Modular Rolling Chassis Assembly for Lighter EV Skateboard Platforms
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Solution Overview
Problem
Current skateboard chassis architectures for electric vehicles are heavy, inflexible, and prone to structural redundancies and galvanic corrosion, with battery housings providing no structural functionality beyond storing energy, leading to inefficiencies and limited design flexibility.
Innovation Solution
A modular rolling chassis assembly with a central housing and detachable front and rear suspension modules that house an electric energy storage system, allowing for customization and reuse of components, reducing redundant structures and integrating structural functionality into the battery housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral frame/chassis/body structure is used for skateboard chassis architecture, then structural strength and rigidity are improved, but weight increases and design flexibility decreases
Solution Approach 1:
The patent divides the integral frame structure into separate modular components: a chassis assembly, a body-in-white, and a suspension system. These modules can be independently manufactured and assembled, reducing overall weight while maintaining structural strength through optimized local designs in each module.
2Stability of the object's composition
If an integral frame/chassis/body structure is used for skateboard chassis architecture, then structural rigidity is improved, but design flexibility and adaptability worsen
Solution Approach 1:
By segmenting the chassis into separate modules (chassis assembly, body-in-white, suspension system), each module can be independently designed and optimized for specific functions. This allows different configurations and adaptations without compromising the rigidity of individual structural components.
Solution Approach 2:
The modular architecture enables dynamic reconfiguration of the vehicle system. Modules can be assembled in different arrangements to create various vehicle types (trucks, vans, buses) while maintaining structural integrity through standardized connection interfaces.
3Reliability
If traditional battery housings are used in skateboard chassis architecture, then battery protection is improved, but structural functionality is reduced and galvanic corrosion risk increases
Solution Approach 1:
The patent merges the battery housing function with the chassis structural components. The battery pack is integrated into the chassis assembly rather than being housed in a separate protective enclosure, eliminating redundant structures and reducing galvanic corrosion risks by using compatible materials throughout the structural system.
4Ease of repair
If battery housing is separate from chassis frame, then battery serviceability is improved, but structural weaknesses and galvanic corrosion opportunities increase
Solution Approach 1:
The battery pack is designed as a removable module within the chassis assembly, allowing easy serviceability while maintaining structural integrity through integrated mounting points and connection interfaces that preserve the structural load path.
Data Source
AI summary
A modular rolling chassis assembly for an electric vehicle includes a central housing extending from a front end to a rear end to define a central cavity. An electric energy storage system (ESS) is disposed or housed in the central cavity. A front suspension module is connected to the front end of the central housing and a rear suspension module is connected to rear end of the central housing to complete a modular build for the rolling chassis assembly which improves on the large, heavy and cost intensive integral chassis associated with the prior skateboard architectures.