Modular EV Frame With Removable Battery Compartments
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Solution Overview
Problem
Heavy-duty vehicles face limited space between longitudinal frame rails, restricting the capacity of battery packs, and existing frames do not facilitate easy mounting, service, and protection of battery modules.
Innovation Solution
A frame module with a central partition wall and transverse battery storage compartments, allowing easy access and mounting of battery modules via side walls, integrated cooling conduits, and structural protection, along with a modular design for enhanced stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If traditional longitudinal frame rails with transverse beams are used, then structural integrity is maintained, but battery storage space is limited
Solution Approach 1:
The frame is divided into modular components: a central partition wall structure and removable side walls. This segmentation allows the battery storage compartments to be integrated into the frame structure itself rather than being constrained by traditional rail-beam architecture, increasing storage volume while maintaining structural integrity through the modular design
Solution Approach 2:
The invention transitions from a traditional longitudinal frame structure to a three-dimensional compartmentalized structure with central partition walls and transverse battery storage compartments. This dimensional reorganization creates additional storage space by utilizing the vertical and transverse dimensions more effectively while preserving the longitudinal structural framework
2Ease of operation
If battery modules are permanently fixed in the frame, then structural stability is improved, but serviceability and accessibility are reduced
Solution Approach 1:
The side walls are designed to be removable rather than permanent, allowing the system to transition between a closed stable structure during operation and an open accessible structure during service. This dynamic design enables battery modules to be easily accessed, removed, or replaced while maintaining structural integrity when the side walls are in place
Solution Approach 2:
The side walls can be removed and taken out from the frame structure to provide direct access to the battery storage compartments. This extraction capability allows service personnel to easily service battery modules without disassembling the entire frame, maintaining structural stability when the side walls are installed while providing excellent serviceability when removed
3Quantity of substance
If more battery modules are stored in the frame, then energy storage capacity increases, but mounting complexity and service difficulty increase
Solution Approach 1:
The battery storage structure is segmented into multiple compartments defined by the central partition wall and side walls. This segmentation allows multiple battery modules to be organized in an orderly fashion, simplifying mounting procedures and service access compared to a monolithic storage space where modules would be difficult to manage
Solution Approach 2:
The frame structure serves multiple functions: it provides structural support, defines battery storage compartments, and includes removable side walls for access. This multi-functionality reduces overall system complexity by combining several functions into a single integrated structure rather than requiring separate components for each function
Data Source
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AI summary
A frame module (110) and a modular frame of an electric vehicle extending along a longitudinal direction (L), the frame module comprising: a longitudinally extending central partition wall (111), a front wall (112) and a rear wall (113), a battery storage structure having first and second battery storage compartments (115, 116) provided on opposite sides of the central partition wall (111), each battery storage compartment being configured to receive at least one battery module (200) and being delimited by the central partition wall and longitudinally extending first and second side walls of the frame module, respectively, the first and second side walls being releasably mounted to the battery storage structure to enable opening of the first and second battery storage compartments (115, 116), respectively.