Intermediate Frame Isolation Structure for Electric Work Vehicle Chassis

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Solution Overview

Problem

Existing electric vehicles lack an efficient structural solution to integrate and isolate electrical components, such as motors and DC-DC converters, from the battery housing while maintaining a robust and efficient power distribution system.

Innovation Solution

The electric work vehicle incorporates an intermediate frame with a plurality of wall portions that define an interior space, where an isolation structure made of insulating material is attached to the wall surface. This configuration allows for the overlap of the isolation structure with both the electric motor and the DC-DC converter, effectively isolating electrical components from the battery housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If electrical components are integrated close to the battery housing for compact power distribution, then power distribution efficiency is improved, but electrical interference and mechanical stress risk increase

Engineering Contradiction:

Improvepower distribution efficiencyVSAvoidelectrical interference

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

An intermediate frame is introduced as a mediator structure between the battery housing and electrical components (motor and DC-DC converter). This intermediate frame provides both structural support for power distribution and electrical isolation through insulating material, resolving the contradiction by enabling close integration while preventing harmful electrical interference.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate frame utilizes composite construction combining metal portions for structural strength and power distribution support with insulating material portions for electrical isolation. This composite approach allows the same structure to simultaneously achieve both power distribution efficiency and electrical interference prevention.

Inventive Principle:

Principle #40Composite materials

2Reliability

If electrical components are isolated from the battery housing to reduce interference, then electrical safety is improved, but structural integrity and power distribution efficiency may worsen

Engineering Contradiction:

Improveelectrical safetyVSAvoidstructural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The intermediate frame employs composite materials combining metal portions for structural integrity and insulating material portions for electrical isolation. The metal portions maintain structural strength and support power distribution, while the insulating material ensures electrical safety, allowing both requirements to be satisfied simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The intermediate frame is segmented into distinct metal portions and insulating material portions, each performing specific functions. The metal portions provide structural support and power distribution pathways, while the insulating portions provide electrical isolation, allowing the system to achieve both structural integrity and electrical safety through functional segmentation.

Inventive Principle:

Principle #1Segmentation

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

This solution enhances the structural integrity and electrical isolation within the electric vehicle, ensuring efficient power distribution and reducing the risk of electrical interference or damage from mechanical stress.

Implementation Method 1

The isolation structure can include an insulating material

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentEP4549219A1Chassis of electric work vehicle including intermediate frame with isolation structure

Publication Date: 2025.05.07 KUBOTA CORP

Figure 1A
Figure 1B
Figure 1C

AI summary

An electric work vehicle (1) includes a chassis, a battery housing (8) supported by the chassis, a rear axle, and an isolation structure (73). The chassis includes an intermediate frame (6) attached to a rear portion of the battery housing (8). The intermediate frame (6) is located between the battery housing (8) and the rear axle in a front-rear direction of the electric work vehicle (1). The intermediate frame includes a plurality of wall portions that define an interior space. At least one of the plurality of wall portions includes a wall surface that faces the interior space. The isolation structure (73) is attached to the wall surface.