Chassis assemblies for electric vehicles

A chassis assembly configured for use with a frame of a vehicle, the chassis assembly comprising:

• a first side rail and a second side rail, the first side rail being generally parallel to, and horizontally offset from, the second side rail;
• and
• a plurality of cross members attached to the first and second side rails, the plurality of cross members comprising a plurality of first cross members, each first cross member of the plurality of first cross members having a first cross member body, a first flange, and a second flange,
• the first cross member body having a length that extends from a first end of the first cross member body to a second end of the first cross member body, the first cross member body having a closed cross sectional configuration that is uniform across the length of the first cross member body,
• the first flange secured to the first end and having a plurality of orifices and an aperture that is sized to receive insertion of the first cross member body, the plurality of orifices of the first flange configured to each receive a mechanical fastener to attach the first flange to the first side rail, and
• the second flange secured to the second end and having a plurality of orifices and an aperture that is sized to receive insertion of the first cross member body, the plurality of orifices of the second flange configured to each receive another mechanical fastener to attach the second flange to the second side rail,
• wherein the plurality of first cross members comprises a proximate first cross member, an intermediate first cross member, and a distal first cross member, and
• wherein the plurality of cross members further include a plurality of second cross members having a cross sectional configuration that is different than the closed cross sectional configuration of the first cross member body, the plurality of second cross members comprising a front second cross member and a rear second cross member, the front second cross member being coupled to a front end of each of the first and second side rails, the rear second cross member being coupled to a rear end of each of the first and second side rails, and
• wherein the front second cross member and the proximate first cross member define, at least in part, a first space, and wherein the chassis assembly further includes a first battery mounting assembly having a cage assembly configured for secure placement of one or more batteries in an interior area of the cage assembly, at least a portion of the cage assembly positioned above the first space, and wherein the cage assembly is directly coupled to only one of the first side rail and the second side rail.

A chassis assembly configured for use with a frame of a vehicle, the chassis assembly comprising:

• a first side rail that extends between a first end and a second end of the first side rail;
• a second side rail that extends between a first end and a second end of the second side rail, the first and second side rails being parallel to each other in a first direction and separated by a space in a second direction, the second direction being orthogonal to the first direction;
• and
• a first battery mounting assembly having a cage assembly configured for secure placement of a plurality of batteries in an interior area of the cage assembly, at least a portion of the cage assembly positioned above the space, the cage assembly being directly coupled to only one of the first side rail and the second side rail to provide a degree of float of the cage assembly between the first and second side rails in a manner that can protect the integrity of the plurality of batteries, and wherein the cage assembly is configured secure a plurality of batteries to the cage assembly in a vertically stacked arrangement.

A chassis assembly configured for use with a frame of a vehicle, the chassis assembly comprising:

• a first side rail that extends in a first direction between a first end and a second end of the first side rail;
• a second side rail that extends in the first direction between a first end and a second end of the second side rail, the first and second side rails being parallel to each other in the first direction and separated by a space in a second direction, the second direction being orthogonal to the first direction, each of the first and second side rails have a base segment, a first segment, and a second segment, the first and second segments extending in the second direction from opposing ends of the base segment, and wherein the base segment, the first segment, and the second segment define a recess;
• a first plurality of suspension mounts coupled to an outer surface of the base segment of the first side rail, and a second plurality of suspension mounts coupled to an outer surface of the base segment of the second side rail;
• and
• a plurality of stiffeners, wherein, for each of the first and second side rails, a stiffener of the plurality of stiffeners is secured to a portion, but not all, of at least the base segment, each stiffener of the plurality of stiffeners being positioned on a corresponding one of the first side rail or the second side rail that aligns with at least one of the first plurality of suspension mounts and the second plurality of suspension mounts,
• wherein each suspension mount of the first and second plurality of suspension mounts is coupled by at least one mechanical fastener passing through the suspension mount, the outer surface of the base segment, and the stiffener such that the stiffener is coplanar with the adjacent suspension mount;
• and wherein the base segment, the first segment, and the second segment define a side rail recess configured for receiving placement of components of the chassis assembly.