Electric vehicle
The electric vehicle's modular block structure addresses inefficiencies in conventional production by enabling off-line assembly and reduced costs through specialized block production, enhancing customization and efficiency.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ZONA ENG & DESIGN SAS DI ZONA MAURO & C
- Filing Date
- 2025-11-10
- Publication Date
- 2026-05-21
AI Technical Summary
Conventional automobile production methods are inefficient and costly, with robots operating in an architecture designed for manual assembly, leading to scattered wiring and high investment costs, lacking innovation in vehicle design.
An electric vehicle structure composed of three separate blocks - front, central, and rear - connected by removable members, minimizing wiring and allowing off-line assembly in a single container, with each block having distinct functions and produced in specialized industrial environments.
Reduces production costs and simplifies assembly by eliminating traditional assembly lines, enabling modular production in different sites with reduced investment, and allows for customizable vehicle features like active suspension and hybrid capabilities.
Smart Images
Figure IB2025061467_21052026_PF_FP_ABST
Abstract
Description
[0001] “Electric vehicle”
[0002] ****
[0003] Field of the invention
[0004] The present invention relates to electric vehicles, and particularly concerns an electric vehicle of the type indicated in the preamble of the annexed claim 1.
[0005] Background of the invention
[0006] The automotive world, when critically observed from the point of view of its technological "modernity", presents some contradictory aspects that make it a reality almost alien to the usual development trends for other mass-market industrial products. Its singularity had a justification, albeit a very relative one, in the "emotional" nature that the automobile possessed until a few decades ago. In fact, besides having to fulfill the obvious transport functions, it was still an indicator of a taste strictly linked to the character traits of the buyer, even in the context of product segments of modest economic level. Today, having become a "mature" product by virtue of years and production numbers, the automobile has been annihilated in its originality by a series of known factors, including reciprocal plagiarism among manufacturers elevated to a system and the common effort of the latter to propose objects of increasingly lower quality. These phenomena have meant that the aforementioned justification no longer has a place. The choice of an automobile is now to be assimilated to that of a household appliance, with which it now even shares the motor, thanks to the recent "electro-fanaticism". Since it seems that no one has ever proudly compared with a friend the speed of the spin cycle of their washing machine, it is easy to understand now how the comparison between manufacturers has shifted to the field of providing features that not only have nothing to do with transport, but even compromise its safety. On this theme, marketing, the silent killer of any real progress, reigns supreme.
[0007] What was once the "automobile", whose progress was measured in terms of the evolution of vehicle dynamics, on which generations of illustrious designers have worked, today is only a self-propelled means whose technical characteristics are no longer even reported in the information sheets. It follows that once this self-propelled tool is connected to all existing telecommunication standards on the planet and also - why not - to the frequencies of the SETI project (Search for Extraterrestrial Intelligence project), nothing will remain but the comparison on the consumer price.
[0008] If this is the albeit sad trend, it will therefore be worth trying to consider the product as a whole from a broader point of view, seeking a type of construction saving that does not consist in depleting materials or components, but in studying production methods.
[0009] To concretely analyze what happens in a current production line of an automobile qualified as "automated", it is necessary to carefully observe how robots are used in such production lines. Thanks to the use of their characteristics of strength and precision, robots are able to replace humans in every phase of vehicle assembly. However, robots operate in a context that was not designed for their use. In other words, the architecture of the vehicle remains substantially unchanged compared to the times of manual assembly and - with the exception of a few components provided with geometric references - the same sequence of operations is observed. In summary, there is a container (the vehicle body) to be filled and furnished, with rare exceptions that at most pre-assemble a powertrain-suspension assembly to be connected on the lower side. Over everything looms finally the tentacular vegetation of the electrical wiring that - although pre-formed - must be connected by crossing walls, conduits, moving parts and internal coverings. It is useless to emphasize how said process is conceptually linked to the cadenced advancement of a line and the bulk of the means to be built.
[0010] The present invention starts from the desire to propose an alternative construction architecture for an electric vehicle, with particular reference, for example, to a small electric city car.
[0011] Object of the invention
[0012] It is therefore a fundamental object of the present invention to propose an alternative construction architecture for an electric vehicle.
[0013] In particular, an object of the invention is to realize a vehicle in which all functional components that are important from the point of view of the electrical power involved are close to each other, so as to minimize the connection distance and so as to be able to position them in a single container assemblable off-line, which on one hand fulfills a structural function and on the other hand defines the external shape of a significant part of the vehicle.
[0014] Another fundamental object of the invention is to realize a structure of an electric vehicle consisting of several modules having mutually independent functions.
[0015] A further object of the invention is to realize a vehicle structure that can be produced with drastically reduced investment costs compared to those necessary to produce conventional vehicles.
[0016] Summary of the invention
[0017] In view of achieving the aforementioned objects, the invention has for its subject an electric vehicle having the general characteristics indicated at the beginning of the present description and characterized in that:
[0018] - the vehicle structure is constituted by three separate blocks, aligned in the longitudinal direction of the vehicle and connected to each other by means of removable connecting members, said blocks including:
[0019] A) a front block comprising:
[0020] - a supporting structure of the front block, preferably made of aluminum alloy, in the form of an annular body including a base body, two side uprignts and an upper cross member connecting the side uprignts, wherein the side uprignts and the upper cross member are defined by a continuous hollow element with a closed section,
[0021] - a front suspension system, including two swing arms that are carried by the base body of the supporting structure of the front block and that support the front wheels of the vehicle,
[0022] - an auxiliary support module, carried by said supporting structure of the front block, and carrying said traction electric motor, a dashboard with an instrument panel, the steering wheel, brake and accelerator pedals and an HVAC system of the vehicle,
[0023] - an electronic vehicle control system, and sensors connected to the electronic control system,
[0024] - an outer casing of said front block, including a windshield, a front bumper, and front light units, B) an intermediate central block that includes:
[0025] - a supporting structure of the central block, including:
[0026] - a hollow platform, carrying therewithin a battery pack for powering the traction electric motor,
[0027] - a rear portal-like structure that rises from the rear end of the platform of the central block, and
[0028] - an upper longitudinal beam connecting the rear portal-like structure of the central block with the upper cross member of the front block,
[0029] - a driver seat and at least one passenger seat carried by said platform of the central block, and
[0030] - guide rails for two sliding side doors,
[0031] C) a rear block including:
[0032] - a supporting structure of the rear block, comprising a base body and a front portal-like structure connected to the rear portal-like structure of the central block,
[0033] - a rear suspension system, including two swing arms that are carried by the base body of the supporting structure of the rear block and that support the rear wheels of the vehicle,
[0034] - rear light units, and
[0035] - a trunk-container, connected in a removable manner to the supporting structure of the rear block and provided with wheels which are displaceable between an inoperative position, when the trunk-container is united with the vehicle, and an operative position, which allows the trunkcontainer to be used as a mobile container on wheels, separately from the vehicle,
[0036] so that the vehicle is devoid of a single platform extending for the entire longitudinal dimension of the vehicle, and said three blocks having mutually mating transverse surfaces connected to each other by means of removable connecting members.
[0037] As is evident from the foregoing, the shape of the vehicle according to the invention departs from typically automotive forms, since a "body", in the conventional sense of this term, no longer exists. The profile of the vehicle thus assumes its own formal autonomy that assimilates it more to the cabins intended to house the operators of self-propelled machines (excavators, dumpers) than to microcars and follows a minimalist approach devoid of any stylistic element or ornamental accessory, in which the function of a front bumper is assigned to inflatable volumes.
[0038] In the vehicle structure according to the invention, the front block combines in itself the functions of structural support for propulsion, steering and braking, road lighting and signaling, instrumentation intended for driving, air conditioning system, electronic control of travel, vehicle attitude sensor system and support of a front suspension assembly. The central block fulfills exclusively structural functions of supporting the seats for the occupants and the travel paths for the sliding doors. The rear block supports the rear suspension assembly, the rear signaling lights and the guides for the removable trunk-container.
[0039] In the vehicle according to the invention, there are therefore no longer any wirings scattered in the volume of the vehicle, but only two printed circuits housed in the longitudinal beam of the central block, with the function of connecting the rear electrical loads.
[0040] In conclusion, the vehicle is devoid of a conventional platform with superimposed elements and is instead constituted by a sequence of autonomous blocks divided by transverse planes and mutually connected with simple removable connecting members (typically bolts).
[0041] The swing arms carrying the front and rear wheels can be configured so as to allow the height of the vehicle relative to the ground and the track of the vehicle to be varied on command.
[0042] The fundamental advantage resulting from the adoption of a vehicle structure according to the present invention consists in the fact that it can be produced with drastically reduced investment costs compared to those necessary to produce conventional vehicles. The front block, the central block and the rear block of the vehicle lend themselves to being produced in even different sites and in different industrial environments. The front block lends itself to being produced in an industry configured for the production of electrical appliances, with criteria and production systems analogous to those normally adopted in this field. The central block requires machining of metallic and plastic materials and the assembly of glass and seats. The rear block can mainly comprise components of plastic material and therefore requires an industrial environment specialized in the production of components of plastic material. The traditional assembly line provided in conventional vehicle production plants is therefore completely disappeared, to the advantage of greater production economy.
[0043] Brief description of the figures
[0044] Figures 1, 2 are two perspective views of a preferred form of embodiment of the vehicle according to the invention,
[0045] figure 3 is an exploded perspective view of the vehicle of figures 1, 2, showing the different blocks constituting the vehicle,
[0046] figures 4-6 are two perspective views and a side view of the front block of the vehicle,
[0047] figure 7 is an exploded perspective view of the main components of the front block of the vehicle,
[0048] figure 8 is a perspective view of the supporting structure of the central block of the vehicle,
[0049] figure 9 is a perspective view of the rear block, with the trunkcontainer removed,
[0050] figure 10 is a perspective view of the rear block, complete with trunkcontainer,
[0051] figure 11 is an exploded perspective view of the rear block and the trunk-container,
[0052] figure 12 is a perspective view of the vehicle showing a sliding door in an open position, and
[0053] figure 13 shows in perspective view a detail of the screw connection between the front block and the central block.
[0054] Detailed description of the invention
[0055] In the drawings, the number 1 indicates as a whole a preferred form of embodiment of the invention. The example refers to an electric vehicle of the "city car" class. The specific example illustrated here is the result of a study aimed at realizing a vehicle with a volume equal to that of an electric car marketed under the name "Smart Fortwo". The choice of this model was not random, since despite its dimensions very similar to those of a heavy quadricycle, it has all the structural and functional characteristics of a real automobile.
[0056] With reference in particular to figure 3, the structure of the vehicle 1 according to the invention comprises a front block 2, an intermediate central block 3 and a rear block 4 provided with a trunk-container 5.
[0057] With reference in particular to figures 4-7, the front block 2 comprises a supporting structure 20, preferably made of aluminum alloy, in the form of an annular body including a base body 20A, two side uprignts 20B and an upper cross member 20C connecting the side uprignts 20B.
[0058] The side uprignts 20B and the upper cross member 20C are defined by a single continuous hollow element, preferably with a closed section, possibly presenting a plurality of stiffening ribs (not illustrated). The front block 2 carries a front suspension system, including two swing arms 21 A carried by the base body 20A of the supporting structure 20 and carrying the front wheels RA of the vehicle.
[0059] With reference in particular to figure 6, in the example, the swing arms 21 are mounted articulated around a transverse axis 21 A to a rear portion of the base body 20A and extend forward (with reference to the direction of advancement of the vehicle) relative to the articulation axis 21 A carrying at their front ends the wheels RA. Elastic means and damping means of any known type (not illustrated) are associated with the swing arms 21.
[0060] With reference in particular to figure 5, the front block 2 includes an auxiliary support module 22 carried by the supporting structure 20 of the front block and carrying in turn a motor assembly M, which in the example is constituted by two electric motors M1, M2 whose output shafts are connected by means of universal joints and half-shafts 23 to the front wheels RA. The support module 22 also carries a dashboard 24 with the steering wheel 25 and brake and accelerator pedals 26.
[0061] The front block 2 also carries the steering system (not illustrated), which can be of any known type.
[0062] The auxiliary support module 22 also supports an electronic control unit E of the vehicle (see figure 7)) which receives signals from a plurality of sensors of various types, including vehicle attitude sensors. The supporting structure 20 of the front block also carries the windshield W (figure 4), blowing fans F part of the HVAC system ("Heating Ventilation and Air Conditioning") of the vehicle, front light units L with LED sources, electronic groups D acting as drivers for the electric motors M1 , M2, a radiator R and a pump P part of the HVAC system and the pump assembly 27 of the braking system of the vehicle. The external body of the front block 2 presents bumpers 29 in the form of inflatable elements.
[0063] With reference in particular to figure 8, the intermediate central block of the vehicle structure according to the invention, indicated as a whole by 3, comprises a supporting structure 30, preferably made of aluminum alloy, including a hollow platform 30A, arranged to receive inside it the battery pack for powering the traction electric motors of the vehicle, a rear portallike structure 30B that rises from the rear end of the platform 30A and that includes two side uprignts 31 connected to each other by an intermediate cross member 32 and by an upper cross member 33. An upper longitudinal beam 30C connects the upper cross member 33 of the portal-like structure 30B with the cross member 20C of the front block 2.
[0064] The supporting structure 30 of the central block 3 also carries the guide rails for two sliding side doors 34 (figure 12 shows a door 34 in an open position).
[0065] With reference to figures 9-11, the rear block 4 comprises a supporting structure 40, preferably made of aluminum alloy, including a base body 40A and a front portal-like structure 40B including two side uprignts 41 connected by an upper cross member 42. The front portal-like structure 40B of the rear block 4 is intended to be connected to the rear portal-like structure 30B of the central block 3.
[0066] The rear block 4 further includes a rear suspension system comprising a pair of swing arms 43 mounted articulated to the base portion 40A of the supporting structure 40 and carrying the rear wheels RP. Elastic means and damping means of any known type (not illustrated) are associated with the swing arms 43.
[0067] Associated with the rear block 4 is a trunk-container 5 that can be completely separated from the rear block 4 (see figure 11) and that is equipped with wheels (not illustrated) movable between an inoperative position, when the trunk-container 5 is mounted on the rear block 4, and an operative position, when the trunk-container 5 is separated from the rear block 4, so that it can be used as a mobile container on wheels and manually movable.
[0068] With reference again to figure 3, the central block 3 defines with its front surface a transverse connection plane to a corresponding rear transverse plane of the front block 2. In the same way, the rear end of the central block 3 defines a transverse connection plane to a front transverse plane of the rear block 4. Said transverse planes of the three blocks 2, 3, 4 are connected to each other by means of removable connecting members, for example bolts (not illustrated).
[0069] It can be provided that the front swing arms 21 and the rear swing arms 43 are part of active suspension systems capable of varying on command the height of the vehicle relative to the ground, and also the track of the vehicle (in which case the arms must also possess an additional degree of freedom, consisting of a rotation around a vertical axis at the portion of connection to the vehicle structure).
[0070] According to a further preferred characteristic, the trunk-container 5 can also contain a power generator composed of an internal combustion engine and related fuel tank, for recharging the battery pack of the vehicle in the case of longer journeys. In this case the electric vehicle transforms into a hybrid vehicle. This solution reduces the load capacity of the trunkcontainer, but can be useful when it is desired to equip the vehicle with an extended range.
[0071] Figure 13 shows a detail of a connection by means of bolts between the lower portion 20A of the supporting structure 20 of the front block 2 and the lower portion 30A of the supporting structure 30 of the central block 3. Said structures are rigidly connected to each other by means of two series of screws B1 , B2 which engage corresponding series of holes 35 formed in said structures and aligned along two transverse directions, longitudinally spaced from each other. A similar arrangement can be provided in other connection areas between the front block and the central block and in the connection between the central block and the rear block.
[0072] Naturally, the principle of the invention remaining the same, the details of construction and the forms of embodiment can vary widely with respect to what has been described and illustrated by way of example only, without thereby departing from the scope of the present invention.
[0073] For example, the vehicle also lends itself to being produced in a three-wheel version, with a single rear wheel, by means of replacement of the rear block.
Claims
CLAIMS1. Electric vehicle, having:- a vehicle structure (2, 3, 4),- a front suspension (21) connecting two front wheels (RA) to the vehicle structure (2),- a rear suspension (43) connecting two rear wheels (RP) to the vehicle structure (4),- a driver seat (S) and at least one passenger seat (S) carried by the vehicle structure (3), and- at least one electric motor (M1, M2) for the traction of the front wheels (RA), carried by the vehicle structure (2),characterized in that:the vehicle structure is constituted by three separate blocks (2, 3, 4), aligned in the longitudinal direction of the vehicle and connected to each other by means of removable connecting members,wherein said blocks (2, 3, 4) include:A) a front block (2) comprising:- a supporting structure (20) of the front block (2), preferably made of aluminum alloy, in the form of an annular body including a base body (20A), two side uprignts (20B) and an upper cross member (20C) connecting the side uprignts (20B), wherein the side uprignts (20B) and the upper cross member (20C) are defined by a continuous hollow element with a closed section,- a front suspension system, including two swing arms (21) that are carried by the base body (20A) of the supporting structure (20) of the front block (2), and that support the front wheels (RA) of the vehicle,- an auxiliary support module (24), carried by said supporting structure (20) of the front block (2) and carrying said at least one traction electric motor (M1, M2), a driver dashboard with an instrument panel, the steering wheel (25), brake and accelerator pedals (26), an HVAC system of the vehicle (P, F, R),- an electronic control system (E) of the vehicle, and sensors connected to the electronic control system,- an outer casing of said front block, including a windshield (W), afront bumper (29), and front light units (L),B) an intermediate central block (3) that includes- a supporting structure (30) of the central block (3), including:- a hollow platform (30A), carrying inside it a battery pack for powering said at least one traction electric motor (M1 , M2),- a rear portal-like structure (30B) that rises from the rear end of the platform (30A) of the central block (3),- an upper longitudinal beam (30C) connecting the rear portal-like structure (30B) of the central block (3) with the upper cross member (20C) of the front block (2),- the driver seat (S) and the at least one passenger seat (S) being carried by said platform (30A) of the central block (3) and- guide rails for two sliding side doors (34)C) a rear block (4) including:- a supporting structure (40) of the rear block (4), comprising a base body (40A) and a front portal-like structure (40B) connected to the rear portal-like structure (30B) of the central block (3),- a rear suspension system, including two swing arms (43) that are carried by the base body (40A) of the supporting structure (40) of the rear block (4), and that support the rear wheels (RP) of the vehicle,- rear light units (LP) and- a trunk-container (5), removably connected to the supporting structure (40) of the rear block (4) and provided with wheels which are displaceable between an inoperative position, when the trunk-container (5) is united with the vehicle (1), and an operative position, which allows the trunk-container (5) to be used as a mobile container, separately from the vehicleso that the vehicle is devoid of a single platform extending for the entire longitudinal dimension of the vehicle,said three blocks (2, 3, 4) having mutually mating transverse surfaces connected to each other by means of said removable connecting members.
2. Vehicle according to claim 1 , characterized in that the swing arms (21 , 43) of the front suspension system and of the rear suspension system are respectively disposed outside said front block (2) and outside said rearblock (4).
3. Vehicle according to claim 1 , characterized in that the swing arms (21 , 43) of the front suspension system and of the rear suspension system are controllable by means of actuators to vary the height of the vehicle relative to the ground and / or the track of the vehicle.
4. Vehicle according to claim 1 , characterized in that the shape of the front part of the vehicle is defined by the housing of the front block (2), including the windshield (W) and a lower portion provided with a bumper (29).
5. Vehicle according to claim 1, characterized in that the trunkcontainer (5) contains a power generator composed of an internal combustion engine and related fuel tank, for recharging the battery pack of the vehicle.