China’s CATL, the world’s largest electric vehicle battery maker, launched the CATL Bedrock Chassis, calling it “the world’s first ultra-safe skateboard chassis.”
With its outstanding performance of withstanding 120 km/h (75 mph) frontal impact without catching fire or exploding, CATL’s Bedrock Chassis sets a new standard for intelligent chassis safety, providing comprehensive protection across all scenarios and speed ranges.
With the battery-centered design, CATL’s Bedrock Chassis utilizes Cell-to-Chassis integration technology, which directly integrates the battery cells into the chassis, allowing for a shared structural design between them. And based on the decoupling of the chassis from the upper body, the Bedrock Chassis is capable of absorbing 85% of the vehicle’s collision energy (compared to around 60% absorbed by traditional chassis).
Through various technological breakthroughs, the Bedrock Chassis successfully passed the world’s first “highest speed + strongest impact” dual extreme safety test. This achievement enables the chassis to pass the 120 km/h (75-mph) frontal central pole impact test without catching fire, exploding or thermal runway, redefining the benchmark for safety in the industry.
Currently, the speed for frontal impact safety test in the commonly used C-NCAP (China New Car Assessment Program) is 56km/h, which, when experiencing a frontal impact at this speed, generates collision energy equivalent to falling from 12-meter-high building. In comparison, a frontal impact at 120km/h (75 mph) is equivalent to falling from a 56-meter-high building, generating a collision energy 4.6 times that of collision at 56km/h (35 mph).
In more stringent frontal pole crash tests, which simulate crashes with non-standard objects such as power poles, large trees, or animals, the impact area is only 1/6 of that in a full-width frontal impact, exponentially increasing impact pressure. At a speed of 120km/h (75 mph), the impact pressure on the chassis per unit area in a frontal central pole impact is 21 times that of the 56 km/h (35 mph) full-width frontal impact in C-NCAP testing.
Due to the extremely high crash speed and intensity, there has been no previous instance of any new energy vehicle daring to challenge a 120km/h (75 mph) frontal pole impact test. With this extreme challenge, CATL’s Bedrock Chassis has blazed a fresh trail for the industry.
CATL’s Bedrock Chassis has delved deep into the realm of structure and material innovation, leveraging three technological breakthroughs to provide unparalleled protection in all scenarios and speed ranges, ensuring rock-solid safety for the entire vehicle.
The CATL Bedrock Chassis introduces a revolutionary three-dimensional biomimetic tortoise shell structure, where the body and energy unit framework are integrated, deeply coupled to provide the energy unit with indestructible protection. And its aircraft carrier-grade arresting structure disperses impact forces across multiple pathways during a crash, gradually decelerating the vehicle and significantly reducing the depth and speed at which obstacles intrude the cabin. The utilization of submarine-grade hot-formed steel with a strength of 2000MPa, aerospace-grade aluminum alloy with a strength of 600MPa, and multiple barrier structures further enhance the chassis’ rigidity, making it virtually impervious.
Moreover, the CATL Bedrock Chassis incorporates an ultra-safe battery cell design, NP technology, and a high-ductility energy-absorbing insulation film, leading the industry in a groundbreaking manner. In terms of high-voltage disconnection, it achieves instantaneous disconnection of high voltage circuit within 0.01 seconds of impact and completes the discharge of residual high-voltage energy in the vehicle within 0.2 seconds, setting a new industry record.
Notably, the battery cells have undergone highly demanding tests, including high-speed sled impact tests at 60 km/h (37 mph), 90-degree bending tests, and breakthrough sawing tests, the battery did not catch fire or explode across all three tests. These tests, all industry-firsts by CATL, have elevated the safety standards of battery cells to new heights.
The global EV battery leader said its newest tech “activates a trillion yuan market” as the new standard for intelligent vehicle design. According to CATL, it will also end the belief that gas-powered cars are safer than EVs.
Addressing the common pain points of high investment, long development cycles, and accelerated product iteration in the industry, the Bedrock Chassis incorporates three core characteristics: internal integration, decoupling of the chassis from the upper body, and external openness. With a rich array of toolkits and solution packages, it offers a scalable software and hardware architecture and standardized interfaces, enabling flexible configurations for different vehicle models and scenarios. This allows the realization of a “one chassis architecture, multiple vehicle models” concept and significantly improves development efficiency and shortens the R&D cycle. The time required for mass production of a vehicle is reduced from the traditional 36 months or longer to 12 to 18 months.
Furthermore, the Bedrock Chassis breaks the limits of safety and modeling, and expands design flexibility through the design of decoupling of the chassis from the upper body. The fourth-generation Cell-to-Chassis (CTC) technology and inverted battery cell technology enhance the utilization of chassis space while reducing the risk of chassis scraping. Additionally, in terms of intelligence, the chassis supports mechanical decoupling, software decoupling and EE decoupling, enabling L3 to L4 intelligent driving capabilities. It provides high adaptability interfaces and promotes collaborative intelligent applications.
Chinese EV brand Avatr, which is co-owned by CATL, state-owned Changan Auto and technology giant Huawei, will be the first to develop EV models based on CATL’s Bedrock chassis, Chen Zhao, president of Avatr said at the press conference.
