EV Conversion Kit With Axle Drive and Underframe Battery Layout

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Solution Overview

Problem

Converting internal combustion vehicles to electric vehicles is time-consuming, costly, and limited by inefficient battery placement and integration with existing transmission systems, which compromises vehicle stability and cabin space, and is often outdated due to rapid battery technology advancements.

Innovation Solution

A conversion kit that integrates an electric motor directly or mechanically with the axle via a driveshaft or transfer case, along with optimized battery placement under the vehicle frame, eliminating the IC motor and transmission, allowing easy access and upgradeability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the existing transmission is retained in IC vehicle conversions, then the conversion process is simplified, but the EV powertrain efficiency is degraded

Engineering Contradiction:

Improveconversion process simplicityVSAvoidEV powertrain efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent removes the existing internal combustion transmission system entirely and replaces it with an electric motor directly coupled to the axle. This extraction of the old transmission system eliminates the efficiency losses associated with retaining the IC transmission, while the direct coupling simplifies the conversion process by eliminating the need for complex integration between old and new systems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical IC transmission system with an electric motor system that directly drives the axle. This substitution eliminates the mechanical inefficiencies of the old transmission while maintaining ease of installation through direct coupling, resolving the contradiction between simplicity and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If battery boxes are tightly engineered to fit difficult-to-access areas, then vehicle stability and cabin space are optimized, but battery removal and replacement becomes very difficult

Engineering Contradiction:

Improvevehicle stabilityVSAvoidbattery accessibility

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The patent divides the battery system into modular units that can be independently accessed and replaced. The battery boxes are designed as separate, removable modules rather than fixed installations, allowing batteries to be easily removed and replaced while maintaining proper vehicle stability through controlled placement in difficult-to-access areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces dynamic accessibility to previously static battery installations. Battery boxes are designed with removable covers or access panels that allow easy entry to batteries in difficult-to-access areas, while the overall mounting structure remains fixed to maintain vehicle stability. This creates a dynamic system where accessibility is improved without compromising stability.

Inventive Principle:

Principle #15Dynamics

3Reliability

If conversions are customized to fit specific vehicle platforms, then optimal performance is achieved, but the conversion process becomes extremely time intensive and expensive

Engineering Contradiction:

Improveconversion performanceVSAvoidconversion time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent creates a universal electric motor and axle coupling system that can be adapted to multiple vehicle platforms without requiring complete customization for each application. The direct coupling mechanism serves multiple functions across different vehicle types, reducing conversion time and cost while maintaining optimal performance through proper adaptation to each platform's specific requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates cost-effective, efficient, and stable conversion of IC vehicles to EVs with improved battery accessibility and compatibility across various vehicle platforms, reducing manufacturing complications and enabling easy upgrades.

Implementation Method 1

an electric motor directly coupled to an axle of the vehicle and adapted to power rotation of the axle

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a battery coupled to the top side of the tray and electrically connected to the electric motor

Methodology Applied

Scientific EffectElectrochemical energy conversion: Battery (electricity)

Data Source

PatentUS20250313075A1Universal Electric Conversion Process for Internal Combustion Vehicles

Publication Date: 2025.10.09 PHOENIX EV MOTORS LLC

AI summary

Electric vehicle conversion kits for IC vehicles and converted electric vehicles. An electric vehicle conversion kit may include an electric motor directly coupled to an axle. Another electric vehicle conversion kit may include an electric motor mechanically coupled to an axle via a driveshaft. Another electric vehicle conversion kit may include an electric motor coupled to a transfer case.