Replaceable EV Battery Ballistic Shield Design
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Solution Overview
Problem
The risk of battery pack fires due to thermal runaway in electric vehicles, particularly when the battery pack is mounted under the car, necessitates enhanced protection against road debris and collision damage.
Innovation Solution
A ballistic shield system is interposed between the battery pack and the road surface, featuring a shield mounting portion, a ballistic shield portion, and connecting members, with a curved slot and edge section for secure attachment, designed to absorb impact energy and minimize transfer to the battery pack, fabricated from materials like aluminum, steel, or composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery pack is mounted under the car to meet performance and range requirements, then the vehicle achieves better performance and range, but the battery pack becomes vulnerable to road debris and collision damage
Solution Approach 1:
A ballistic shield is introduced as an intermediary component between the road surface and the battery pack. The shield includes a shield portion positioned between the road and battery pack, a mounting portion attached to the battery pack, and connecting members coupling them together. This intermediary structure protects the battery pack from road debris and collisions while maintaining the undercarriage mounting configuration.
2Object-affected harmful factors
If a ballistic shield is added to protect the battery pack, then protection against road debris is improved, but the device complexity and weight increase
Solution Approach 1:
The ballistic shield is divided into distinct functional segments: a shield portion for protection, a mounting portion for attachment to the battery pack, and connecting members for coupling. This segmentation allows each component to be optimized independently and simplifies installation and replacement procedures.
Solution Approach 2:
The mounting portion is designed with a curved edge section that can be inserted through a linear slot and rotated to achieve proper orientation. The connecting members can be configured in different orientations (perpendicular, angled away, or angled towards the curved edge section), providing universal applicability to different battery pack configurations and installation scenarios.
3Object-affected harmful factors
If traditional mounting techniques are used to protect the battery pack, then some protection is achieved, but the ease of repair and replacement is reduced
Solution Approach 1:
The mounting portion is pre-configured with a curved edge section designed to fit through a linear slot in the mounting base. This preliminary configuration allows for quick alignment and insertion during installation, and facilitates rapid removal and replacement when damage occurs, eliminating the need for complex disassembly procedures.
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 ballistic shield effectively absorbs impact energy, reducing the risk of damage and fire by distributing the force away from the battery pack, providing enhanced protection and ease of installation and replacement.
Implementation Method 1
The ballistic shield is interposed between the battery pack and the road surface... effectively absorbs impact energy, reducing the risk of damage and fire by distributing the force away from the battery pack
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 ballistic shield that is configured to deform and absorb impact energy, thereby minimizing the transference of impact energy to the battery pack and the batteries contained within the pack. The ballistic shield is designed to hook into a mounting base attached to the battery pack, thereby simplifying both its installation and, when necessary, its replacement.