Modular Composite Chassis for EV Weight and Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in creating a modular rolling chassis for lightweight yet robust vehicles, particularly electric vehicles, using composite materials without custom forming, while ensuring appropriate weight distribution, torsional rigidity, and bending rigidity, which is complex due to the demands of lower volume manufacturing.
Innovation Solution
A modular rolling chassis design featuring a platform frame with composite panels, lateral battery compartments, and subframes that include cooling systems, where the platform frame is constructed from composite panels, and the battery module forms a structural support member, allowing for removability and ease of assembly, and providing structural support and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to construct the chassis, then the weight is reduced significantly, but the manufacturing complexity and difficulty of forming custom parts increases
Solution Approach 1:
The chassis is divided into modular segments including a platform frame, front subframe, rear subframe, and battery modules. Each segment can be manufactured separately using standard composite forming processes, then assembled together. This segmentation allows complex composite structures to be broken down into manageable pieces that don't require custom forming for the entire chassis.
Solution Approach 2:
The battery modules serve dual functions: they provide electrical power storage and act as structural support members within the chassis. The battery compartments are integrated into the platform frame design, eliminating the need for separate structural elements in those locations. This multi-functionality reduces overall chassis weight while simplifying manufacturing.
2Manufacturing precision
If custom forming is used for composite parts, then the chassis can achieve required weight distribution and rigidity, but the manufacturing process becomes more demanding and costly
Solution Approach 1:
The chassis design segments the structure into standardized modules (platform frame, subframes, battery modules) that can be manufactured using conventional composite forming techniques. Each module is designed with standardized connection interfaces, allowing precise weight distribution to be achieved through modular assembly rather than complex custom forming of the entire chassis.
Solution Approach 2:
The design allows for adjustment of weight distribution and rigidity parameters by selecting different battery module configurations, positions, and orientations within the standardized platform frame. This enables tuning of chassis characteristics without requiring custom forming, as the modular architecture permits reconfiguration through assembly rather than manufacturing changes.
3Strength
If the battery module is permanently integrated into the chassis, then structural rigidity is maximized, but ease of maintenance and replacement is reduced
Solution Approach 1:
The battery system is segmented into removable modules that interface with the platform frame through standardized mounting mechanisms. These modules maintain structural rigidity when installed but can be independently removed and replaced without affecting the overall chassis integrity, enabling easy maintenance while preserving structural strength.
Solution Approach 2:
The battery module connection system transitions from a fixed permanent integration to a dynamic removable connection. The modules are designed with quick-connect interfaces that provide rigid structural attachment during operation but allow for rapid disconnection and replacement, adapting the structural integrity from static to dynamic based on operational needs.
4Strength
If the chassis is designed as a single integrated structure, then torsional and bending rigidity are optimized, but manufacturing efficiency and assembly speed are reduced
Solution Approach 1:
The chassis is segmented into separately manufacturable modules (platform frame, front subframe, rear subframe, battery modules) that can be produced simultaneously in different locations or on different production lines. The modules are then rapidly assembled using standardized interfaces, improving manufacturing efficiency while maintaining torsional and bending rigidity through the integrated modular structure.
Solution Approach 2:
Multiple functional components are merged into integrated modules that can be manufactured as single units. For example, battery compartments are merged with structural support elements, and subframes are designed to incorporate multiple mounting points and structural functions. This merging reduces the total number of separate parts while maintaining rigidity, and enables more efficient manufacturing and assembly.
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 approach enables the creation of a lightweight yet robust chassis that is an order of magnitude lighter than traditional steel chassis, achieving optimal weight distribution and torsional and bending rigidity without the need for custom forming, facilitating efficient manufacturing and maintenance through modular assembly.
Implementation Method 1
the at least one cooling exhaust perhaps including an exhaust fan, such that air received at the cooling intake flows rearward through the pair of lateral battery compartments and is exhausted proximate the rear bulkhead
Implementation Method 2
The platform frame may be constructed from composite panels
Data Source
AI summary
The present invention relates to a modular way to build a rolling chassis using composite materials without custom forming, and yielding appropriate weight distribution (centre of gravity) and torsional and bending rigidity.