivity, temperature and chemical resistance, and much more are key factors. In addition to products for the automotive industry, the plastics specialist has also established itself in the e-bike and e-scooter segment with innovative solutions for reliable battery protection.

E-scooter – up to 196 battery cells individually packaged

A high packing density of the battery cells with only a thin wall thickness of the cell holder – this is exemplified by the solution developed by Pöppelmann K-TECH® for the customer Bosch. The cell holders for batteries used in electric scooters are designed for different battery packs of up to 196 cells. The unique solution from the plastics specialist combines maximum safety with a compact design. Each battery cell is individually packaged and fully enclosed by a secure, impact-resistant shell. A spring suspension ensures protection for the sensitive cells. To meet the customer's high accuracy requirements for the product, the plastics specialist employs elaborate measurement programs, from CT scanning to 3D tactile measurement. Since space is limited, Pöppelmann K-TECH® pushed the wall thickness design to just 0.7 mm, approaching the limits of what is possible – without compromising safety. The cell holder easily passed the required propagation test, also known as the "nail test".

E-bike – Function integration saves time, material, and weight

For components for electric bicycles, the goal is: they should be as lightweight as possible so that the finished vehicle has a low overall weight. Pöppelmann K-TECH® has developed a particularly lightweight solution with the battery housing base shells for e-bike batteries. The plastic parts are manufactured via injection molding and consist of three components. Their key feature is function integration, which is among the company's core competencies: instead of a conventional screw connection with O-rings, this component replaces a total of ten O-rings with an injection-molded seamless, precisely fitting 1k-PUR seal, ensuring reliable sealing. This not only saves weight but also reduces assembly and inspection time for the parts.

Experience with all common cell concepts

Thanks to many years of experience in developing materials and products that meet the special requirements of e-mobility, Pöppelmann K-Tech® can realize a wide range of solutions for different battery cell types – from round cells to pouch cells to prismatic cells. Customers benefit from short development times, high flexibility, and coordinated processes from a single source: from design through rapid development tools and in-house toolmaking, which includes sample or pre-series production with state-of-the-art in-house 3D printers, to efficient high-end series production. This ensures that Pöppelmann K-TECH® always offers an optimal solution for the complex and demanding requirements in battery technology for e-vehicles.