Structural Battery Assembly for Lightweight Off-Road Frames
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Solution Overview
Problem
Existing off-road vehicles, particularly electric and hybrid recreational off-road vehicles, face challenges such as high manufacturing costs, complexity, and weight due to traditional frame designs. Additionally, current electric off-road vehicle configurations are often bulky, inflexible, and require significant maintenance downtime due to complex drivetrain and energy storage systems.
Innovation Solution
The proposed solution involves an off-road vehicle design with a frame assembly divided into front, middle, and rear portions, featuring at least one electric motor mounted to each portion, a battery assembly electrically coupled to the motors, and a final drive unit operatively coupled to the wheels. This configuration allows for improved torque distribution and reduced maintenance through modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional frame designs are used to provide necessary strength and rigidity, then the frame can resist bending and torsional forces, but the frame becomes highly complex and heavy
Solution Approach 1:
The patent combines the frame structure with the battery assembly housing into a unified structural unit. The battery assembly housing serves dual purposes: it protects the battery components and simultaneously functions as a structural frame element that resists bending and torsional forces. This merging eliminates the need for a separate, complex traditional frame while maintaining necessary strength and rigidity.
2Strength
If traditional frame designs are used to provide necessary strength and rigidity, then the frame can resist bending and torsional forces, but the frame becomes heavy
Solution Approach 1:
The patent merges the frame function with the battery assembly housing, eliminating redundant structural components. The battery housing is designed to bear structural loads, thereby reducing the need for additional frame materials and reducing overall vehicle weight while maintaining necessary strength.
Solution Approach 2:
The battery assembly housing is designed to perform multiple functions: it protects the battery, provides structural support, and resists bending and torsional forces. This multi-functionality reduces the need for separate dedicated frame components, thereby reducing overall weight.
3Power
If complex drivetrain and energy storage components are used in electric off-road vehicles, then the vehicle can provide high torque output, but the configuration becomes bulky and inflexible
Solution Approach 1:
The patent divides the drivetrain into modular components distributed throughout the vehicle structure. The battery assembly is segmented into multiple modules that can be independently positioned and configured. This segmentation allows for flexible arrangement of high-power components without creating a bulky centralized configuration, enabling high torque output with reduced complexity.
4Power
If complex drivetrain and energy storage components are used in electric off-road vehicles, then the vehicle can provide high torque output, but the configuration becomes bulky
Solution Approach 1:
The battery and drivetrain components are segmented into distributed modules rather than centralized units. This allows efficient space utilization and reduces overall vehicle volume while maintaining high power output capability through optimized component placement and compact modular design.
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 design enhances the off-road vehicle's performance by reducing weight and manufacturing costs while improving flexibility and reducing maintenance downtime. The modular configuration allows for easier adaptation to user needs and improved energy efficiency.
Implementation Method 1
a battery pack received in the chamber of the housing, at least one electrical connection extending from the battery pack towards the exterior side of the housing
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.