EV Exoskeleton Chassis Layout for Battery Space and Stability
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Solution Overview
Problem
Existing electric vehicle chassis designs, particularly for trucks, limit the space available for battery installation due to the presence of a metal frame, restricting battery capacity and increasing the risk of crash impact damage.
Innovation Solution
A frameless exoskeleton structure is used, integrating the battery as a part of the exoskeleton, with electric drive units and a unified exterior surface forming the chassis, enhancing structural rigidity and allowing for a centered battery layout that maximizes space and reduces the risk of tilting and oversteering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a classical frame-based chassis is used, then structural strength and stability are ensured, but the space available for battery installation is limited
Solution Approach 1:
The patent removes the classical frame structure from the vehicle chassis, extracting the load-bearing function and replacing it with an exoskeleton design where the battery pack itself serves as a structural component. This eliminates the space-consuming frame while maintaining structural integrity through the battery's integrated positioning and support functions.
Solution Approach 2:
The battery pack is designed to serve multiple functions: it provides energy storage, acts as a structural support element, and contributes to the vehicle's chassis geometry. The battery's housing and mounting structure simultaneously fulfill protective, supportive, and spatial-defining roles, eliminating the need for separate frame components.
2Quantity of substance
If the battery size is increased to maximize capacity, then energy provision is improved, but the vehicle's center of gravity rises and stability decreases
Solution Approach 1:
The patent transitions from conventional longitudinal battery placement to a transverse arrangement where batteries are positioned side-by-side across the vehicle width. This dimensional reconfiguration allows maximum battery capacity while maintaining a low center of gravity, as the extended width does not adversely affect vertical weight distribution and stability.
3Object-affected harmful factors
If a frame structure is used for side impact protection, then crash safety is improved, but the battery housing volume is reduced
Solution Approach 1:
The patent merges the protective housing function with the battery pack structure itself. The battery housing is designed to simultaneously protect the battery cells and provide the necessary structural strength for crash protection, eliminating the need for separate protective frames or additional housing layers.
4Stability of the object's composition
If the battery is mounted under the chassis, then center of gravity is lowered and safety is improved, but servicing becomes more difficult
Solution Approach 1:
The battery system is segmented into modular battery packs that can be independently removed and replaced. This modular design allows servicing to be performed by simply detaching individual battery units from the chassis, significantly reducing maintenance complexity despite the under-chassis mounting position.
Data Source
AI summary
A combined chassis-body structure for an electric vehicle, the structure having a frameless form of an exoskeleton. The structure includes: four electric drive unit sockets, each having a bottom inlet and accommodating therein an electric drive unit, wherein each electric drive unit has a support structure to which there is connected an electric motor housing and a suspension with a driving wheel, wherein the support structure of the electric drive unit is connected to a support structure of the corresponding socket; a battery pack seat having a bottom inlet and accommodating therein a battery pack; and an exterior surface that forms an outline of a chassis and a lower part of the body of the vehicle and is suitable for placing a driver's cabin on top of the exterior surface; wherein the seat for the battery pack, the electric drive unit sockets and the exterior surface are formed as two separate, individually integral elements of the exoskeleton that are coupled together along a longitudinal axis of the vehicle.