Scalable Vehicle Frame Platform for Multi-Segment EV Production
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Solution Overview
Problem
Existing vehicle manufacturing processes require distinct frames for different vehicle segments, leading to expensive and time-consuming product development, high waste, and increased business risk due to diverse components and constructions.
Innovation Solution
A modular platform with a scalable frame structure that includes adjustable rails and cross-members, allowing for customization of wheelbase, wheel track, and ground clearance, using extruded components to maintain structural integrity and reduce part variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If distinct frames are designed and manufactured for different vehicle segments, then each vehicle type can be optimized for its specific requirements, but product development becomes expensive and time-consuming with high waste
Solution Approach 1:
The patent applies universality by designing a single modular frame platform that can serve multiple vehicle segments (SUVs, sedans, coupes) through configurable components. The frame includes adjustable wheelbases, interchangeable body mounts, and standardized battery pack interfaces, allowing one platform to produce various vehicle types without requiring entirely distinct frame designs for each segment.
Solution Approach 2:
The frame is segmented into modular components including front and rear frame portions, adjustable wheelbase sections, and interchangeable body mounting points. This segmentation allows specific portions of the frame to be configured or replaced depending on the desired vehicle type, enabling customization while maintaining overall platform consistency.
2Adaptability or versatility
If distinct frames with diverse components are manufactured for different vehicle segments, then each vehicle can be optimized for its specific requirements, but manufacturing processes become complex and time-consuming
Solution Approach 1:
The frame design uses universal mounting interfaces and standardized component connections that work across all vehicle segments. The same basic frame structure can accommodate different body styles, suspension types, and battery configurations through simple component swaps rather than redesigning the entire frame construction.
Solution Approach 2:
Different portions of the frame can be locally optimized for specific vehicle requirements while maintaining overall structural consistency. For example, the front frame portion can be configured for SUV applications while the rear portion remains standardized, or wheelbase lengths can be adjusted locally without affecting other frame sections.
3Reliability
If distinct frames are designed for different vehicle segments, then each vehicle type can meet its specific performance requirements, but waste and business risk increase
Solution Approach 1:
The modular frame design allows components to be reused across different vehicle productions. When producing different vehicle segments from the same platform, frame portions, mounting brackets, and structural elements can be recovered and reused in subsequent vehicle assemblies, significantly reducing manufacturing waste compared to producing entirely distinct frames for each segment.
Solution Approach 2:
A single frame platform design serves multiple vehicle segments, eliminating the need to manufacture entirely separate frame structures for each vehicle type. This universal platform approach reduces material waste from unused components and lowers business risk by spreading development costs across multiple product lines.
Data Source
AI summary
A modular platform for a vehicle includes a scalable frame structure. The scalable frame structure includes a front frame portion configured to receive a front vehicle suspension, a rear frame portion configured to receive a rear vehicle suspension, and a pair of rails extending between the front frame portion and the rear frame portion along opposing sides of the frame structure. A length of the pair of rails is scalable to adjust a wheelbase of the vehicle between the front vehicle suspension and the rear vehicle suspension. A battery pack is supported on the frame structure.