Canoo has been granted a patent for a manufacturing process that allows for the production of electric vehicles with a more compact design. The process involves manufacturing the upper body portion and lower body platform separately and then merging them. This allows for ease of manufacture and includes steps such as e-coating and aligning the chassis. The process also includes end-of-production vehicle testing and finishing. GlobalData’s report on Canoo gives a 360-degree view of the company including its patenting strategy. Buy the report here.

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According to GlobalData’s company profile on Canoo, Battery pack swapping was a key innovation area identified from patents. Canoo's grant share as of September 2023 was 52%. Grant share is based on the ratio of number of grants to total number of patents.

Manufacturing process for an electric vehicle with separate parts

Source: United States Patent and Trademark Office (USPTO). Credit: Canoo Inc

A recently granted patent (Publication Number: US11772725B2) outlines a manufacturing process for electric vehicles that eliminates the need for a traditional paint shop. The process involves the manufacturing of an upper body portion and a lower body portion, which are then merged to form the assembled electric vehicle.

The upper body portion is manufactured by creating a top hat structure using colored thermoplastic components and closures. This top hat is then e-coated, a process that involves applying an electrically charged coating to the surface for improved durability. Wiring harnesses, body panels, doors, fittings, HVAC ducts and vents, glass, and interior components are all applied to the upper body frame.

Simultaneously, the lower body portion is manufactured by providing a ladder frame that encloses battery elements on the sides. The ladder frame is also e-coated, and the battery elements and other components of the skateboard platform are assembled with the ladder frame. The ladder frame also receives a drivetrain, control system, HVAC system, drivetrain cooling system, energy storage system, and energy storage heating and cooling system.

Once both the upper and lower body portions are complete, they are merged to form the assembled electric vehicle. The chassis of the vehicle is aligned, and end-of-production vehicle testing is performed. This testing includes evaluating the cause-effect relationship between controls within the upper body portion and components within the lower body portion.

Notably, the manufacturing process described in the patent does not require a paint shop. Instead, the use of colored thermoplastic components and e-coating provides the desired aesthetic and durability for the vehicle's exterior.

Overall, this patented manufacturing process offers a streamlined and efficient method for producing electric vehicles. By eliminating the need for a paint shop, the process reduces costs and environmental impact while still achieving a high-quality finish.

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GlobalData, the leading provider of industry intelligence, provided the underlying data, research, and analysis used to produce this article.

GlobalData Patent Analytics tracks bibliographic data, legal events data, point in time patent ownerships, and backward and forward citations from global patenting offices. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.