The u-type electric AXLE drivetrain for vehicles

Abstract

The U-type electric axle drivetrain in vehicles has the following characteristics: The motor and gear set are separated from the differential gear set and solid axle. The motor and gear set are connected to the differential gear set and solid axle by joints and drive shaft to the rear. The motor shaft is parallel or nearly the drive shaft to the rear when viewed from above. The motor and gear set can be attached to the chassis in two ways: The motor shaft is parallel or nearly and the motor shaft is perpendicular or nearly to the solid axle when viewed from above. Separating the motor and gear set from the differential gear set and solid axle, this causes the differential gear set and solid axle to have a reduced unsprung mass. As a result, vibration is reduced as well. In addition, the differential gear set and solid axle share parts with engine-driven axle, making it more cost-effective.

Description

[0001] THE U-TYPE ELECTRIC AXLE DRIVETRAIN FOR VEHICLES

[0002] Field of the Invention

[0003] The present invention is related to the field of automotive engineering, specifically in solid axle drivetrain utilizing electric motors to drive the axle shaft.

[0004] Background of the Invention

[0005] The conventional solid axle drivetrain utilizes a large and heavy engine to drive the axle shaft. The advancement in electric motor technology has resulted in motors becoming more powerful and more compact, displacing the engine. Multiple techniques have emerged for driving the axle shaft with electric motors with the 3 main components, namely 1. motor and gear set 2. differential gear set and 3. solid axle as described in the following examples:

[0006] A US patent publication number US 11,959,548 B 1 with the title of invention “AXLE ASSEMBLY AND METHOD OF CONTROL” disclosed a structure comprising 3 main components, namely motor and gear set, differential gear set, and solid axle, where the motor shaft aligns perpendicular to the solid axle. The integration of the main components increases both axle’s unsprung mass and vibration. Nonetheless, the in-line solid axle design resembles the engine-driven axle, thereby enabling cost efficiency.

[0007] A US patent publication number US 11,623,513 B2 with the title of invention “ELECTRIC DRIVE AXLE IN A VEHICLE” disclosed a structure comprising 3 main components, namely motor and gear set, differential gear set, and solid axle, where the motor shaft aligns parallel with the solid axle. The integration of the main components increases both axle’s unsprung mass and vibration. Nonetheless, the in-line solid axle design resembles the engine-driven axle, thereby enabling cost efficiency.

[0008] A US patent publication number US 2021 / 0252959 Al with the title of invention “ELECTRIC SOLID AXLE” disclosed a structure comprising 3 main components, namely motor and gear set, differential gear set, and solid axle, with a common axis between the motor shaft and solid axle. The integration of the main components increases both axle’s unsprung mass and vibration. Nonetheless, the in-line solid axle design resembles the engine-driven axle, thereby enabling cost efficiency.

[0009] A US patent publication number US 2020 / 0346506 Al with the title of invention “ELECTRIC AXLE DRIVETRAIN ASSEMBLY” disclosed an integrated structure comprising a motor and gear set, and differential gear set, separating from the solid axle. The separation of the main components reduces the axle's unsprung mass and vibration. However, the in-curve design of the solid axle, curves around the differential gear set, introduces the potential for unbalance in the solid axle, resulting in less loading capacity and manufacturing challenges which are difficult to manufacture than the in-line solid axle.

[0010] A US patent publication number US 2019 / 0100095 Al with the title of invention “SUSPENSION REAR AXLE COMPRISING TWO ELECTRIC MOTORS” disclosed a structure comprising two motors and gear set and a separate solid axle without a differential gear set. The separation of the main components contributes to a reduction in unsprung mass and vibration. Each motor includes a drive shaft for driving forward. However, the inclusion of two motors has increased overall cost.

[0011] According to the present invention, it disclosed a U-type electric axle drivetrain involving the separation of the motor and gear set from the differential gear set and solid axle. The separation of the main components results in a reduction of the unsprung mass and subsequently decreases vibrations. The motor and gear set are connected to the differential gear set and solid axle by joints and drive shaft to the rear. The motor shaft aligns parallel or nearly parallel to the drive shaft to the rear when viewed from above. The motor and gear set can be attached to the chassis in two ways: The motor shaft aligns parallel or nearly parallel, and perpendicular or nearly perpendicular to the solid axle when viewed from above. Additionally, the solid axle is inline design, resembling the engine-driven axle, thereby enabling cost-efficiency.

[0012] Summary of the Invention

[0013] The U-type electric axle drivetrain in vehicles has the following characteristics: the motor and gear set are separated from the differential gear set and solid axle. The motor and gear set are connected to the differential gear set and solid axle by joints and drive shaft to the rear. The motor shaft aligns parallel or nearly parallel to the drive shaft to the rear when viewed from above. The motor and gear set can be attached to the chassis in two ways: The motor shaft aligns parallel or nearly parallel and perpendicular or nearly perpendicular to the solid axle when viewed from above.

[0014] Separating the motor and gear set from the differential gear set and solid axle causes the differential gear set and solid axle to have a reduced unsprung mass. As a result, vibration is reduced as well. In addition, the differential gear set and solid axle share parts with engine-driven axle, contributing to more cost-effective. Detailed Description of the Invention

[0015] According to Fig. 1, the U-type electric axle drivetrain for vehicles comprising 8 main parts connected in sequence as follows: 1. a motor (1) 2. a first gear set 3. a first joint (7) 4. a drive shaft to the rear (8) 5. a second joint (9) 6. a second gear set 7. a differential gear, and 8. a solid axle (15), with a motor shaft (2) aligned parallel or nearly parallel to the drive shaft to the rear (8) when viewed from above. The motor (1) can be attached to the chassis in the form of two ways, including the way that the motor shaft (2) aligned parallel or nearly parallel to the solid axle (15) as shown in Fig.2a and perpendicular or nearly perpendicular to the solid axle (15) as shown in Fig.2b when viewed from above. Fig.1 illustrates the motor shaft (2) aligned parallel or nearly parallel to the drive shaft to the rear (8) and the solid axle (15) when viewed from above.

[0016] The motor (1) has a motor shaft (2) aligned parallel or nearly parallel to the drive shaft to the rear (8) when viewed from above, attached to the chassis with a motor carrier (16) in the from of two ways, including the way that the motor shaft (2) aligned parallel or nearly parallel to the solid axle (15) as shown in Fig.2a and perpendicular or nearly perpendicular to the solid axle (15) as shown in Fig.2b when viewed from above.

[0017] The first gear set is a reduction gear using spur gear or helical gear or planetary gear at least 1 set whose function is to reduce the motor speed and transmit torque to the side. Fig.1 shows a reduction gear using spur gear or helical gear of 2 sets: gear (3), (4) and gear (5), (6).

[0018] The first joint (7) is a typical joint, generally using a cardan joint.

[0019] The drive shaft to the rear (8), generally uses a propeller shaft with sliding yoke. Its function is to transmit torque to the rear of the motor (1) and absorb vibrations together with the first joint (7) and second joint (9) from the second gear set, differential gear, and solid axle (15) to the motor (1) and first gear set, they are aligned parallel or nearly parallel to the motor shaft (2) when viewed from above.

[0020] The second joint (9) is a typical joint, generally using a cardan joint.

[0021] The second gear set is a reduction gear using a gear set selecting from at least one of spur gear, helical gear, bevel gear or planetary gear, functioning in reducing the motor speed and transmitting torque to the side. Fig.1 illustrates a reduction gear using spur gear or helical gear of 1 sets : gear (10), (11). The differential gear generally used a typical differential gear mounted in a differential box (12) that distributes torque to the left axle shaft (13) and right axle shaft (14). Fig.l shows only the differential box (12).

[0022] The solid axle (15) generally used a typical solid axle or portal axle. It is a solid tube with wheels mounted at both ends, fixed or with a steering system. Internally, there is a second gear set, differential gear, left axle shaft (13) and right axle shaft (14) which are linked to the chassis with typical leaf springs or link arms.

[0023] Brief Description of the Drawings

[0024] FIG. 1 illustrates a partial section view of the U-type electric axle drivetrain. FIG. 2a illustrates one embodiment of the motor attached to the chassis in the way that the motor aligns parallel to the chassis.

[0025] FIG. 2b illustrates one embodiment of the motor attached to the chassis in the way that the motor aligns perpendicular to the chassis.

[0026] Best Mode of the Invention As described in the Detailed Description of the Invention.

[0027] Industrial Applicability

[0028] The U-type electric axle drivetrain for vehicles is applied to the automotive industry addressing solid axle drivetrain utilizing electric motors to drive the axle.

Claims

AMENDED CLAIMS received by the International Bureau on 17 September 2025 (17.09.2025)1. A U-type electric axle, being electric drive axle, part of a vehicle's suspension system, which originally comprising a motor shaft and propeller shaft arranged inline or nearly inline and perpendicular or nearly perpendicular to a solid axle when viewed from above, and u- type electric axle having different arrangements to save space for small / midsize trucks and still share most of the same parts, comprising three main parts: conventional motor (1) and drivetrain (3, 4, 5, 6), such as gearsets, with the output shafts parallel or nearly parallel to the motor shaft (2) when viewed from above wherein the motor (1) and drivetrain (3, 4, 5, 6) are mounted to the body or chassis; conventional propeller shaft (8) and joint (7, 9), with the joint's input / output shafts in line or nearly in line with the propeller shaft (8) when viewed from above, wherein the input shaft is connected to the output shaft of the first main part, and the output shaft is connected to the input shaft of the third main part; conventional solid axle (15) and drivetrain (10, 11, 12, 13, 14), such as the differential, with the input shaft parallel or nearly parallel to the solid axle (15) when viewed from above wherein the solid axle (15) is mounted to the body or chassis using conventional suspension; wherein the U-type electric axles, with motor shaft (2), propeller shaft (8), and solid axle (15) — are parallel or nearly parallel when viewed from above.[0001][0002]STATEMENT UNDER ARTICLE 19 (1)[0003]Statement regarding inventive step[0004]Since the original claim for U-type electric axles is unclear, the original claim and Figures 2a and 2b are cancelled, and the new claims are completely rewritten as in the Amended Claims and are summarized as follows:[0005]U-type electric axles consist of three main parts:[0006]1. Conventional motor (1) and drivetrain (3, 4, 5, 6), output shaft parallel to the motor shaft (2), mounted to the body or chassis.[0007]2. Conventional propeller shaft (8) and joint (7, 9), connected to the output shaft of the first main part and the input shaft of the third main part.[0008]3. Conventional solid axle (15) and drivetrain (10, 11, 12, 13, 14), input shaft parallel to the solid axles, mounted to the body or chassis using conventional suspension.[0009]U-type electric axles— with motor shaft (2), propeller shaft (8), and solid axle (15)— are parallel when viewed from above.[0010]The parallel arrangement of three main conventional parts of U-type electric axles is unique and has significantly less unsprung mass and saves more space than conventional electric solid axles, so U-type electric axles have an inventive step. It also compares the differences from other reference patents as follows:[0011]Y-Dl / EP4411177A1[0012]-The motor and solid axle are mounted to the chassis using a suspension and are not separated.[0013]-There is no propeller shaft.[0014]Y-D2 / W02015019085A2[0015]-There are two propeller shafts.[0016]-The solid axle has an input shaft not parallel to the solid axle.[0017]A / US20110259657A1[0018]-There is no propeller shaft.[0019]-There is no solid axle.[0020]A / US20210188031A1[0021]-This unique propeller shaft is one type of the conventional propeller shaft (8).[0022]A / US6431298B1[0023]-The motor and solid axle are mounted to the chassis using a suspension.[0024]-There is no propeller shaft.[0025]-The solid axle has an input shaft not parallel to the solid axle.

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