EV Chassis Cross-Member Assembly for Battery Torsion Protection

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Solution Overview

Problem

Electric vehicles face challenges in protecting battery integrity from torsional forces and twisting movements that can damage battery cells, unlike traditional internal combustion engines.

Innovation Solution

A chassis assembly with parallel side rails and cross members featuring a uniform, closed cross-sectional configuration and flanges with asymmetrical orifices to secure cross members, along with a battery mounting assembly that allows for float and removably couples batteries, enhancing stiffness and minimizing twisting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid chassis structure is used to protect batteries, then battery protection improves, but torsional flexibility deteriorates

Engineering Contradiction:

Improvebattery protectionVSAvoidtorsional flexibility

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The chassis is divided into modular components including side rails, cross members, and a battery cage assembly. The cross members are detachably connected to side rails through flanges and fasteners, allowing the structure to be segmented into replaceable units that can be independently reinforced or replaced based on damage patterns.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The chassis employs composite construction combining aluminum extrusions for side rails, steel or aluminum cross members, and a cage-style battery enclosure. This multi-material approach optimizes the balance between protective rigidity and controlled flexibility, with each material selected for its specific strength-to-weight ratio and torsional characteristics.

Inventive Principle:

Principle #40Composite materials

2Strength

If cross members are securely attached to both side rails, then structural stiffness improves, but ability to absorb torsional forces deteriorates

Engineering Contradiction:

Improvestructural stiffnessVSAvoidtorsional force absorption

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The connection system between cross members and side rails is designed to be dynamically responsive. The flange and fastener assembly allows the cross members to maintain secure attachment during normal operation while permitting controlled relative movement when subjected to extreme torsional loads, effectively transforming the rigid connection into a semi-rigid, adaptive joint.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flange acts as an intermediary element between the cross member and side rail. This intermediate component provides a dedicated attachment interface that can accommodate stress distribution and slight misalignments, allowing the primary structural members to remain stiff while the intermediary absorbs some torsional energy through its own deformation characteristics.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the chassis is designed for maximum rigidity, then battery integrity protection improves, but damage from torsional forces deteriorates

Engineering Contradiction:

Improvebattery integrityVSAvoidresistance to torsional damage

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The chassis design incorporates energy-absorbing features in advance of potential torsional impacts. The modular cross member system with flange connections is pre-configured to allow controlled deformation and energy dissipation during torsional events, protecting the battery enclosure from the full force of such impacts while maintaining structural integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The design accepts that some torsional deformation will occur and converts this potentially harmful effect into a beneficial energy dissipation mechanism. The modular connection points and semi-rigid joints are designed to deform in controlled ways during torsional events, absorbing impact energy that would otherwise be transmitted directly to the battery enclosure, thereby protecting it from damage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS12594824B2Chassis assemblies for electric vehicles

Publication Date: 2026.04.07 WORKHORSE GROUP INC

AI summary

A chassis assembly for an electric vehicle that can include a plurality of cross members having closed section cross sectional configurations that can be generally uniform between opposing flanges that secure the cross members to opposing side rails of a chassis. Such flanges can include asymmetrically arranged orifices that receive fasteners used to secure the cross members to the adjacent side rail. A first battery mounting assembly can extend above a space between the side rails and secure a plurality of batteries in a vertical arrangement. The first battery mounting assembly can accommodate a degree of float between the first and second side rails in a manner that can protect the integrity of the batteries. A second battery mounting assembly can be utilized for mounting other batteries in a manner that can enhance the ease with which those batteries can be removed from at least the chassis assembly.