Foldable Electric Scooter Frame With Nested Stamping Assemblies

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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 reduce weight and increase folding capabilities.

Engineering Contradictions & Design Principles

VSEngineering 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

Engineering Contradiction:

Improvescooter structure strengthVSAvoidscooter weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The scooter frame is divided into multiple stampable components including telescoping plates, fork assemblies, and deck sections. Each component is separately stamped from sheet metal and then assembled together, enabling both weight reduction and folding capability while maintaining structural strength through optimized joint designs

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The manufacturing process transitions from extrusion to stamping, changing the physical state and formation method of frame components. This parameter change enables the use of thinner gauge metals with higher strength-to-weight ratios and allows for integrated folding mechanisms to be built into the stamping patterns

Inventive Principle:

Principle #35Parameter changes

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

Engineering Contradiction:

Improvescooter structural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The frame is segmented into multiple stampable parts that can be manufactured using standard sheet metal stamping equipment, eliminating the need for expensive extrusion dies and machinery. These segmented components are then assembled using simplified connection methods that reduce manufacturing complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention adopts inexpensive stamping tools and standard sheet metal materials instead of costly extrusion equipment and specialized alloys. The stamped components are designed to be lightweight and potentially replaceable, reducing overall manufacturing investment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If traditional scooter design is used, then motor power is improved, but scooter compactness and portability deteriorate

Engineering Contradiction:

Improvemotor powerVSAvoidscooter volume

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

The scooter employs a nested folding mechanism where the front fork assembly telescopes into the main body, the rear fork folds parallel to the deck, and the handlebar collapses into the front fork. This nested arrangement allows the powered scooter to be compacted to a fraction of its operational volume for portability

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The scooter incorporates dynamic folding joints and telescoping mechanisms that allow the structure to transition between extended operational configuration and compact storage configuration. The motor and powertrain are positioned to accommodate both states, maintaining power output while enabling compact folding

Inventive Principle:

Principle #15Dynamics

4Stability of the object's composition

If traditional scooter design is used, then riding stability is improved, but ease of transportation and storage deteriorates

Engineering Contradiction:

Improveriding stabilityVSAvoidease of transportation

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The folding mechanism uses nested arrangements where fork assemblies telescope into and parallel to the main body, allowing the stable riding structure to collapse into a compact, portable form factor that maintains structural integrity in both states

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The scooter is segmented into modular folding sections with standardized connection points, enabling the stable riding platform to be easily collapsed and reconfigured for transportation while maintaining ride stability when deployed

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11999431B1Compact foldable scooter and method of using the same

Publication Date: 2024.06.04 CORDERO ARMANDO LUIS

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.