Composite Monocoque EV Flatbed for Low-Floor Cargo Space
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Solution Overview
Problem
Current systems for manufacturing utility and delivery vehicles face limitations, including poor thermal insulation, elevated floor levels, and reduced storage capacity due to internal chassis and powertrain components, which affect efficiency and accessibility.
Innovation Solution
The use of a monocoque structure made from composite materials, eliminating the internal chassis and powertrain components, and incorporating a modular mold system to form a single-piece, monolithic structure with a low floor design, enhancing insulation and storage capacity while maintaining a lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an internal chassis and powertrain components are used in utility vehicles, then structural support and power generation are provided, but thermal insulation performance deteriorates and storage capacity is reduced
Solution Approach 1:
The patent removes the internal chassis and powertrain components from the utility vehicle structure. Instead, a monocoque body structure provides structural support, while the extracted space creates an insulated envelope for thermal protection and increases available storage volume in the cargo area.
2Strength
If an internal chassis is used in utility vehicles, then structural framework is provided, but floor elevation increases and storage capacity is reduced
Solution Approach 1:
The patent extracts the internal chassis framework and replaces it with a monocoque body structure. This elimination of the raised chassis allows the floor to be positioned lower, maximizing the height of the cargo area and improving accessibility while maintaining structural integrity through the integrated body design.
3Power
If powertrain components are installed in utility vehicles, then propulsion capability is provided, but storage capacity and accessibility are reduced
Solution Approach 1:
The patent removes traditional powertrain components from the vehicle structure. The monocoque design integrates propulsion systems into the body structure itself, eliminating separate engine bays and transmission tunnels that would otherwise reduce cargo volume. This extraction of conventional powertrain architecture maximizes storage capacity while maintaining propulsion capability.
4Object-affected harmful factors
If a monocoque structure is used, then thermal insulation and storage capacity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the monocoque body into modular sections that can be manufactured separately and then assembled. This segmentation allows each module to be produced using standardized processes, reducing overall manufacturing complexity while maintaining the thermal insulation benefits and storage capacity of the integrated monocoque design.
Data Source
AI summary
In certain embodiments, an electric vehicle includes a front cage, a rear floor, an intermediate section, a utility cabinet, and a flatbed. In other embodiments, an electric vehicle includes a front cage, a rear floor, an intermediate section, and a flatbed. In some embodiments, the front cage at least partially defines an operator cabin, the rear floor is positioned rearward of the front cage in a longitudinal direction, and the intermediate section is disposed at least partially between the front cage and the rear floor in the longitudinal direction.