Debris Capture Plate for EV Undercarriage Battery Protection
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Solution Overview
Problem
Electric vehicles with undercarriage-mounted battery packs face risks of damage and thermal runaway due to road debris, which can lead to catastrophic fires, as existing protection methods are insufficient for this configuration.
Innovation Solution
A debris capture plate system is mounted in front of the battery pack, designed to deform and trap road debris, with plate stiffeners and notches promoting controlled deformation to prevent damage, and a blocking plate to ensure downward deformation, fabricated from metal materials like aluminum or steel, and attached to the battery pack enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery pack is mounted under the car to meet consumer expectations for range and performance, then the vehicle can achieve reasonable levels of range and performance, but the battery pack becomes vulnerable to damage from road debris and collisions
Solution Approach 1:
A debris capture plate is introduced as an intermediary component between the road surface and the battery pack. This plate deforms upon impact with debris, trapping the debris and preventing it from reaching the battery pack, thus resolving the contradiction by maintaining undercarriage mounting for range while adding protective mediation for safety
Solution Approach 2:
The debris capture plate is positioned and designed to deform beforehand in anticipation of debris impact. By being pre-configured to deform and trap debris before the debris can reach the battery pack, the system provides prior cushioning protection that maintains both the undercarriage mounting configuration and battery safety
2Reliability
If a ballistic shield is placed between the road surface and the battery pack to protect from debris, then the battery pack is shielded from potential harm, but the device complexity and weight increase
Solution Approach 1:
The debris capture plate is designed with deformation capabilities rather than being a rigid ballistic shield. This dynamic approach allows the plate to deform and adapt to impact forces, trapping debris effectively while using less material and reducing overall system complexity compared to a traditional rigid shield
Solution Approach 2:
The protection mechanism changes from a static rigid barrier to a dynamic deformable structure. By changing the physical parameters of the protection element (from rigid to deformable), the system achieves effective debris trapping with reduced material requirements and lower complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively traps road debris, preventing it from damaging the battery pack and reducing the risk of thermal runaway, thereby enhancing safety and reliability of electric vehicles.
Implementation Method 1
the capture plate configured to deform and trap debris that hits the capture plate's leading edge
Implementation Method 2
Each plate stiffener includes at least one deformation control feature that promotes a preconfigured pattern of capture plate deformation when a piece of debris impacts the plate's leading edge
Data Source
AI summary
A battery pack protection system is provided for use with an electric vehicle in which the battery pack is mounted under the car. The system utilizes a debris capture plate mounted in front of the battery pack and positioned such that the leading edge of the mounted capture plate is positioned closer to the underlying road surface than the lowermost battery pack surface. Capture plate stiffeners, which are mounted to the capture plate, use deformation control features (e.g., notches) to promote a preconfigured pattern of capture plate deformation when a piece of debris impacts the plate's leading edge. The deformed capture plate then traps the debris and stops it from passing under the battery pack, thereby preventing the battery pack from possible debris impact damage.