Modular Pickup Truck Frame Overlap Joint for Longer Battery Packs
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Solution Overview
Problem
Existing pick-up truck chassis frame structures have limited rechargeable energy storage system package volume due to a transition zone between the mid bay rails and the rear bay rails, which restricts the length of the rechargeable energy storage system package volume.
Innovation Solution
A modular pick-up truck chassis frame structure is designed with a pair of elongated mid bay rails and rear bay rails that form an overlapping joint, with reinforcement members connecting the rails to maximize the volume of the rechargeable energy storage system. The rechargeable energy storage chamber is positioned between the mid bay rails and extends rearward, and between the rear bay rails within the overlapping joint region, allowing for increased package volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If a transition zone is provided between mid bay rails and rear bay rails for structural connection, then the frame structure integrity is maintained, but the rechargeable energy storage system package volume is limited
Solution Approach 1:
The frame structure is divided into distinct mid bay rails and rear bay rails segments that overlap and connect through reinforcement members, allowing the energy storage system to extend into the transition zone while maintaining structural integrity through modular connection points
Solution Approach 2:
The reinforcement members extend outboard from the rails in addition to connecting them longitudinally, creating a three-dimensional connection structure that provides structural strength without occupying additional longitudinal space that would limit battery package volume
2Strength
If reinforcement members are added to connect mid bay rails and rear bay rails, then the frame structure strength is improved, but the rechargeable energy storage system package volume is reduced
Solution Approach 1:
The reinforcement members serve multiple functions: they connect the mid bay rails to rear bay rails for structural strength, extend outboard to provide additional connection points, and are positioned to minimize interference with the energy storage system package volume
Solution Approach 2:
Instead of having the reinforcement members run longitudinally along the rails (which would occupy space), they extend outboard perpendicular to the rail length, providing structural connection while clearing the longitudinal space needed for maximum energy storage system volume
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
The modular chassis frame structure effectively maximizes the rechargeable energy storage system package volume, enabling longer battery packs and enhancing the electric vehicle's range and performance.
Implementation Method 1
The first pair of reinforcement members and the second pair of reinforcement members are welded to the pair of elongated mid bay rails and the pair of elongated rear bay rails.
Data Source
AI summary
A vehicle frame structure including a pair of elongated mid bay rails with a cross beam extending between rear ends of the pair of mid bay rails. A pair of elongated rear bay rails define an overlapping joint with the pair of elongated mid bay rails, wherein a first pair of reinforcement members connect forward ends of the pair of rear bay rails to the pair of elongated mid bay rails and a second pair of reinforcement members connect rearward ends of the pair of mid bay rails to the pair of elongated rear bay rails.