Frameless EV Exoskeleton Structure for Larger Structural Battery Packs
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Solution Overview
Problem
Existing frame-based chassis structures in electric vehicles, particularly trucks, limit the space available for battery installation, compromising battery capacity and safety, and require separate protection mechanisms.
Innovation Solution
A frameless exoskeleton structure is used, integrating the battery as part of the exoskeleton, enhanced by electric drive units, which provides structural support and rigidity, allowing for maximum battery space utilization and simplified servicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If a classical frame-based chassis is used, then the vehicle structure provides structural support and mounting points, 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 redundant structural element that was limiting battery space. The frameless design allows batteries to occupy the entire width of the chassis, directly resolving the space limitation imposed by traditional frames.
Solution Approach 2:
The battery pack is designed to serve dual functions: as the energy storage component and as part of the structural support system. The battery housing and mounting structure provide both mechanical support and protection, eliminating the need for a separate frame while maximizing battery capacity.
2Quantity of substance
If the battery size is increased to maximize capacity, then more energy is available for longer mileage, but the battery requires more space that conflicts with the frame structure
Solution Approach 1:
By removing the frame structure, the patent eliminates the spatial conflict between the frame and large-capacity batteries. The frameless design allows the battery to expand to maximize capacity without being constrained by frame boundaries.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning the battery pack at the bottom of the chassis, below the passenger compartment. This three-dimensional arrangement allows maximum battery capacity while maintaining adequate space for other vehicle components.
3Reliability
If the battery is mounted under the chassis to lower the center of gravity, then safety and servicing are improved, but the battery still requires a frame for protection which reduces volumetric capacity
Solution Approach 1:
The battery pack housing serves dual purposes as both the protective enclosure and the structural mounting element. This eliminates the need for a separate frame while maintaining protection and accessibility, thereby preserving maximum volumetric capacity.
Solution Approach 2:
The patent merges the protective frame function with the battery housing into a single integrated structure. The battery pack itself becomes the structural element that provides both protection and mounting, eliminating redundant components and maximizing space utilization.
4Volume of stationary object
If a frameless exoskeleton structure is used to maximize battery space, then battery capacity is increased, but the structural support function must be provided by alternative means
Solution Approach 1:
The battery pack and electric drive units are designed to provide structural support in addition to their primary functions. The battery housing and mounting structures serve as the exoskeleton, providing necessary strength and rigidity while maximizing battery space.
Solution Approach 2:
The patent employs composite material structures and optimized geometries in the battery housing and exoskeleton components to achieve high strength-to-weight ratios. This allows the frameless design to maintain structural integrity while maximizing battery capacity.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4B
AI summary
A combined chassis-body structure for an electric vehicle, the structure having a frameless form of an exoskeleton (10) comprising: four electric drive unit sockets (12), each having a bottom inlet and accommodating therein an electric drive unit (20), wherein each electric drive unit (20) comprises a support structure (21) to which there is connected an electric motor housing (23) and a suspension (24) with a driving wheel (25), wherein the support structure (21) of the electric drive unit (20) is connected to a support structure (121) of the corresponding socket (12); a battery pack seat (13) having a bottom inlet and accommodating therein a battery pack (30); and an exterior surface (11) 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 (17) on top of the exterior surface (11); wherein the seat (13) for the battery pack (30), the electric drive unit sockets (12) and the exterior surface (11) are formed as two separate, individually integral elements (10A, 10B) of the exoskeleton (10) that are coupled together along a longitudinal axis of the vehicle.