Foldable Electric Scooter Frame Using Stamped Plate Assemblies
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Solution Overview
Problem
Traditional electric scooters are large, heavy, and difficult to fold, making them inconvenient for transportation and storage, and their manufacturing methods require expensive equipment and skilled labor, limiting their compactness and weight reduction.
Innovation Solution
A compact foldable electric scooter design featuring a front fork assembly, rear fork assembly, telescoping plate assembly, and handlebar assembly that can be easily folded using pivoting mechanisms, combined with a manufacturing method involving stamping and assembly of two-dimensional scooter parts to minimize weight and volume, allowing the scooter to be carried in a backpack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional extrusion manufacturing method is used, then scooter structure strength is improved, but scooter weight increases and folding capability is limited
Solution Approach 1:
The scooter frame is divided into multiple stamped metal plate components (main body plate, front fork plates, rear fork plates) that can be separately manufactured and then assembled together, replacing the traditional monolithic extruded structure. This segmentation enables both weight reduction and folding capability while maintaining structural strength through proper connection design.
Solution Approach 2:
The frame structure incorporates movable pivot connections between plate components, transforming the rigid static extruded structure into a dynamic assembly that can fold and unfold. This dynamic design allows the scooter to transition between extended riding configuration and compact folded configuration, solving both the weight and folding capability issues.
2Stability of the object's composition
If traditional extrusion manufacturing method is used, then scooter structural integrity is improved, but manufacturing cost and equipment investment increase
Solution Approach 1:
The frame is segmented into multiple stamped plate parts that can be manufactured using standard stamping presses rather than expensive extrusion equipment. This segmentation allows for simpler, more cost-effective manufacturing while maintaining structural integrity through the assembly and connection of these individual plates.
Solution Approach 2:
The invention replaces expensive, specialized extrusion dies and equipment with simpler, cheaper stamped plate components. While individual plates may need replacement over time, the initial manufacturing cost and equipment investment are significantly reduced, making the scooter more economically viable.
3Strength
If traditional bent tube welding method is used, then scooter strength is improved, but manufacturing complexity and skilled labor requirements increase
Solution Approach 1:
The continuous bent tube structure is segmented into discrete stamped plate components with predefined connection points. This segmentation replaces complex welding operations with simpler mechanical connections between plates, reducing manufacturing complexity and skilled labor requirements while maintaining strength through proper connection design.
Solution Approach 2:
Instead of joining tubular segments through welding (building up structure), the invention uses stamped plates with connection features that mechanically join (building out structure). This inverted approach simplifies the manufacturing process by eliminating welding operations and reducing the need for skilled labor.
Data Source
AI summary
A foldable electric scooter and a manufacture method of the same. The foldable electric scooter includes a main body assembly, a front fork assembly located at the front end of the main body assembly, a rear fork assembly located at the rear end of the main body assembly, a telescoping plate assembly located on top of the front fork assembly and a handlebar assembly located on top of the telescoping plate assembly. The foldable electric scooter has a double headset design that increases a rake angle for more steering stability while still keeping the steering upright for an upright holding of the handlebars. The foldable electric scooter is manufactured by stamping of flat plate material.