Modular automotive platform and assembly method

Abstract

A modular vehicle assembly platform is disclosed. In some embodiments, the platform may comprise a cast bulkhead, a cast cowl, one or more cast front strut towers, a front subframe, a crosscar beam, one or more door rings, a structural central floor including a battery, a cast structural rear floor, a cast upper rear section (or D-ring), and a rear motor cradle. The platform may allow the use of common parts and structures across different vehicle types.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 501,787, filed on May 12, 2023, and U.S. Provisional Patent Application No. 63 / 570,565, filed on March 27, 2024, under 35 USC (United States Patent Law) Section 119(e). The entire contents of each of these applications are hereby incorporated by reference into this specification in their entirety.

[0002] [Technical Field] The subject matter of the present disclosure relates generally to modular automotive platforms, related modular components, and assembly methods. The modular automotive platform can be composed of castings of high - strength materials (such as aluminum), and can improve assembly and repair methods by reducing the number of parts and enhancing the compatibility of parts between different types of vehicles.

Background Art

[0003] Modern vehicles, such as automobiles, are complex machines containing thousands of parts. Many of these parts are specific to the vehicle type / category (e.g., sedan, coupe, SUV, crossover, pickup truck, van, cargo van, etc.), and even specific to a particular vehicle model and year. Despite technological advancements incorporating automation, the process of assembling and repairing vehicles largely follows the assembly line model developed by Henry Ford. For example, the vehicle frame is welded, electrical wiring is installed, mechanical components such as the engine and brakes are inserted into the frame, the windshield and rear window are fitted along with the seats and tires, the doors are installed, and in the case of electric vehicles, the battery pack or fuel cell is installed. These traditional procedures in the assembly process tend to be labor-intensive, rely on large, expensive machinery and precise positioning to integrate parts, and often result in large quantities of unusable scrap parts and materials. Manufacturers also need to keep extra stock of vehicle type (model) or vehicle model-specific parts to avoid production delays.

[0004] Therefore, there is a need for new methods and systems for the manufacture, assembly, and repair of automobiles that are simplified by reducing the number of parts and processes required in the assembly or repair process, while allowing for improved interchangeability of parts and assemblies. [Overview of the project]

[0005] An embodiment of a vehicle bulkhead is disclosed. The bulkhead may comprise a top portion having one or more top mating surfaces for structurally connecting the bulkhead to the cowl of the vehicle. The bulkhead may comprise a front portion having one or more front mating surfaces for structurally connecting the bulkhead to one or more strut towers of the vehicle. The bulkhead may comprise a rear portion having one or more door ring mating features for structurally connecting the bulkhead to one or more door rings of the vehicle. The bulkhead may comprise a single piece of cast material.

[0006] Another embodiment of a bulkhead for a vehicle is disclosed. The bulkhead may comprise a body made of a single piece of cast material and having a plurality of faces separated by a plurality of edges. The plurality of faces may include a top face having one or more top mating surfaces and a bottom face located opposite the top face. The plurality of faces may include a front surface having one or more front mating surfaces and extending from the top face to the bottom surface, and a rear surface having one or more rear mating surfaces and extending from the top face to the bottom surface. The plurality of faces may further include one or more sides extending from the top face to the bottom surface and from the front surface to the rear surface. Both the front surface and the rear surface may be adjacent to the one or more sides, and the one or more rear mating surfaces may be positioned close to one or more rear edges of the edges, the rear edges may separate the rear surface from the one or more sides.

[0007] Another embodiment of a bulkhead for a vehicle is disclosed. The bulkhead may comprise a body formed from a single piece of cast material, the body having one or more top mating surfaces contoured to form a top structural joint with the cowl of the vehicle, and one or more door ring mating features contoured to form one or more side structural joints with one or more door rings of the vehicle. The one or more top mating surfaces and the one or more door ring mating features may be integral with the body. The body may restrict the movement of the cowl relative to the one or more door rings when forming the top structural joint and the one or more side structural joint.

[0008] An embodiment of a vehicle cowl is disclosed. The vehicle cowl may comprise a body portion formed from a single piece of cast material. The body portion may have one or more bulkhead mating surfaces that structurally engage with complementary mating surfaces on the vehicle's bulkhead, the one or more bulkhead mating surfaces may include a central section having a first height and one or more outer sections having a second height. The body portion may also have one or more doorring mating features that structurally engage with complementary mating surfaces on one or more doorrings, the one or more doorring mating features may be positioned along one or more substantially vertical outer edges of the cowl.

[0009] Another embodiment of a cowl for a vehicle is disclosed. The cowl for the vehicle may include one or more bulkhead mating surfaces contoured to form one or more bulkhead structural joints with complementary mating surfaces on the bulkhead of the vehicle. The cowl for the vehicle may include one or more door ring mating features contoured to form one or more door ring structural joints with complementary mating surfaces on one or more door rings of the vehicle. The cowl for the vehicle may include two upper shock mounts that structurally engage with each of the front strut towers of the vehicle, the two upper shock mounts being able to restrict the movement of the front strut towers relative to each other when the front strut towers are structurally engaged by the upper shock mounts. The cowl for the vehicle may consist of a single piece of cast material.

[0010] Another embodiment of a vehicle cowl is disclosed. The vehicle cowl may include one or more bulkhead mating surfaces that structurally abut against the bulkhead of the vehicle. The vehicle cowl may include one or more doorring mating features that structurally abut against one or more doorrings of the vehicle. The vehicle cowl may include first and second upper shock mounts for structural coupling to the first and second front strut towers of the vehicle, respectively, the first and second upper shock mounts, when coupled to the first and second front strut towers, respectively, the first front strut towers can restrict the movement of the first front strut tower relative to the second front strut tower. The vehicle cowl may consist of a single piece of cast material.

[0011] An embodiment of a front assembly for a vehicle is disclosed. The front assembly for the vehicle may comprise two front strut towers, each consisting of a single piece made of a cast material. The front assembly for the vehicle may comprise a crosscar beam, each structurally connected to the two front strut towers at a first joint and a second joint, such that a first distance between the first and second joints can be associated with a first vehicle type among a plurality of known vehicle types. The front assembly for the vehicle may comprise a front subframe, structurally connected to the bottom of the two front strut towers, such that the front subframe can be positioned in close proximity to the crosscar beam.

[0012] Another embodiment of a front assembly for a vehicle is disclosed. The front assembly for the vehicle may comprise a first front strut tower and a second front strut tower, and a crosscar beam structurally engaged with the first front strut tower and the second front strut tower to restrict the movement of the first front strut tower relative to the second front strut tower. The front assembly for the vehicle may comprise a front subframe structurally connected from below to the first front strut tower and the second front strut tower and positioned in close proximity to the crosscar beam.

[0013] Another embodiment of a front assembly for a vehicle is disclosed. The front assembly for the vehicle may comprise two front strut towers, each consisting of a single piece of cast material, the two front strut towers may include one or more first bulkhead mating surfaces contoured to structurally connect to the bulkhead of the vehicle. The front assembly for the vehicle may comprise a front subframe positioned below the two front strut towers, the front subframe may include an integrated crossbar beam and one or more second bulkhead mating surfaces, the integrated crossbar beam may be structurally connected to the two front strut towers to restrict the movement of the two front strut towers relative to each other, and the one or more second bulkhead mating surfaces may be contoured to structurally connect to the bulkhead.

[0014] An embodiment of a door ring for a vehicle is disclosed. The door ring may comprise a first outer wall that forms at least a portion of the exterior of the vehicle and extends along the perimeter of a cavity for receiving one or more doors of the vehicle. The door ring may comprise a second outer wall positioned inside the first outer wall and extending along at least a portion of the perimeter of the cavity. The door ring may comprise an inner planar wall positioned inside the second outer wall. The door ring may comprise an inner frame that is structurally attached to the inner planar wall and forms at least a portion of the interior of the vehicle. The first outer wall, the second outer wall, and the inner planar wall may be structurally attached to one another along at least a portion of the perimeter of the cavity.

[0015] Another embodiment of a door ring for a vehicle is disclosed. The door ring may comprise an outer layer, an inner layer structurally attached to the outer layer, and one or more holes provided in each of the outer layer and the inner layer, wherein the outer layer may have a first mating surface on its outer side, the inner layer may have a second mating surface on its outer side, and the one or more holes may extend through the first mating surface and the second mating surface. The first mating surface may be substantially parallel to the second mating surface.

[0016] Another embodiment of a door ring for a vehicle is disclosed. The door ring may comprise a first mating surface having a first group of one or more holes for receiving one or more first connectors, the first mating surface being structurally compatible with one or more other vehicle components. The door ring may comprise a second mating surface having a second group of one or more holes for receiving one or more second connectors, the second mating surface being structurally compatible with the one or more other vehicle components. The first mating surface may be substantially parallel to the second mating surface, and the first mating surface may be offset from the second mating surface by a certain distance.

[0017] An embodiment of a rear structural floor for a vehicle is disclosed. The rear structural floor may comprise one or more top mating surfaces contoured to structurally engage with the upper rear section of the vehicle, one or more door ring mating features contoured to structurally engage with one or more door rings of the vehicle, one or more rear motor cradle mounting points on the underside of the rear structural floor, and one or more battery mating surfaces on the front of the rear structural floor. The rear structural floor may consist of a single piece of cast material. The one or more top mating surfaces, the one or more door ring mating features, the one or more rear motor cradle mounting points, and the one or more battery mating surfaces may be integrally constructed with the rear structural floor.

[0018] Another embodiment of a rear structural floor for a vehicle is disclosed. The rear structural floor may comprise one or more top mating surfaces integral with the rear structural floor and an upper rear section, the upper rear section may have one or more bottom mating surfaces integral with the upper rear section, the one or more bottom mating surfaces may be complementary to the top mating surfaces of the rear structural floor, and the one or more bottom mating surfaces may be structurally engaged with the one or more top mating surfaces. The rear structural floor may comprise a rear motor cradle structurally connected to the rear structural floor. The rear structural floor and the upper rear section may each consist of a single piece of cast material.

[0019] Another embodiment of a rear structural floor for a vehicle is disclosed. The rear structural floor may comprise one or more top mating surfaces integral with the rear structural floor and an upper rear section, the upper rear section may have one or more bottom mating surfaces integral with the upper rear section, the one or more bottom mating surfaces may be complementary to the top mating surfaces of the rear structural floor, and the one or more bottom mating surfaces may be structurally engaged with the one or more top mating surfaces. The upper rear section may be specific to one of one or more vehicle types, and the rear structural floor may be common to one or more vehicle types.

[0020] An embodiment of a vehicle battery structure is disclosed. The battery structure may include a structural ring having a first mating surface and a second mating surface. The structural ring may form at least three parts, including a front portion contoured to structurally engage with the bulkhead of the vehicle, a middle portion contoured to structurally engage with one or more door rings of the vehicle, and a rear portion contoured to structurally engage with the rear structural floor of the vehicle. The battery structure may further include an electric vehicle battery disposed within the structural ring.

[0021] Another embodiment of a battery structure for a vehicle is disclosed. The battery structure may comprise a structural ring having a first mating surface and a second mating surface; one or more first holes in the structural ring and the first mating surface; one or more second holes in the structural ring and the second mating surface; one or more first connectors in the one or more first holes; one or more second connectors in the one or more second holes; and an electric vehicle battery disposed within the structural ring. The first mating surface may be parallel to the second mating surface, and the one or more first connectors and the one or more second connectors may structurally connect the battery structure to a component of a vehicle.

[0022] An embodiment of a central vehicle floor is disclosed. The central vehicle floor may include a structural ring having a first mating surface and a second mating surface. The structural ring may form at least three parts, including a front portion that structurally engages with a bulkhead, an intermediate portion that structurally engages with one or more door rings, and a rear portion that structurally engages with a rear structural floor. The central vehicle floor may include an electric vehicle battery disposed within the structural ring and a fuel tank disposed within the structural ring.

[0023] An embodiment of a vehicle platform for constructing a vehicle is disclosed. The vehicle platform may comprise a front structure having a bulkhead and a cowl structurally connected to the bulkhead. The vehicle platform may comprise two door rings structurally connected to the front structure, the two door rings may be provided one on each side of the vehicle. The vehicle platform may comprise a rear structure structurally connected to each of the two door rings. The rear structure may comprise a rear structure floor and an upper rear section structurally connected to the rear structure floor.

[0024] Another embodiment of a vehicle platform for constructing a vehicle is disclosed. The vehicle platform may include two door rings specific to one of a plurality of vehicle types, a bulkhead for use in the plurality of vehicle types structurally connected to the two door rings, and a cowl specific to the one of the plurality of vehicle types structurally connected to the bulkhead. The vehicle platform may include a rear structural floor for use in the plurality of vehicle types structurally connected to the two door rings, and an upper rear section specific to the one of the plurality of vehicle types structurally connected to the rear structural floor. The bulkhead, the cowl, the rear structural floor, and the upper rear section may each be individual parts of cast aluminum.

[0025] A vehicle assembly method is disclosed. The method may include fastening a bulkhead to a vehicle cowl to form a front structure, fastening an upper rear section to a rear structural floor to form a rear structure, fastening two door rings, the front structure, and the rear structure to form a vehicle body, and fastening a front axle assembly, a rear axle assembly, and a central floor to the vehicle body.

[0026] Further implementations, features, and aspects of the technology of this disclosure, as well as the advantages provided thereby, are described in more detail below and can be understood by referring to the following detailed description, the accompanying drawings, and the claims.

[0027] This reference is made to the accompanying drawings. The accompanying drawings, although not necessarily drawn to scale, are incorporated in and constitute a part of this disclosure, showing various implementations and aspects of the technology of this disclosure and serving to explain the principles of the technology of this disclosure together with the following description.

Brief Description of the Drawings

[0028] [Figure 1A]Figures 1A to 1C are an isometric front view (Figure 1A), an isometric side view (Figure 1B), and an isometric plan view (Figure 1C) of a cast aluminum bulkhead (firewall) of a modular automobile according to a specific embodiment of the technology of the present disclosure. [Figure 1B] Figures 1A to 1C are an isometric front view (Figure 1A), an isometric side view (Figure 1B), and an isometric plan view (Figure 1C) of a cast aluminum bulkhead (firewall) of a modular automobile according to a specific embodiment of the technology of the present disclosure. [Figure 1C] Figures 1A to 1C are an isometric front view (Figure 1A), an isometric side view (Figure 1B), and an isometric plan view (Figure 1C) of a cast aluminum bulkhead (firewall) of a modular automobile according to a specific embodiment of the technology of the present disclosure.

[0029] [Figure 2A] Figures 2A to 2D are an isometric side view (Figure 2A), an isometric plan view (Figure 2B), an isometric bottom view (Figure 2C), and an isometric rear view (Figure 2D) of a cowl of a modular automobile according to a specific embodiment of the technology of the present disclosure. [Figure 2B] Figures 2A to 2D are an isometric side view (Figure 2A), an isometric plan view (Figure 2B), an isometric bottom view (Figure 2C), and an isometric rear view (Figure 2D) of a cowl of a modular automobile according to a specific embodiment of the technology of the present disclosure. [Figure 2C] Figures 2A to 2D are an isometric side view (Figure 2A), an isometric plan view (Figure 2B), an isometric bottom view (Figure 2C), and an isometric rear view (Figure 2D) of a cowl of a modular automobile according to a specific embodiment of the technology of the present disclosure. [Figure 2D] Figures 2A to 2D are an isometric side view (Figure 2A), an isometric plan view (Figure 2B), an isometric bottom view (Figure 2C), and an isometric rear view (Figure 2D) of a cowl of a modular automobile according to a specific embodiment of the technology of the present disclosure.

[0030] [Figure 3A]Figures 3A to 3C are isometric front view (Figure 3A), isometric top view (Figure 3B), and isometric side view (Figure 3C) of the left strut tower of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 3B] Figures 3A to 3C are isometric front view (Figure 3A), isometric top view (Figure 3B), and isometric side view (Figure 3C) of the left strut tower of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 3C] Figures 3A to 3C are isometric front view (Figure 3A), isometric top view (Figure 3B), and isometric side view (Figure 3C) of the left strut tower of a modular automobile according to a particular embodiment of the technology of the present disclosure.

[0031] [Figure 3D] Figures 3D and 3E are perspective views of the left strut tower (Figure 3D) and the right strut tower (Figure 3E) of a modular vehicle according to a particular embodiment of the technology of the present disclosure. [Figure 3E] Figures 3D and 3E are perspective views of the left strut tower (Figure 3D) and the right strut tower (Figure 3E) of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0032] [Figure 4A] Figures 4A and 4B are isometric plan view (Figure 4A) and isometric side view (Figure 4B) of a modular vehicle structural front subframe according to a particular embodiment of the technology of the present disclosure. [Figure 4B] Figures 4A and 4B are isometric plan view (Figure 4A) and isometric side view (Figure 4B) of a modular vehicle structural front subframe according to a particular embodiment of the technology of the present disclosure.

[0033] [Figure 5A] Figures 5A to 5C are isometric plan view (Figure 5A), isometric side view (Figure 5BC), and isometric rear view (Figure 5C) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure. [Figure 5B]Figures 5A to 5C are isometric plan view (Figure 5A), isometric side view (Figure 5BC), and isometric rear view (Figure 5C) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure. [Figure 5C] Figures 5A to 5C are isometric plan view (Figure 5A), isometric side view (Figure 5BC), and isometric rear view (Figure 5C) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure.

[0034] [Figure 5D] Figures 5D and 5E are perspective views of a modular vehicle front assembly according to a specific embodiment of the technology of this disclosure. [Figure 5E] Figures 5D and 5E are perspective views of a modular vehicle front assembly according to a specific embodiment of the technology of this disclosure.

[0035] [Figure 5F] Figures 5F to 5H are isometric plan view (Figure 5F), isometric front view (Figure 5GC), and isometric side view (Figure 5H) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure. [Figure 5G] Figures 5F to 5H are isometric plan view (Figure 5F), isometric front view (Figure 5GC), and isometric side view (Figure 5H) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure. [Figure 5H] Figures 5F to 5H are isometric plan view (Figure 5F), isometric front view (Figure 5GC), and isometric side view (Figure 5H) of a modular vehicle front assembly according to a particular embodiment of the technology of the present disclosure.

[0036] [Figure 6A] Figures 6A and 6B are isometric left side view (Figure 6A) and isometric right side view (Figure 6B) of a left door ring assembly of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 6B]Figures 6A and 6B are isometric left side view (Figure 6A) and isometric right side view (Figure 6B) of a left door ring assembly of a modular automobile according to a particular embodiment of the technology of the present disclosure.

[0037] [Figure 6C] Figure 6C is an isometric front view of the left door ring assembly of a modular automobile according to a particular embodiment of the technology of the present disclosure.

[0038] [Figure 6D] Figures 6D to 6F are cross-sectional perspective views of a modular left door ring assembly assembled in a vehicle, at various mounting points, according to a particular embodiment of the technology of the present disclosure. [Figure 6E] Figures 6D to 6F are cross-sectional perspective views of a modular left door ring assembly assembled in a vehicle, at various mounting points, according to a particular embodiment of the technology of the present disclosure. [Figure 6F] Figures 6D to 6F are cross-sectional perspective views of a modular left door ring assembly assembled in a vehicle, at various mounting points, according to a particular embodiment of the technology of the present disclosure.

[0039] [Figure 6G] Figure 6G is an isometric rear view of the left door ring assembly of a modular automobile according to a particular embodiment of the technology of this disclosure.

[0040] [Figure 6H] Figure 6H is a perspective view of left and right door ring assemblies mounted via a roof cross member of a modular automobile, according to a particular embodiment of the technology of the present disclosure.

[0041] [Figure 7A] Figures 7A and 7B are isometric side view (Figure 7A) and isometric plan view (Figure 7B) of a modular vehicle rear structural floor according to a particular embodiment of the technology of the present disclosure. [Figure 7B]Figures 7A and 7B are isometric side view (Figure 7A) and isometric plan view (Figure 7B) of a modular vehicle rear structural floor according to a particular embodiment of the technology of the present disclosure.

[0042] [Figure 7C] Figure 7C is a perspective view of the rear structural floor of a modular vehicle according to a specific embodiment of the technology of this disclosure.

[0043] [Figure 7D] Figure 7D is an isometric bottom view of the rear structural floor of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0044] [Figure 8A] Figures 8A to 8D are isometric front view (Figure 8A), isometric side view (Figure 8B), isometric rear view (Figure 8C), and isometric top view (Figure 8D) of a D-ring section of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 8B] Figures 8A to 8D are isometric front view (Figure 8A), isometric side view (Figure 8B), isometric rear view (Figure 8C), and isometric top view (Figure 8D) of a D-ring section of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 8C] Figures 8A to 8D are isometric front view (Figure 8A), isometric side view (Figure 8B), isometric rear view (Figure 8C), and isometric top view (Figure 8D) of a D-ring section of a modular automobile according to a particular embodiment of the technology of the present disclosure. [Figure 8D] Figures 8A to 8D are isometric front view (Figure 8A), isometric side view (Figure 8B), isometric rear view (Figure 8C), and isometric top view (Figure 8D) of a D-ring section of a modular automobile according to a particular embodiment of the technology of the present disclosure.

[0045] [Figure 9A] Figure 9A is a perspective view of a rear motor cradle of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0046] [Figure 9B] Figures 9B and 9C are an isometric plan view (Figure 9B) and an isometric side view (Figure 9C) of a rear motor cradle of a modular vehicle according to a particular embodiment of the technology of the present disclosure. [Figure 9C] Figures 9B and 9C are an isometric plan view (Figure 9B) and an isometric side view (Figure 9C) of a rear motor cradle of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0047] [Figure 10A] Figure 10A is a perspective view of an assembled rear structural floor and D-ring section of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0048] [Figure 10B] Figure 10B is a perspective view of an assembled left door ring assembly, rear structural floor, D-ring section, rear motor cradle, and structural battery of a modular vehicle according to a specific embodiment of the technology of the present disclosure.

[0049] [Figure 10C] Figure 10C is a perspective view of a modular vehicle rear assembly according to a particular embodiment of the technology of this disclosure.

[0050] [Figure 10D] Figures 10D and 10E are isometric side view (Figure 10D) and isometric bottom view (Figure 10E) of a modular vehicle rear assembly according to a particular embodiment of the technology of the present disclosure. [Figure 10E] Figures 10D and 10E are isometric side view (Figure 10D) and isometric bottom view (Figure 10E) of a modular vehicle rear assembly according to a particular embodiment of the technology of the present disclosure.

[0051] [Figure 11A] Figure 11A is a perspective view of a modular vehicle structural battery according to a specific embodiment of the technology of this disclosure.

[0052] [Figure 11B] Figure 11B is an isometric plan view of a modular vehicle structural battery according to a specific embodiment of the technology of this disclosure.

[0053] [Figure 11C] Figure 11C is a perspective view of an assembled left door ring assembly, rear structural floor, and structural battery of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0054] [Figure 11D] Figure 11D is a perspective view of an assembled left door ring assembly and structural battery of a modular vehicle according to a specific embodiment of the technology of this disclosure.

[0055] [Figure 11E] Figure 11E is a perspective view of an assembled bulkhead, cowl, left strut tower, structural front subframe, and structural battery of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0056] [Figure 11F] Figures 11F and 11G are cross-sectional perspective views of an assembled bulkhead and structural battery of a modular vehicle according to a particular embodiment of the technology of this disclosure. [Figure 11G] Figures 11F and 11G are cross-sectional perspective views of an assembled bulkhead and structural battery of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0057] [Figure 11H] Figure 11H is a cross-sectional perspective view of an assembled crossbar beam, bulkhead, and structural battery of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0058] [Figure 11I]Figures 11I and 11J are cross-sectional perspective views of an assembled rear structural floor and structural battery of a modular vehicle according to a particular embodiment of the technology of the present disclosure. [Figure 11J] Figures 11I and 11J are cross-sectional perspective views of an assembled rear structural floor and structural battery of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0059] [Figure 12A] Figure 12A is an exploded view of a modular cast automobile according to a specific embodiment of the technology of this disclosure.

[0060] [Figure 12B] Figure 12B is an exploded view of the front and rear cast structures of a modular vehicle according to a specific embodiment of the technology of this disclosure.

[0061] [Figure 12C] Figure 12C is an exploded view of the front and rear cast structures and left and right door ring assemblies of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0062] [Figure 12D] Figure 12D is an assembled diagram of the vehicle upper assembly, left and right strut towers, structural front subframe, rear motor cradle, and structural battery of a modular vehicle according to a particular embodiment of the technology of the present disclosure.

[0063] [Figure 12E] Figure 12E is an exploded view of a modular cast automobile with alternative upper components, according to a particular embodiment of the technology of this disclosure.

[0064] [Figure 12F]Figure 12F is an assembled diagram of the vehicle upper assembly, left and right strut towers, structural front subframe, rear motor cradle, and structural battery of a modular vehicle with alternative upper components of Figure 12E, according to a particular embodiment of the technology of the present disclosure.

[0065] [Figure 13] Figure 13 is an assembled diagram of a modular automobile according to a particular embodiment of the technology of this disclosure.

[0066] [Figure 14A] Figure 14A is an assembled perspective view of a plug-in hybrid variation of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0067] [Figure 14B] Figure 14B is an isometric bottom view of the central structural floor structure of a plug-in hybrid variation of a modular vehicle, according to a specific embodiment of the technology of the present disclosure.

[0068] [Figure 14C] Figure 14C is an isometric bottom view of a structural front subframe having an integrated crosscar beam for a modular vehicle, according to a particular embodiment of the technology of the present disclosure.

[0069] [Figure 14D] Figure 14D is an assembled diagram of a plug-in hybrid variation of a modular vehicle according to a particular embodiment of the technology of this disclosure.

[0070] [Figure 14E] Figure 14E is a detailed assembled diagram of an internal combustion engine in a plug-in hybrid variation of a modular vehicle, according to a particular embodiment of the technology of the present disclosure.

[0071] [Figure 15]Figure 15 is a flowchart illustrating a method for assembling a modular automobile according to a specific embodiment of the technology of this disclosure. [Modes for carrying out the invention]

[0072] This specification discloses systems and methods for modular vehicle manufacturing. Modular vehicle manufacturing (MMVM) can refer to creating a single vehicle platform that can be used to create a number of different vehicle types in different vehicle segments by minimizing differences in parts. For example, the vehicle platforms for MMVM described herein can be used to manufacture vans, sport utility vehicles (SUVs), crossover utility vehicles (CUVs), sedans, hatchbacks, microcars, convertibles, supercars, and pickup trucks. MMVM can be used to manufacture vehicles driven by electric motors (EVs), vehicles driven by internal combustion engines (ICEs), or hybrid electric vehicles or plug-in hybrid electric vehicles. This can be achieved by creating universal parts common to all vehicle types. Universal parts can connect to or interact with custom parts used to customize the universal parts to suit individual vehicle types. For example, a bulkhead part (e.g., bulkhead 100) can be shared among all vehicle types. Cowling components (e.g., cowling 200) can be specific to a vehicle type, contributing to the unique appearance and performance of that vehicle type. This approach allows universal parts to be shared across all vehicle types, reducing costs and allowing for commonality and interchangeability of parts, while still enabling customization for specific vehicle types (e.g., by combining common universal parts with additional universal and / or customized parts).

[0073] Furthermore, MMVM may rely on advanced vehicle manufacturing methods, such as cast body panels and components. Body components may be castings of high-strength materials (e.g., aluminum). Other cast metals or materials may also be used. By using cast body panels and components, the number of parts used in manufacturing the vehicle body can be significantly reduced. Moreover, cast body components can be made stronger, more geometrically precise, and designed into a variety of shapes that were not possible with conventional methods. This makes it possible to create large modular automotive body components (e.g., firewalls or bulkheads) that can be designed for use across an entire line of vehicle segments.

[0074] Furthermore, this makes it possible to create the main body panels, which are structural components of the vehicle, in a way that was impossible with conventional methods. Therefore, these methods make it possible to create lighter, more structurally rigid, and stronger vehicles.

[0075] Exemplary embodiments of the technology of this disclosure, as shown in the accompanying drawings and disclosed herein, are given in detail by reference. Where convenient, the same reference numerals are used throughout the drawings to refer to the same or similar parts.

[0076] Figure 13 shows how many of the components described herein can be combined to provide a modular automobile assembly according to the art of this disclosure. Specific components shown in Figure 13 will be described further below with reference to the remaining drawings. For example, the modular automobile described herein may consist of numerous parts such as a firewall 100, a cowl 200, front strut towers 300, 350, a crosscar beam 370, a front subframe 400, a left door ring 600, a right door ring 650, a door ring crossmember 690, a rear structural floor 700, a D-ring 800, a rear subframe 900, and a structural battery 1100. Some or all of the components described as part of the modular automobile may be large cast parts. Such components may be cast from a variety of materials, such as aluminum.

[0077] Because cast parts have unique structural properties that differ from typical vehicle manufacturing methods, it may be possible to configure them to possess features that were not previously considered (e.g., load distribution / load support capabilities). Furthermore, because cast parts have these unique structural properties and can be configured in unique shapes, new and unique mounting methods can be used between vehicle components, thereby enabling these components to be mounted and / or connected using new devices and methods. This allows vehicles to be designed to use new assembly methods, resulting in vehicles with superior structural properties (e.g., higher rigidity) than conventional vehicles.

[0078] By using the methods described herein, parts that were not typically structural in conventional vehicles, or were only structural to a limited extent, can be designed to become structural parts (or major structural parts) of the vehicle. This allows the vehicle to be manufactured with fewer components and to be easier to assemble and repair. By using the methods described herein, the use of fasteners (e.g., bolts, studs, nuts, and screw holes) can be permitted to attach parts (e.g., cast parts) that previously had to be attached via more complex methods (e.g., welding using precision robots).

[0079] Furthermore, by using the methods described herein, parts can be designed for multiple vehicle types. This allows for the interchangeability of numerous components between multiple vehicle types (e.g., sedans and trucks), enabling the manufacture of more vehicle types on a single vehicle platform. Parts and / or mounting methods can be designed to meet the strength characteristics or needs of a first vehicle type (e.g., the largest vehicle type), but can also be designed to be compatible with and / or usable in a second vehicle type (e.g., the smallest vehicle type).

[0080] The mounting methods described herein may consist of one or more cast and uncast parts for assembling a complete vehicle. The mounting method may include a first component comprising one or more first mating surfaces and one or more second mating surfaces. The one or more first mating surfaces may be substantially parallel to the one or more second mating surfaces. The one or more first mating surfaces may be offset from the one or more second mating surfaces in one dimension (e.g., vertical but not horizontal with respect to the vehicle being assembled) or in two dimensions (e.g., vertical and horizontal). The one or more first mating surfaces and the one or more second mating surfaces may be contoured to the shape of a vehicle component and may be integral with the vehicle component. Each of the one or more first mating surfaces and the one or more second mating surfaces may have one or more curved portions and one or more straight portions, which may be parallel over the entire curved portion (e.g., the two curved portions are parallel if any plane perpendicular to one curved portion is also perpendicular to the other curved portion). The one or more first mating surfaces and the one or more second mating surfaces may be substantially parallel to the longitudinal axis of a component, substantially perpendicular to the longitudinal axis of a component, substantially parallel to the direction of movement of the vehicle, substantially perpendicular to the direction of movement of the vehicle, substantially parallel to the longitudinal axis of the vehicle, and / or substantially perpendicular to the longitudinal axis of the vehicle. The longitudinal axis of the vehicle may be an axis extending from the front of the vehicle to the rear of the vehicle. The latitudinal axis of the vehicle may be an axis extending from the left side of the vehicle to the right side of the vehicle. Both the one or more first mating surfaces and the one or more second mating surfaces may be perpendicular to one or more third mating surfaces. The one or more first mating surfaces and the one or more second mating surfaces may be connected by the one or more third mating surfaces.The one or more first mating surfaces, the one or more second mating surfaces, and the one or more third mating surfaces may be configured to structurally connect, pair, align, or connect with one or more first complementary mating surfaces, one or more second complementary mating surfaces, and one or more third complementary mating surfaces on different vehicle components.

[0081] The one or more first mating surfaces, the one or more first complementary mating surfaces, the one or more second mating surfaces, and the one or more second complementary mating surfaces may be configured with aligned holes for receiving one or more connectors (e.g., studs, bolts) so that the mating surfaces (and their respective components) can be joined together. The aligned holes may be threaded (having screw threads) and configured to accommodate screw inserts, inserts, bracing plates, or other parts for assisting the joining of components. The one or more connectors may be the same length or of different lengths. When one or more first mating surfaces are used to join one or more first complementary mating surfaces, the one or more connectors may be of a first length. When one or more second mating surfaces are used to join one or more second complementary mating surfaces, the one or more connectors may be of a second length. Connectors used in combination with mating surfaces closest to the inside of the vehicle may be longer than connectors used in combination with mating surfaces closest to the outside of the vehicle. As described herein, using connectors of varying lengths in combination with multiple mating surfaces on various components to construct a vehicle can improve the structural rigidity of the vehicle. Connectors can be inserted into one or more aligned holes such that the length dimension of the connector (e.g., the longest dimension) can be substantially perpendicular to the plane of the first or second mating surface. Furthermore, when the third mating surface is positioned between the first and second mating surfaces and offset from them, the length dimension of the connector can be substantially parallel to the plane of the third mating surface. When mounted to the first mating surface, the length dimension of the first connector can be substantially parallel to the length dimension of the second connector mounted to the second mating surface.

[0082] By using these mounting methods, individual components can be joined together, dynamic loads can be transmitted between them, and the rigidity and strength of the vehicle are greatly improved. Machining surfaces and complementary mating surfaces can be designed to press against each other to limit the degrees of freedom of movement of different components. Aligned holes and associated connectors can allow one component to be fastened to another. For example, when components such as the bulkhead 100, cowl 200, structural battery 1100, door rings 600, 650, rear structural floor 700, and D-ring 800 are joined using the described mounting methods, they effectively form a structural cage. While improving rigidity and strength as described above, this also improves the safety of occupants in the vehicle. Furthermore, this allows for the design and use of multi-purpose or universal components (for example, the structural battery 1100 or bulkhead 100 can be designed to meet the strength requirements of multiple different vehicle types). Moreover, the mounting methods can be universal across many different vehicle types.

[0083] Figures 1A to 1C illustrate a bulkhead 100 (e.g., a vehicle firewall) for a modular vehicle. The bulkhead 100 may be a single cast aluminum part. The bulkhead 100 may include structural features (e.g., baffles, gussets, or molded structural members) as part of the cast to increase its structural rigidity. For example, the bulkhead 100 may include a structural gusset 130, as shown particularly in Figure 1A. Structural features such as webbing and gussets may be rectangular in shape. Molded structural members may include a "C-shaped" crossbar molded within the bulkhead. The bulkhead 100 may have a curved or trapezoidal shape, which may improve structural rigidity. The bulkhead 100 may be bent outward or forward of the vehicle. The shape of the bulkhead may be optimized for structural rigidity and using crash modeling. Furthermore, the disclosed bulkhead 100 design can provide the vehicle with significantly higher structural rigidity than conventional designs. In some embodiments, a significant amount of structural load is transferred to the bulkhead (more than 50%) compared to conventional designs. This can be achieved by using cast structural features that allow structural loads to be transferred between the bulkhead 100 and other structural components such as the left door ring assembly 600 and the structural battery 1100, as described later.

[0084] The bulkhead 100 may be common across many vehicle types and may be designed or sized to fit the smallest product (for example, the dimensions of the bulkhead 100 may be designed to fit the dimensions of the smallest vehicle type, such as a microcar or a supercar). The bulkhead 100 may be designed to have the strength necessary to operate with the largest (size) product or product requiring maximum strength (e.g., to withstand a crash of a large SUV). In some embodiments, the width dimension of the bulkhead 100 may be expandable depending on the application and may be determined by the size of the electric vehicle battery (e.g., structural battery 1100) or the track width of the desired vehicle. The bulkhead 100 may include one or more mating surfaces (e.g., mating surfaces shown in Figure 1C using cross-hatching). On the top side, the bulkhead 100 may include one or more top mating surfaces (e.g., mating surface 125 shown in Figure 1C) used to fit the cowl piece 200, as will be further described below. In some embodiments, the one or more top mating surfaces may include one or more holes (e.g., holes 126, which may be threaded) for receiving one or more connectors (e.g., threaded connectors such as studs or bolts). The one or more top mating surfaces may be one or more heights relative to the bottom of the bulkhead 100. The central top mating surface may be higher than the outer edge mating surfaces. The outer edge mating surfaces may be present on both sides of the bulkhead 100. The cowl 200 may have mating surfaces complementary to the top mating surfaces. For example, this may allow the cowl 200 to "snap" into the bulkhead 100 for a tight, snug fit. The bulkhead 100 and the cowl 200 can then be fastened to each other using connectors.

[0085] The bulkhead 100 may include, on its front and rear surfaces, second mating surfaces (e.g., mating surfaces 120a, 120b, 120c (see Figure 1C)) used to structurally connect the bulkhead 100 to the door rings 600, 650, structural batteries 1100, and / or strut towers 300, 350 (as further described below). These mating surfaces may include structural joints. Any mating surface may be a cast feature of the bulkhead 100 that allows the cowl 200, door rings 600, 650, and / or strut towers 300, 350 to be aligned with the bulkhead 100. In some embodiments, the first and / or second mating surfaces may be tight-fitting or interlocking-fitting with corresponding parts. In some embodiments, the bulkhead 100 may have three or more mating surfaces. For example, to interface with the left door ring 600, the bulkhead 100 may include a first mating surface 120a including a hole 121a for a connector, and a second mating surface 120b including a hole 121b for a connector. The first and second mating surfaces 120a, 120b are integral with the bulkhead 100 and may be positioned on the edge of the bulkhead. The first and second mating surfaces 120a, 120b may be contoured to conform to the shape of the bulkhead. The first and second mating surfaces 120a, 120b may include one or more straight portions and one or more curved portions. The first and second mating surfaces 120a, 120b may be substantially parallel to each other across the one or more straight portions and the one or more curved portions (e.g., parallel curves). The first and second mating surfaces 120a, 120b may be separated by a dimensional offset to form a third mating surface 120c. The dimensional offset can be one-dimensional (e.g., perpendicular to the vehicle being assembled, but not horizontal) or multi-dimensional (e.g., vertical and horizontal). The third mating surface 120c may be substantially perpendicular to the first and second mating surfaces 120a, 120b. This structure may be mirrored on the opposite side of the vehicle to structurally connect the bulkhead 100 to the right door ring 650. Additional mating surfaces may exist if other vehicle components have complementary surfaces to the bulkhead 100 (e.g., structural battery 1100).The use of multiple mating surfaces described herein allows for high-strength and high-rigidity connections between components while maintaining a minimal contact area. The offset of multiple rows of mating surfaces can restrict movement or create resistance between two components (e.g., by limiting degrees of freedom). This can increase the strength of the connection by forming a moment arm. This can enhance the rigidity and strength of the vehicle body, thereby improving occupant safety and protection in the event of an accident.

[0086] The bulkhead 100 may have a latitudinal dimension shown on axis LI (Figure 1C). The latitudinal dimension may be associated with the width of the vehicle from left to right. The latitudinal dimension may be perpendicular to the longitudinal dimension of the vehicle. The longitudinal dimension may be associated with the length of the vehicle from front to rear. The longitudinal dimension may also be the direction of movement of the vehicle. In some embodiments, in some cross-sections, the first mating surface 120a, the second mating surface 120b, or the third mating surface 120c may be substantially parallel or substantially perpendicular to the latitudinal dimension or the longitudinal dimension.

[0087] The bulkhead 100 may use a similar mounting method to the first mating surface 120a, the second mating surface 120b, or the third mating surface 120c in other locations, for example, at the interface with the battery 1100. Similarly, other components of the vehicle, such as the door rings 600, 650, the structural battery 1100, the rear structural floor 700, and the D-ring 800, may include similar mounting features with multiple mating surfaces, as described herein with respect to the bulkhead 100.

[0088] The bulkhead 100 may include holes or other elements used to securely fasten the bulkhead 100 to other parts of the vehicle (e.g., front strut towers 300, 350, structural battery 1100, cowl 200, and door rings 600, 650). The bulkhead 100 may be designed to restrict the movement of the vehicle components relative to other components (e.g., the movement of the strut towers 300, 350 relative to cowl 200 or door rings 600, 650). These holes may be used to align different parts to the bulkhead 100 during vehicle assembly. These holes may be used for fasteners or connectors to fasten parts to the bulkhead 100. For example, the bulkhead 100 may include a hole 105 (Figure 1A) for a first fastening to the shock tower and a landing section 106 (Figure 1B) for the first fastening to the shock tower. The bulkhead 100 may also include a second fixing hole 110 (Figure 1A) for a shock tower and a landing section 111 (Figure 1B) for the second fixing to the shock tower. The bulkhead 100 may further include one or more fixing holes 115 (Figure 1A) configured to securely fasten the bulkhead 100 to other parts of the vehicle (e.g., the crosscar beam 370 and / or structural battery 1100). The bulkhead 100 may have a realignment feature 1150 for aligning with the crosscar beam 370 (Figure 11H). The realignment feature 1150 may be configured to receive horizontal crosscar beam mounting bolts 374. Specifically, the bulkhead 100 may include one or more holes 121a, 121b (Figure 1C) for fastening the bulkhead 100 to a door ring (e.g., left door ring assembly 600), and / or a hole 126 for fastening the bulkhead 100 to a cowl (e.g., cowl 200).

[0089] In some embodiments, the bulkhead 100 may include circular recesses 135 and / or recesses 140 (Figure 1A). Recesses (e.g., circular recess 135) may be cast in the bulkhead 100 to provide mounts for vehicle components such as brake boosters or steering assemblies. Recesses (e.g., recess 140) may also be used to provide space for vehicle components such as electric motors that may be located in front of the bulkhead 100. Recesses and bends in the bulkhead 100 may also provide additional structural rigidity. The bulkhead 100 may also have recesses to improve occupant comfort or occupant space (e.g., recesses to add legroom to the occupant compartment, or recesses to secure additional space for a glove box).

[0090] In conventional automotive structures, bulkheads (e.g., firewalls) typically consist of approximately 8 to 16 parts, depending on their complexity. This necessitates the welding of numerous machine-formed parts to form the bulkhead. Furthermore, conventional bulkhead welding requires numerous specially configured, high-precision fasteners (holders) to position the parts securely and precisely before welding. Conventional bulkheads also suffer from inherent structural integrity. The bulkhead of the method of this disclosure avoids this complexity and also has the advantage of being able to form structural shapes that are typically not possible with sheet metal. Because the bulkhead of this design is a single part, assembly is greatly simplified by increasing tolerances and reducing assembly problems. For example, components such as bulkhead 100 may include structural shapes that enhance the strength of the vehicle by casting vertical webbing. This resists bending and twisting while also reducing weight (e.g., compared to larger solid parts). Some components may include cast inbox sections that span across the vehicle.

[0091] Figures 2A to 2D illustrate the cowl 200 of a modular automobile. The bulkhead 100 illustrated in Figures 1A to 1C may be combined with a single cowl piece 200 to form a bulkhead system. The cowl 200 and bulkhead 100 may be combined with other parts, such as front strut towers 300, 350, to form a front cast structure. The bulkhead 100 of several disclosed embodiments may be used universally across multiple vehicle types (e.g., SUVs, pickup trucks, microcars, supercars). The cowl 200 may be specific to each particular vehicle type (e.g., the cowl piece for a supercar may be slimmer and have an additional incline relative to the windshield). While the cowl 200 may differ for different vehicle types, it may include certain feature parts common to all vehicle types. For example, the cowl of each vehicle type may include one or more complementary mating surfaces that fit the first mating surface of the bulkhead 100, such as mating surface 260 (Figure 2C). The one or more complementary mating surfaces may include holes, other elements, or cast features that complement the mating surface of the cowl 200 with the mating surface of the bulkhead 100, such as mating holes 205 (Figure 2B) and mating holes 261 (Figure 2C). The mating holes 261 may or may not be threaded. The mating surface 260 may have two separate heights or levels to complement the bulkhead 100. The cowl piece 200 may also include one or more complementary mating surfaces that are complementary to one or more additional components of the vehicle, such as a shock mount 215 (Figure 2B), shock fixing hole 216 (Figure 2B), fender and exterior mounting area 220 (Figure 2A), windshield mating surface 230 (Figure 2B), integrated instrument panel mount 240 (Figure 2B), and integrated structural support 250 (Figure 2C). The cowl 200 may have one or more mating surfaces that interact with one or more door rings, such as mating surfaces 270a, 270b and door ring fixing holes 271a, 271b (Figure 2D), and these mating surfaces may be analogous to the mating surfaces 120a, 120b, 120c described with reference to the bulkhead 100.Similar to the bulkhead 100, the axis L2 (Figure 2C) may be a latitude dimension. The mating surfaces 270a and 270b may be substantially parallel to the latitude dimension. By using castings for each component, each component can be made highly precise in dimensions. In some embodiments, components may be designed to be complementary and may be assembled together in only one manner and may be bolted or welded while maintaining dimensional accuracy. Alternatively, other fastening methods may be used, as outlined below (not repeated here for brevity).

[0092] Furthermore, the cowl 200 in some disclosed embodiments is structurally significantly more rigid than conventional designs and can provide the vehicle with significantly higher structural rigidity. This may be a result of a cast structure having a cast structural shape such as a support gusset 250 (Figure 2C), and / or complementary surfaces that allow the cowl 200 to interact with the bulkhead 100. The cowl 200 may include an upper crosscar structure connection between two door rings, as will be further described below. In some embodiments, the cowl 200 may include an instrument panel structure. The structure of the instrument panel may vary between vehicles. The instrument panel may be centrally located latitudally on the cowl 200. In some embodiments, the cowl 200 may include part of the dashboard.

[0093] In some embodiments, the cowl 200 can be structurally connected to both the front strut towers 300 and 350 around the shock mounts 215 and shock fixing holes 216 located on each side of the vehicle. The structural connection of the cowl 200 between the front strut towers may have the advantage of reducing deflection between the front strut towers and providing additional rigidity to reduce body roll. Thus, in this configuration, the cowl 200 can function as an integrated strut bar or strut tower brace by restricting the movement of the front strut towers 300 and 350 relative to each other.

[0094] Figures 3A to 3D illustrate a left cast front strut tower 300 configured to connect to a bulkhead 100 and / or cowl piece 200. Figure 3E illustrates a right cast front strut tower 350, which may have one or more features or components similar to those of the left cast front strut tower 300. The cast front strut towers 300, 350 can be combined with the bulkhead system, for example, as shown in Figure 5D or Figure 11E. The cast front strut towers 300, 350 may include cast structural elements (e.g., gussets) to improve structural rigidity. The cast front strut towers 300, 350 may also include complementary mating surfaces having elements (e.g., holes, cast features) that align with elements in the bulkhead 100 to structurally engage the front strut towers 300, 350 with the bulkhead 100. For example, strut towers 300, 350 may include a crash bar mating surface 302 (Figure 3A), a shock mount 304 (Figures 3D, 3E), one or more shock mounting holes 305 (Figure 3B), one or more bulkhead mating surfaces 310 (Figure 3C), one or more structural front subframe mating points 312 (Figure 3C), and crosscar beam mounting points / surfaces 320 (Figures 3D, 3E). The complementary mating surfaces of the cast front strut towers 300, 350 may be similar in other respects to the complementary mating surfaces of the cowl 200 and / or bulkhead 100, and are therefore not described again here for brevity.

[0095] In some embodiments, the cast front strut towers 300, 350 may include one or more internal structural shapes 306 (Figure 3B), external structural shapes 308 (Figure 3C), and / or conical structural shapes 311 (Figure 3C). These structural shapes may help prevent the front strut towers 300, 350 from excessive deflection and movement from the suspension when the vehicle moves over terrain. Thus, these structural shapes may help transmit and distribute structural loads by supporting mating surfaces against other components (e.g., bulkhead 100 and cowl 200).

[0096] In a typical configuration in this region, a combination of ultra-high-strength steel and mild steel is first punched out using sheet metal to form the shape, and then precisely positioned and welded together. After this subsystem is precisely welded, it is welded into the vehicle using additional positioning and welding equipment. The disclosed embodiments may allow for easier installation using fewer components.

[0097] According to the art of the present disclosure, in some embodiments, a crosscar beam 370 may be used to adjust the position between two cast front strut towers 300, 350, as will be further described below with reference to Figure 5A. The crosscar beam 370 may be a separate cast part, which may be individualized for each vehicle type by track width. The crosscar beam 370 may be adjusted to interface with the bulkhead 100 at the bottom of the bulkhead 100 and with the structural front subframe 400. The cast front strut towers 300, 350 may be welded to the crosscar beam 370. The assembly of the front strut towers and the crosscar beam may then be bolted to the bulkhead 100 and the structural front subframe 400. The crosscar beam 370 may be bolted to the bulkhead 100 and / or battery 1100 via mounting bolts 374 (Figure 11H). The mounting bolt 374 may be configured to align with point 372 where the integrated gusset of the crosscar beam is approximately equal between the upper surface and the lower surface of the crosscar beam 370.

[0098] Using a single-piece cast strut tower allows for easy and precise fastening of a single component into place without the need for additional parts or equipment, thanks to the integrated positioning features. This component can be manufactured to meet the specific structural requirements of the vehicle, accommodating the installation of upper suspension mounting points with minimal additional features. Vehicle structural requirements can vary based on the requirements of the specific vehicle segment (e.g., a pickup truck that travels off-road or carries heavier loads may have a stronger cast strut tower than a microcar). By assembling modular vehicles in this way, the bulkhead assembly can remain identical across multiple models (e.g., pickup trucks and microcars), while the strut tower casting can be modified to suit the vehicle's needs. This interchangeability of main body components is central to MMVM. The complementary mating surfaces of the front strut towers 300, 350 and bulkhead 100 can be designed to meet the strength requirements of the highest needs (e.g., an off-road truck or SUV may have the highest strength requirements for the front strut tower mating surfaces).

[0099] For example, Figure 5D (further described below) shows a front assembly 500 of a modular vehicle, including an assembled front bulkhead 100, front strut towers 300, 350, and a structural front subframe 400. The parts shown in Figures 1A to 3E can be assembled together with other cast body parts. Body parts can be formed to fit or interlock directly with each other, so that the parts can fit together precisely as described above. Furthermore, many internal body parts can remain identical or be substantially similar (e.g., having identical mating surfaces) despite being used in different vehicle segments and different vehicle models. This process allows for the addition of measuring features to the parts, and one of several alternative fastening methods can be used to join the components. In some embodiments, welding or complex fasteners are not required to complete the assembly.

[0100] Returning to Figures 4A and 4B, these figures show the structural front subframe 400. The structural front subframe 400 may be used to hold the vehicle's electric motor. The structural front subframe 400 may be a single, integrated cast component. The structural front subframe 400 may be rigidly attached to the underside of the vehicle's main body. The use of the subframe 400 in this manner is possible because the vehicle's front main body is made from a cast component in such a way that it has the structural strength necessary to directly support the front subframe 400. In other words, the subframe 400 is firmly fastened to the vehicle and its structure can be lent (utilized) by other structures of the vehicle. This eliminates the need for extra material, weight, and unnecessary tools. The front subframe 400 may be coupled to the vehicle's main body using complementary mating surfaces on the main body and on the front subframe 400, for example, using the strut tower mating surface 410. The strut tower mating surface 410 can be structurally coupled to the bottom of the strut tower at the subframe mating point 312. In some embodiments, the front subframe 400 can be directly and structurally attached to the crosscar beam 370 and / or firewall 100 (e.g., using horizontal bolts). This is superior to typical vehicle subframes that are softly attached to the vehicle using bolts and rubber mounts. In the event of an automobile accident, a typical vehicle subframe has only about as much strength as its weakest point, typically a bolt or connector. Such a rigid attachment of the subframe of this disclosure allows for a significant increase in rigidity. In some embodiments, the structural front subframe 400 may include one or more structural shapes 420 (Figure 4A), such as gussets. The front subframe 400 may also have mounting locations for electric motors, and electric motors may be located within the front subframe. The front subframe 400 may also include connections for suspension components, such as lower shock mounts 415.

[0101] Additionally, the No. 1 bar of the main structural components, which is the primary crossbar member located in the lower front of most vehicles, can be integrated into the front subframe (e.g., front subframe 400). This feature can significantly contribute to crash performance because it covers the lower front of the vehicle from front to rear and terminates the axial load at the primary crossbar / No. 1 bar. The ability of the No. 1 bar to be integrated into the subframe may be a result of a combination of the rigid attachment of the subframe to the main body and the design of the bulkhead 100. The structural geometry of the bulkhead 100, front strut towers 300, 350, and / or front subframe 400 can allow for the transmission of loads throughout the entire structure.

[0102] The vehicle's crumple zone can be integrated into the front assembly. The crumple zone can be strategically deployed to maximize the use of the cast aluminum structure. The crumple zone can be developed to accommodate various vehicle masses. By allowing sufficient distance to manage different vehicle weights and combining this with an adjusted crumple zone density, significant carryover of cast aluminum parts is possible. The front end of shock towers 300, 350 may be a plane defined as the designated impact stop surface of the vehicle. The adjustment of the crumple zone density can be designed to suit the heaviest mass vehicles (such as SUVs) and adjusted to smaller vehicles as needed.

[0103] Figures 5A to 5H show one embodiment of the front assembly 500. As particularly shown in Figures 5A to 5C, the front assembly may include one or more strut tower assemblies (e.g., 300, 350) mounted on the front subframe 400. The front subframe 400 may be bolted to the strut towers 300, 350 and the crosscar beam 370. The cowl 200 may extend above the top of the shock tower to provide additional support to the shock and / or shock tower (Figure 5D). As particularly shown in Figures 5E to 5G, the front assembly 500 may include left and right fenders 502, 552, wheel liners, crash support components such as mounting plates 504 and crash boxes 506 and crash box brackets 508, and a front bumper bar 510. The front assembly 500 may be compatible with a variety of different suspension systems. For example, as shown in Figures 5E to 5G, the front suspension system may include a front 520 and rear 521 of the lower control arm, a knuckle and / or spindle 522, first and second shock mounting members 524, 526, a coilover shock 525, a half shaft 528, and / or an upper control arm 530.

[0104] The front strut towers 300, 350 are attached to the front bulkhead 100 via horizontally extending bolts (for example, bolts extending parallel to the direction of travel of the vehicle). These bolts may be inserted from the inside of the front bulkhead 100 and coupled complementarily to the nuts or threads of each front shock tower 300, 350. In some embodiments, these bolts may be inserted from the front side of the vehicle into the nuts or threads of the front bulkhead 100. Furthermore, the front subframe 400 may be bolted to the shock tower assembly using vertical bolts inserted from the bottom of the vehicle. These vertical bolts may be screwed into the threads or nuts of the front strut towers 300, 350 and / or the front bulkhead 100. The front assembly constructed as described (e.g., front assembly 500) may allow the vehicle to be assembled such that the front drive unit assembly (e.g., electric motor, cradle, shock, strut, wheel, brake, tire, and other necessary parts) may be assembled separately and then fully joined to the front assembly from the bottom as a single unit (for example, the motor may be bolted to the front subframe 400, and the shock may include a stud inserted into a hole in the shock tower and cowl piece 200, allowing a nut to be joined to the stud from the top, enabling an assembled structural unit). Since these parts may be assembled separately from the main production line and then installed in the main body section, manufacturing time and cost are significantly reduced. In one embodiment, the front strut towers 300, 350, front subframe 400 and crosscar beam 370 may be assembled separately from the main assembly line together with the suspension, motor and engine components and supplied as a single unit. The entire unit can be bolted to the bulkhead 100 and cowl 200 as part of an assembly.

[0105] In some embodiments, as particularly shown in Figures 5E to 5F, a steering rack 540 (which may be an electric power steering rack) may be mounted to both strut towers 300 and 350 and may extend between the strut towers 300 and 350. The steering rack 540 may be positioned above a front motor 545 (e.g., electric) and / or cradle assembly. A steering tie rod 532 may extend from the steering rack 540 through a hole in the strut tower component to a knuckle 522 for rotating the wheel. The steering tie rod 532 may be mounted to the relevant component when installed in the vehicle during manufacturing.

[0106] Figures 6A to 6H illustrate a door ring assembly and its components in a modular automobile. Door ring assembly 600 may be the left door ring assembly, and door ring assembly 650 may be the right door ring assembly. Since these left and right door assemblies may contain the same or similar components, for brevity only the components of the left door ring assembly 600 are described here. A door ring assembly may consist of four or more parts. Door ring assembly 600 may include an A-pillar, a can rail, a C-pillar, a dog leg, and / or a rocker piece as a single assembly. In some embodiments, door ring assembly 600 may have a structure comprising a front section 601, a top section 602 including a door latch 649, and a rear section 603, each having different characteristics. The door ring may be assembled as a single structure before being fitted into the rest of the vehicle assembly (for example, as shown in Figures 6A and 6B). The components of a door ring (e.g., door ring 600) may be assembled by welding, but the door ring as a single assembly may be bolted into the vehicle as a single piece. The door ring (e.g., door ring 600) may be modular, as its design may be modified to meet the needs of specific vehicle types while maintaining structural specifications and compatibility with other components such as the bulkhead 100. The door ring (e.g., door ring 600) or its components may include complementary mating surfaces to the bulkhead 100 and / or cowl 200. These complementary mating surfaces may have similar properties to those of the cowl 200 and will not be described again here for brevity.

[0107] Conventional automotive structures typically consist of A-pillars, can rails, B-C pillar connections, and roof bow connections, which are typically constructed from various grades of steel, mild steel, hardened steel, and boron steel. In some embodiments, the system may include an entire door structure ring without a B-pillar. When configured in this way, hot-punched high-strength steel may form the main outer portion, while cold-punched mild steel may contribute to the formation of the inner portion. This combination achieves optimal wall thickness without adding unnecessary weight. This may involve removing boron steel components or using components without boron steel. Boron steel is expensive, and in some embodiments, its use may be bypassed or avoided in order to reduce costs. Furthermore, customized internal materials may be added as needed depending on the vehicle's application to meet vehicle rigidity and provide competitive safety characteristics while reducing the number of parts and weight. Hot-punched high-strength steel may be used as needed for durability testing in the high-strength region of the door ring. Cold-stamped mild steel may be used to connect door ring components that are not hot-stamped high-strength steel. Using hot-stamped high-strength steel in this way helps prevent torsional loads resulting from the removal of the B-pillar. In some embodiments, some components of the door ring 600 may have a specific structure. For example, a portion of the front 601 (e.g., the portion forming the rocker) may be designed with a hollow internal space for housing foamed metal. Foamed metal may be used within the rocker assembly to help with side impact protection. The foamed metal may be pre-formed into a rectangular beam shape. The rocker assembly may be designed to fit the pre-formed rectangular beam of foamed metal. Using foamed metal within the rocker assembly can add a compressible layer that is not currently found in automotive side impact designs.

[0108] This method allows for versatility in vehicle form and segment because the main body (vehicle body) can be lengthened or shortened by modifying the design of the door ring (e.g., door ring 600, door loop). Certain elements or aspects of the door loop may remain identical across multiple vehicle types (e.g., complementary mating surfaces). Creating the door ring (e.g., door ring 600) in this way simplifies variations in logistics, storage, and assembly lines because the entire component can be assembled together at the supplier and arrive at the assembly process as a single unit. Assembling the door ring (e.g., door ring 600) in this way allows for additional versatility in vehicle form and segment. For example, the entire door ring (e.g., door ring 600) can be assembled at the supplier and shipped to the vehicle assembly line as a single unit. In smaller vehicles, the locker (part of the door ring assembly) can be shortened, and in larger vehicles, the locker can be lengthened.

[0109] Designing the door ring in this manner (e.g., door ring 600) may eliminate the need for a B-pillar as part of the door ring. In conventional designs, the B-pillar separates the front door from the rear door. By using the assembly method detailed herein, the door ring (e.g., door ring 600) shown in Figures 6A and 6B provides sufficient strength, stiffness, and rigidity to eliminate the need for a B-pillar. This is important for modularity, as it allows for greater similarity between vehicles in internal features while modifying external features (e.g., the door). A battery (e.g., structural battery 1100) may communicate with (interlock with) the door ring near the center of the rocker section. The battery (e.g., structural battery 1100) may include a support cross structure (e.g., cross member 1140) extending laterally across the top of the battery. The support cross structure may communicate with (interlock with) the door rings on both sides of the vehicle. The support cross structure of the battery (e.g., structural battery 1100) may include complementary mating surfaces that conform to complementary mating surfaces of the door ring. The support cross structure may form mounting points for the vehicle seats. The complementary mating surfaces may include holes or partial formations in the support cross structure or the door ring. The support cross structure may increase the structural rigidity of the vehicle, allowing sufficient strength without a B-pillar. The battery (e.g., structural battery 1100) may communicate (interlock) with the door ring and other parts of the vehicle using interfaces, as particularly shown in Figure 11D.

[0110] In some embodiments, the structural functionality of the B-pillar may be transferred to the front and / or rear doors. The front and / or rear doors may include structural elements that mimic the performance of the B-pillar. The front and / or rear doors may be hinged at the front and rear of the door ring so that both doors open toward the center of the vehicle where the B-pillar was typically located. The front and / or rear doors may include their own interfaces that work in conjunction with the top and bottom of the door ring to provide additional structural support. This is important in ensuring a secure connection of the door to the body during collisions and under high deformation. The door ring may also include latches for attachment to the front and / or rear doors.

[0111] In some embodiments, the door ring 600 may include features that overlap and / or interlock with the bulkhead 100, cowl piece 200, structural battery 1100, rear structural floor 700, and / or D-ring 800 (more described below). The overlapping and / or interlocking features of the door ring 600 may extend across the entire side of the door ring 600 or may be present only in specific parts of the door ring 600. In some embodiments, the door ring 600 may include a portion of the D-ring 800, or may be absent from such portion. The door ring 600 may further include one or more latch portions and one or more hinge portions for interacting with and / or receiving one or more vehicle doors. The left door ring (600) and the right door ring (650) may be connected by a roof portion, which may help increase the structural rigidity of the vehicle.

[0112] Figure 6D is a cross-sectional view of one embodiment of the door ring 600 at the mounting surface with the structural battery 1100, showing the internal portions of the door ring and battery at the mounting surface. By using complementary mounting surfaces as shown, the door ring 600 and structural battery 1100 can distribute the load more effectively and maintain increased structural rigidity compared to conventional vehicles. Furthermore, the assembly and fastening of the door ring 600 and structural battery 1100 can be performed in multiple coordinate directions, which can facilitate robotic assembly.

[0113] Figure 6E is a cross-sectional view of one embodiment of the door ring 600 at its mounting surface to the bulkhead 100, showing the internal portions of the door ring and bulkhead at the mounting surface. By using complementary mounting surfaces as shown, the door ring 600 and bulkhead 100 can distribute loads more effectively and maintain increased structural rigidity compared to conventional vehicles. Furthermore, the assembly and fastening of the door ring 600 and bulkhead 100 can be performed in multiple coordinate directions, which can facilitate robotic assembly.

[0114] Figure 6F is a cross-sectional view of one embodiment of the door ring 600 at the mounting surface with the rear structural floor 700, showing the door ring and the internal portion of the rear structural floor at the mounting surface. By using complementary mounting surfaces as shown, the door ring 600 and the rear structural floor 700 can distribute loads more effectively and maintain increased structural rigidity compared to conventional vehicles. Furthermore, the assembly and fastening of the door ring 600 and the rear structural floor 700 can be performed in multiple coordinate directions, which can facilitate robotic assembly.

[0115] In some embodiments, the door ring 600 (shown in Figures 6C to 6G) may be assembled from several different layers. In some embodiments, the door ring may have four layers. The door ring may include one or more of the following: a first outer wall 610, a second outer wall 620, an inner planar wall 630, and an inner formwork 640. The first outer wall 610, the second outer wall 620, the inner planar wall 630, and the inner formwork 640 may be joined in common by one or more ridges. One or more ridges may be located on the inside (e.g., an inner ridge 611) or outside (e.g., an outer ridge 612) of the door ring. The ridge may allow the first outer wall, the second outer wall, the inner planar wall, and the inner formwork to be welded together (e.g., using spot welding). One or more ridges (e.g., an inner ridge 611) may be used as anchor points for the door seal.

[0116] The first outer wall 610 may provide high strength and may include a hot-rolled metal such as aluminum. The second outer wall 620 may provide additional, milder strength to the first outer wall. The inner planar wall 630 may provide high strength and may provide first mounting points to the battery 1100, bulkhead 100, cowl 200, rear structural floor 700, and D-ring 800. The inner form 640 may provide high strength and may provide second mounting points to the battery 1100, bulkhead 100, cowl 200, rear structural floor 700, and D-ring 800. Both the inner planar wall and the inner form may further include internal welded nut plates (e.g., 635a, 645a). The internal welded nut plates 635a, 645a may be L-shaped brackets with internal gussets. Internal welded nut plates 635a, 645a may include threaded inserts (screw inserts) or other mounting means. Internal welded nut plates 635a, 645a may be welded to the inner planar wall and / or inner foam during assembly. Internal welded nut plates 635a, 645a may be positioned inside the door ring to connect to other parts of the vehicle, such as the battery 1100, bulkhead 100 (e.g., 635b, 645b), cowl 200, rear structural floor 700 (e.g., 635c, 645c), and D-ring 800. Internal welded nut plates 635a, 645a may provide distributed clamping forces that help reinforce the connection to the door ring and / or other parts of the vehicle. Internal welded nut plates 635a, 645a may be configured to accept mounting means (e.g., accommodate threaded portions) and mounting means (e.g., bolts or studs) may be used to fasten other parts of the vehicle to the door ring. In other embodiments, the door ring 600 may be fastened to threaded portions on other vehicle components. The inner planar wall may be configured to receive a first-size mounting means, and the inner form may be configured to receive a second-size mounting means. The first size may differ from the second size. The first size may be shorter than the second size. Using mounting means of various sizes may increase the strength of the joint between the door ring and other parts of the vehicle.This can contribute to increased vehicle rigidity, allowing the vehicle to distribute structural loads more effectively than vehicles designed in other ways. These mounting methods can also help make vehicle assembly more efficient. The cross-section (internal and external) of the door ring may vary along its entire periphery, however, the mounting features may remain the same.

[0117] The inner planar wall 630 may include one or more complementary mating surfaces that fit one or more additional components of the vehicle. For example, the inner planar wall 630 may include bulkhead fixing holes 631b (Figure 6C), structural floor fixing holes 631c (Figure 6G), battery fixing nuts 636a (Figure 6D), battery outer fixing surface 637a (Figure 6D), battery fixing surface 638a (Figure 6D), bulkhead plate 635b (Figure 6E), bulkhead fixing nuts 636b (Figure 6E), bulkhead outer fixing surface 637b (Figure 6E), bulkhead fixing surface 638b (Figure 6E), rear structural floor plate 635c (Figure 6F), rear structural floor fixing nuts 636c (Figure 6F), rear structural floor outer fixing surface 637c (Figure 6F), and rear structural floor fixing surface 638c (Figure 6F). In the design of this disclosure, multiple fixing holes may exist for each mating surface.

[0118] The door ring 600 may further include an inner form 640 (Figures 6E to 6F). The inner form 640 may itself include one or more complementary mating surfaces, such as bulkhead fixing holes 641b (Figure 6C), rear structural floor fixing holes 641c (Figure 6G), battery inner fixing surface 647a (Figure 6D), bulkhead plate 645b (Figure 6E), bulkhead inner fixing surface 647b (Figure 6E), rear structural floor plate 645c (Figure 6F), and rear structural floor inner fixing surface 647c (Figure 6F).

[0119] The door ring 600 may further include a lateral mounting point 646 configured to attach to a D-ring and an upper door latch 649 (Figure 6B). A roof cross member 690 may be used to connect the left door ring assembly 600 and the right door ring assembly 650 (Figure 6H). A windshield may extend between the cowl piece 200, each door ring 600, 650, and the roof cross member 690. In some embodiments, multiple roof cross members 690 may be present. Alternatively, the roof cross member 690 may be a larger, flatter connecting component that covers a wider portion of the roof area.

[0120] The door ring may have one or more (in some embodiments, two or more) parallel landing sections. Vehicle body components may have complementary parallel landing sections, similar to those described with reference to the bulkhead 100, to which components may be attached. Bolts, studs, or other connectors may extend through the parallel landing sections to secure the body to the door ring. Parallel landing sections coupled with connectors may restrict the freedom of movement of the door ring relative to other body components. Thus, vehicle body components and the door ring may be secured to each other, distributing any load across the joint. This can substantially increase the rigidity of the vehicle. Connectors (e.g., bolts or studs) may be configured such that a first bolt is inserted from a first side (e.g., the bottom) and a second bolt is inserted from the same side (e.g., the first side). Inserting connectors from the same side may simplify the assembly of different parts of the vehicle. The connectors may be the same size or different sizes (for example, the bolts may be of varying lengths). The main body component or door ring may include complementary threaded parts or thread inserts to receive the bolts and fasten the door ring to the main body component. In another embodiment, the connectors may be inserted from different sides (for example, the first connector may be inserted from the first side (e.g., the bottom) and the second connector from the second side (e.g., the top)). The door rings 600, 650 may also include one or more studs 691 for connecting to the D-ring 800.

[0121] Figures 7A to 7D show the rear structural floor 700. The structural floor 700 is located at the rear of the vehicle and may provide a base structure for mounting a single-piece rear motor cradle 900 (which will be further described below with respect to Figures 9A to 9C).

[0122] In some embodiments, the rear structural floor 700 may include an integrated wheel well 710 and one or more mounting points 720 for the D-ring 800 and / or one or more mounting points 730 for the rear motor cradle 900, as particularly shown in Figure 7A. The rear structural floor 700 may include various mounting points 630, 732, 734 for the rear motor cradle 900, as particularly shown in Figure 7D. These mounting points 730, 732, 734 may be mirrored on both sides of the vehicle. The battery mounting area 740 may have inner row mounting points 742 and / or outer row mounting points 744 (Figure 7B). The rear structural floor 700 may further include a rear motor cradle access cavity 750 (Figure 7B), mounting surfaces 760A, 760B, 760C (Figure 7C) for door rings, and / or cast structural shapes 770 (Figure 7C) for distributing structural loads. The mounting surfaces 760A, 760B, 760C may structurally engage with the door rings 600, 650, as described with reference to the bulkhead 100. The cast structural shapes 770 may include gussets between high-stress areas, such as inner row mounting points 742 and / or outer row mounting points 744, which may help the rear structural floor distribute structural loads.

[0123] The rear motor cradle 900 may hold a rear electric motor that supplies power to the vehicle, as will be further described below. By using a cast aluminum structure for the floor, an upper e-axle carrier (e.g., the upper portion that holds the rear motor cradle 900 in a typical electric vehicle) may be unnecessary. The structural floor 700 may add structure to the vehicle by casting box sections in a crosscar style, thereby reinforcing the entire vehicle with a minimum number of parts. This can significantly improve the structural rigidity of the vehicle by using structural shapes that prevent or reduce deflection of components. The rear structural floor 700 may have similarities in design to the bulkhead 100 (which will not be described here for brevity), but may include, for example, door rings or complementary mating surfaces with other parts, cast structures or alignment features, or design objectives (e.g., for the smallest or largest product). The rear structural floor 700 may be designed to have significantly higher rigidity than the floor of a typical vehicle. In some embodiments, the rear structural floor 700 may include all or part of the wheel well. The rear structural floor 700 may include a gusset. The rear structural floor 700 may include one or more open areas for receiving or performing maintenance on the rear e-axle components.

[0124] In some embodiments, the structural floor 700 may allow for a flat floor design. The structural floor 700 can significantly contribute to the overall strength of the vehicle, as well as to the structural integrity of the e-axle. Furthermore, in certain embodiments, the structural floor 700 allows for maximum cargo width without intrusion from suspension fasteners into the cabin area. This further allows the structural floor 700 to be used in various vehicle configurations while maintaining the same door ring and battery structural interface for similarity between vehicle variations.

[0125] The rear motor cradle 900 may be fastened to the structural floor 700 using a rigid fastening method (e.g., without rubber dampers between the e-axle and the structural floor 700). To reduce noise transmission, the rear suspension may be specially designed to perform at maximum capacity while reducing road noise that may be transmitted into the cabin area through its components. The motor mount for the electric motor may be hydraulic and may be tuned to eliminate high frequencies.

[0126] In some embodiments of this disclosure, the typical upper half of the electric motor assembly carrier is no longer required. Furthermore, the entire motor drive line and suspension can be held on a single component, significantly reducing the complexity of installation on the vehicle. Moreover, the entire e-axle, including the suspension, can be partially assembled (subassembled) outside the vehicle and attached to the vehicle using four or more fasteners. The fasteners can connect the rear motor cradle 900 vertically to the structural floor 700. In some embodiments, horizontal fasteners may also be used.

[0127] Figures 9A to 9C illustrate the rear motor cradle 900 described herein. The rear motor cradle 900 may include a mount 910 to the structural floor 700, an air suspension mount 920, and / or an upper control arm mount 930. In some embodiments, the rear motor cradle 900 may include a suspension when assembled with the vehicle or the rear structural floor 700. The rear motor cradle 900 may accommodate a variety of different suspension characteristics. The suspension may include dual airbags on each side. In some embodiments, the rear motor cradle 900 may include one airbag on each side and one damper on each side. In some embodiments, one airbag on each side may be positioned longitudinally forward of the half-shaft of the electric motor, and the damper may be positioned longitudinally rear of the half-shaft of the electric motor. In some embodiments, the positions of the airbags and dampers may be reversed, that is, each airbag may be positioned rearward in the longitudinal direction of the half-shaft of the electric motor, and the damper may be positioned forward in the longitudinal direction of the half-shaft of the electric motor.

[0128] Figures 8A to 8D illustrate a D-ring section 800 (e.g., upper rear). The D-ring 800 may be specific to the vehicle type (e.g., coupe, truck). The D-ring 800 may be bolted to the rear structural floor 700. The D-ring section 800 may include a rear door mounting surface 810 and / or rear door mounting holes 812. The D-ring section 800 may include a roof structural feature 820 and / or a lower structural feature 830, which may be configured to reduce deflection and / or body roll. The D-ring section 800 may include a door ring mounting feature 822, which may be configured to receive a door ring stud 691. The D-ring section 800 may include a mounting point 840, a rear window cavity 850, a pressure relief vent cavity 860, and / or a rear door cavity 870. The D-ring section 800 may be configured to fasten to the rear structural floor 700, as particularly shown in Figure 10A, or to fasten to the door ring 600, as particularly shown in Figure 10B. The method of fastening the D-ring may be the same as those described with reference to the other components. In some embodiments, the D-ring may be structurally attached to the door ring 600 in a similar manner to that of the rear structural floor 700.

[0129] Conventionally, D-rings (e.g., D-ring 800) are composed of numerous stamped metal parts and require several fixing and welding operations, as well as several post-welding treatments, to ensure waterproofing and improve visual aesthetics. Often, this involves mastic application to each joint, post-welding cleaning, and final painting. Often, these areas are a source of quality problems, but these quality problems can be avoided by the modular assembly system of this disclosure.

[0130] In some embodiments, the D-ring 800 can accommodate a cast rear bow (bow-shaped) component, which not only allows for greater versatility in shape, strength, and simplicity, but also provides an opportunity for bolt fastening applications, thereby reducing the need for complex welding processes and equipment. Another advantage may be the ability to incorporate and mold dimensionally controlled features. Furthermore, the cast rear roof bow may include an integrated water management area and similar cast features at the rear of the wheelhouse. This can reduce the total number of parts and assembly points. Additional advantages include better liftgate fit and gap control during final assembly due to the significant reduction in the number of parts and tolerance stacking control.

[0131] This differs from conventional construction methods in which the rear roof bow was made from several stamped parts. In previous construction methods, the rear bow, being in the vehicle's visible area, was subjected to post-weld cleaning and surface treatment. In conventional construction methods, the part was welded to the vehicle, which required several methods (processes) of position control and measurement control.

[0132] Figures 10C to 10E illustrate a rear assembly 1000, which includes a rear structural floor 700, a D-ring section 800, and a rear motor cradle 900. The rear assembly 1000 may also include a rear electric motor, a rear bumper bar 1002 (Figure 10A), and rear suspension components (including a lower control arm 1004, an upper control arm front section 1006, an upper control arm rear section 1007, a knuckle or spindle 1008, and an airbag suspension component 1010). In some embodiments, the rear motor cradle 900 may incorporate electric rear steering, which may include a rear steering rack 1020a (Figure 10C) and tie rods (e.g., tie rod 1022). In some embodiments, the rear motor cradle may include other suspension linkage mechanisms (e.g., a stabilizer bar 1020b) (Figure 10E). In other embodiments, air or spring suspension may be used at the front and / or rear.

[0133] Figures 11A to 11H illustrate an integrated, removable structural battery system 1100 for a modular vehicle. The battery 1100 may be an integrated component of the vehicle structure. One or more dimensions of the battery 1100 may be designed to be the minimum dimensions for all vehicle types (for example, the width of the battery may be designed to fit the width of the smallest vehicle type (e.g., a microcar)). The width of the battery 1100 may be a parameter defined in relation to other parts of the vehicle, such as the width of the bulkhead 100. The length of the battery 1100 may vary based on the length of the vehicle. The battery assembly may include a homogeneous structural ring surrounding the battery pack, regardless of the size of the battery. The structural ring may hold the battery in place while being tightened or bolted from below to other parts of the vehicle. Fasteners (e.g., bolts) may be of various lengths and may be positioned in multiple rows (for example, an inner row of bolts positioned closer to the center of the vehicle may be longer than an outer row of bolts positioned closer to the outside of the vehicle). The varying heights of multiple rows of fasteners can form a conical structural shape. This can increase strength by forming a moment arm. The structural ring can be designed to increase the rigidity of the vehicle. The structural ring can accommodate the integration of an access panel that can be accessed via screws from the bottom of the vehicle. The access panel can be removed to allow for maintenance of individual battery modules. By using a structural ring for batteries in this way, the length of the vehicle can be easily modified to better suit multiple vehicle types.

[0134] As particularly shown in Figure 11A, the battery 1100 may include a front mounting area 1110. This front mounting area 1110 may include mating surfaces 1111a, 1111b, 1111c, and first and second fixing holes 1112, 1114 for the firewall. The battery 1100 may also include a doorring mounting area 1120, which may include mating surfaces 1121a, 1121b, 1121c. As particularly shown in Figure 11B, the doorring mounting area 1120 may further include first and second fixing holes 1122, 1124 from the doorring to the battery (for example, for engaging with a battery fixing nut or a feature similar to that of a nut insert 636a). As shown in Figures 11A and 11B, the battery 1100 may include a rear mounting area 1130 (configured to be attached, for example, to the rear structural floor 700), which may include mating surfaces 1131a, 1131b, 1131c, and inner and outer fixing portions 1132, 1134 to the rear structural floor 700 (for example, to engage with features similar to those of the inner row mounting point 742 and the outer row mounting point 744). As particularly shown in Figure 11C, the battery 1100 may include a cross member 1140 having a cross section gusset. The battery 1100 may use mating surfaces, similar to those described with reference to the bulkhead 100.

[0135] Figure 11F is a first cross-sectional view of one embodiment of the structural battery 1100 at the mounting surface with the bulkhead 100, showing the structural battery 1100 and the internal portion of the bulkhead at the mounting surface (e.g., the front mounting area 1110 of the battery 1100). Figure 11G is a second cross-sectional view of one embodiment of the structural battery 1100 at the mounting surface with the bulkhead 100. In the first cross-sectional view (Figure 11F), a first mounting method 1114 (e.g., using an outer row of bolts) may be used to connect the structural battery 1100 to the bulkhead 100. In the second cross-sectional view (Figure 11F), a second mounting method 1112 (e.g., using an inner row of bolts) may be used to connect the structural battery 1100 to the bulkhead 100. This mounting method may be similar to the mounting method for attaching the door ring 600 to the battery 1100 (e.g., using an inner row of bolts that are larger in size than the outer row of bolts). The mounting points may be offset from each other (for example, the inner row of bolts and associated holes may be offset from the outer row of bolts and associated holes). The structural battery 1100 may have internal gussets to support loads at the mounting points, as particularly shown in Figures 11C, 11F, 11G, and 11H. The bulkhead 100 may have cast features or gussets at the mounting points (for example, holes or threads for receiving bolts 374). The crosscar beam 370 may have structural features (e.g., support gussets 372) that are aligned with structural features of the structural battery 1100 and / or bulkhead 100 (for example, the gussets 372 of the crosscar beam 370 may be centrally joined where the inner row of bolts secures the structural battery 1100 to the bulkhead 100, and the gussets of the crosscar beam 370 may be furthest away where the outer row of bolts secures the structural battery 1100 to the bulkhead 100). By using complementary mounting surfaces as shown, the structural battery 1100 and bulkhead 100 can distribute loads more effectively and maintain increased structural rigidity compared to conventional vehicles.Furthermore, the assembly and fastening of the structural battery 1100 and the bulkhead 100 can be performed in multiple coordinate directions, which may facilitate assembly by robots.

[0136] Figure 11I is a first cross-sectional view of one embodiment of the structural battery 1100 at the mounting surface with the rear structural floor 700, showing the structural battery 1100 and the internal portion of the rear structural floor 700 at the mounting surface. Figure 11J is a second cross-sectional view of one embodiment of the structural battery 1100 at the mounting surface with the rear structural floor 700. In the first cross-sectional view (Figure 11I), a second mounting method 1132 (e.g., an inner row of bolts) may be used to connect the structural battery 1100 to the rear structural floor 700. In the second cross-sectional view (Figure 11J), a first mounting method 1134 (e.g., an outer row of bolts) may be used to connect the structural battery 1100 to the rear structural floor 700. The structural battery 1100 may have an internal set for supporting loads at the mounting points. The mounting method may be similar to the mounting method for attaching the door ring 600 to the battery 1100 (e.g., using an inner row of bolts larger in size than the outer row of bolts). Mounting points may be offset from each other (for example, the inner row of bolts and associated holes may be offset from the outer row of bolts and associated holes). The rear structural floor 700 may have cast features (e.g., holes or threads for receiving bolts, e.g., inner row mounting point 742, outer row mounting point 744) or gussets (e.g., cast structural shape 770) at or around the mounting points to support and / or transmit structural loads between the structural battery 1100 and the rear structural floor 700, and / or to aid in assembly. Features (e.g., structural features) of the rear motor cradle 900 may be aligned with structural features of the rear structural floor 700 and / or the battery 1100. By using complementary mounting surfaces as shown, the structural battery 1100 and the rear structural floor 700 can distribute loads more effectively and maintain increased structural rigidity compared to conventional vehicles. Furthermore, the assembly and fastening of the structural battery 1100 and the rear structural floor 700 can be performed in multiple coordinate directions, which may facilitate assembly by robots.

[0137] Figures 12A to 12D are drawings showing exploded and assembled views of modular components used to manufacture a modular automobile. Figure 12A shows an exploded view of a modular cast automobile 1200, including many of the components described herein (e.g., bulkhead 100, cowl 200, strut towers 300, 350, structural front subframe 400, door rings 600, 650, rear structural floor 700, D-ring section 800, rear motor cradle 900, battery 1100). Figure 12B shows an exploded view of assembling the front cast structure 1210 from the bulkhead 100 and cowl 200, and an exploded view of assembling the rear cast structure 1220 from the rear structural floor 700 and D-ring section 800. Figure 12C shows an exploded view of the assembly of some of the components described herein, for example, by attaching the door rings 600, 650 and the roof cross member 690 to join the front cast structure 1210 and the rear cast structure 1220. Figure 12D shows a completed vehicle upper assembly 1230 including the door rings 600, 650 and the front and rear cast structures 1210, 1220. The vehicle upper assembly 1230 (e.g., the vehicle body) can be joined to the strut towers 300, 350, the structural front subframe 400, the battery 1100, and the rear motor cradle 900 to form a complete vehicle structure. The strut towers 300, 350, the front subframe 400, and the rear motor cradle 900 can be fully assembled (e.g., including motor, suspension, brake, and steering components) when attached to the vehicle upper assembly 1230.

[0138] The modular components described in the aforementioned diagram (for example, the bulkhead assembly (including bulkhead 100, cowl 200, strut towers 300, 350, crosscar beam 370, two door rings 600, structural floor 700, structural battery 1100)) can be combined to form a high-strength cabin safety cage. This also simplifies the overall assembly process while reducing weight and maintaining high dimensional accuracy. Embodiments of this disclosure may be applied not only to electric vehicles but also to gas vehicles, diesel vehicles, or alternative fuel vehicles.

[0139] Figures 12E and 12F illustrate the modularity of the modular vehicle assembly of the embodiments of the present disclosure. That is, one or more components of the assembly, as shown in Figures 12A to 12D, can be replaced with other different components to produce different vehicle types. For example, door rings 696 and 695 can be used instead of door rings 650 and 600, crossbar 697 can be used instead of crossbar 690, D-ring section 895 can be used instead of D-ring section 800, vehicle upper assembly 1231 can be used instead of vehicle upper assembly 1230, and rear cast structure 1221 can be used instead of rear cast structure 1220. Thus, the resulting vehicles can be completely different vehicle types (for example, the vehicles in Figures 12A to 12D are hatchbacks, and the vehicles in Figures 12E to 12F are coupes) and can also be visually different. However, the vehicle may have several similar components and similar mounting methods or mounting interfaces.

[0140] By using modular components in this way, the vehicle can be assembled using methods different from typical vehicle assembly. For example, several stages of assembly may follow method 1500 as shown in Figure 15. Firstly, in block 1502, the bulkhead 100 is fastened and / or bonded to the cowl piece 200 to form the front cast structure, and separately, in block 1504, the D-ring 800 is fastened and / or bonded to the rear structure floor 700 to form the rear cast structure. Secondly, in block 1506, the door ring, roof header, and the front and rear cast structures are joined to form the main body. Thirdly, in block 1508, the battery 1100 and the front and rear e-axles (or propulsion units) are joined to the main body. By assembling the front cast structure, rear cast structure, door ring, battery, and e-axles separately from the main assembly line (e.g., pre-assembly), the complexity of the main assembly line is reduced. Accordingly, for pre-assembly purposes, multiple cast aluminum parts can be fastened and bonded together to form a single unit that can be added as part of the main body. This allows for substantial reductions in the cost of parts, fastening processes, and assembly processes, as well as equipment and investment costs. Modular parts assembled in this manner (e.g., by the mounting methods and designs described herein) can result in a vehicle body with high torsional rigidity (e.g., stiffness).

[0141] In the disclosed embodiments, the method of disclosure can significantly simplify both the total number of parts and the ease of assembly while maintaining an extremely high degree of rigidity. Furthermore, the method of disclosure can also have broad versatility, as most of its components can be used in multiple vehicle segments. In situations where the vehicle type does not allow for the direct reuse (carryover) of identical parts (e.g., bulkhead 100), the modular automotive design allows for the easy substitution of differently designed parts (e.g., cowl 200). Moreover, if the finished vehicle is damaged (e.g., due to a collision), unlike sheet metal parts which would need to be cut out and custom-made to fit, the main body parts can be removed and easily replaced.

[0142] Furthermore, by designing components with interoperability in mind and by using aluminum casting, a high degree of dimensional control is permitted without complex welding. Various fasteners can be used to fasten (fix) the components (e.g., flow-drill screws (FDS), self-piercing rivets (SPR), cast screw inserts, and standard fasteners such as bolts, nuts, and screws). Adhesives can be used to join the cast parts (e.g., D-ring 800 and structural floor 700). The adhesive can be selected based on the temperature range and time required for curing. Preferably, the temperature range for curing the adhesive is less than 110°C, and preferably the adhesive can be cured in less than 30 seconds. By using an adhesive within these parameter ranges, the stability of the Gigacast aluminum components can be promoted, and warping of the Gigacast can be avoided.

[0143] Furthermore, the use of modular components in this way can also improve the manufacturing process. By using large components that can be assembled off-site (e.g., cowl 200), the assembly of the entire vehicle and its main body can be completed even in factories with very limited manufacturing space. Moreover, since several variations of the vehicle (e.g., microcars, trucks, supercars) all share similar parts (e.g., lower components such as structural battery 1100 share similar connection points), multiple different vehicles can be manufactured on a single assembly line (e.g., the upper part of the vehicle may include unique parts with their own connection points, such as D-ring 800).

[0144] In some embodiments, the vehicle's e-axle can be fully housed (e.g., including a complete electric motor, electronic braking system, steering system, suspension system, electronic control unit (ECU), wiring harness, wheels, and tires). The complete e-axle can be installed in the vehicle during assembly as part of a front or rear motor cradle 400, 900. After the e-axle is installed, the vehicle can be moved along the assembly line without the use of external means (e.g., conveyor belts, rollers, etc.). Thus, a vehicle with an e-axle installed can be moved around the factory and further components (e.g., trim, seats, doors, etc.) can be installed.

[0145] A system for transporting a vehicle under assembly may include one or more transceivers (e.g., one or more antennas capable of sending and receiving WiFi, 4G, 5G, or Bluetooth), one or more motor controllers, one or more brake controllers, one or more steering controllers, one or more vehicle sensors (e.g., LiDAR sensors), one or more body control units (BCUs), one or more processors, and memory for communicating with the one or more processors and storing commands. The system may also include one or more servers, each containing one or more server processors and server memory for storing server commands, which can coordinate (make work with) the vehicle's movement with other factory components (e.g., other robotic assemblies for installing additional parts). The commands may be configured to allow the e-axle or vehicle system to operate in assembly mode. Assembly mode may be a mode in which, after the e-axle is assembled and parts are installed, all vehicles on the assembly line can move autonomously in a synchronized and organized manner. Antennas may use radio signals to broadcast the position of each vehicle on the assembly line. Therefore, the server may send instructions for the vehicle to move forward or stop based on the position of the vehicle and the positions of other vehicles. Pre-assembled vehicles may use LIDAR sensors (e.g., front LIDAR sensor, rear LIDAR sensor, side LIDAR sensor) to track the positions of other vehicles on the assembly line. Using this method, pre-assembled vehicles may be able to track vehicles ahead, follow vehicles ahead, and / or maintain a distance from vehicles ahead. By coordinating the movement of vehicles in this way, the system may be able to move various vehicles along the assembly line using their own power source (e.g., using batteries and motors mounted on the vehicles). A conveyor belt is not required because parts can be placed as the vehicles move along the line.

[0146] For safety and other reasons, the server may transmit or broadcast a continuous signal over a network (e.g., a Wi-Fi network) indicating that the system should continue operating (e.g., a pre-assembled vehicle should continue moving along the assembly line). This signal may be transmitted at regular time intervals. A vehicle ECU (e.g., a BCU or motor controller) operating in assembly mode may be configured to operate as long as the “continue operation” signal is received within a threshold time. If the vehicle ECU no longer receives the “continue operation” signal (e.g., the threshold time is exceeded), the vehicle ECU may be configured to stop the vehicle (e.g., by turning off the motor or applying the brakes). This system may be used in emergencies (e.g., during a factory power outage, as pre-assembled vehicles are not connected to the factory power supply) to stop vehicles from moving on the assembly line.

[0147] The vehicle platform described herein can be used with a variety of different propulsion methods and systems. For example, the vehicle platform may be configured to support a battery electric vehicle configuration, an internal combustion engine configuration, a hybrid vehicle configuration, or a plug-in hybrid vehicle (PHEV) configuration. Figures 14A to 14E show one embodiment of a plug-in hybrid vehicle configuration. Overall, the plug-in hybrid vehicle configuration shown in Figures 14A to 14E may share most of its components and / or mounting methods with other embodiments (e.g., an embodiment shown in Figure 13).

[0148] Figure 14A is a bottom perspective view of the PHEV configuration of the modular vehicle 1400. This configuration replaces the structural battery 1100 with a central structural floor 1410 that includes a battery 1420 and a fuel tank 1430. Other components of the PHEV configuration of the modular vehicle 1400 may include a muffler 1442 connected to the end of an exhaust pipe 1440 below the rear structural floor 700, and a front structural subframe having an integrated crosscar beam 145.

[0149] Figure 14B is an isometric view of the central structural floor 1410. The central structural floor 1410 may be substantially similar in size and / or structure to the structural ring of the structural battery 1100 and may be attached in a similar manner to other components of the vehicle (e.g., door rings 600, 650, rear structural floor 700, and bulkhead 100). The central structural floor may include exhaust path sections 1411 on each side for the exhaust pipe 1440 from the internal combustion engine 1460. The exhaust path sections 1411 may include notches 1412 in the structure of the central structural floor 1410 to allow the exhaust pipe 1440 to be routed to the rear of the vehicle without hanging down below the rest of the vehicle components. A fuel tank 1430 may be held in place by straps 1431a, 1431b to the central structural floor 1410.

[0150] Figure 14C is an isometric view of the front structural subframe 1450. The front structural subframe 1450 may be similar to the front subframe 400. The front structural subframe 1450 may be specifically configured to mount an internal combustion engine (e.g., the internal combustion engine 1460 shown in Figure 14E) inside the vehicle. The front subframe 1450 may have an integrated crosscar beam (e.g., a crosscar beam similar to the crosscar beam 370), which may be directly mounted to the bulkhead 100 or the central structural floor 1410. The front subframe 1450 may be configured to support the heavier weight of the internal combustion engine (e.g., the internal combustion engine 1460).

[0151] Figure 14D is a top perspective view of the PHEV configuration of the modular vehicle 1400. The central structural floor 1410 may have a top side panel 1413, which may function as the floor of the vehicle. The central structural floor 1410 may have a fuel tank cover 1432, which may rise above the remainder of the top side 1413 to allow the fuel tank 1430 to have a larger capacity. The fuel tank cover 1432 may be positioned to serve as the base for the rear seats of the vehicle.

[0152] In some embodiments, the devices, systems, or methods of the present disclosure may include one or more of the following (closed) sections.

[0153] Section 1: A bulkhead for a vehicle, The top portion includes one or more top mating surfaces for structurally connecting the bulkhead to the cowl of the vehicle, The bulkhead includes a front section comprising one or more front mating surfaces for structurally connecting the bulkhead to one or more strut towers of the vehicle, A rear section including one or more door ring mating features for structurally connecting the bulkhead to one or more door rings of the vehicle, Equipped with, The bulkhead is constructed from a single piece of cast material. A bulkhead characterized by the following:

[0154] Section 2: The single component of the aforementioned casting material is aluminum. The bulkhead according to item 1, characterized in that it is a bulkhead.

[0155] Section 3: At least a portion of the one or more of the door ring alignment features is positioned close to the left and right edges of the rear of the bulkhead, The one or more door ring alignment features are integrally structured with the bulkhead. The bulkhead according to item 1, characterized in that it is a bulkhead.

[0156] Section 4: The one or more door ring mating features further include two or more first mating surfaces, each having one or more curved portions and one or more straight portions. The two or more first mating surfaces are substantially parallel to each other. The bulkhead according to item 3, characterized in that

[0157] Section 5: The one or more door ring mating features further include one or more second mating surfaces, each having one or more curved portions and one or more straight portions. The one or more second mating surfaces are substantially perpendicular to the two or more first mating surfaces. The bulkhead according to item 4, characterized in that

[0158] Item 6: The two or more first mating surfaces are offset by a first dimension by the one or more second mating surfaces. The two or more first mating surfaces are the contour shape of the rear of the bulkhead that is shaped to fit at least a portion of the one or more door rings of the vehicle. The bulkhead according to item 5, characterized in that it is a bulkhead.

[0159] Section 7: The two or more first mating surfaces further include holes for one or more connectors. Each hole in one of the two or more first mating surfaces is offset from each hole in another of the two or more first mating surfaces. The bulkhead according to item 4, characterized in that

[0160] Section 8: The one or more front mating surfaces structurally connect the bulkhead to the vehicle's crosscar beam and restrict the movement of the one or more strut towers relative to the cowl. The bulkhead according to item 1, characterized in that it is a bulkhead.

[0161] Section 9: A bulkhead for a vehicle, A main body composed of a single piece of cast material, having multiple surfaces separated by multiple edges. Equipped with, The aforementioned multiple surfaces are A top surface having one or more top mating surfaces, The bottom surface is located on the opposite side of the top surface, Having one or more front mating surfaces, a front surface extending from the top surface to the bottom surface, Having one or more rear mating surfaces, the rear surface extends from the top surface to the bottom surface, One or more sides extending from the top surface to the bottom surface, and from the front surface to the rear surface, Includes, The aforementioned front surface is adjacent to the one or more of the aforementioned sides, The aforementioned rear surface is adjacent to the one or more of the aforementioned sides, The one or more rear mating surfaces are positioned in close proximity to one or more rear edges of the edges. The rear edge separates the rear surface from the one or more sides. A bulkhead characterized by the following:

[0162] Section 10: The bulkhead in question is a structural component of the vehicle. The one or more top mating surfaces structurally engage with a first complementary mating surface on the cowl of the vehicle to restrict movement between the cowl and the bulkhead. The one or more rear mating surfaces structurally engage with a second complementary mating surface on one or more door rings of the vehicle to restrict movement between the cowl and the bulkhead. The one or more front mating surfaces structurally engage with a third complementary mating surface on one or more strut towers of the vehicle to restrict movement between the cowl and the bulkhead. The bulkhead according to item 9, characterized by the features described herein.

[0163] Section 11: The one or more top mating surfaces further include one or more top holes for one or more top connectors, The one or more rear mating surfaces further include one or more rear holes for one or more rear connectors, The one or more front mating surfaces further include one or more front holes for one or more front connectors. The bulkhead according to item 10, characterized in that

[0164] Section 12: At least one of the one or more top holes, the one or more rear holes, or the one or more front holes is threaded, The one or more top connectors, the one or more rear connectors, or the one or more front connectors are bolts, studs, or a combination thereof. The bulkhead according to item 11, characterized in that

[0165] Section 13: The aforementioned one or more rear mating surfaces are further, Two or more first parallel planes extending substantially parallel to each other, One or more second parallel surfaces extending substantially perpendicular to the two or more first parallel surfaces, positioned between the two or more first parallel surfaces, and offsetting the two or more first parallel surfaces by a vertical dimension, A bulkhead according to item 10, characterized by having the following:

[0166] Section 14: Each of the two or more first parallel surfaces accepts one or more connectors. The two or more first parallel surfaces and the one or more second parallel surfaces are integrally structured with the main body. The bulkhead according to item 13, characterized by the features described herein.

[0167] Section 15: The two or more first parallel surfaces and the one or more second parallel surfaces correspond to the first corresponding parallel surface and the second corresponding parallel surface of the one or more door rings, respectively. The bulkhead according to item 13, characterized by the features described herein.

[0168] Section 16: The aforementioned front surface has a structural shape that is integrated with the main body. The structural shape includes gussets, brackets, or combinations thereof that help transmit structural loads between the bulkhead, the cowl, the one or more door rings, and the one or more strut towers. The bulkhead according to item 10, characterized in that

[0169] Section 17: The bulkhead is configured for use in multiple vehicle types. The bulkhead is configured to conform to the dimensional constraints of the smallest of the multiple vehicle types, The bulkhead is configured to meet the strength requirements of the largest of the multiple vehicle types. The bulkhead according to item 9, characterized by the features described herein.

[0170] Section 18: A bulkhead for a vehicle, Main body formed from a single piece of cast material Equipped with, The main body is, One or more top mating surfaces contoured to form a cowl and top structural joint of the vehicle, One or more door ring mating features are contoured to form one or more door rings and one or more side structural joints of the vehicle, Includes, The one or more top mating surfaces and the one or more door ring mating feature portions are integrally structured with the main body portion. When the main body forms the top structural joint and the one or more side structural joints, it restricts the movement of the cowl relative to the one or more door rings. A bulkhead characterized by the following:

[0171] Section 19: The one or more top mating surfaces include a first top mating surface and at least one second top mating surface that is perpendicularly offset from the first top mating surface. The one or more door ring mating features further include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a certain distance. The bulkhead according to item 18, characterized in that

[0172] Section 20: The main body is, One or more front mating surfaces contoured to form one or more strut towers and one or more front structural joints of the vehicle. It further includes, When the main body forms the one or more front structural joints and the one or more side structural joints, it restricts the movement of the one or more strut towers relative to the one or more door rings. The bulkhead according to item 19, characterized in that

[0173] Section 21: It is a cowl for a vehicle, Main body formed from a single piece of cast material Equipped with, The main body is, One or more bulkhead mating surfaces that structurally engage with complementary mating surfaces on the bulkhead of the vehicle, One or more door ring mating features that structurally engage with complementary mating surfaces on one or more door rings, Includes, The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height. The one or more door ring alignment features are positioned along one or more substantially vertical outer edges of the cowl. A cowl for a vehicle characterized by the following features.

[0174] Section 22: The main body is, One or more upper shock mounts for structurally supporting one or more front shocks It further includes, The aforementioned casting material is aluminum. A cowl for a vehicle according to item 21, characterized in that it is a vehicle cowl.

[0175] Section 23: The main body is, One or more strut tower mounts for forming one or more structural joints with the first and second front strut towers of the vehicle. It further includes, When the main body forms the one or more structural joints, it functions as an integrated strut bar, thereby restricting the movement of the first strut tower relative to the second strut tower. A cowl for a vehicle according to item 22, characterized in that it is a vehicle cowl.

[0176] Section 24: The main body of the cowl has a size and shape specific to the first vehicle type among a plurality of predetermined vehicle types. The one or more bulkhead mating surfaces are common to the plurality of predetermined vehicle types, The one or more door ring alignment features are common to the plurality of predetermined vehicle types. A cowl for a vehicle according to item 21, characterized in that it is a vehicle cowl.

[0177] Section 25: The one or more door ring mating features include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a lateral distance. A cowl for a vehicle according to item 21, characterized in that it is a vehicle cowl.

[0178] Section 26: The first height is different from the second height, The one or more bulkhead mating surfaces further include holes for receiving connectors for fastening the cowl to the bulkhead. A cowl for a vehicle according to item 21, characterized in that it is a vehicle cowl.

[0179] Section 27: It is a cowl for a vehicle, One or more bulkhead mating surfaces are contoured to form a complementary mating surface on the bulkhead of the vehicle and one or more bulkhead structural joints, One or more door ring mating features are contoured to form complementary mating surfaces on one or more door rings of the vehicle and one or more door ring structural joints, Two upper shock mounts that structurally engage with each of the front strut towers of the aforementioned vehicle, Equipped with, The two upper shock mounts restrict the movement of the front strut towers relative to each other when the front strut towers are structurally engaged by the upper shock mounts. The cowl for this vehicle is made from a single piece of cast material. A cowl for a vehicle characterized by the following features.

[0180] Section 28: The one or more door ring alignment features are positioned in close proximity to one or more substantially vertical edges of the cowl for the vehicle, The one or more door ring mating features further include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a certain distance laterally. A cowl for a vehicle according to item 27, characterized in that it is a vehicle cowl.

[0181] Section 29: The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height. The first height is different from the second height. A cowl for a vehicle according to item 27, characterized in that it is a vehicle cowl.

[0182] Section 30: The cowl for this vehicle is specific to the first of several known vehicle types. The one or more bulkhead mating surfaces are common to the multiple known vehicle types. A cowl for a vehicle according to item 27, characterized in that it is a vehicle cowl.

[0183] Section 31: One or more fender mating surfaces including one or more holes for receptacleably receiving one or more connectors of the vehicle's fender Furthermore, The casting material for the cowl of the vehicle is cast aluminum. A cowl for a vehicle according to item 27, characterized in that it is a vehicle cowl.

[0184] Section 32: It is a cowl for a vehicle, One or more bulkhead mating surfaces that structurally contact the bulkhead of the vehicle, One or more door ring alignment features that structurally contact one or more door rings of the vehicle, First and second upper shock mounts for structural connection to the first and second front strut towers of the respective vehicles, Equipped with, When the first and second upper shock mounts are coupled to the first and second front strut towers, respectively, they restrict the movement of the first front strut tower relative to the second front strut tower. The cowl for this vehicle is made from a single piece of cast material. A cowl for a vehicle characterized by the following features.

[0185] Section 33: The cowl for this vehicle is specific to the first of several known vehicle types. The one or more bulkhead mating surfaces are common to the multiple known vehicle types. A cowl for a vehicle according to item 32, characterized in that it is a vehicle cowl.

[0186] Section 34: The door ring alignment feature portion of the cowl for the vehicle has a size and shape such that it is aligned with the one or more door ring alignment feature portions of the bulkhead. A cowl for a vehicle according to item 33, characterized in that it is a vehicle cowl.

[0187] Section 35: The door ring mating feature of the cowl for the vehicle includes two or more first mating surfaces positioned substantially parallel to each other, The two or more first mating surfaces are offset by a certain distance over the entire length of the two or more first mating surfaces. A cowl for a vehicle according to item 34, characterized in that it is a vehicle cowl.

[0188] Section 36: The two or more first mating surfaces include holes for receiving connectors for fastening the cowl for the vehicle to one or more door rings of the vehicle. The one or more bulkhead mating surfaces, the one or more door ring mating features, the first upper shock mount, and the second upper shock mount are integrally structured with the vehicle cowl. A cowl for a vehicle according to item 35, characterized in that it is a vehicle cowl.

[0189] Section 37: One or more panel mounting features that can be connected to an instrument panel, One or more windshield mounting features that can be connected to the bottom of the windshield, One or more fender mating surfaces that can be connected to one or more front fenders, A cowl for a vehicle according to item 32, further comprising the following:

[0190] Section 38: The one or more panel attachment features are positioned to connect the instrument panel at a central portion of a side surface of the vehicle cowl. The vehicle cowl according to claim 37, characterized in that.

[0191] Claim 39: The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height, wherein the first height is different from the second height The vehicle cowl according to claim 32, characterized in that.

[0192] Claim 40: The one or more door ring mating features are positioned along one or more substantially vertical edges of the vehicle cowl. The vehicle cowl according to claim 32, characterized in that.

[0193] Claim 41: A front assembly for a vehicle, comprising: Two front strut towers, each consisting of a single part of a casting material; A cross beam structurally connected to the two front strut towers at a first joint and a second joint respectively; A front subframe structurally connected to the bottoms of the two front strut towers; Comprising: A first distance between the first joint and the second joint is associated with a first vehicle type among a plurality of known vehicle types; The front subframe is positioned close to the cross beam. The front assembly, characterized in that.

[0194] Claim 42: The cross beam has a size and shape specific to the first vehicle type among the plurality of known vehicle types. The two front strut towers are common to the aforementioned multiple known vehicle types. The front assembly according to item 41, characterized in that

[0195] Section 43: Two crash boxes connected to the two front strut towers, A bumper bar having a rear section connected to the two crash boxes, The front assembly according to item 41, further comprising the following:

[0196] Section 44: The two front strut towers are, One or more bulkhead mating surfaces for structural connection to the bulkhead of the vehicle, One or more upper shock mounts for receiving the upper parts of one or more shocks of the vehicle, One or more crosscar beam mating surfaces for structurally connecting to the aforementioned crosscar beam, The front assembly according to item 41, further comprising:

[0197] Section 45: The one or more upper shock mounts of each of the two front strut towers structurally engage with one or more complementary upper shock mounts on the cowling of the vehicle, and the cowling restricts the movement of the two front strut towers relative to each other. The front assembly according to item 44, characterized in that

[0198] Section 46: The front subframe includes an upper mounting surface and a rear mounting surface, The upper mounting surface is structurally connected to the bottom of each of the two front strut towers and includes holes for receiving connectors for securing the front subframe to each of the two front strut towers. The rear mounting surface is structurally connected to the crosscar beam and includes holes for receiving connectors for fixing the front subframe to the crosscar beam. The front assembly according to item 41, characterized in that

[0199] Section 47: A front assembly for a vehicle, The first front strut tower and the second front strut tower, A crosscar beam that is structurally engaged with the first front strut tower and the second front strut tower to restrict the movement of the first front strut tower relative to the second front strut tower, A front subframe is structurally connected from below to the first front strut tower and the second front strut tower, and is positioned in close proximity to the crosscar beam. A front assembly characterized by comprising:

[0200] Section 48: The first front strut tower and the second front strut tower are each composed of a single part made of cast material. The first front strut tower and the second front strut tower are, One or more bulkhead mating surfaces contoured to structurally engage with the bulkhead of the vehicle, One or more upper shock mounts for receiving the upper parts of one or more shocks of the vehicle, One or more crosscar beam mating surfaces contoured to structurally engage with the crosscar beam, Includes The front assembly according to item 47, characterized in that

[0201] Section 49: The one or more upper shock mounts of the first front strut tower and the second front strut tower are structurally engaged with complementary upper shock mounts on the cowling of the vehicle. The front assembly according to item 48, characterized in that...

[0202] Item 50: The cross beam is connected to the first front strut tower and the second front strut tower by welding. The cross beam is specific to a first vehicle type among a plurality of known vehicle types. The first front strut tower and the second front strut tower are common to the plurality of known vehicle types. The cross beam further includes one or more mating surfaces that are contoured to structurally engage with the bulkhead. The front assembly according to item 48, characterized in that...

[0203] Item 51: Each vehicle type among the plurality of known vehicle types is associated with a preset distance between the first front strut tower and the second front strut tower. The cross beam is specialized for the first vehicle type by positioning the first front strut tower and the second front strut tower at a first preset distance associated with the first vehicle type. The front assembly according to item 50, characterized in that...

[0204] Item 52: A steering rack mounted on the first front strut tower and the second front strut tower, positioned above the front subframe. The front assembly according to item 47, further comprising...

[0205] Item 53: The front subframe includes an upper mounting surface and a rear mounting surface. The upper mounting surface is structurally connected to the bottom of each of the first front strut tower and the second front strut tower using one or more connectors. The rear mounting surface is structurally connected to the crosscar beam. The front assembly according to item 47, characterized in that

[0206] Section 54: The crosscar beam includes at least one first mounting surface, The first mounting surface is structurally connected to the bulkhead of the vehicle. The front assembly according to item 47, characterized in that

[0207] Section 55: An electric motor located within the aforementioned front subframe, One or more suspension components mounted between the front subframe and the first front strut tower and the second front strut tower, The front assembly according to item 47, further comprising the following:

[0208] Section 56: A front assembly for a vehicle, Two front strut towers, each consisting of a single piece of cast material, A front subframe positioned below the two front strut towers, Equipped with, The two front strut towers include one or more first bulkhead mating surfaces contoured to structurally connect to the bulkhead of the vehicle, The front subframe includes an integrated crossbar beam and one or more second bulkhead mating surfaces, The integrated crossbar beam is structurally connected to the two front strut towers, thereby restricting the movement of the two front strut towers relative to each other. The one or more second bulkhead mating surfaces are contoured to be structurally connected to the bulkhead. A front assembly characterized by the following:

[0209] Section 57: Internal combustion engine structurally connected to the front subframe The front assembly according to item 56, further comprising the following:

[0210] Section 58: The integrated crosscar beam is specific to a first vehicle type among a plurality of predetermined vehicle types, The two front strut towers are common to the plurality of predetermined vehicle types. The front assembly according to item 56, characterized in that

[0211] Section 59: Two crash boxes connected to the two front strut towers, A bumper bar having a rear section connected to the two crash boxes, The front assembly according to item 56, further comprising the following:

[0212] Section 60: One or more steering rack mounts, which are integral structures with each of the two front strut towers, A steering rack attached to one or more steering rack mounts on each of the two front strut towers, Furthermore, The steering rack is positioned above the front subframe. The front assembly according to item 59, characterized in that

[0213] Section 61: It is a vehicle door, A first outer wall that forms at least a portion of the exterior of the vehicle and extends along the perimeter of a cavity for receiving one or more doors of the vehicle, A second outer wall is positioned inside the first outer wall and extends along at least a portion of the periphery of the cavity, An inner planar wall positioned on the inside of the second outer wall, An inner frame structurally attached to the inner planar wall and forming at least a part of the interior of the vehicle, Equipped with, The first outer wall, the second outer wall, and the inner planar wall are structurally attached to each other along at least a portion of the perimeter of the cavity. A door ring characterized by the following features.

[0214] Section 62: The aforementioned inner planar wall includes a first mating surface, The inner frame includes a second mating surface, The first mating surface and the second mating surface are substantially parallel, The first mating surface is the first outer surface of the inner planar wall, The second mating surface is the second outer surface of the inner frame. The door ring according to item 61, characterized in that it is a door ring.

[0215] Section 63: The aforementioned inner planar wall includes a third surface, The first mating surface and the second mating surface are separated by the third surface. The third surface is substantially perpendicular to the first mating surface and the second mating surface, The third surface is the third outer surface of the inner planar wall. The door ring according to item 62, characterized in that

[0216] Section 64: The inner planar wall and the inner frame further include one or more holes for receiving one or more connectors. The door ring according to item 63, characterized in that it is a door ring.

[0217] Section 65: The one or more connectors structurally attach the door ring to one or more of the following: the bulkhead, the vehicle cowl, the vehicle battery, the rear structural floor, the D-ring, or a combination thereof. The door ring according to item 64, characterized by the features described therein.

[0218] Section 66: The aforementioned inner planar wall further includes one or more first inner surfaces, The inner frame further includes one or more second inner surfaces, The door ring in question is, One or more reinforcing plates containing one or more reinforcing holes Furthermore, The one or more reinforcing plates are arranged such that the one or more reinforcing holes are adjacent to the one or more first inner surfaces and the one or more second inner surfaces, and the one or more reinforcing holes are aligned with the one or more holes in the inner planar wall and the inner frame. The door ring according to item 64, characterized by the features described therein.

[0219] Section 67: The one or more reinforcing plates further include threaded inserts aligned with the one or more reinforcing holes for holding the one or more connectors, The one or more reinforcing plates further include: A first side surface positioned along one or more first inner surfaces, or positioned along one or more second inner surfaces, A second side substantially perpendicular to the first side, A gusset extending between the first side and the second side, The door ring according to item 66, characterized by including

[0220] Section 68: The one or more connectors received by the inner planar wall are of a different length from the one or more connectors received by the inner frame. The door ring according to item 65, characterized in that it is a door ring.

[0221] Section 69: The first outer wall is made of hot-rolled metal. The first outer wall, the second outer wall, and the inner planar wall are welded along the perimeter of the cavity. The door ring according to item 61, characterized in that it is a door ring.

[0222] Section 70: It is a door ring for a vehicle, The outer layer, An inner layer structurally attached to the outer layer, One or more holes provided in each of the outer layer and the inner layer, Equipped with, The outer layer includes a first mating surface on the outside of the outer layer, The inner layer includes a second mating surface on the outside of the inner layer, The one or more holes mentioned above extend through the first mating surface and the second mating surface, The first mating surface is substantially parallel to the second mating surface. A door ring characterized by the following features.

[0223] Section 71: One or more connectors extending through the one or more holes to fasten the door ring to one or more vehicle parts. Furthermore, The first mating surface is offset from the second mating surface. The door ring according to item 70, characterized in that it is a door ring.

[0224] Section 72: The one or more vehicle parts include one or more first complementary mating surfaces that structurally contact the first mating surface of the door ring, The one or more vehicle parts include one or more second complementary mating surfaces that structurally contact the second mating surface of the door ring. The door ring according to item 71, characterized in that it is a door ring.

[0225] Section 73: The one or more vehicle components may further include a bulkhead, a cowl for the vehicle, a battery for the vehicle, a rear structural floor, a D-ring, or a combination thereof. The door ring according to item 72, characterized in that

[0226] Section 74: The one or more connectors further include a first group of connectors and a second group of connectors, The first group of connectors extends through the one or more holes in the outer layer, The second group of connectors extends through the one or more holes in the inner layer, The first group of connectors has a different length from the second group of connectors. The door ring according to item 72, characterized in that

[0227] Section 75: The first group of connectors is shorter than the second group of connectors. The door ring according to item 74, characterized by the features described herein.

[0228] Section 76: One or more reinforcing plates for securing the one or more connectors The door ring according to item 74, further comprising the following:

[0229] Section 77: The aforementioned first group of connectors is offset from the aforementioned second group of connectors. The door ring according to item 74, characterized by the features described herein.

[0230] Section 78: It is a door ring for a vehicle, A first mating surface having a first group of one or more holes for receiving one or more first connectors, A second mating surface having a second group of one or more holes for receiving one or more second connectors, The first mating surface structurally engages with one or more other vehicle parts, The second mating surface structurally engages with the one or more other vehicle parts, The first mating surface is substantially parallel to the second mating surface, The first mating surface is offset by a certain distance from the second mating surface. A door ring characterized by the following features.

[0231] Section 79: Two or more layers, One or more reinforcing plates in the two or more layers, Furthermore, The first layer among the two or more layers includes the first mating surface, The second layer among the two or more layers includes the second mating surface, The one or more reinforcing plates surround the one or more holes, The one or more first connectors are shorter than the one or more second connectors. The aforementioned one or more other vehicle components include a bulkhead, a cowl for the vehicle, a battery for the vehicle, a rear structural floor, a D-ring, or a combination thereof. The door ring according to item 78, characterized by the features described therein.

[0232] Section 80: The door ring does not include a B-pillar, an upper latch for securing one or more doors, a lower latch for securing one or more doors, and one or more hinges. The door ring according to item 61, characterized in that it is a door ring.

[0233] Section 81: A rear structural floor for a vehicle, One or more top mating surfaces contoured to structurally engage with the upper rear section of the vehicle, One or more door ring mating features are contoured to structurally engage with one or more door rings of the vehicle, One or more rear motor cradle mounting points on the underside of the rear structural floor, The front part of the rear structural floor has one or more battery mating surfaces, Equipped with, The rear structural floor is composed of a single piece of cast material. The one or more top mating surfaces, the one or more door ring mating features, the one or more rear motor cradle mounting points, and the one or more battery mating surfaces are integrally structured with the rear structural floor. A rear structural floor characterized by the following features.

[0234] Section 82: The one or more battery mating surfaces are The first battery mating surface, The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear structural floor according to item 81, characterized in that

[0235] Section 83: A first group of holes in the first battery mating surface for receiving one or more groups of first connectors, A second group of holes in the second battery mating surface for receiving one or more second connector groups, Furthermore, The rear structural floor restricts the movement of the one or more door rings relative to the upper rear section. The rear structural floor according to item 82, characterized by the features described above.

[0236] Section 84: The holes in the first group and the holes in the second group further include female threaded portions. The female screw portion of the hole in the first group selectively communicates with the first connector group, The female threaded portion of the hole in the second group selectively communicates with the second connector group. The rear structural floor is structurally connected to the battery. The rear structural floor according to item 83, characterized by the features described therein.

[0237] Section 85: The holes in the first group are offset laterally from the holes in the second group. The rear structural floor according to item 84, characterized by the features described above.

[0238] Section 86: The holes in the first group are supported by an external gusset. The rear structural floor according to item 85, characterized by the features described therein.

[0239] Section 87: The aforementioned door ring alignment feature further, The first door ring mating surface, The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear structural floor according to item 81, characterized in that

[0240] Section 88: Two wheel wells integrated with the rear structural floor. Furthermore, The one or more rear motor cradle mounting points include six mounting points. The rear structural floor according to item 81, characterized in that

[0241] Section 89: The one or more top mating surfaces, the one or more door ring mating features, the one or more rear motor cradle mounting points, and the one or more battery mating surfaces are common to multiple vehicle types. The rear structural floor according to item 81, characterized in that

[0242] Section 90: Rear vehicle assembly, Rear structural floor and Upper rear section and A rear motor cradle structurally connected to the aforementioned rear structural floor, Equipped with, The rear structural floor includes one or more top mating surfaces which are integral with the rear structural floor. The upper rear section includes one or more bottom mating surfaces which are integrally constructed with the upper rear section. The one or more bottom mating surfaces are complementary to the top mating surface of the rear structural floor. The one or more bottom mating surfaces are structurally engaged with the one or more top mating surfaces. The aforementioned rear structural floor and the aforementioned upper rear section are each composed of a single piece of cast material. A rear vehicle assembly characterized by the following:

[0243] Section 91: The aforementioned upper rear section is specific to one of the one or more vehicle types, The aforementioned rear structural floor is common to the one or more vehicle types. The one or more top mating surfaces and the one or more bottom mating surfaces restrict the movement of the rear structural floor relative to the upper rear section. The rear vehicle assembly according to item 90, characterized in that

[0244] Section 92: The aforementioned upper rear section further comprises, One or more door rings and one or more door ring mating features structurally engaged with the door ring, One or more rear door joint features, One or more channels for water management, One or more frames, Includes, The one or more door ring alignment features, the one or more rear door alignment features, the one or more channels for water management, and the one or more frames are integrally structured with the upper rear section. The rear vehicle assembly according to item 90, characterized in that

[0245] Section 93: The aforementioned one or more frames further, One or more rear windows, Two rear air vents, One or more rear doors, The rear vehicle assembly according to claim 90, characterized by including the following:

[0246] Section 94: The aforementioned rear structural floor further comprises, One or more door rings and one or more door ring mating features structurally engaged with the door ring, One or more battery mating surfaces, One or more rear cradle mounting points, Includes, The rear vehicle assembly further comprises, An electric motor positioned on the rear motor cradle, The rear suspension component connected to the rear motor cradle, Rear cradle connector and Includes, The rear motor cradle is attached to the rear structural floor at the rear cradle mounting point by fixing the rear motor cradle with the rear cradle connector. The rear vehicle assembly according to item 90, characterized in that

[0247] Section 95: The aforementioned one or more battery mating surfaces further include: The first battery mating surface, The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear vehicle assembly according to item 94, characterized in that

[0248] Section 96: The aforementioned door ring alignment feature further, The first door ring mating surface, The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear vehicle assembly according to item 94, characterized in that

[0249] Section 97: Rear vehicle assembly, Rear structural floor and Upper rear section and Equipped with, The rear structural floor includes one or more top mating surfaces which are integral with the rear structural floor. The upper rear section includes one or more bottom mating surfaces which are integrally constructed with the upper rear section. The one or more bottom mating surfaces are complementary to the top mating surface of the rear structural floor. The one or more bottom mating surfaces are structurally engaged with the one or more top mating surfaces. The aforementioned upper rear section is specific to one of the one or more vehicle types, The aforementioned rear structural floor is common to the one or more vehicle types. A rear vehicle assembly characterized by the following:

[0250] Section 98: The aforementioned rear structural floor further comprises, One or more door ring mating features that structurally engage with one or more door rings, One or more battery mating surfaces that structurally engage with the battery, One or more rear cradle mounting points, including The rear vehicle assembly according to item 97, characterized in that

[0251] Section 99: The aforementioned one or more battery mating surfaces further include: The first battery mating surface, The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear vehicle assembly according to item 98, characterized in that

[0252] Section 100: The aforementioned door ring alignment feature further, The first door ring mating surface, The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear vehicle assembly according to item 98, characterized in that

[0253] Section 101: A battery structure for vehicles, A structural ring including a first mating surface and a second mating surface, An electric vehicle battery is disposed within the structural ring, Equipped with, The aforementioned structural ring is A front portion contoured to structurally engage with the bulkhead of the vehicle, An intermediate portion contoured to structurally engage with one or more door rings of the vehicle, A rear portion contoured to structurally engage with the rear structural floor of the aforementioned vehicle, Forming at least three parts including A battery structure characterized by the following features.

[0254] Section 102: One or more first holes for one or more first connectors, extending substantially vertically through the structural ring and aligned with the first mating surface, One or more second holes for one or more second connectors, extending substantially vertically through the structural ring and aligned with the second mating surface, The battery structure according to item 101, further comprising the above.

[0255] Section 103: In each of the bulkhead, the one or more door rings, and the rear structural floor, there are one or more first complementary mating surfaces and one or more second complementary mating surfaces Furthermore, The first mating surface is substantially parallel to the second mating surface, The first mating surface is aligned with the one or more first complementary mating surfaces, The second mating surface is aligned with the one or more second complementary mating surfaces. The battery structure according to item 102, characterized by the features described herein.

[0256] Section 104: The one or more first connectors are longer than the one or more second connectors. The battery structure according to item 103, characterized by the features described herein.

[0257] Section 105: The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The battery structure according to item 104, characterized by the features described above.

[0258] Section 106: The one or more first holes are offset from the one or more second holes. The first group of the one or more first holes in the front portion is aligned with the first structural feature of the crosscar beam. The second group of the one or more second holes in the front portion is aligned with the second structural feature of the crosscar beam. The battery structure according to item 105, characterized by the features described herein.

[0259] Section 107: The structural ring includes a third mating surface, The third mating surface is substantially perpendicular to the first mating surface and the second mating surface. The third mating surface is aligned with one or more third complementary mating surfaces. The battery structure according to item 105, characterized by the features described herein.

[0260] Section 108: The one or more first connectors and the one or more second connectors are bolts, The bolts are inserted from below the electric vehicle battery and connect the electric vehicle battery to the bulkhead, the one or more door rings, and the rear structural floor, respectively, in the front section, the middle section, and the rear section. The battery structure according to item 105, characterized by the features described herein.

[0261] Section 109: Cross member with two ends Furthermore, The first of the two ends is connected to the first door ring, The second of the two ends is connected to the second door ring. The battery structure according to item 101, characterized by the features described herein.

[0262] Section 110: A battery structure for vehicles, A structural ring including a first mating surface and a second mating surface, The structural ring and one or more first holes in the first mating surface, The structural ring and one or more second holes in the second mating surface, One or more first connectors in the one or more first holes, One or more second connectors in the one or more second holes, An electric vehicle battery is disposed within the structural ring, Equipped with, The first mating surface is parallel to the second mating surface, The one or more first connectors and the one or more second connectors structurally connect the battery structure to the vehicle components. A battery structure characterized by the following features.

[0263] Section 111: The one or more second holes are offset from the one or more first holes. The battery structure according to item 110, characterized by the features described herein.

[0264] Section 112: The first mating surface corresponds to one or more first complementary mating surfaces on the component of the vehicle, The second mating surface corresponds to one or more second complementary mating surfaces on the component of the vehicle. The battery structure according to item 110, characterized by the features described herein.

[0265] Section 113: The one or more first complementary mating surfaces and the one or more second complementary mating surfaces are located on a bulkhead, one or more door rings, a rear structural floor, or a combination thereof. The battery structure according to item 112, characterized by the features described herein.

[0266] Section 114: The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The battery structure according to item 113, characterized by the features described herein.

[0267] Section 115: It is the central floor of the vehicle, A structural ring including a first mating surface and a second mating surface, An electric vehicle battery is disposed within the structural ring, A fuel tank arranged within the aforementioned structural ring, Equipped with, The aforementioned structural ring is The front portion that structurally engages with the bulkhead, An intermediate portion that structurally engages with one or more door rings, The rear portion that structurally engages with the rear structural floor, Forming at least three parts including A central vehicle floor is a distinctive feature.

[0268] Section 116: The electric vehicle battery is located in front of the structural ring, The fuel tank is located behind the structural ring, The fuel tank is attached to the structural ring at its bottom using one or more retaining straps. The central vehicle floor as described in item 115, characterized by the features described herein.

[0269] Section 117: The structural ring includes one or more recesses, The one or more recesses are for routing one or more exhaust pipes. The central vehicle floor as described in item 116, characterized by the features described herein.

[0270] Section 117: One or more first holes for one or more first connectors, extending substantially vertically through the structural ring and aligned with the first mating surface, One or more second holes for one or more second connectors, extending substantially vertically through the structural ring and aligned with the second mating surface, The central vehicle floor according to item 116, further comprising the following:

[0271] Section 119: In order to structurally connect to the central vehicle floor, the bulkhead, the one or more door rings, and the rear structural floor each have one or more first complementary mating surfaces and one or more second complementary mating surfaces Furthermore, The first mating surface is parallel to the second mating surface, The first mating surface is aligned with the one or more first complementary mating surfaces, The second mating surface is aligned with the one or more second complementary mating surfaces. The central vehicle floor as described in item 118, characterized by the features described herein.

[0272] Section 120: The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The central vehicle floor as described in item 119, characterized by the features described herein.

[0273] Section 121: A vehicle platform for building vehicles, Front structure and, Two door rings structurally connected to the aforementioned front structure, A rear structure structurally connected to each of the two aforementioned door rings, Equipped with, The aforementioned front structure includes a bulkhead and a cowl structurally connected to the bulkhead. The two aforementioned door rings are provided one on each side of the vehicle. The aforementioned rear structure includes a rear structural floor and an upper rear section structurally connected to the rear structural floor. A vehicle platform characterized by the following features.

[0274] Section 122: A central floor including a structural ring structurally connected to the front structure, the two door rings, and the rear structure. Furthermore, The aforementioned front structure, the two door rings, and the aforementioned rear structure form the vehicle body. The vehicle body and the central floor form a structural cage that restricts the relative movement of the front structure, the two door rings, the rear structure, and the central floor. A vehicle platform according to item 121, characterized by the features described herein.

[0275] Section 123: Front axle assembly and, Rear axle assembly and, Furthermore, The front axle assembly includes two strut towers, a front subframe structurally connected to the two strut towers, and a front electric motor mounted within the front subframe. The central floor further includes a vehicle battery disposed within the structural ring, The rear axle assembly includes a rear motor cradle and a rear electric motor mounted within the rear motor cradle. A vehicle platform according to item 122, characterized by the features described herein.

[0276] Section 124: Each of the bulkhead, cowl, rear structural floor, upper rear section, and the two strut towers is a separate component made of cast aluminum. A vehicle platform according to item 123, characterized by the features described herein.

[0277] Section 125: The vehicle body is configured to meet the strength requirements of the largest of the multiple vehicle types. A vehicle platform as described in item 124, characterized by the features described herein.

[0278] Section 126: The front axle assembly, the rear axle assembly, the central floor, the bulkhead, and the rear structural floor are common to all of the above vehicle types. The cowl, the two door rings, and the upper rear section are specific to at least one vehicle type among the plurality of automobile types. A vehicle platform as described in item 124, characterized by the features described herein.

[0279] Section 127: The vehicle is a battery electric vehicle or a plug-in hybrid electric vehicle. A vehicle platform according to item 121, characterized by the features described herein.

[0280] Section 128: It is a vehicle platform, Two door rings specific to one of the multiple vehicle types, A bulkhead for use in the aforementioned multiple vehicle types, structurally connected to the two door rings, A cowl specific to one of the multiple vehicle types, which is structurally connected to the bulkhead, A rear structural floor for use with the aforementioned multiple vehicle types, structurally connected to the two aforementioned door rings, An upper rear section specific to one of the multiple vehicle types, which is structurally connected to the rear structural floor, Equipped with, The bulkhead, the cowl, the rear structural floor, and the upper rear section are each individual parts made of cast aluminum. A vehicle platform characterized by the following features.

[0281] Section 129: A front axle assembly for use in the aforementioned multiple vehicle types, A central floor for use in the aforementioned multiple vehicle types, A rear axle assembly for use in the aforementioned multiple vehicle types, The vehicle platform according to item 128, further comprising the following:

[0282] Section 130: A central floor further including a battery, structurally connected to the bulkhead, the two door rings, and the rear structural floor. The vehicle platform according to item 129, further comprising the following:

[0283] Section 131: The aforementioned front axle assembly further comprises, Two strut towers, The front subframe is structurally connected to the two strut towers, Includes, The aforementioned rear axle assembly further comprises, Rear motor cradle including A vehicle platform according to item 130, characterized by the features described herein.

[0284] Section 132: The rear motor cradle further includes an internal combustion engine, The aforementioned central floor further includes a fuel tank. A vehicle platform according to item 131, characterized by the features described herein.

[0285] Section 133: Exhaust system Furthermore, The central floor further includes one or more recesses for the exhaust pipes of the exhaust system. A vehicle platform according to item 132, characterized by the features described herein.

[0286] Section 134: The aforementioned front subframe includes a front electric motor. The rear motor cradle includes a rear electric motor. A vehicle platform according to item 131, characterized by the features described herein.

[0287] Section 135: To form the front structure, the process involves fastening the bulkhead to the vehicle cowl, The process involves fastening the upper rear section to the rear structural floor in order to form the rear structure, The process involves fastening two door rings, the front structure, and the rear structure together to form the vehicle body, The process involves fastening the front axle assembly, the rear axle assembly, and the central floor to the vehicle body, A vehicle assembly method characterized by comprising the following features.

[0288] Section 136: The bulkhead, the vehicle cowl, the rear structural floor, and the upper rear section are each single pieces made of cast aluminum. The method described in item 135, characterized by the features described herein.

[0289] Section 137: The aforementioned central floor includes a battery. The method according to item 136, characterized by the features described herein.

[0290] Section 138: The aforementioned central floor includes a fuel tank. The method according to item 137, characterized by the features described herein.

[0291] Section 139: The aforementioned front axle assembly further comprises, Two strut towers, The front subframe, including the front propulsion unit, Crosscar beam and Includes, The aforementioned rear axle assembly further comprises, Rear cradle including rear propulsion unit including The method described in item 135, characterized by the features described herein.

[0292] Section 140: The front axle assembly, the rear axle assembly, and the two door rings are assembled separately from the front and rear structures. The method described in item 139, characterized by the features described herein.

[0293] This specification provides numerous specific details. However, it should be understood that implementations of the technology described herein can be practiced without these specific details. Where otherwise, well-known methods, structures, and technologies are not described in detail so as not to hinder the understanding of this description. References such as “one embodiment,” “several embodiments,” “exemplary embodiments,” “various embodiments,” “one implementation,” “one implementation,” “exemplary implementation,” “various implementations,” and “several implementations” indicate that implementations of the technology described herein may include certain features, structures, or characteristics, but not all implementations necessarily include such specific features, structures, or characteristics. Furthermore, repeated use of the phrase “in one implementation” does not necessarily refer to the same implementation (although it may).

[0294] Throughout this specification and the claims, unless the context clearly indicates otherwise, the following terms have at least the meanings expressly associated herein: The term “connected” means that one function, feature, structure or characteristic is directly connected to or communicated with another function, feature, structure or characteristic. The term “combined” means that one function, feature, structure or characteristic is directly or indirectly connected to or communicated with another function, feature, structure or characteristic. The term “or” is intended to mean comprehensive “or”. Furthermore, the articles “a,” “an,” and “the” are intended to mean one or plural unless otherwise specified or unless the context clearly indicates a singular form. The terms “comprising,” “containing,” or “including” mean that at least the specified element or process is present in the article or process, and do not exclude the presence of other elements or process steps even if those other elements or process steps have the same function as the specified one.

[0295] It should be understood that reference to one or more method steps does not preclude the existence of additional or intervening method steps between those explicitly identified steps. Similarly, reference to one or more components within a device or system should be understood not to preclude the existence of additional or intervening components between those explicitly identified components.

[0296] While embodiments of systems or methods are described herein, embodiments having the same or substantially similar features may be implemented as systems and / or methods instead.

[0297] Where used herein, unless otherwise specified, the use of ordinal adjectives such as “first,” “second,” and “third” to describe a common subject simply indicates that different instances (examples) of a similar subject are being referred to, and is not intended to imply that the subjects described in this manner must be in a given order, temporally, spatially, sequentially, or in any other manner.

[0298] While the specific embodiments described herein are those considered to be the most practical and diverse embodiments to date, this disclosure should not be limited to the disclosed embodiments, but rather is intended to cover a wide range of modifications and equivalent configurations included in the appended claims. Certain terms are used herein, but they are used only in a general descriptive sense and are not intended to be limiting.

[0299] This description, using examples, discloses specific embodiments of the Art, enabling those skilled in the art to practice these specific embodiments, including the creation and use of apparatuses or systems and the execution of incorporated methods. The patentable scope of specific embodiments of the Art is defined in the claims and may include other embodiments that a person skilled in the art could conceive. Such other embodiments are intended to be within the claims if they have components that do not differ from the language of the claims, or if they include equivalent components that do not substantially differ from the language of the claims.

Claims

1. A bulkhead for a vehicle, The top portion includes one or more top mating surfaces for structurally connecting the bulkhead to the cowl of the vehicle, The bulkhead includes a front section comprising one or more front mating surfaces for structurally connecting the bulkhead to one or more strut towers of the vehicle, A rear section including one or more door ring alignment features for structurally connecting the bulkhead to one or more door rings of the vehicle, Equipped with, The bulkhead is constructed from a single piece of cast material. A bulkhead characterized by the following:

2. The single component of the aforementioned casting material is aluminum. The bulkhead according to feature 1.

3. At least a portion of the one or more of the door ring alignment features is positioned close to the left and right edges of the rear of the bulkhead. The one or more door ring alignment features are integrally structured with the bulkhead. The bulkhead according to feature 1.

4. The one or more door ring mating features further include two or more first mating surfaces, each having one or more curved portions and one or more straight portions. The two or more first mating surfaces are substantially parallel to each other. The bulkhead according to feature 3.

5. The one or more door ring mating features further include one or more second mating surfaces, each having one or more curved portions and one or more straight portions. The one or more second mating surfaces are substantially perpendicular to the two or more first mating surfaces. The bulkhead according to feature 4.

6. The two or more first mating surfaces are offset by a first dimension by the one or more second mating surfaces. The two or more first mating surfaces are the contour shape of the rear of the bulkhead that is shaped to fit at least a portion of the one or more door rings of the vehicle. The bulkhead according to feature 5.

7. The two or more first mating surfaces further include holes for one or more connectors. Each hole in one of the two or more first mating surfaces is offset from each hole in another of the two or more first mating surfaces. The bulkhead according to feature 4.

8. The one or more front mating surfaces structurally connect the bulkhead to the vehicle's crosscar beam and restrict the movement of the one or more strut towers relative to the cowl. The bulkhead according to feature 1.

9. A bulkhead for a vehicle, A main body composed of a single piece of cast material, having multiple surfaces separated by multiple edges. Equipped with, The aforementioned multiple surfaces are A top surface having one or more top mating surfaces, The bottom surface is located on the opposite side of the top surface, Having one or more front mating surfaces, a front surface extending from the top surface to the bottom surface, Having one or more rear mating surfaces, the rear surface extends from the top surface to the bottom surface, One or more sides extending from the top surface to the bottom surface, and from the front surface to the rear surface, Includes, The aforementioned front surface is adjacent to the one or more of the aforementioned sides, The aforementioned rear surface is adjacent to the one or more of the aforementioned side surfaces. The one or more rear mating surfaces are positioned in close proximity to one or more rear edges of the edges. The rear edge separates the rear surface from the one or more sides. A bulkhead characterized by the following:

10. The bulkhead in question is a structural component of the vehicle. The one or more top mating surfaces structurally engage with a first complementary mating surface on the cowl of the vehicle to restrict movement between the cowl and the bulkhead. The one or more rear mating surfaces structurally engage with a second complementary mating surface on one or more door rings of the vehicle to restrict movement between the cowl and the bulkhead. The one or more front mating surfaces structurally engage with a third complementary mating surface on one or more strut towers of the vehicle to restrict movement between the cowl and the bulkhead. The bulkhead according to feature 9.

11. The one or more top mating surfaces further include one or more top holes for one or more top connectors, The one or more rear mating surfaces further include one or more rear holes for one or more rear connectors, The one or more front mating surfaces further include one or more front holes for one or more front connectors. The bulkhead according to claim 10.

12. At least one of the one or more top holes, the one or more rear holes, or the one or more front holes is threaded, The one or more top connectors, the one or more rear connectors, or the one or more front connectors are bolts, studs, or a combination thereof. The bulkhead according to feature 11.

13. The aforementioned one or more rear mating surfaces are further, Two or more first parallel planes extending substantially parallel to each other, One or more second parallel surfaces extending substantially perpendicular to the two or more first parallel surfaces, positioned between the two or more first parallel surfaces, and offsetting the two or more first parallel surfaces by a vertical dimension, The bulkhead according to claim 10, characterized by having the following:

14. Each of the two or more first parallel surfaces accepts one or more connectors. The two or more first parallel surfaces and the one or more second parallel surfaces are integrally structured with the main body. The bulkhead according to feature 13.

15. The two or more first parallel surfaces and the one or more second parallel surfaces correspond to the first corresponding parallel surface and the second corresponding parallel surface of the one or more door rings, respectively. The bulkhead according to feature 13.

16. The aforementioned front surface has a structural shape that is integrated with the main body. The structural shape includes gussets, brackets, or combinations thereof that help transmit structural loads between the bulkhead, the cowl, the one or more door rings, and the one or more strut towers. The bulkhead according to claim 10.

17. The bulkhead is configured for use in multiple vehicle types. The bulkhead is configured to conform to the dimensional constraints of the smallest of the multiple vehicle types, The bulkhead is configured to meet the strength requirements of the largest of the multiple vehicle types. The bulkhead according to feature 9.

18. A bulkhead for a vehicle, Main body formed from a single piece of cast material Equipped with, The main body is, One or more top mating surfaces contoured to form a cowl and top structural joint of the vehicle, One or more door ring mating features are contoured to form one or more door rings and one or more side structural joints of the vehicle, Includes, The one or more top mating surfaces and the one or more door ring mating feature portions are integrally structured with the main body portion. When the main body forms the top structural joint and the one or more side structural joints, it restricts the movement of the cowl relative to the one or more door rings. A bulkhead characterized by the following:

19. The one or more top mating surfaces include a first top mating surface and at least one second top mating surface that is perpendicularly offset from the first top mating surface. The one or more door ring mating features further include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a certain distance. The bulkhead according to feature 18.

20. The main body is, One or more front mating surfaces contoured to form one or more strut towers and one or more front structural joints of the vehicle. It further includes, When the main body forms the one or more front structural joints and the one or more side structural joints, it restricts the movement of the one or more strut towers relative to the one or more door rings. The bulkhead according to feature 19.

21. It is a cowl for a vehicle, Main body formed from a single piece of cast material Equipped with, The main body is, One or more bulkhead mating surfaces that structurally engage with complementary mating surfaces on the bulkhead of the vehicle, One or more door ring mating features that structurally engage with complementary mating surfaces on one or more door rings, Includes, The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height. The one or more doorring alignment features are positioned along one or more substantially vertical outer edges of the cowl. A cowl for a vehicle characterized by the following features.

22. The main body is, One or more upper shock mounts for structurally supporting one or more front shocks It further includes, The aforementioned casting material is aluminum. A cowl for a vehicle according to feature 21.

23. The main body is, One or more strut tower mounts for forming one or more structural joints with the first and second front strut towers of the vehicle. It further includes, When the main body forms the one or more structural joints, it functions as an integrated strut bar, thereby restricting the movement of the first strut tower relative to the second strut tower. A cowl for a vehicle according to feature 22.

24. The main body of the cowl has a size and shape specific to the first vehicle type among a plurality of predetermined vehicle types. The one or more bulkhead mating surfaces are common to the plurality of predetermined vehicle types, The one or more door ring alignment features are common to the plurality of predetermined vehicle types. A cowl for a vehicle according to feature 21.

25. The one or more door ring mating features include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a lateral distance. A cowl for a vehicle according to feature 21.

26. The first height is different from the second height, The one or more bulkhead mating surfaces further include holes for receiving connectors for fastening the cowl to the bulkhead. A cowl for a vehicle according to feature 21.

27. It is a cowl for a vehicle, One or more bulkhead mating surfaces are contoured to form a complementary mating surface on the bulkhead of the vehicle and one or more bulkhead structural joints, One or more door ring mating features are contoured to form complementary mating surfaces on one or more door rings of the vehicle and one or more door ring structural joints, Two upper shock mounts that structurally engage with each of the front strut towers of the aforementioned vehicle, Equipped with, The two upper shock mounts restrict the movement of the front strut towers relative to each other when the front strut towers are structurally engaged by the upper shock mounts. The cowl for this vehicle is made from a single piece of cast material. A cowl for a vehicle characterized by the following features.

28. The one or more door ring alignment features are positioned in close proximity to one or more substantially vertical edges of the cowl for the vehicle, The one or more door ring mating features further include two or more non-planar first mating surfaces that extend substantially parallel to each other and are offset by a certain distance laterally. A cowl for a vehicle according to feature 27.

29. The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height. The first height is different from the second height. A cowl for a vehicle according to feature 27.

30. The cowl for this vehicle is specific to the first of several known vehicle types. The one or more bulkhead mating surfaces are common to the multiple known vehicle types. A cowl for a vehicle according to feature 27.

31. One or more fender mating surfaces including one or more holes for receptacleably receiving one or more connectors of the vehicle's fender Furthermore, The casting material for the cowl of the vehicle is cast aluminum. A cowl for a vehicle according to feature 27.

32. It is a cowl for a vehicle, One or more bulkhead mating surfaces that structurally contact the bulkhead of the vehicle, One or more door ring alignment features that structurally contact one or more door rings of the vehicle, First and second upper shock mounts for structural connection to the first and second front strut towers of the respective vehicles, Equipped with, When the first and second upper shock mounts are coupled to the first and second front strut towers, respectively, they restrict the movement of the first front strut tower relative to the second front strut tower. The cowl for this vehicle is made from a single piece of cast material. A cowl for a vehicle characterized by the following features.

33. The cowl for this vehicle is specific to the first of several known vehicle types. The one or more bulkhead mating surfaces are common to the multiple known vehicle types. A cowl for a vehicle according to feature 32.

34. The door ring alignment feature portion of the cowl for the vehicle has a size and shape such that it is aligned with the one or more door ring alignment feature portions of the bulkhead. A cowl for a vehicle according to feature 33.

35. The door ring mating feature of the cowl for the vehicle includes two or more first mating surfaces positioned substantially parallel to each other, The two or more first mating surfaces are offset by a certain distance over the entire length of the two or more first mating surfaces. A cowl for a vehicle according to feature 34.

36. The two or more first mating surfaces include holes for receiving connectors for fastening the cowl for the vehicle to one or more door rings of the vehicle. The one or more bulkhead mating surfaces, the one or more door ring mating features, the first upper shock mount, and the second upper shock mount are integrally structured with the vehicle cowl. A cowl for a vehicle according to feature 35.

37. One or more panel mounting features that can be connected to an instrument panel, One or more windshield mounting features that can be connected to the bottom of the windshield, One or more fender mating surfaces that can be connected to one or more front fenders, A cowl for a vehicle according to claim 32, further comprising the above.

38. The one or more panel mounting features are positioned to connect the instrument panel in the central portion of the side of the vehicle cowl. A cowl for a vehicle according to the feature described in 37.

39. The one or more bulkhead mating surfaces include a central section having a first height and one or more outer sections having a second height. The first height is different from the second height. A cowl for a vehicle according to feature 32.

40. The one or more door ring alignment features are positioned along one or more substantially vertical edges of the vehicle cowl. A cowl for a vehicle according to feature 32.

41. A front assembly for a vehicle, Two front strut towers, each consisting of a single piece of cast material, A crosscar beam is structurally connected to the two front strut towers at the first joint and the second joint, respectively, A front subframe structurally connected to the bottom of the two front strut towers, Equipped with, The first distance between the first joint and the second joint is associated with a first vehicle type among a plurality of known vehicle types, The front subframe is positioned in close proximity to the crosscar beam. A front assembly characterized by the following:

42. The crosscar beam has a size and shape specific to the first vehicle type among the plurality of known vehicle types, The two front strut towers are common to the aforementioned multiple known vehicle types. The front assembly according to feature 41.

43. Two crash boxes connected to the two front strut towers, A bumper bar having a rear section connected to the two crash boxes, The front assembly according to claim 41, further comprising the following:

44. The two front strut towers are, One or more bulkhead mating surfaces for structural connection to the bulkhead of the vehicle, One or more upper shock mounts for receiving the upper parts of one or more shocks of the vehicle, One or more crosscar beam mating surfaces for structurally connecting to the aforementioned crosscar beam, The front assembly according to claim 41, further comprising:

45. The one or more upper shock mounts of each of the two front strut towers structurally engage with one or more complementary upper shock mounts on the cowling of the vehicle, and the cowling restricts the movement of the two front strut towers relative to each other. The front assembly according to feature 44.

46. The front subframe includes an upper mounting surface and a rear mounting surface, The upper mounting surface is structurally connected to the bottom of each of the two front strut towers and includes holes for receiving connectors for fixing the front subframe to each of the two front strut towers. The rear mounting surface is structurally connected to the crosscar beam and includes holes for receiving connectors for fixing the front subframe to the crosscar beam. The front assembly according to feature 41.

47. A front assembly for a vehicle, The first front strut tower and the second front strut tower, A crosscar beam that is structurally engaged with the first front strut tower and the second front strut tower to restrict the movement of the first front strut tower relative to the second front strut tower, A front subframe is structurally connected from below to the first front strut tower and the second front strut tower, and is positioned in close proximity to the crosscar beam. A front assembly characterized by comprising:

48. The first front strut tower and the second front strut tower are each composed of a single part made of cast material. The first front strut tower and the second front strut tower are, One or more bulkhead mating surfaces contoured to structurally engage with the bulkhead of the vehicle, One or more upper shock mounts for receiving the upper parts of one or more shocks of the vehicle, One or more crosscar beam mating surfaces, contoured to structurally engage with the crosscar beam, Includes The front assembly according to feature 47.

49. The one or more upper shock mounts of the first front strut tower and the second front strut tower are structurally engaged with the complementary upper shock mounts on the cowl of the vehicle. The front assembly according to feature 48.

50. The crosscar beam is connected to the first front strut tower and the second front strut tower by welding. The aforementioned crosscar beam is specific to a first vehicle type among several known vehicle types, The first front strut tower and the second front strut tower are common to the plurality of known vehicle types, The crosscar beam further includes one or more mating surfaces contoured to structurally engage with the bulkhead. The front assembly according to feature 48.

51. Each of the aforementioned known vehicle types is associated with a predetermined distance between the first front strut tower and the second front strut tower. The crosscar beam is specific to the first vehicle type by positioning the first front strut tower and the second front strut tower at a first preset distance associated with the first vehicle type. The front assembly according to claim 50, characterized in that way.

52. A steering rack mounted on the first front strut tower and the second front strut tower, positioned above the front subframe. The front assembly according to claim 47, further comprising the following:

53. The front subframe includes an upper mounting surface and a rear mounting surface, The upper mounting surface is structurally connected to the bottom of the first front strut tower and the second front strut tower, respectively, using one or more connectors. The rear mounting surface is structurally connected to the crosscar beam. The front assembly according to feature 47.

54. The crosscar beam includes at least one first mounting surface, The first mounting surface is structurally connected to the bulkhead of the vehicle. The front assembly according to feature 47.

55. An electric motor located within the aforementioned front subframe, One or more suspension components mounted between the front subframe and the first front strut tower and the second front strut tower, The front assembly according to claim 47, further comprising the following:

56. A front assembly for a vehicle, Two front strut towers, each consisting of a single piece of cast material, A front subframe positioned below the two front strut towers, Equipped with, The two front strut towers include one or more first bulkhead mating surfaces contoured to structurally connect to the bulkhead of the vehicle, The aforementioned front subframe includes an integrated crossbar beam and one or more second bulkhead mating surfaces, The integrated crossbar beam is structurally connected to the two front strut towers, thereby restricting the relative movement of the two front strut towers. The one or more second bulkhead mating surfaces are contoured to be structurally connected to the bulkhead. A front assembly characterized by the following:

57. Internal combustion engine structurally connected to the front subframe The front assembly according to claim 56, further comprising the following:

58. The integrated crosscar beam is specific to a first vehicle type among a plurality of predetermined vehicle types. The two front strut towers are common to the plurality of predetermined vehicle types. The front assembly according to claim 56.

59. Two crash boxes connected to the two front strut towers, A bumper bar having a rear section connected to the two crash boxes, The front assembly according to claim 56, further comprising the following:

60. One or more steering rack mounts, which are integral structures with each of the two front strut towers, A steering rack attached to one or more steering rack mounts on each of the two front strut towers, Furthermore, The steering rack is positioned above the front subframe. The front assembly according to feature 59.

61. It is a vehicle door, A first outer wall that forms at least a portion of the exterior of the vehicle and extends along the perimeter of a cavity for receiving one or more doors of the vehicle, A second outer wall is positioned inside the first outer wall and extends along at least a portion of the periphery of the cavity, An inner planar wall positioned on the inside of the second outer wall, An inner frame structurally attached to the inner planar wall and forming at least a part of the interior of the vehicle, Equipped with, The first outer wall, the second outer wall, and the inner planar wall are structurally attached to each other along at least a portion of the perimeter of the cavity. A door ring characterized by the following features.

62. The inner planar wall includes a first mating surface, The inner frame includes a second mating surface, The first mating surface and the second mating surface are substantially parallel, The first mating surface is the first outer surface of the inner planar wall, The second mating surface is the second outer surface of the inner frame. The door ring according to feature 61.

63. The aforementioned inner planar wall includes a third surface, The first mating surface and the second mating surface are separated by the third surface. The third surface is substantially perpendicular to the first mating surface and the second mating surface. The third surface is the third outer surface of the inner planar wall. The door ring according to feature 62.

64. The inner planar wall and the inner frame further include one or more holes for receiving one or more connectors. The door ring according to feature 63.

65. The one or more connectors structurally attach the door ring to one or more of the following: the bulkhead, the vehicle cowl, the vehicle battery, the rear structural floor, the D-ring, or a combination thereof. The door ring according to feature 64.

66. The inner planar wall further includes one or more first inner surfaces, The inner frame further includes one or more second inner surfaces, The door ring in question is, One or more reinforcing plates including one or more reinforcing holes Furthermore, The one or more reinforcing plates are arranged such that the one or more reinforcing holes are adjacent to the one or more first inner surfaces and the one or more second inner surfaces, and are aligned with the one or more holes in the inner planar wall and the inner frame. The door ring according to feature 64.

67. The one or more reinforcing plates further include threaded inserts aligned with the one or more reinforcing holes for holding the one or more connectors, The one or more reinforcing plates further include: A first side surface positioned along one or more first inner surfaces, or positioned along one or more second inner surfaces, A second side that is substantially perpendicular to the first side, A gusset extending between the first side and the second side, The door ring according to claim 66, including the following:

68. The one or more connectors received by the inner planar wall are of a different length from the one or more connectors received by the inner frame. The door ring according to claim 65.

69. The first outer wall is made of hot-rolled metal. The first outer wall, the second outer wall, and the inner planar wall are welded along the perimeter of the cavity. The door ring according to feature 61.

70. It is a door ring for a vehicle, The outer layer, An inner layer structurally attached to the outer layer, One or more holes provided in each of the outer layer and the inner layer, Equipped with, The outer layer includes a first mating surface on the outside of the outer layer, The inner layer includes a second mating surface on the outside of the inner layer, The one or more holes extend through the first mating surface and the second mating surface, The first mating surface is substantially parallel to the second mating surface. A door ring characterized by the following features.

71. One or more connectors extending through the one or more holes to fasten the door ring to one or more vehicle parts. Furthermore, The first mating surface is offset from the second mating surface. The door ring according to feature 70.

72. The one or more vehicle parts include one or more first complementary mating surfaces that structurally contact the first mating surface of the door ring, The one or more vehicle parts include one or more second complementary mating surfaces that structurally contact the second mating surface of the door ring. The door ring according to feature 71.

73. The one or more vehicle components mentioned above further include a bulkhead, a vehicle cowl, a vehicle battery, a rear structural floor, a D-ring, or a combination thereof. The door ring according to feature 72.

74. The one or more connectors further include a first group of connectors and a second group of connectors. The first group of connectors extends through the one or more holes in the outer layer, The second group of connectors extends through the one or more holes in the inner layer, The first group of connectors has a different length from the second group of connectors. The door ring according to feature 72.

75. The first group of connectors is shorter than the second group of connectors. The door ring according to feature 74.

76. One or more reinforcing plates for securing the one or more connectors The door ring according to claim 74, further comprising the above.

77. The first group of connectors is offset from the second group of connectors. The door ring according to feature 74.

78. It is a door ring for a vehicle, A first mating surface having a first group of one or more holes for receiving one or more first connectors, A second mating surface having a second group of one or more holes for receiving one or more second connectors, The first mating surface structurally engages with one or more other vehicle parts, The second mating surface structurally engages with the one or more other vehicle parts, The first mating surface is substantially parallel to the second mating surface, The first mating surface is offset from the second mating surface by a certain distance. A door ring characterized by the following features.

79. Two or more layers, One or more reinforcing plates in the two or more layers, Furthermore, The first layer among the two or more layers includes the first mating surface, The second layer among the two or more layers includes the second mating surface, The one or more reinforcing plates surround the one or more holes, The one or more first connectors are shorter than the one or more second connectors. The aforementioned one or more other vehicle components include a bulkhead, a vehicle cowl, a vehicle battery, a rear structural floor, a D-ring, or a combination thereof. The door ring according to feature 78.

80. The door ring does not include a B-pillar, an upper latch for securing one or more doors, a lower latch for securing one or more doors, and one or more hinges. The door ring according to feature 61.

81. A rear structural floor for a vehicle, One or more top mating surfaces contoured to structurally engage with the upper rear section of the vehicle, One or more door ring mating features are contoured to structurally engage with one or more door rings of the vehicle, One or more rear motor cradle mounting points on the underside of the rear structural floor, The front part of the rear structural floor has one or more battery mating surfaces, Equipped with, The rear structural floor is composed of a single piece of cast material. The one or more top mating surfaces, the one or more door ring mating features, the one or more rear motor cradle mounting points, and the one or more battery mating surfaces are integrally structured with the rear structural floor. A rear structural floor characterized by the following features.

82. The one or more battery mating surfaces are The first battery mating surface and The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear structural floor according to claim 81.

83. A first group of holes in the first battery mating surface for receiving one or more groups of first connectors, A second group of holes in the second battery mating surface for receiving one or more second connector groups, Furthermore, The rear structural floor restricts the movement of the one or more door rings relative to the upper rear section. The rear structural floor according to claim 82.

84. The holes in the first group and the holes in the second group further include female threaded portions. The female screw portion of the hole in the first group selectively communicates with the first connector group, The female threaded portion of the hole in the second group selectively communicates with the second connector group. The rear structural floor is structurally connected to the battery. The rear structural floor according to claim 83.

85. The holes in the first group are offset laterally from the holes in the second group. The rear structural floor according to feature 84.

86. The holes in the first group are supported by an external gusset. The rear structural floor according to claim 85, characterized by the features described above.

87. The aforementioned door ring alignment feature further, The first door ring mating surface and The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear structural floor according to claim 81.

88. Two wheel wells that are integrated with the rear structural floor. Furthermore, The one or more rear motor cradle mounting points include six mounting points. The rear structural floor according to claim 81.

89. The one or more top mating surfaces, the one or more door ring mating feature portions, the one or more rear motor cradle mounting points, and the one or more battery mating surfaces are common to multiple vehicle types. The rear structural floor according to claim 81.

90. Rear vehicle assembly, Rear structural floor and Upper rear section and A rear motor cradle structurally connected to the aforementioned rear structural floor, Equipped with, The rear structural floor includes one or more top mating surfaces which are integrally formed with the rear structural floor. The upper rear section includes one or more bottom mating surfaces which are integrally formed with the upper rear section. The one or more bottom mating surfaces are complementary to the top mating surface of the rear structural floor. The one or more bottom mating surfaces are structurally engaged with the one or more top mating surfaces. The aforementioned rear structural floor and the aforementioned upper rear section are each composed of a single piece of cast material. A rear vehicle assembly characterized by the following:

91. The aforementioned upper rear section is specific to one of the one or more vehicle types, The aforementioned rear structural floor is common to the one or more vehicle types. The one or more top mating surfaces and the one or more bottom mating surfaces restrict the movement of the rear structural floor relative to the upper rear section. The rear vehicle assembly according to claim 90, characterized in that it is a rear vehicle assembly.

92. The aforementioned upper rear section further comprises, One or more door rings and one or more door ring mating features structurally engaged with the door ring, One or more rear door joint features, One or more channels for water management, One or more frames, Includes, The one or more door ring alignment features, the one or more rear door alignment features, the one or more channels for water management, and the one or more frames are integrally structured with the upper rear section. The rear vehicle assembly according to claim 90, characterized in that it is a rear vehicle assembly.

93. The aforementioned one or more frames further, One or more rear windows, Two rear air vents, One or more rear doors, The rear vehicle assembly according to claim 90, characterized by including the following:

94. The aforementioned rear structural floor further comprises, One or more door rings and one or more door ring mating features structurally engaged with the door ring, One or more battery mating surfaces, One or more rear cradle mounting points, Includes, The rear vehicle assembly further comprises, An electric motor positioned on the rear motor cradle, The rear suspension component connected to the rear motor cradle, Rear cradle connector and Includes, The rear motor cradle is attached to the rear structural floor at the rear cradle mounting point by fixing the rear motor cradle with the rear cradle connector. The rear vehicle assembly according to claim 90, characterized in that it is a rear vehicle assembly.

95. The one or more battery mating surfaces further include: The first battery mating surface and The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear vehicle assembly according to feature 94.

96. The aforementioned door ring alignment feature further, The first door ring mating surface and The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear vehicle assembly according to feature 94.

97. Rear vehicle assembly, Rear structural floor and Upper rear section and Equipped with, The rear structural floor includes one or more top mating surfaces which are integrally formed with the rear structural floor. The upper rear section includes one or more bottom mating surfaces which are integrally formed with the upper rear section. The one or more bottom mating surfaces are complementary to the top mating surface of the rear structural floor. The one or more bottom mating surfaces are structurally engaged with the one or more top mating surfaces. The aforementioned upper rear section is specific to one of the one or more vehicle types, The aforementioned rear structural floor is common to the one or more vehicle types. A rear vehicle assembly characterized by the following:

98. The aforementioned rear structural floor further comprises, One or more door ring mating features that structurally engage with one or more door rings, One or more battery mating surfaces that structurally engage with the battery, One or more rear cradle mounting points, including The rear vehicle assembly according to claim 97, characterized by its features.

99. The one or more battery mating surfaces further include: The first battery mating surface and The second battery mating surface, Includes, The first battery mating surface and the second battery mating surface are substantially parallel. The rear vehicle assembly according to feature 98.

100. The aforementioned door ring alignment feature further, The first door ring mating surface and The second door ring mating surface, Includes, The first door ring mating surface and the second door ring mating surface are substantially parallel. The rear vehicle assembly according to feature 98.

101. A battery structure for vehicles, A structural ring including a first mating surface and a second mating surface, An electric vehicle battery is disposed within the structural ring, Equipped with, The aforementioned structural ring is A front portion contoured to structurally engage with the bulkhead of the vehicle, An intermediate portion contoured to structurally engage with one or more door rings of the vehicle, A rear portion contoured to structurally engage with the rear structural floor of the aforementioned vehicle, Forming at least three parts including A battery structure characterized by the following features.

102. One or more first holes for one or more first connectors, extending substantially vertically through the structural ring and aligned with the first mating surface, One or more second holes for one or more second connectors, extending substantially vertically through the structural ring and aligned with the second mating surface, The battery structure according to claim 101, further comprising the above.

103. Each of the bulkhead, the one or more door rings, and the rear structural floor has one or more first complementary mating surfaces and one or more second complementary mating surfaces Furthermore, The first mating surface is substantially parallel to the second mating surface, The first mating surface is aligned with the one or more first complementary mating surfaces. The second mating surface is aligned with the one or more second complementary mating surfaces. The battery structure according to feature 102.

104. The one or more first connectors are longer than the one or more second connectors. The battery structure according to feature 103.

105. The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The battery structure according to feature 104.

106. The one or more first holes are offset from the one or more second holes. The first group of the one or more first holes in the front portion is aligned with the first structural feature of the crosscar beam. The second group of the one or more second holes in the front portion is aligned with the second structural feature portion of the crosscar beam. The battery structure according to feature 105.

107. The structural ring includes a third mating surface, The third mating surface is substantially perpendicular to the first mating surface and the second mating surface. The third mating surface is aligned with one or more third complementary mating surfaces. The battery structure according to feature 105.

108. The one or more first connectors and the one or more second connectors are bolts, The bolts are inserted from below the electric vehicle battery and connect the electric vehicle battery to the bulkhead, the one or more door rings, and the rear structural floor, respectively, in the front section, the middle section, and the rear section. The battery structure according to feature 105.

109. Cross member with two ends Furthermore, The first of the two ends is connected to the first door ring, The second of the two ends is connected to the second door ring. The battery structure according to feature 101.

110. A battery structure for vehicles, A structural ring including a first mating surface and a second mating surface, The structural ring and one or more first holes in the first mating surface, The structural ring and one or more second holes in the second mating surface, One or more first connectors in the one or more first holes, One or more second connectors in the one or more second holes, An electric vehicle battery is disposed within the structural ring, Equipped with, The first mating surface is parallel to the second mating surface, The one or more first connectors and the one or more second connectors structurally connect the battery structure to the vehicle components. A battery structure characterized by the following features.

111. The one or more second holes are offset from the one or more first holes. The battery structure according to feature 110.

112. The first mating surface corresponds to one or more first complementary mating surfaces on the component of the vehicle, The second mating surface corresponds to one or more second complementary mating surfaces on the component of the vehicle. The battery structure according to feature 110.

113. The one or more first complementary mating surfaces and the one or more second complementary mating surfaces are located on a bulkhead, one or more door rings, a rear structural floor, or a combination thereof. The battery structure according to feature 112.

114. The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The battery structure according to feature 113.

115. It is the central floor of the vehicle, A structural ring including a first mating surface and a second mating surface, An electric vehicle battery is disposed within the structural ring, A fuel tank arranged within the aforementioned structural ring, Equipped with, The aforementioned structural ring is The front portion that structurally engages with the bulkhead, An intermediate portion that structurally engages with one or more door rings, The rear portion that structurally engages with the rear structural floor, Forming at least three parts including A central vehicle floor is a distinctive feature.

116. The electric vehicle battery is located in front of the structural ring, The fuel tank is located behind the structural ring, The fuel tank is attached to the structural ring at its bottom using one or more retaining straps. The central vehicle floor according to feature 115.

117. The structural ring includes one or more recesses, The one or more recesses are for routing one or more exhaust pipes. The central vehicle floor according to feature 116.

118. One or more first holes for one or more first connectors, extending substantially vertically through the structural ring and aligned with the first mating surface, One or more second holes for one or more second connectors, extending substantially vertically through the structural ring and aligned with the second mating surface, The central vehicle floor according to claim 116, further comprising the above.

119. In order to structurally connect to the central vehicle floor, the bulkhead, the one or more door rings, and the rear structural floor each have one or more first complementary mating surfaces and one or more second complementary mating surfaces Furthermore, The first mating surface is parallel to the second mating surface, The first mating surface is aligned with the one or more first complementary mating surfaces. The second mating surface is aligned with the one or more second complementary mating surfaces. The central vehicle floor according to feature 118.

120. The structural ring further includes one or more internal gussets, The one or more first holes and the one or more second holes extend through the one or more internal gussets. The central vehicle floor according to feature 119.

121. A vehicle platform for building vehicles, Front structure and, Two door rings structurally connected to the aforementioned front structure, A rear structure structurally connected to each of the two aforementioned door rings, Equipped with, The aforementioned front structure includes a bulkhead and a cowl structurally connected to the bulkhead. The two aforementioned door rings are provided one on each side of the vehicle. The aforementioned rear structure includes a rear structural floor and an upper rear section structurally connected to the rear structural floor. A vehicle platform characterized by the following features.

122. A central floor including a structural ring structurally connected to the front structure, the two door rings, and the rear structure. Furthermore, The aforementioned front structure, the two door rings, and the aforementioned rear structure form the vehicle body. The vehicle body and the central floor form a structural cage that restricts the relative movement of the front structure, the two door rings, the rear structure, and the central floor. The vehicle platform according to feature 121.

123. Front axle assembly and, Rear axle assembly and, Furthermore, The front axle assembly includes two strut towers, a front subframe structurally connected to the two strut towers, and a front electric motor mounted within the front subframe. The central floor further includes a vehicle battery disposed within the structural ring, The rear axle assembly includes a rear motor cradle and a rear electric motor mounted within the rear motor cradle. The vehicle platform according to claim 122.

124. Each of the bulkhead, cowl, rear structural floor, upper rear section, and the two strut towers is a separate component made of cast aluminum. The vehicle platform according to feature 123.

125. The vehicle body is configured to meet the strength requirements of the largest of the multiple vehicle types. The vehicle platform according to feature 124.

126. The front axle assembly, the rear axle assembly, the central floor, the bulkhead, and the rear structural floor are common to all of the above vehicle types. The cowl, the two door rings, and the upper rear section are specific to at least one vehicle type among the plurality of automobile types. The vehicle platform according to feature 124.

127. The vehicle is a battery electric vehicle or a plug-in hybrid electric vehicle. The vehicle platform according to feature 121.

128. It is a vehicle platform, Two door rings specific to one of the multiple vehicle types, A bulkhead for use in the aforementioned multiple vehicle types, structurally connected to the two door rings, A cowl specific to one of the multiple vehicle types, which is structurally connected to the bulkhead, A rear structural floor for use with the aforementioned multiple vehicle types, structurally connected to the two aforementioned door rings, An upper rear section specific to one of the multiple vehicle types, which is structurally connected to the rear structural floor, Equipped with, The bulkhead, the cowl, the rear structural floor, and the upper rear section are each individual parts made of cast aluminum. A vehicle platform characterized by the following features.

129. A front axle assembly for use in the aforementioned multiple vehicle types, A central floor for use in the aforementioned multiple vehicle types, A rear axle assembly for use in the aforementioned multiple vehicle types, The vehicle platform according to claim 128, further comprising the above.

130. A central floor, further including a battery, is structurally connected to the bulkhead, the two door rings, and the rear structural floor. The vehicle platform according to claim 129, further comprising the above.

131. The aforementioned front axle assembly further comprises, Two strut towers, The front subframe is structurally connected to the two strut towers, Includes, The aforementioned rear axle assembly further comprises, Rear motor cradle including The vehicle platform according to claim 130.

132. The rear motor cradle further includes an internal combustion engine, The aforementioned central floor further includes a fuel tank. The vehicle platform according to feature 131.

133. Exhaust system Furthermore, The central floor further includes one or more recesses for the exhaust pipes of the exhaust system. The vehicle platform according to feature 132.

134. The aforementioned front subframe includes a front electric motor. The rear motor cradle includes a rear electric motor. The vehicle platform according to feature 131.

135. To form the front structure, the process involves fastening the bulkhead to the vehicle cowl, The process involves fastening the upper rear section to the rear structural floor in order to form the rear structure, The process involves fastening two door rings, the front structure, and the rear structure together to form the vehicle body, The process involves fastening the front axle assembly, the rear axle assembly, and the central floor to the vehicle body, A vehicle assembly method characterized by comprising the following features.

136. The bulkhead, the vehicle cowl, the rear structural floor, and the upper rear section are each single pieces made of cast aluminum. The method according to 135, characterized by the features described above.

137. The aforementioned central floor includes a battery The method according to 136, characterized by the features described above.

138. The aforementioned central floor includes a fuel tank. The method according to feature 137.

139. The aforementioned front axle assembly further comprises, Two strut towers, The front subframe, including the front propulsion unit, Crosscar beam and Includes, The aforementioned rear axle assembly further comprises, Rear cradle including rear propulsion unit including The method according to 135, characterized by the features described above.

140. The front axle assembly, the rear axle assembly, and the two door rings are assembled separately from the front and rear structures. The method according to feature 139.

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