Integrated EV Battery Chassis Structure for Lightweight Servicing
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Solution Overview
Problem
Current electric vehicle platforms are inflexible, leading to increased weight, height, and manufacturing complexity, with separate chassis and battery pack structures that occupy significant space and require costly servicing.
Innovation Solution
A vehicle construction using continuous elongated profiles, such as extruded aluminum frames, with integrated battery support and modular components, allowing for flexible assembly and servicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate chassis and battery pack structures are used, then crash safety and cargo carrying capacity are ensured, but vehicle weight and height increase
Solution Approach 1:
The patent merges the chassis structure and battery pack structure into a single integrated assembly. The battery pack is mounted directly to the chassis frame members, eliminating the need for separate protective structures. This integration maintains crash safety through the structural design of the combined assembly while reducing overall vehicle weight by eliminating redundant components.
Solution Approach 2:
The chassis frame members serve multiple functions: they provide structural support for crash safety, serve as mounting structures for the battery pack, and act as protective enclosures. This multi-functionality eliminates the need for separate dedicated battery protection structures, reducing vehicle weight while maintaining safety requirements.
2Strength
If separate chassis and battery pack structures are used, then structural integrity is maintained, but packaging space is consumed
Solution Approach 1:
The battery pack structure is merged with the chassis structure, where the chassis frame members directly support and protect the battery cells. This integration eliminates the need for separate battery enclosure space, optimizing packaging efficiency while maintaining structural integrity through the unified design.
3Ease of repair
If battery packs are designed for removal, then servicing is enabled, but assembly complexity and tooling costs increase
Solution Approach 1:
The battery pack is segmented into modular units that can be easily accessed and serviced. The design allows individual battery modules or the entire pack to be removed through simplified attachment mechanisms, enabling servicing without complex disassembly procedures or specialized tooling.
4Adaptability or versatility
If multiple chassis configurations are produced, then vehicle versatility is achieved, but tooling and manufacturing costs increase
Solution Approach 1:
The integrated chassis-battery structure is designed with universal mounting points and standardized frame members that can accommodate different battery pack configurations and cargo body types. This universality allows a single base platform to serve multiple vehicle configurations, reducing the need for specialized tooling and fixtures for each variant.
Data Source
AI summary
A vehicle includes a first inner frame member, a second inner frame member spaced apart from the first inner frame member and a lower battery plate coupled between the first inner frame member and the second inner frame member. A plurality of top chassis cross members is supported by the first inner frame member and the second inner frame member. A battery disposed between the first inner frame member, the second inner frame member, the lower battery plate and the plurality of top chassis cross members. A first outer rocker member is adjacent to and outboard of the first inner frame member. A second outer rocker member is adjacent to and outboard of the second inner frame member. A floor deck plate is supported by the top chassis cross member.