Modular Off-Road Vehicle Frame With Structural Battery Integration
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Solution Overview
Problem
Existing off-road vehicles, particularly electric and hybrid ATVs, face challenges such as complex and heavy frames, high manufacturing costs, and inflexible drivetrain configurations that hinder adaptability and increase maintenance time.
Innovation Solution
The proposed off-road vehicle features a frame assembly with a modular design, incorporating a structural battery assembly that serves as a load-bearing component, and a drivetrain system with multiple electric motors and final drive units, allowing for flexible torque distribution and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If typical ATV frames are constructed with sufficient strength and rigidity using complex space or open structure frames, then the frame can resist high bending and torsional forces, but the frame becomes heavy and costly to manufacture
Solution Approach 1:
The frame is divided into modular sections including a front section, middle section, and rear section that can be independently manufactured and assembled. This segmentation allows for optimized material distribution and reduced overall weight while maintaining structural integrity through standardized connection points and modular architecture.
Solution Approach 2:
The patent employs composite material construction for the frame, combining materials with different properties to achieve optimal strength-to-weight ratio. The frame structure integrates materials that provide both rigidity for resisting bending and torsional forces and reduced weight compared to traditional single-material construction.
2Power
If multiple drivetrain and energy storage components are integrated into electric ATVs, then high torque output is achieved, but the configuration becomes bulky and inflexible
Solution Approach 1:
The drivetrain system is segmented into independent modular units including electric motors, battery assemblies, and final drive units. Each module can be independently positioned, removed, or replaced without affecting other components, providing flexibility in configuration while maintaining high torque output capability through coordinated operation of multiple modules.
Solution Approach 2:
The drivetrain components are designed with universal mounting interfaces and standardized connection protocols that allow the same components to serve multiple functions or be configured in different arrangements. This multi-functionality enables the system to adapt to various torque requirements and terrain conditions without requiring specialized components for each scenario.
3Reliability
If traditional battery installation methods are used in electric ATVs, then battery assembly is secured, but maintenance downtime increases due to disassembly and reconnection requirements
Solution Approach 1:
The battery system is designed as a self-contained modular assembly with integrated electrical connections and mounting mechanisms. This segmentation allows the entire battery unit to be installed or removed as a single component without requiring disassembly of electrical connections or reconnection procedures, significantly reducing maintenance downtime while maintaining secure installation through dedicated mounting points.
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 configuration enhances the vehicle's strength, reduces weight and manufacturing costs, improves adaptability to different terrains, and decreases maintenance time by allowing for easier battery access and modular component upgrades.
Implementation Method 1
at least one electric motor mounted to at least one of the front portion, the middle portion and the rear portion of the frame assembly
Implementation Method 2
at least one battery assembly electrically coupled to the at least one electric motor for providing electric power to the at least one electric motor
Data Source
AI summary
Electric and hybrid off-road vehicles, accessories and frames therefor are provided. An off-road vehicle comprises a frame assembly, at least one front and rear wheel, at least one electric motor, at least one battery and at least one final drive unit operatively coupled to at least one wheel. The electric motor is operatively coupled to the final drive unit for transferring torque from the electric motor to the wheel. A battery assembly having electric components integrated thereto is provided. A structural battery is configured to provide a structural connection between at least two of a top, bottom, front and rear portions of a frame assembly for an off-road vehicle, and for receiving loads therefrom. Improved drivetrain arrangements provide flexibility in operating an off-road vehicle and improve overall performance. The environmental impact of off-road vehicles is reduced. Weight and complexity of off-road vehicle frames are reduced without affecting stability or safety.