Description:TECHNICAL FIELD
[0001] The present subject matter relates, in general, to electric vehicles (EVs) and, particularly, to gas deflectors for evacuating gases released from battery packs of the EVs during a thermal runaway event.
BACKGROUND
[0002] Electric vehicles are powered by battery packs comprising multiple battery cells and modules arranged in series and parallel configurations. A battery cell is the fundamental unit of energy storage, and its thermal and electrical characteristics influence the overall performance and safety of the battery pack. Modules are formed by grouping multiple cells and enclosing them within a mechanical structure to provide physical protection and electrical connectivity.
[0003] During normal operation, battery cells generate heat due to charging, discharging, and power delivery. Under certain conditions, excessive heat generation may occur, leading to a thermal runaway event. Thermal runaway is a condition in which the heat generated within a cell exceeds the rate at which it can be dissipated, potentially causing the cell to fail and triggering a chain reaction across adjacent cells. This sequential failure is referred to as thermal propagation.
[0004] Regulatory requirements AUTOMOTIVE INDUSTRY STANDARD (AIS) 156 (Amendment 2) mandate that the Rechargeable Electrical Energy Storage System (REESS) should withstand thermal propagation which is triggered by an internal short circuit, leading to a single cell thermal runaway and subsequent thermal propagation and shall not result in fire and explosion to ensure vehicle safety and occupant protection.
[0005] Effective management of high-temperature gases and flames generated during thermal runaway is essential to prevent damage to vehicle components and to maintain the structural integrity of the battery pack. The
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gases must be safely evacuated from the battery enclosure to avoid pressure buildup and minimize the risk of fire or explosion.
SUMMARY OF THE INVENTION
[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0007] In an embodiment of the present invention, an electric vehicle (EV) comprising a frame having at least one cross member mounted on the left-hand side (LH) of the frame and at least one cross member mounted on the right-hand side (RH) of the frame to support a battery pack within the frame, is provided. A housing of the battery pack is enclosed between a LH cross member and a RH cross member. Further, the EV comprises a pair of gas deflectors comprising a first gas deflector and a second gas deflector. The first gas deflector is coupled to the LH cross member, and the second gas deflector is coupled to the RH cross member. Each of the gas deflectors comprises a planar surface, and a sidewall along a periphery of the planar surface. The planar surface is oriented substantially perpendicular to a direction along which gases are expelled from at least one gas vent provided on a surface of the housing of the battery pack during a thermal runaway event, and an outer edge of the sidewall that makes contact with the surface of the housing is outwardly tapered. The planar surface, bound by the sidewall, defines a continuous hollow volume such that the at least one gas vent opens into the hollow volume, and at least one opening in the sidewall forms at least one outlet channel to allow the gases to be expelled out of the hollow volume.
[0008] In accordance with example embodiments of the present invention, the first gas deflector coupled to the LH cross member is oriented such that the first gas deflector covers at least one gas vent on the surface
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of the housing of the battery pack. Similarly, the second gas deflector coupled to the RH cross member is oriented such that the second gas deflector covers two gas vents on the surface of the housing of the battery pack. Both the gas deflector serve to allow the gasses to expand and cool down and channel the gasses along an axis oriented towards a front end of the EV, in a direction away from the rider.
[0009] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.
[0011] Figure 1 illustrates a side view of an electric vehicle along with a gas deflector, in accordance with an implementation of the present subject matter.
[0012] Figure 2A illustrates a side view of the first gas deflector mounted on a left-hand side (LH) cross member of the frame, in accordance with an implementation of the present subject matter.
[0013] Figure 2B illustrates a side view of the second gas deflector mounted on a left-hand side (RH) cross member of the frame, in accordance with an implementation of the present subject matter.
[0014] Figure 3A and 3B each illustrate a side view of the first gas deflector and the second gas deflector coupled to the LH cross member and the RH cross member of the frame of the vehicle, respectively, in accordance with an implementation of the present subject matter.
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[0015] Figure 4 illustrates the gas deflectors coupled on either side of the vehicle frame to the respective cross members along with the battery pack, in accordance with an implementation of the present subject matter.
[0016] Figure 5 illustrates a top view of the deflectors mounted on either side of the frame, in accordance with an implementation of the present subject matter.
[0017] Figure 6A and 6B each illustrate a top view and an inner side view, respectively, of the first deflector, in accordance with an implementation of the present subject matter.
[0018] Figure 6C and 6D each illustrate a top view and an inner side view of the second deflector, respectively, in accordance with an implementation of the present subject matter.
[0019] Figure 7 illustrates a cross-sectional side view of the gas deflector mounted on the cross member, in accordance with an implementation of the present subject matter.
DESCRIPTION OF EMBODIMENTS
[0020] The present subject matter relates to a gas deflector for evacuating the gases released from a battery pack of the EV during a thermal runaway event.
[0021] In an event of a thermal runaway, a battery cell, such as a lithium-ion cell generates heat at a rate several times higher than the rate at which the heat can be dissipated. The thermal runaway of the battery cell may cause thermal propagation in a battery module in which the battery cell is located and may cause thermal runaway to occur in one or more of the remaining cells within the battery module. The thermal propagation caused due to the continuous thermal runaway within the battery module may further lead to fire and explosion in the battery module.
[0022] Batteries, such as Lithium-ion batteries, have various uses due to their utility and advantages over other types of batteries. In an example, Lithium-ion batteries may be used in the Electric Vehicles (EVs). As the demand for batteries for EVs is increasing, there is also a growing need to
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make the EVs safer. An event such as the thermal propagation can be severely detrimental to the safety of a user of the electric vehicle. The battery modules used in the EVs are susceptible to thermal runaway, during which a malfunctioning cell emits high-temperature, high-pressure gases and flames.
[0023] In existing EV designs, the battery pack is mounted within a compact frame structure, often surrounded by plastic body panels and other sensitive components. During the thermal runaway event, gases expelled from the battery pack may come into direct contact with these components, leading to melting, deformation, or ignition of plastic parts. The absence of a dedicated mechanism to isolate and redirect these gases increases the risk of fire and structural damage to the vehicle.
[0024] The expelled gases during thermal runaway are typically released through vents provided on a housing of the battery pack. In the absence of a controlled evacuation path, these gases may accumulate within the housing of the battery pack, causing pressure buildup and increasing the likelihood of explosion inside the battery pack. Additionally, the uncontrolled release of flames and hot gases from the battery pack not only compromises the structural integrity of the vehicle but also poses a significant safety risk to the rider. Exposure to flames or high-pressure gases during vehicle operation may cause physical injury to the rider and may violate safety standards and regulations governing electric vehicle battery systems.
[0025] Existing battery pack designs for controlled release of runaway gases are oftentimes not up to the required safety standards and lack structural integration with the vehicle frame and do not provide a compact, efficient mechanism for gas evacuation. The absence of a dedicated mounting structure for gas management components complicates assembly and maintenance and may result in inefficient use of space within the vehicle frame.
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[0026] Moreover, conventional systems fail to provide for flame arrestors, which increase their complexity and expense. Design restrictions are further tightened by government safety regulations that forbid visible flames outside battery casings. Thus, there is still a need for a compact, cost-effective, and simple venting solution that safeguards the EV and the battery pack during the thermal runaway.
[0027] The present subject matter is related to an electric vehicle (EV). The electric vehicle comprises a frame having at least one cross member mounted on the left-hand side (LH) of the frame and at least one cross member mounted on the right-hand side (RH) of the frame to support a battery pack within the frame. A housing of the battery pack is enclosed between a LH cross member and a RH cross member. Further, the EV comprises a pair of gas deflectors comprising a first gas deflector and a second gas deflector. The first gas deflector is coupled to the LH cross member, and the second gas deflector is coupled to the RH cross member. Each of the gas deflectors comprises a planar surface, and a sidewall along a periphery of the planar surface. The planar surface is oriented substantially perpendicular to a direction along which gases are expelled from at least one gas vent provided on a surface of the housing of the battery pack during a thermal runaway event, and an outer edge of the sidewall that makes contact with the surface of the housing is outwardly tapered. The planar surface bound by the sidewall is to define a continuous hollow volume such that the at least one gas vent that opens into the hollow volume, and at least one opening in the sidewall to form at least one outlet channel to allow the gases to be expelled out of the hollow volume.
[0028] The claimed subject matter addresses the above-described technical problems by providing a gas deflector coupled to cross members mounted on the frame of the electric vehicle. The gas deflector comprises a planar surface oriented perpendicular to the axis of gas expulsion from the battery pack of the EV, with openings aligned to the gas vents of the battery housing. The continuous wall surrounding the planar surface defines the
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hollow volume that allows expansion of gases during the thermal runaway event. The outlet channel formed in the wall enables controlled venting of gases away from the battery pack and vehicle components. This configuration prevents direct contact of high-temperature gases and flames with plastic body panels and other sensitive parts, thereby reducing the risk of fire and structural damage to the EV.
[0029] Further, by coupling the gas deflector with the frame-mounted cross members, the claimed subject matter provides a structurally supported evacuation path for gases such that the hollow volume and outlet channel allow pressure relief and redirection of gases underneath the vehicle, minimizing the likelihood of pressure buildup and explosion in the battery pack. Furthermore, the flanged edges, i.e., sidewalls of the gas deflector assist in suppressing flames, contributing to compliance with safety standards and improving overall vehicle safety during thermal runaway events.
[0030] The present subject matter is further described with reference to the accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[0031] Although embodiments for methods and systems for the present subject matter have been described in a language specific to structural features and/or methods, it is to be understood that the present subject matter is not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as exemplary embodiments for the present subject matter.
[0032] In accordance with an embodiment of the present invention, Figure 1 illustrates a side view of an electric vehicle 100 along with a gas
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deflector 102. The figure depicts the gas deflector 102 mounted on the left-hand side of a frame (not shown) of the electric vehicle 100. Although only one side is shown, the gas deflector 102 is coupled on both the left-hand side and the right-hand side of the frame. Each gas deflector 102 is positioned such that a sidewall or an inner wall of the gas deflector 102 is oriented substantially perpendicular to a direction along which gases are expelled from one or more gas vents located on a surface of a housing of a battery pack of the EV 100 during a thermal runaway event.
[0033] Each gas deflector 102 comprises at least one outlet channel (elaborated subsequently) configured to vent gases expelled from the battery pack. The outlet channel directs the gases along an axis oriented towards a front end of the electric vehicle 100, in a direction away from the rider and the battery pack. The gas deflector 102 is configured to prevent the expelled gases from contacting any body panels of the electric vehicle 100 by redirecting the gases towards the front end and downward underneath the vehicle 100, as depicted by the arrows in Figure 1. This helps in preventing damage to the plastic components of the vehicle 100 and reduces the risk of injury to the rider. The gas deflector 102 further creates a continuous hollow volume (elaborated below) that provides space to allow the gases to expand and cool before exiting the outer surface of the battery pack housing.
[0034] In one example, the gas deflector 102 is implemented in a two-wheeler electric vehicle 100. In a specific implementation, the two-wheeler is an electric motorcycle.
[0035] While this figure depicts a specific shape of the gas deflector 102, it will be clear to a person skilled in the art that the shape shown in the figure is not a limitation. Rather, the shape of the gas deflector 102 of the present invention is flexible with respect to the frame of the vehicle 100, the shape of the battery pack, and the arrangement of the gas vents on the surface of the housing of the battery pack.
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[0036] In accordance with an embodiment of the present invention, Figures 2A and 2B illustrate side views of a first gas deflector 102-1 and a second gas deflector 102-2 coupled to a frame 104 of an electric vehicle 100. Figure 2A shows the first gas deflector 102-1 mounted on a left-hand side (LH) cross member 106-1 of the frame 104, and Figure 2B shows the second gas deflector 102-2 mounted on a right-hand side (RH) cross member 106-2 of the frame 104. The LH cross member 106-1 and the RH cross member 106-2 are positioned on opposite sides of the frame 104 and are configured to support the battery pack within the frame 104. These cross members 106 also provide structural integrity to the frame 104 and protect the battery pack of the EV 100 from lateral impact.
[0037] Each of the gas deflectors 102 is coupled to a respective cross member 106, either by welding or bolting.
[0038] The location of the first gas deflector 102-1 and the second gas deflector 102-2, collectively referred to as gas deflectors 102, corresponds to the location of the gas vents on the surface of the housing of the battery pack. In the illustrated embodiment, the first gas deflector 102-1, which is mounted on the LH cross member 106-1, is positioned to cover at least one single gas vent on the left-hand side surface of the housing 108 of the battery pack. The second gas deflector 102-2, which is mounted on the RH cross member 106-2, is positioned to cover two gas vents on the right-hand side surface of the housing 108 of the battery pack.
[0039] Each of the gas deflectors 102 is located beneath the frame 104 of the vehicle 100, in a space between the housing 108 of the battery pack and the frame 104 of the vehicle 100. This placement ensures that the gas deflectors 102 are in close proximity to the gas vents on the surface of the housing 108 of the battery pack, enabling them to effectively block and redirect the gases expelled during a thermal runaway event.
[0040] The housing 108 of the battery pack is positioned between the LH cross member 106-1 and the RH cross member 106-2 and comprises various surface features such as ridges or protrusions to maintain a secure
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interface with the frame 104. These ridges coincide with the continuous hollow volume defined within each gas deflector, enabling the formation of one or more outlet channels in the gas deflectors 102. These outlet channels are configured to vent hot gases expelled from the battery pack during a thermal runaway event. Additionally, mounting features are provided on the gas deflectors 102 to facilitate secure attachment to the respective cross members 106 mounted on the frame 104 of the vehicle 100.
[0041] In accordance with an embodiment of the present invention, Figure 3A and Figure 3B illustrate a side view of a first gas deflector 102-1 and a second gas deflector 102-2 coupled to the LH cross member 106-1 and the RH cross member 106-2 of the frame 104 of the vehicle 100, respectively. As previously described, the cross members 106 are mounted on either side of the frame 104 and are configured to support the battery pack while also providing structural rigidity and protection against lateral impact. As shown in the figure, each of the gas deflectors 102 is mounted on the inner side of its respective cross member 106, such that the gas deflectors 102 are positioned adjacent to the surface of the housing 108 of the battery pack.
[0042] Each gas deflector 102 is secured to its corresponding cross member 106 either by welding or bolting. To facilitate this attachment, each gas deflector 102 includes predefined mounting points that are configured to receive fasteners or welding joints. These mounting points are strategically located to ensure proper alignment and secure coupling with the cross members 106. The use of predefined attachment locations simplifies the assembly process and ensures consistent positioning of the gas deflectors 102 on both sides of the frame 104.
[0043] Further, each gas deflector 102 is oriented such that the continuous hollow volume defined by the gas deflector 102 encloses a portion of the housing 108 of the battery pack. This orientation allows the gas deflector 102 to contain the gases expelled from one or more gas vents
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located on the housing 108 of the battery pack during the thermal runaway event, and allows them to expand and cool down.
[0044] In accordance with an embodiment of the present invention, Figure 4 illustrates the gas deflectors 102 coupled on either side of the frame 104 of the vehicle 100 to the respective cross members 106 along with the battery pack. The gas deflectors 102 are mounted on either side of the frame 104 and are positioned adjacent to the housing 108 of the battery pack. The battery pack is supported between the LH cross member 106-1 and the RH cross member 106-2, and the gas deflectors 102 are configured to manage the gases expelled from the battery pack during the thermal runaway event.
[0045] As described previously, each gas deflector 102 comprises a planar surface and a sidewall extending along the periphery of the planar surface. The planar surface is oriented such that it lies substantially perpendicular to the direction along which gases are expelled from one or more gas vents provided on the surface of the housing 108 of the battery pack. This orientation ensures that the expelled gases are directed into the gas deflector 102 rather than dispersing uncontrollably within the structure of the vehicle 100.
[0046] The sidewall, in combination with the planar surface, defines a continuous hollow volume. The hollow volume is defined by the planar surface that is oriented substantially perpendicular to the direction of gas expulsion from the gas vent on the housing 108 of the battery pack. This planar surface is enclosed on all sides by the sidewall that extends along the periphery of the planar surface, thereby forming a continuous three-dimensional enclosure. The sidewall includes at least one opening that serves as an outlet channel 110, allowing gases entering the hollow volume from the gas vent to be safely expelled out of the housing 108 of the battery pack. This hollow volume is positioned to receive gases directly from the gas vents provided on the surface of the housing 108 of the battery pack. The gas vents open into this hollow volume, allowing the gases to expand
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within the enclosed space. This expansion helps in reducing the pressure and temperature of the gases before they are vented out of the battery pack via the gas deflector 102. To enable the gases to exit the hollow volume, an opening is provided in the sidewall of each gas deflector 102. The opening provided on the sidewall of the gas deflector 102 forms one or more outlet channels through which the gases are expelled in a controlled direction away from the components of the vehicle 100 and the rider.
[0047] In one example, the first gas deflector 102-1, which is coupled to the LH cross member 106-1, is oriented such that it covers at least one gas vent located on the surface of the housing 108 of the battery pack. In a preferred embodiment, the first gas deflector 102-1 covers two gas vents 122 on the surface of the housing 108 of the battery pack. In another example, the second gas deflector 102-2, which is coupled to the RH cross member 106-2, is oriented to cover two gas vents on the housing 108 of the battery pack. The positioning of the gas deflectors 102 ensures that each gas vent is aligned with the corresponding hollow volume that allows for efficient capture and redirection of the expelled gases.
[0048] The configuration of the gas deflectors 102, as shown in Figure 4, enables the gases released during a thermal runaway event to be managed in a controlled manner. By enclosing the gas vents within the hollow volume and providing outlet channels 110 for gas evacuation, the gas deflectors 102 prevent the gases from contacting nearby components such as the body panels of the vehicle 100 and also prevent any injury to the rider. This arrangement of the gas deflectors 102 on the frame 104 of the vehicle 100 contributes to improved safety and structural protection of the EV 100.
[0049] In accordance with an embodiment of the present invention, Figure 5 illustrates a top view of the deflectors 102 mounted on either side of the frame 104. The frame 104 comprises a proximal end and a distal end. The proximal end of the frame 104 supports key functional components of the vehicle 100, including the battery pack, the motor for transmission, and
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the seating arrangement for the rider. The distal end of the frame extends rearward and supports the seating arrangement for a pillion rider. The gas deflectors 102 are mounted near the proximal end of the frame 104, where the battery pack is located, and are positioned on the LH cross member 106-1 and the RH cross member 106-2, respectively. This placement ensures that the gas deflectors 102 are in close proximity to the gas vents provided on the surface of the housing 108 of the battery pack, so that they allow for efficient capture and redirection of gases expelled during a thermal runaway event.
[0050] Further, the top view depicted in Figure 5 highlights the spatial arrangement of the gas deflectors 102 relative to the frame 104 and other components of the electric vehicle 100. By being mounted on the inner sides of the cross members 106, the gas deflectors 102 are positioned to face the battery pack directly, with their hollow volumes aligned to receive gases from the corresponding gas vents provided on the surface of the housing 108 of the battery pack. This configuration allows the gas deflectors 102 to function effectively without interfering with other structural or functional elements of the vehicle 100.
[0051] As discussed previously, in one example implementation, the electric vehicle 100 may be a two-wheeler such as an electric motorcycle, where space constraints and rider safety are important considerations. In such configurations, the compact mounting of the gas deflectors 102 near the proximal end of the frame ensures that the hot gases are vented away from the rider and sensitive body panels of the vehicle 100, contributing to improved safety and thermal management.
[0052] As illustrated in Figure 5, the present configuration of the electric vehicle 100 includes a frame 104 having cross members 106 positioned to support and enclose the battery pack. The gas deflectors are mounted on each of the cross members on either side of the frame of the vehicle 100 to manage the gases expelled from the battery pack during a thermal runaway event. However, it should be understood that the frame 104 configuration
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shown in the figures is merely an example, and other structural arrangements are possible. In alternative implementations, the frame may include differently positioned cross members 106 or support structures, and the placement of the gas deflectors 102 may be adapted accordingly. Regardless of the specific configuration, the gas deflectors 102 are intended to serve the same functional purpose, i.e., blocking and redirecting the expelled gases away from the rider and other critical components of the vehicle 100 in a controlled and safe manner.
[0053] In accordance with an embodiment of the present invention, Figures 6A to 6D illustrate a top and an inner side view of the first deflector 102-1 and the second deflector 102-2, respectively. These figures depict the spatial arrangement of the first deflector 102-1 and the second deflector (102-2) as they are mounted on the LH cross member 106-1 and the RH cross member 106-2, positioned on either side of the frame 104 of the vehicle 100. In one exemplary embodiment, the gas deflectors 102 are fabricated from stainless steel, which offers desirable properties such as corrosion resistance and structural integrity. However, it is to be understood that the deflectors may alternatively be constructed from any suitable metal, such as aluminum, titanium, or other alloys, depending on application requirements and performance considerations.
[0054] Furthermore, as illustrated in the figures, the planar surface of each of the gas deflectors 102 comprises a plurality of mounting features 112, such as holes or slots, which are provided to receive fasteners. These fasteners enable the secure coupling of the respective gas deflectors 102 to the LH cross member 106-1 and the RH cross member 106-2.
[0055] In addition, the sidewall 114 extending along the periphery of the planar surface 116 of each deflector is designed with a series of recesses 118. Each recess 118 is strategically positioned at locations corresponding to the points of contact between the deflector 102 and the ridges or protrusions present on the surface of the housing 108 of the battery pack. The dimensions and contours of these recesses are specifically matched to
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the profile of the ridges or the protrusions present on the surface of the housing 108 of the battery pack. By doing so, the deflectors 102 can securely sit against the surface of the housing 108 of the battery pack. This configuration results in full-surface contact, thereby eliminating the possibility of uneven support on the surface of the housing. Further, these figures show an outwardly tapered outer edge 114-1 of the sidewall 114 that makes contact with the surface of the housing 108 of the battery pack.
[0056] The gas deflectors 102 described may be manufactured using conventional sheet metal forming methods such as stamping, deep drawing, or metal pressing to achieve their precise geometry and mounting features. For deflectors fabricated from stainless steel or similar metals, these processes allow the formation of planar surfaces 116 and peripheral recesses 118 with high accuracy and repeatability. Details of standard manufacturing steps and process variations have been omitted for brevity.
[0057] In accordance with an embodiment of the present invention, Figure 7 illustrates a cross-sectional side view of the gas deflector 102 mounted on the cross member 106. The outer edge 114-1 of the sidewall 114 that makes contact with the surface of the housing 108 of the battery pack is outwardly tapered, which forms flanges or flanging structures. The flanging 120 is formed by bending or shaping the outer edge 114-1 of the sidewall 114 of the gas deflector 102, made of sheet metal material, creating a lip or extension that lies in close proximity to or in contact with the surface of the housing 108 of the battery pack housing.
[0058] The flanging structure 120 serves multiple purposes. Functionally, it enhances the sealing interface between the gas deflector 102 and the battery housing, helping to contain the expelled gases within the hollow volume and prevent leakage into surrounding areas. More importantly, the flanging 120 assists in suppressing flames that may be released from the gas vent 122 of the housing 108 of the battery pack during a thermal runaway event. By creating a physical barrier and increasing the surface area at the gas exit interface, the flanging 120 helps to disrupt the
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flame front and reduce the likelihood of flame propagation beyond the deflector 102.
[0059] In example implementations, the flanging 120 may be continuous along the perimeter of the sidewall 114 or selectively applied at critical regions where flame suppression and structural stability are most needed.
[0060] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. As such, the present disclosure should not be limited to the description of the preferred examples and implementations contained therein.
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I/We Claim:
1. An electric vehicle (EV) (100), comprising:
a frame (104) having at least one cross member (106-1) mounted on the left-hand side (LH) of the frame and at least one cross member (106-2) mounted on the right-hand side (RH) of the frame (104) to support a battery pack within the frame (104), wherein a housing (108) of the battery pack is enclosed between a LH cross member (106-1) and a RH cross member (106-2);
a pair of gas deflectors (102) comprising a first gas deflector (102-1) and a second gas deflector (102-2), wherein the first gas deflector (102-1) is coupled to the LH cross member (106-1) and the second gas deflector (102-2) is coupled to the RH cross member (106-2), and
wherein each of the gas deflectors (102) comprises:
a planar surface (116), and a sidewall (114) along a periphery of the planar surface (116), wherein
the planar surface (116) is oriented substantially perpendicular to a direction along which gases are expelled from at least one gas vent (122) provided on a surface of the housing (108) of the battery pack during a thermal runaway event, and wherein
an outer edge (114-1) of the sidewall (114) that makes contact with the surface of the housing (108) is outwardly tapered;
the planar surface (116) bound by the sidewall (114) is to define a continuous hollow volume such that the at least one gas vent (122) that opens into the hollow volume, and
at least one opening in the sidewall (114) to form at least one outlet channel (110) to allow the gases to be expelled out of the hollow volume.
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2. The electric vehicle (100) as claimed in claim 1, wherein the at least one outlet channel (110) vents out the gases along an axis oriented towards a front end of the EV (100), in a direction away from the rider.
3. The electric vehicle (100) as claimed in claim 1, wherein the first gas deflector (102-1) coupled to the LH cross member (106-1) is oriented such that the first gas deflector (102-1) covers at least one gas vent (122) on the surface of the housing (108) of the battery pack.
4. The electric vehicle (100) as claimed in claim 1, wherein the second gas deflector (102-2) coupled to the RH cross member (106-2) is oriented such that the second gas deflector (102-2) covers two gas vents (122) on the surface of the housing (108) of the battery pack.
5. The electric vehicle (100) as claimed in claim 1, wherein each of the gas deflectors comprises at least one flange (120), positioned along the periphery of the continuous wall, to suppress flames during the thermal runaway event.
6. The electric vehicle (100) as claimed in claim 1, wherein each of the first gas deflector (102-1) and the second gas deflector (102-2) is coupled to each of the at least one LH cross member (106-1) and at least one RH cross member (106-2) by welding or bolting.
7. The electric vehicle (100) as claimed in claim 6, wherein the planar surface (116) of each of the first gas deflector (102-1) and the second gas deflector (102-2) includes a plurality of mounting features (112) configured to receive fasteners for coupling the first gas deflector (102-1) and the second gas deflector (102-2) to the at least one cross member on either side of the frame.
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8. The electric vehicle (100) as claimed in claim 1, wherein the gas deflector (102) is made of stainless steel.
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ABSTRACT
GAS DEFLECTORS FOR BATTERY PACKS OF ELECTRIC VEHICLES
The invention relates to an electric vehicle (EV) (100) comprising a frame (104) that supports a battery pack via a left-hand side (LH) cross member (106-1) and a right-hand side (RH) cross member (106-2), with the housing (108) of the battery pack enclosed between them. A pair of gas deflectors, first (102-1) on the LH cross member and second (102-2) on the RH cross member, manage gas expulsion during thermal runaway. Each gas deflector (102) includes a planar surface (116) and a sidewall (114) along a periphery of the planar surface to form a continuous hollow volume. The planar surface (116) is substantially perpendicular to the gas expulsion direction from at least one gas vent (122) on the housing (108). An outer edge (114-1) of the sidewall (114) sits flush and is outwardly tapered. Each sidewall (114) includes at least one opening forming an outlet channel (110) to direct expelled gases safely.
(To be published with Figure 1) , Claims:I/We Claim:
1. An electric vehicle (EV) (100), comprising:
a frame (104) having at least one cross member (106-1) mounted on the left-hand side (LH) of the frame and at least one cross member (106-2) mounted on the right-hand side (RH) of the frame (104) to support a battery pack within the frame (104), wherein a housing (108) of the battery pack is enclosed between a LH cross member (106-1) and a RH cross member (106-2);
a pair of gas deflectors (102) comprising a first gas deflector (102-1) and a second gas deflector (102-2), wherein the first gas deflector (102-1) is coupled to the LH cross member (106-1) and the second gas deflector (102-2) is coupled to the RH cross member (106-2), and
wherein each of the gas deflectors (102) comprises:
a planar surface (116), and a sidewall (114) along a periphery of the planar surface (116), wherein
the planar surface (116) is oriented substantially perpendicular to a direction along which gases are expelled from at least one gas vent (122) provided on a surface of the housing (108) of the battery pack during a thermal runaway event, and wherein
an outer edge (114-1) of the sidewall (114) that makes contact with the surface of the housing (108) is outwardly tapered;
the planar surface (116) bound by the sidewall (114) is to define a continuous hollow volume such that the at least one gas vent (122) that opens into the hollow volume, and
at least one opening in the sidewall (114) to form at least one outlet channel (110) to allow the gases to be expelled out of the hollow volume.
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2. The electric vehicle (100) as claimed in claim 1, wherein the at least one outlet channel (110) vents out the gases along an axis oriented towards a front end of the EV (100), in a direction away from the rider.
3. The electric vehicle (100) as claimed in claim 1, wherein the first gas deflector (102-1) coupled to the LH cross member (106-1) is oriented such that the first gas deflector (102-1) covers at least one gas vent (122) on the surface of the housing (108) of the battery pack.
4. The electric vehicle (100) as claimed in claim 1, wherein the second gas deflector (102-2) coupled to the RH cross member (106-2) is oriented such that the second gas deflector (102-2) covers two gas vents (122) on the surface of the housing (108) of the battery pack.
5. The electric vehicle (100) as claimed in claim 1, wherein each of the gas deflectors comprises at least one flange (120), positioned along the periphery of the continuous wall, to suppress flames during the thermal runaway event.
6. The electric vehicle (100) as claimed in claim 1, wherein each of the first gas deflector (102-1) and the second gas deflector (102-2) is coupled to each of the at least one LH cross member (106-1) and at least one RH cross member (106-2) by welding or bolting.
7. The electric vehicle (100) as claimed in claim 6, wherein the planar surface (116) of each of the first gas deflector (102-1) and the second gas deflector (102-2) includes a plurality of mounting features (112) configured to receive fasteners for coupling the first gas deflector (102-1) and the second gas deflector (102-2) to the at least one cross member on either side of the frame.
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8. The electric vehicle (100) as claimed in claim 1, wherein the gas deflector (102) is made of stainless steel.