Modern EVs rely on under-body covers to improve aerodynamics, reduce drag, and protect the vehicle’s underside from dirt and debris. However, lightweight materials commonly used in these panels often cause fluttering and flapping issues at higher speeds. Ford’s newly patented design, filed with the European Patent Office, aims to eliminate these problems. The company claims its solution not only addresses the drawbacks of traditional panels but is also more cost-effective to produce, offering a practical upgrade for electric vehicle designs.
The Critical Role of Under-Body Panels in EV Efficiency
Aerodynamic efficiency is especially important for EVs if they’re to eke the last bit of range out of their batteries. For this reason, they’re all fitted with smooth under-body panels that cover the battery casing, front and rear subframes, powertrain, and suspension. These covers aren’t structural members, but act as finishers to provide a smooth surface for lower drag. The problem is that thin, lightweight plastic and carpet-based covers are not rigid enough, and wind flowing rapidly over them can cause flapping and fluttering.
Ford’s Innovative Under-Body Cover Design
Ford’s patented under-body cover system is a thoughtfully engineered solution to common EV challenges. It consists of three main components: the cover itself, a support beam, and a panel molded over the beam, likely to ensure a secure and durable assembly. While the patent doesn’t specify the material of the cover, internal ribbing shown in the drawings suggests a plastic or composite material designed for added rigidity. This rigidity likely increases weight, but the enhanced aerodynamic performance and durability appear to justify the tradeoff.
The support beam, made of stamped metal, plays a critical role in maintaining structure and stability, ensuring the cover remains firmly in place under all conditions. It also eliminates aerodynamic issues like fluttering and flapping, which not only compromise refinement but also reduce aerodynamic efficiency. These noise-related problems are particularly noticeable in EVs, as the absence of a gas engine amplifies other sound sources. Ford’s design directly addresses this issue, providing a quieter and more aerodynamically efficient solution—an improvement that may not have been as critical in noisier internal combustion engine vehicles.
