Structural Battery Frame Assembly for Lightweight Off-Road EVs
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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 featuring a frame assembly with a front, middle, and rear portion, equipped with at least one electric motor, a battery assembly, and a final drive unit. This configuration allows for improved torque transfer and reduced weight, while also incorporating a structural battery assembly that serves as a load-bearing component, enhancing the vehicle's structural integrity and reducing the need for additional mounting brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional space frames are used to provide necessary strength and rigidity, then the frame can resist bending and torsional forces, but the frame becomes highly complex and uses significant material leading to high manufacturing costs and weight
Solution Approach 1:
The battery assembly is integrated into the frame structure to serve dual purposes: as an energy storage component and as a structural element that provides bending and torsional rigidity. This merging eliminates the need for separate structural supports, reducing overall frame complexity and material usage while maintaining required strength
Solution Approach 2:
The battery assembly performs multiple functions simultaneously: it stores electrical energy, provides structural support for the frame, and acts as a mounting platform for other vehicle components. This multi-functionality reduces the total number of components needed and simplifies the overall vehicle architecture
2Use of energy by moving object
If traditional battery assemblies are used in electric off-road vehicles, then the vehicle can operate electrically, but the configuration becomes bulky and inflexible with predetermined arrangements that cannot be adapted to users' needs
Solution Approach 1:
The battery assembly is merged with the frame structure itself, allowing the energy storage system to be customized in shape, size, and placement according to specific application requirements without compromising structural integrity. This enables flexible adaptation to different user needs and terrain requirements
3Power
If complex drivetrain components are used to provide high torque output, then the vehicle can pull heavy equipment, but the components become bulky and require significant maintenance downtime due to disassembly and reassembly
Solution Approach 1:
The drivetrain is segmented into modular components (electric motor, battery assembly, final drive units) that can be independently accessed and serviced. The battery assembly's integration with the frame provides easy access points for maintenance without requiring complete disassembly of the vehicle structure
Solution Approach 2:
The modular design enables quick replacement and maintenance of drivetrain components by the operator without requiring extensive technical expertise or specialized equipment, significantly reducing maintenance downtime
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 achieves a more efficient and cost-effective off-road vehicle by reducing weight and manufacturing complexity, while improving torque output and maintaining efficiency. The structural battery assembly enhances the vehicle's structural integrity and simplifies frame design, leading to a more robust and reliable off-road vehicle.
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.