IL320693A - Parts and assemblies of electric vehicles and industrial processes for their production - Google Patents

Description

P-657224-IL PARTS AND ASSEMBLIES OF ELECTRIC VEHICLES AND INDUSTRIAL PROCESSES OF MANUFACTURING THE SAME TECHNICAL FIELD id="p-1" id="p-1" id="p-1" id="p-1"

[0001] In general, the present invention pertains to the arts of mechanics and [0001] electricity. In particular, the invention relates to parts and assemblies of electric vehicles and industrial processes of manufacturing the same.

BACKGROUND ART id="p-2" id="p-2" id="p-2" id="p-2"

[0002] It is believed that the current state of the closest art is represented by [0001] US12090780. US12090780 discloses a vehicle wheel configured to assemble a motor having an uneven weight distribution, including a rim having an asymmetric structure. In US12090780, the rim comprising a drop center for mounting a tire, side sections extending axially outward from both sides of the drop center, bead bases extending axially outwards from said side sections, and flanges disposed axially [0001] outward of said bead bases. In US12090780, the bead bases having nonsymmetrical lengths to compensate the uneven weight distribution of said motor on the rim. In US12090780, the drop center having a drop diameter that is compatible with the diameter of the motor for inserting and encapsulating said motor therein, and the asymmetric structure of the rim compensates the uneven weight [0001] distribution of said motor on the rim, thus, maintains said wheel balanced with a minimal overall offset from the center line of the rim.

P-657224-IL SUMMARY OF THE INVENTION id="p-3" id="p-3" id="p-3" id="p-3"

[0003] The following summary of the invention is provided to exhibit the basic understanding of some principles, underlying various aspects and features of the invention. This summary is not an extensive overview of the invention and as such it is not necessarily intended to particularly identify all key or critical elements of the [0001] invention and is not to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the following more detailed. id="p-4" id="p-4" id="p-4" id="p-4"

[0004] The invention was made in view of the deficiencies of the prior art and provides systems, methods and processes for overcoming these deficiencies. [0001] According to some embodiments and aspects of the present invention, there is provided a process of manufacturing a structured integrally reinforced handlebar steering rod including: providing a die assembly, including: a constant die moiety, configured for extrusion of an essentially hollow rod, with an interior partition extending therein, dividing an interior lumen of the hollow rod into at least two [0001] portions; a movable die moiety, operationally connectable to the constant die moiety, configured to selectively obstruct a portion of the constant die moiety, configured for extrusion of the interior partition; a manipulator mechanism operatively connected to the movable die moiety, configured to dynamically alter a position of the movable die moiety during extrusion process; selectively extruding [0001] through the die assembly, including: extruding through the constant die moiety, the essentially hollow rod, with the interior partition therein, thereby forming a reinforced portion of the rod; actuating the manipulator mechanism to move the movable die moiety, to selectively obstruct the portion of the constant die moiety, configured for P-657224-IL extrusion of the interior partition; extruding through the constant die moiety, with the movable die moiety selectively obstructing the portion of the constant die moiety, configured for extrusion of the interior partition, thereby forming a non-reinforced portion of the rod, without an interior partition extending therein; forming a structured shape of the rod, by bending the non-reinforced portion of the rod, without the [0001] interior partition. id="p-5" id="p-5" id="p-5" id="p-5"

[0005] In some embodiments the process further includes synchronizing the manipulator mechanism with an extrusion speed, thereby transitions between the reinforced and non-reinforced portions of the rod occur seamlessly and without structural defects. [0001] id="p-6" id="p-6" id="p-6" id="p-6"

[0006] In some embodiments the process further includes controlling a transition timing, wherein an actuation of the movable die moiety is precisely timed during extrusion to ensure the interior partition is formed only in required sections of the rod. id="p-7" id="p-7" id="p-7" id="p-7"

[0007] In some embodiments, the material structured integrally reinforced [0001] handlebar steering rod is any one of: aluminum alloy, carbon fiber-reinforced polymer, titanium alloy, and magnesium alloy. id="p-8" id="p-8" id="p-8" id="p-8"

[0008] According to some embodiments and aspects of the present invention, there is provided a structured integrally reinforced handlebar steering rod including: a reinforced portion of the rod, with an interior partition extending therein, dividing [0001] an interior lumen of the rod into at least two portions; a non-reinforced portion of the, without the interior partition extending therein, remaining the interior lumen of the rod essentially hollow; a structured shape of the rod, formed by bending the P-657224-IL non-reinforced portion of the rod, without the interior partition. id="p-9" id="p-9" id="p-9" id="p-9"

[0009] According to some embodiments and aspects of the present invention, there is provided a vehicle wheel driven assembly including: a driving unit, including: an electric motor, configured to generate rotational torque; an encasement configured to accommodate the motor; a dismantlable wheel rim, removably [0001] mountable onto the encasement; a plurality of bolts, threaded through the wheel rim and configured to secure the wheel rim to the encasement; wherein a width of the driving unit is less than three-quarters of a width of the dismantlable wheel rim. id="p-10" id="p-10" id="p-10" id="p-10"

[0010] In some embodiments, the width of the driving unit is 60 percent of the width of the dismantlable wheel rim. [0001] id="p-11" id="p-11" id="p-11" id="p-11"

[0011] In some embodiments, the width of the driving unit is less than percent of the width of the dismantlable wheel rim of a frontal wheel. id="p-12" id="p-12" id="p-12" id="p-12"

[0012] In some embodiments, the electric motor is any one of: a DC (Direct Current) motor, Brushless motor, AC (Alternating Current) motor, servo motor, induction motor, synchronous reluctance motor, permanent magnet motor. [0001] id="p-13" id="p-13" id="p-13" id="p-13"

[0013] According to some embodiments and aspects of the present invention, there is provided a vehicle wheel driven assembly including: a driving unit, including: an electric motor, configured to generate rotational torque; an encasement configured to accommodate the motor; a dismantlable wheel rim, removably mountable onto the encasement; a plurality of bolts, threaded through the wheel rim [0001] and configured to secure the wheel rim to the encasement; wherein a vertical centerline of the dismantlable wheel rim coincides with a mass centerline of the assembly, around which a mass of the assembly is symmetrically distributed.

P-657224-IL id="p-14" id="p-14" id="p-14" id="p-14"

[0014] In some embodiments, the vertical centerline is a geometric line passing through a middle of the dimension of thickness of the dismantlable wheel rim. id="p-15" id="p-15" id="p-15" id="p-15"

[0015] In some embodiments, the vertical centerline passes at the center of mass of the dismantlable wheel rim, defining symmetrical distribution of the mass of the vehicle wheel driven assembly about the vertical centerline. [0001] id="p-16" id="p-16" id="p-16" id="p-16"

[0016] In some preferred embodiments, the geometric line passing through a middle of the dimension of thickness of the dismantlable wheel rim and the line passing at the center of mass of the dismantlable wheel rim coincide. id="p-17" id="p-17" id="p-17" id="p-17"

[0017] According to some embodiments and aspects of the present invention, there is provided an electric vehicle chassis including: a structural framework for an [0001] electric vehicle, including: an anterior portion configured for mounting frontal wheels subassembly thereon; a posterior portion configured for mounting a rear carrier thereon, wherein the rear carrier is elevated from a ground; a centrical portion, integrated into the chassis, including a lower pedestal forming a horizontal standing platform, configured to support a rider; a battery unit, configured to be enhoused [0001] within an encasement positioned within the lower pedestal of the chassis, wherein the encasement is configured to securely hold the battery unit; an electronic controller unit, positioned separately and remotely from the battery unit, wherein the electronic control unit is encased within a modular encasement mounted onto the rear carrier and elevated above the lower pedestal. [0001] id="p-18" id="p-18" id="p-18" id="p-18"

[0018] In some embodiments, the anterior portion further includes a suspension system configured to absorb shocks and vibrations transmitted from the frontal wheels subassembly during operation.

P-657224-IL id="p-19" id="p-19" id="p-19" id="p-19"

[0019] In some embodiments, the posterior portion includes a detachable mounting mechanism configured to allow the rear carrier to be readily connectable to and/or disconnectable from the structural framework. id="p-20" id="p-20" id="p-20" id="p-20"

[0020] In some embodiments, the battery unit and the electronic controller unit are separated to minimize exposure of the electronic controller unit to water. [0001] id="p-21" id="p-21" id="p-21" id="p-21"

[0021] In some embodiments, the battery unit and the electronic controller unit are separated to prevent heat generated by the battery unit from affecting the electronic controller unit. id="p-22" id="p-22" id="p-22" id="p-22"

[0022] In some embodiments, the battery unit is any one of: lithium-ion batteries, lithium-polymer batteries, nickel-metal hydride batteries, solid-state [0001] batteries, lead-acid batteries, and hydrogen fuel cells. id="p-23" id="p-23" id="p-23" id="p-23"

[0023] In some embodiments, the encasement enhousing the battery unit is vibration-dampened to protect the battery unit from mechanical stress during operation. id="p-1" id="p-1" id="p-1" id="p-1"

[0001] DEFINITIONS id="p-24" id="p-24" id="p-24" id="p-24"

[0024] The term matching or a term similar thereto, as referred to herein, is to be construed as having a cross-sectional area and/or shape of a component equal or essentially similar to a cross-sectional area and/or shape of another component.

It should be acknowledged that the components may only to be similar in the cross- [0001] sectional areas and/or shapes, to satisfy the term matching or similar, so long as the cross-sectional areas of the components can be mated and/or inserted into each P-657224-IL other and/or the combination thereof essentially fits together and/or occupy essentially the same space. id="p-25" id="p-25" id="p-25" id="p-25"

[0025] The term structured, as referred to herein, is to be construed as including any geometrical shape, exceeding in complexity a plain linear shape or a shape embodying a simple and/or standardized circular, elliptical or polygonal contour or [0001] profile. Any more complex shape than a plain linear shape or a shape embodying a simple and/or standardized circular, elliptical or polygonal contour or profile, constitutes an example of structured geometry. id="p-26" id="p-26" id="p-26" id="p-26"

[0026] The term structured, as referred to herein, is to be construed as including any geometrical shape, exceeding in complexity a plain linear shape, contour or [0001] profile. Any more complex shape than a plain linear shape, contour or profile constitutes an example of structured geometry, including a shape embodying a circular, elliptical or polygonal contour or shape, contour or profile. id="p-27" id="p-27" id="p-27" id="p-27"

[0027] The term modular, as referred to herein, should be construed as a including a stand-alone and/or autonomically functioning of structured unit. The [0001] term modular inter alia means a standardized unit that may be conveniently installed or deployed without significant impact to the environment. The term modular, however, doesn’t necessarily mean providing for ease of interchange or replacement. The term modular is optionally satisfied solely by providing for ease of onetime deployment or installation. [0001] id="p-28" id="p-28" id="p-28" id="p-28"

[0028] The terms connected, coupled, connectable and/or "in connection with" refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interactions. Components P-657224-IL can be operatively coupled to each other even though they are not in direct contact with each other. The term "abutting" refers to items that are in direct physical contact with one another, although the items do not necessarily have to be attached to one another. id="p-29" id="p-29" id="p-29" id="p-29"

[0029] By operationally connected and operably coupled or similar terms used [0001] herein is meant connected in a specific way (e.g., in a manner allowing fluid to move and/or electric power or signal to be transmitted) that allows the disclosed system and its various components to operate effectively in the manner described herein. id="p-30" id="p-30" id="p-30" id="p-30"

[0030] The term readily connectable, as referred to herein, should be construed as including any structure and/or member that is configured to be conveniently [0001] connected to other structure and/or member and/or components of a larger system or assembly. The term readily connectable, however, doesn’t necessarily mean readily disconnectable or removable. The term readily connectable is optionally satisfied by providing for ease of onetime connection or coupling. id="p-31" id="p-31" id="p-31" id="p-31"

[0031] The term fastener or a term similar thereto, as referred to herein, is to be [0001] construed as any suitable structure, material and/or device that effects an attachment, mounting and/or affixing, in a non-limiting manner including the examples of: bolts, screws, staples, pins, clips, magnetic couplings, zippers, snaps, magnets, non-permanent adhesives, adhesives, welding, nails, rivets, buckles, straps, stings, knots, hook and loop fasteners such as VELCRO (RTM), which is a [0001] trademark registered to Velcro Industries B.V. id="p-32" id="p-32" id="p-32" id="p-32"

[0032] The terms firm rigid, or stiff, as referred to herein, are to be construed as having rigidity modulus value, otherwise referred to as the shear modulus, of 4800 P-657224-IL MPa or more. Materials are considered to be firm rigid, or stiff but not tensile, when such materials are incapable of being efficiently elastically flexed or bent. Stiff materials, such as steel, are defined as having rigidity modulus value well exceeding 4800 MPa. id="p-33" id="p-33" id="p-33" id="p-33"

[0033] The terms method and process as used herein are to be construed as [0001] including any sequence of steps or constituent actions, regardless a specific timeline for the performance thereof. The particular steps or constituent actions of any given method or process are not necessarily in the order they are presented in the claims, description or flowcharts in the drawings, unless the context clearly dictates otherwise. Any particular step or constituent action included in a given [0001] method or process may precede or follow any other particular step or constituent action in such method or process, unless the context clearly dictates otherwise. Any particular step or constituent action and/or a combination thereof in any method or process may be performed iteratively, before or after any other particular step or action in such method or process, unless the context clearly dictates otherwise. [0001] Moreover, some steps or constituent actions and/or a combination thereof may be combined, performed together, performed concomitantly and/or simultaneously and/or in parallel, unless the context clearly dictates otherwise. Moreover, some steps or constituent actions and/or a combination thereof in any given method or process may be skipped, omitted, spared and/or opted out, unless the context [0001] clearly dictates otherwise. id="p-34" id="p-34" id="p-34" id="p-34"

[0034] In the specification or claims herein, any term signifying an action or operation, such as: a verb, whether in base form or any tense, gerund or present/past participle, is not to be construed as necessarily to be actually P-657224-IL performed but rather in a constructive manner, namely as to be performed merely optionally or potentially. id="p-35" id="p-35" id="p-35" id="p-35"

[0035] The term substantially as used herein is a broad term, and is to be given its ordinary and customary meaning to a person of ordinary skill in the art (and is not to be limited to a special or customized meaning), and refers without limitation [0001] to being largely but not necessarily entirely of that quantity or quality which is specified. id="p-36" id="p-36" id="p-36" id="p-36"

[0036] The term essentially means that the composition, method or structure may include additional ingredients, stages and or parts, but only if the additional ingredients, the stages and/or the parts do not materially alter the basic and new [0001] characteristics of the composition, method or structure claimed. id="p-37" id="p-37" id="p-37" id="p-37"

[0037] As used herein, the term essentially changes a specific meaning, meaning an interval of plus or minus ten percent (± 10%). For any embodiments disclosed herein, any disclosure of a particular value, in some alternative embodiments, is to be understood as disclosing an interval approximately or about [0001] equal to that particular value (i.e., ± 10%). id="p-38" id="p-38" id="p-38" id="p-38"

[0038] As used herein, the terms about or approximately modify a particular value, by referring to a range equal to the particular value, plus or minus twenty percent (+/−20%). For any of the embodiments, disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a [0001] disclosure of a range equal to about that particular value (i.e. +/−20%). id="p-39" id="p-39" id="p-39" id="p-39"

[0039] As used herein, the term or is an inclusive or operator, equivalent to the term and/or, unless the context clearly dictates otherwise; whereas the term and as P-657224-IL used herein is also the alternative operator equivalent to the term and/or, unless the context clearly dictates otherwise. id="p-40" id="p-40" id="p-40" id="p-40"

[0040] It should be understood, however, that neither the briefly synopsized summary nor particular definitions hereinabove are not to limit interpretation of the invention to the specific forms and examples but rather on the contrary are to cover [0001] all modifications, equivalents and alternatives falling within the scope of the invention.

DESCRIPTION OF THE DRAWINGS id="p-41" id="p-41" id="p-41" id="p-41"

[0041] The present invention will be understood and appreciated more [0001] comprehensively from the following detailed description taken in conjunction with the appended drawings in which: id="p-42" id="p-42" id="p-42" id="p-42"

[0042] FIG 1A is a perspective view of a prior art asymmetric motorized wheel rim, which is Figure 2A of US 12090780; id="p-43" id="p-43" id="p-43" id="p-43"

[0043] FIG 1B is a cross-sectional view of a prior art asymmetric motorized [0001] wheel rim, which is Figure 2B of US 12090780; id="p-44" id="p-44" id="p-44" id="p-44"

[0044] FIG 2 is a perspective view of electric vehicle, showing different parts and assemblies of the electric vehicle, in accordance with some aspects and embodiments of the present invention; id="p-45" id="p-45" id="p-45" id="p-45"

[0045] FIG 3A is a perspective view of a vehicle showing a structured integrally [0001] reinforced handlebar steering rod, according to some embodiments of the present invention; P-657224-IL id="p-46" id="p-46" id="p-46" id="p-46"

[0046] FIG 3B is a cross-sectional view along plane M-M of a reinforced portion of the structured integrally reinforced handlebar steering rod, according to some embodiments of the present invention; id="p-47" id="p-47" id="p-47" id="p-47"

[0047] FIG 3C is a perspective view of a structured integrally reinforced handlebar steering rod of a vehicle, according to some embodiments of the present [0001] invention; id="p-48" id="p-48" id="p-48" id="p-48"

[0048] FIG 3D is a cross-sectional view along plane P-P of non-reinforced portion of the structured integrally reinforced handlebar steering rod, according to some embodiments of the present invention; id="p-49" id="p-49" id="p-49" id="p-49"

[0049] FIG 4 is a flowchart of a process of manufacturing a structured integrally [0001] reinforced handlebar steering rod, according to some embodiments of the present invention; id="p-50" id="p-50" id="p-50" id="p-50"

[0050] FIG 5A is a front view of vehicle wheel driven assembly, according to some embodiments of the present invention; id="p-51" id="p-51" id="p-51" id="p-51"

[0051] FIG 5B is an exploded front view of vehicle wheel driven assembly, [0001] according to some embodiments of the present invention; id="p-52" id="p-52" id="p-52" id="p-52"

[0052] FIG 6A is a perspective view of electric vehicle showing a chassis, according to some embodiments of the present invention; id="p-53" id="p-53" id="p-53" id="p-53"

[0053] FIG 6B is a perspective view of electric vehicle chassis, according to some embodiments of the present invention. [0001] id="p-54" id="p-54" id="p-54" id="p-54"

[0054] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown merely by way of example in the drawings. The drawings are not necessarily complete and P-657224-IL components are not essentially to scale; emphasis instead being placed upon clearly illustrating the principles underlying the present invention.

DETAILED DISCLOSURE OF EMBODIMENTS id="p-55" id="p-55" id="p-55" id="p-55"

[0055] Prior to elaborating any embodiment of the present invention, in order to [0001] present the background for the inventive concept more vividly, reference is firstly made to FIG 1A and 1B , which are Figures 2A and 2B of US12090780, showing a perspective and cross-sectional views of an asymmetric motorized wheel rim 200 .

Wheel rim 200 of US12090780 has a relatively shallow drop center 202 for mounting a tire, side sections 204A-D extending axially outward from both sides of [0001] the drop center 202 at a predefined angle up to safety humps 206A-D, bead bases 208A-D extending axially outwards from side sections 204A-D, and flared flanges 210A-D disposed axially outward of bead bases 208A-D. id="p-56" id="p-56" id="p-56" id="p-56"

[0056] Rim 200 is designed to have a relatively shallow drop center 202 with a drop diameter 212 compatible with the diameter of motor 102 to entail insertion and [0001] accommodation of the motor 102 within the rim 200 . Bead bases 208A-D have non-symmetrical lengths to compensate the uneven weight distribution of said motor on said rim. Rim 200 comprises a first section 220 forming a first support structure and a second section 222 which is wider than first section 220 forming a second support structure. The first section 220 and the second section 222 are [0001] occupied by electric motor 202 and support the wheel. The structure of motorized wheel rim 200 is asymmetric, line 207 is the centerline of mass of rim 200 but not the geometrical centerline of the width of rim 200 . Mass centerline line 207 of rim P-657224-IL 200 thus does not coincide with the geometrical centerline of the width of rim 200 (not shown). id="p-57" id="p-57" id="p-57" id="p-57"

[0057] The asymmetric structure of rim 200 , allows encapsulating motor 102 within rim 204 with a minimal overall offset from the center line. The asymmetric structure of rim 200 maximizes the space occupied by motor 102 while reducing the [0001] loads on the axle of the wheel and on the steering system. Such design keeps the vehicle as light as possible, i.e., eliminating the use of steel for balancing the weights on the wheel while keeping the wheel balanced, while keeping the weight of the combined tire and wheel assembly equalized so that the wheel is balanced and spins smoothly at various speeds. [0001] id="p-58" id="p-58" id="p-58" id="p-58"

[0058] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of actual implementation are described in this specification. It should be appreciated that various features or elements described in the context of some embodiment may be interchangeable with features or elements of any other embodiment described in the specification. Moreover, it will [0001] be appreciated that for the development of any actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with technology- or business-related constraints, which may vary from one implementation to another, and the effort of such a development might be complex and time-consuming, but would nevertheless be a routine [0001] undertaking for those of ordinary skill in the art having the benefit of this disclosure. id="p-59" id="p-59" id="p-59" id="p-59"

[0059] In accordance with some embodiments of the present invention, reference is now made to FIG 2 to 3D , showing structured integrally reinforced handlebar steering rod 12 of vehicle 10 . In some embodiments, as shown in FIG P-657224-IL 3A and 3C , structured integrally reinforced handlebar steering rod 12 comprises reinforced portion 14 and non-reinforced portion 16 . In some embodiments, as shown in 3B which is a cross-sectional view along plane M-M of reinforces portion 14 , reinforced portion 14 of rod 12 comprises interior partition 18 extending therein, dividing interior lumen 20 of rod 12 into at least two portions. [0001] id="p-60" id="p-60" id="p-60" id="p-60"

[0060] In some embodiments, as shown in 3D , which is a cross-sectional view along plane P-P of non-reinforced portion 16 , non-reinforced portion 16 is without interior partition 18 , remaining interior lumen 20 of rod 12 essentially complete and hollow. In some embodiments, structured integrally reinforced handlebar steering rod 12 further comprises a structured non-linear shape. The structured shape of [0001] integrally reinforced handlebar steering rod 12 is formed by bending non-reinforced portion 16 of rod 12 , without interior partition 18 therein. In some examples, structured integrally reinforced handlebar steering rod 12 is made of aluminum alloy, carbon fiber-reinforced polymer, titanium alloy and magnesium alloy. id="p-61" id="p-61" id="p-61" id="p-61"

[0061] In accordance with some embodiments of the present invention, [0001] reference is now made to FIG 4 , showing a flowchart of process 600 of manufacturing a structured integrally reinforced handlebar steering rod, such as integrally reinforced handlebar steering rod 12 of vehicle 10shown in FIG 2 . In some embodiments, process 600 is configured to optimize a balance between structural integrity and flexibility, allowing the integrally reinforced handlebar steering rod to [0001] meet diverse performance requirements in various applications, such as bicycles, motorcycles, scooters, all-terrain vehicles (ATVs) or other vehicles requiring precise steering control. id="p-62" id="p-62" id="p-62" id="p-62"

[0062] In some embodiments, process 600 comprises step 602 of providing a P-657224-IL die assembly. In some embodiments, the die assembly comprises a constant die moiety. The constant die moiety is configured for extrusion of an essentially hollow rod, with an interior partition extending therein, dividing an interior lumen of the hollow rod into at least two portions, such as interior partition 18 that dividing interior lumen 20 of rod 12 into at least two portions, as shown in FIG 3B . [0001] id="p-63" id="p-63" id="p-63" id="p-63"

[0063] In some embodiments, the die assembly further comprises a movable die moiety. The movable die moiety is operationally connectable to the constant die moiety. The movable die moiety is configured to selectively obstruct a portion of the constant die moiety, configured for extrusion of the interior partition, such as interior partition 18shown in FIG 3B . [0001] id="p-64" id="p-64" id="p-64" id="p-64"

[0064] In some embodiments, the die assembly further comprises a manipulator mechanism. The manipulator mechanism is operatively connected to the movable die moiety. The manipulator mechanism is configured to dynamically alter a position of the movable die moiety during the extrusion process. In some embodiments, the process further comprises a step of mounting the die assembly [0001] to an extruder, for the extrusion process. id="p-65" id="p-65" id="p-65" id="p-65"

[0065] In some embodiments, process 600 proceeds to step 604 of selectively extruding an integrally reinforced handlebar steering rod, such as rod 12 of vehicle 10shown in FIG 2 , through the die assembly. In some embodiments, step 604 comprises extruding through the constant die moiety, the essentially hollow rod, [0001] with the interior partition therein, thereby forming the reinforced portion of the rod. id="p-66" id="p-66" id="p-66" id="p-66"

[0066] In some embodiments, step 604 further comprises actuating the manipulator mechanism to move the movable die moiety, to selectively obstruct the P-657224-IL portion of the constant die moiety, configured for extrusion of the interior partition.

In some embodiments, step 604 further comprises a step of synchronizing the manipulator mechanism with the operational speed of the extruder, thereby the transition between the reinforced and non-reinforced portions of the rod occurs seamlessly and without structural defects. [0001] id="p-67" id="p-67" id="p-67" id="p-67"

[0067] In some embodiments, step 604 further comprises a step of controlling a transition timing, in which an actuation of the movable die moiety is precisely timed during extrusion to ensure the interior partition is formed only in the required section/s of the rod. In some embodiments, step 604 yet further comprises extruding through the constant die moiety, with the movable die moiety selectively obstructing [0001] the portion of the constant die moiety, configured for extrusion of the interior partition, thereby once again forming a non-reinforced portion of the rod, without an interior partition extending therein, after the reinforced portion of the rod. id="p-68" id="p-68" id="p-68" id="p-68"

[0068] In some embodiments, process 600 further proceeds to step 606 of forming the structured shape of the rod. The structured shape of the rod is typically [0001] formed by bending the non-reinforced portion of the rod, without the interior partition therein. id="p-69" id="p-69" id="p-69" id="p-69"

[0069] In accordance with some embodiments of the present invention, reference is now made to FIG 5Aand 5B , showing a front view of vehicle wheel driven assembly 300 in FIG 5Aand an exploded view thereof in FIG 5B . In some [0001] embodiments, vehicle wheel driven assembly 300 comprises driving unit 302 . id="p-70" id="p-70" id="p-70" id="p-70"

[0070] In some embodiments, driving unit 302 comprises an electric motor.

Electric motor is configured to generate rotational torque. In some examples, P-657224-IL electric motor is a DC (Direct Current) motor, Brushless motor, AC (Alternating Current) motor, servo motor, induction motor, synchronous reluctance motor, permanent magnet motor. In some embodiments, driving unit 202 further comprises encasement 306 . Encasement 306 is configured to accommodate the electric motor. [0001] id="p-71" id="p-71" id="p-71" id="p-71"

[0071] In some embodiments, vehicle wheel driven assembly 300 further comprises dismantlable wheel rim 308 . Dismantlable wheel rim 308 is removably mountable onto encasement 306 . id="p-72" id="p-72" id="p-72" id="p-72"

[0072] In some embodiments, vehicle wheel driven assembly 300 further comprises plurality of bolts 310 . Bolts 310 are threaded through dismantlable wheel [0001] rim 308 . Bolts 310 are configured to secure wheel rim 308 to encasement 306 . id="p-73" id="p-73" id="p-73" id="p-73"

[0073] In some embodiments, width D1 of driving unit 302 is approximately less than three-quarters of width D2 of dismantlable wheel rim 308 . In some preferred embodiments, width D1 of driving unit 302 is approximately 60 percent of width D2 of dismantlable wheel rim 308 . In some preferred embodiments, width D1 of driving [0001] unit 302 is less than approximately 60 percent of width D2 of dismantlable wheel rim 308 of vehicle wheel driven assembly 300 . id="p-74" id="p-74" id="p-74" id="p-74"

[0074] In some embodiments, vertical centerline 400 of dismantlable wheel rim 308 coincides with a mass centerline of assembly 300 , around which a mass of assembly 300 is symmetrically distributed. [0001] id="p-75" id="p-75" id="p-75" id="p-75"

[0075] In some embodiments, vertical centerline 400 is a line passing through a middle of a thickness of dismantlable wheel rim 308 . In some embodiments, vertical centerline 400 is located at a geometric center of the thickness of P-657224-IL dismantlable wheel rim 308 , concomitantly serving as a reference for defining a symmetry of a mass distribution of vehicle wheel driven assembly 300 . id="p-76" id="p-76" id="p-76" id="p-76"

[0076] While the prior art motorized wheel rim 200 , disclosed in US12090780, implements an asymmetric configuration of the rim to balance against the weight of the motor, so as to reduce the loads on the axle and steering system, such [0001] configuration is inherently limited by structural constraints. Specifically, the mass centerline 207 of the prior art rim 200 does not align with a geometrical centerline of the assembly, as the asymmetric structure compensates the uneven mass distribution. This is a direct result of the motor being encapsulated within the rim, necessitating non-symmetrical bead bases 208A-D and differing lengths for the first [0001] section 220 and the second section 222 . id="p-77" id="p-77" id="p-77" id="p-77"

[0077] In some embodiments, the present invention overcomes the limitations of prior art by introducing dismantlable wheel rim 308 with vertical line 400 , which is the geometrical centerline of rim 308 , coinciding with the mass centerline of entire assembly 300 . Unlike the prior art, vertical centerline 400 of the present invention is [0001] positioned through the geometric center of the thickness of dismantlable wheel rim 308 and also coinciding with the mass centerline of entire assembly 300 . In some embodiments, the mass of assembly 300 is symmetrically distributed around vertical centerline 400 , when the rim accommodates an electric motor. id="p-78" id="p-78" id="p-78" id="p-78"

[0078] In some embodiments, width D1 of driving unit 302 is less than [0001] approximately three-quarters of width D2 of dismantlable wheel rim 308 , thereby ensuring that driving unit 302 is compactly integrated within the width dimension of dismantlable wheel rim 308 without outwardly protruding from its width, allowing wheel rim 308 structure to maintain its structural integrity and achieve a balanced P-657224-IL mass distribution around vertical centerline 400 . id="p-79" id="p-79" id="p-79" id="p-79"

[0079] By comparison, in US12090780, the width of the driving unit exceeds three-quarters and actually the entire of the width of the wheel rim structure. This configuration leads to a proportional imbalance, where the driving unit occupies a dominant portion of the rim's width. Accordingly this prior art configuration [0001] compromises the uniformity of the mass distribution of the rim itself, particularly because the rim's asymmetric structure is designed to compensate for the specific weight of the particular motor. This results in unequal dimensions between the first section 220 and the second section 222 , further exacerbating the imbalance in load- bearing properties. [0001] id="p-80" id="p-80" id="p-80" id="p-80"

[0080] In accordance with some embodiments of the present invention, reference is now made to FIG 6Aand 6B , showing a perspective view of electric vehicle 10and chassis 400 . In some embodiments, electric vehicle chassis 400 comprises structural framework 402 for electric vehicle 10 . In some embodiments, structural framework 402 comprises anterior portion 404 . Anterior portion 404 is [0001] configured for mounting frontal wheels subassembly 406 thereon. id="p-81" id="p-81" id="p-81" id="p-81"

[0081] In some embodiments, anterior portion 404 further comprises a suspension system. The suspension system is configured to absorb shocks and vibrations transmitted from frontal wheels subassembly 406 during operation. id="p-82" id="p-82" id="p-82" id="p-82"

[0082] In some embodiments, structural framework 402 further comprises [0001] posterior portion 408 . Posterior portion 408 is configured for mounting rear carrier 410 thereon. Rear carrier 410 is elevated from the ground. In some embodiments, posterior portion 408 comprises a detachable mounting mechanism configured to P-657224-IL allow rear carrier 410 to be removably attached to structural framework 402 . id="p-83" id="p-83" id="p-83" id="p-83"

[0083] In some embodiments, structural framework 402 further comprises centrical portion 412 . Centrical portion 412 is integrated into chassis 400 . In some embodiments, centrical portion 412 comprises lower pedestal 413 forming horizontal standing platform 414 . Horizontal standing platform 414 is configured to [0001] support the rider. id="p-84" id="p-84" id="p-84" id="p-84"

[0084] In some embodiments, structural framework 402 further comprises battery unit 416 . Battery unit 416 is configured to be enhoused within encasement 418 positioned within lower pedestal 413 of chassis 400 . In some embodiments, encasement 418 is configured to securely hold the battery unit. In some [0001] embodiments, encasement 418 enhousing battery unit 416 is vibration-dampened to protect battery unit 416 from mechanical stress during operation. id="p-85" id="p-85" id="p-85" id="p-85"

[0085] In some embodiments, battery unit 416is rechargeable and removable from encasement 418 for replacement and external charging. In some examples, battery unit 416is in a non-limiting manner at least one of: a lithium-ion batterie, [0001] lithium-polymer batterie, nickel-metal hydride batterie, solid-state batterie, lead-acid batterie, and hydrogen fuel cell. id="p-86" id="p-86" id="p-86" id="p-86"

[0086] In some embodiments, structural framework 402 further comprises an electronic controller unit 420 . Electronic controller unit 420 is positioned separately and remotely from battery unit 416 . Electronic controller unit 420 is encased within [0001] modular encasement 422 mounted onto rear carrier 410 and elevated above lower pedestal 413 . In some embodiments, modular encasement 422 is a waterproof and/or watertight and/or dustproof.

P-657224-IL id="p-87" id="p-87" id="p-87" id="p-87"

[0087] In some embodiments, battery unit 416 and electronic controller unit 420 are separated to minimize exposure of electronic controller unit 420 to water and/or moisture and/or other environmental factors and/or the elements that may affect its performance. In some embodiments, battery unit 416 and electronic controller unit 420 are separated to prevent heat generated by the battery unit 416 from affecting [0001] electronic controller unit 420 . id="p-88" id="p-88" id="p-88" id="p-88"

[0088] It will be appreciated by persons skilled in the art of the invention that various features and/or elements elaborated in the context of a specific embodiment described hereinabove and/or referenced herein and/or illustrated by a particular example in a certain drawing enclosed hereto, whether method, system, device or [0001] product, is/are interchangeable with features and/or elements of any other embodiment described in the specification and/or shown in the drawings. Moreover, skilled persons would appreciate that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the invention is defined by the claims which follow. [0001]

Claims (20)

P-657224-IL CLAIMS

1. A process of manufacturing a structured integrally reinforced handlebar steering rod comprising: (a) providing a die assembly, comprising: (I) a constant die moiety, configured for extrusion of an essentially hollow rod, with an interior partition extending therein, dividing an interior lumen of said hollow rod into at least two portions; (II) a movable die moiety, operationally connectable to said constant die moiety, configured to selectively obstruct a portion of said constant die moiety, configured for extrusion of said interior partition; (III) a manipulator mechanism operatively connected to said movable die moiety, configured to dynamically alter a position of said movable die moiety during extrusion process; (b) selectively extruding through said die assembly, comprising: (I) extruding through said constant die moiety, said essentially hollow rod, with said interior partition therein, thereby forming a reinforced portion of said rod; (II) actuating said manipulator mechanism to move said movable die moiety, to selectively obstruct said portion of said constant die moiety, configured for extrusion of said interior partition; (III) extruding through said constant die moiety, with said movable die moiety selectively obstructing said portion of said constant die moiety, configured for extrusion of said interior partition, thereby forming a non-reinforced P-657224-IL portion of said rod, without an interior partition extending therein; (c) forming a structured shape of said rod, by bending said non-reinforced portion of said rod, without said interior partition.

2. The process as in claim 1, further comprises synchronizing said manipulator mechanism with an extrusion speed, thereby transitions between said reinforced and non-reinforced portions of said rod occur seamlessly and without structural defects.

3. The process as in claim 1, further comprises controlling a transition timing, wherein an actuation of said movable die moiety is precisely timed during extrusion to ensure said interior partition is formed only in required sections of said rod.

4. The process as in claim 1, wherein said rod is made of a material selected from the group consisting of: aluminum alloy, carbon fiber-reinforced polymer, titanium alloy, and magnesium alloy.

5. A structured integrally reinforced handlebar steering rod comprises: (a) a reinforced portion of said rod, with an interior partition extending therein, dividing an interior lumen of said rod into at least two portions; (b) a non-reinforced portion of said, without said interior partition extending therein, remaining said interior lumen of said rod essentially hollow; (c) a structured shape of said rod, formed by bending said non-reinforced portion of said rod, without said interior partition. P-657224-IL

6. The structured integrally reinforced handlebar steering rod as in claim 5, wherein said rod is made of a material selected from the group consisting of: aluminum alloy, carbon fiber-reinforced polymer, titanium alloy, and magnesium alloy.

7. A vehicle wheel driven assembly comprises: (a) a driving unit, comprising: (I) an electric motor, configured to generate rotational torque; (II) an encasement configured to accommodate said motor; (b) a dismantlable wheel rim, removably mountable onto said encasement; (c) a plurality of bolts, threaded through said wheel rim and configured to secure said wheel rim to said encasement; wherein a width of said driving unit is less than three-quarters of a width of said dismantlable wheel rim.

8. The vehicle wheel driven assembly as in claim 7, wherein said width of said driving unit is 60 percent of said width of said dismantlable wheel rim.

9. The vehicle wheel driven assembly as in claim 7, wherein said width of said driving unit is less than 60 percent of said width of said dismantlable wheel rim of a frontal wheel.

10. The vehicle wheel driven assembly as in claim 7, wherein said electric motor is selected from the group consisting of: a DC (Direct Current) motor, Brushless motor, P-657224-IL AC (Alternating Current) motor, servo motor, induction motor, synchronous reluctance motor, permanent magnet motor.

11. A vehicle wheel driven assembly comprises: (a) a driving unit, comprising: (I) an electric motor, configured to generate rotational torque; (II) an encasement configured to accommodate said motor; (b) a dismantlable wheel rim, removably mountable onto said encasement; (c) a plurality of bolts, threaded through said wheel rim and configured to secure said wheel rim to said encasement; wherein a vertical centerline of said dismantlable wheel rim coincides with a mass centerline of said assembly, around which a mass of said assembly is symmetrically distributed.

12. The assembly as in claim 11, wherein said vertical centerline is a line passing through a middle of a thickness of said dismantlable wheel rim.

13. The assembly as in claim 11, wherein said vertical centerline is located at a geometric center of said thickness of said dismantlable wheel rim, thereby defining a symmetry of a mass distribution of said vehicle wheel driven assembly.

14. An electric vehicle chassis comprising: (a) a structural framework for an electric vehicle, comprising: (I) an anterior portion configured for mounting frontal wheels subassembly P-657224-IL thereon; (II) a posterior portion configured for mounting a rear carrier thereon, wherein said rear carrier is elevated from a ground; (III) a centrical portion, integrated into said chassis, comprising a lower pedestal forming a horizontal standing platform, configured to support a rider; (b) a battery unit, configured to be enhoused within an encasement positioned within said lower pedestal of said chassis, wherein said encasement is configured to securely hold said battery unit; (c) an electronic controller unit, positioned separately and remotely from said battery unit, wherein said electronic control unit is encased within a modular encasement mounted onto said rear carrier and elevated above said lower pedestal.

15. The electric vehicle chassis as in claim 14, wherein said anterior portion further comprises a suspension system configured to absorb shocks and vibrations transmitted from said frontal wheels subassembly during operation.

16. The electric vehicle chassis as in claim 14, wherein said posterior portion comprises a detachable mounting mechanism configured to allow said rear carrier to be removably attached to said structural framework.

17. The electric vehicle chassis as in claim 14, wherein said battery unit and said electronic controller unit are separated to minimize exposure of said electronic controller unit to water. P-657224-IL

18. The electric vehicle chassis as in claim 14, wherein said battery unit and said electronic controller unit are separated to prevent heat generated by said battery unit from affecting said electronic controller unit.

19. The electric vehicle chassis as in claim 14, wherein said battery unit is selected from the group consisting of: lithium-ion batteries, lithium-polymer batteries, nickel-metal hydride batteries, solid-state batteries, lead-acid batteries, and hydrogen fuel cells.

20. The electric vehicle chassis as in claim 14, wherein said encasement enhousing said battery unit is vibration-dampened to protect said battery unit from mechanical stress during operation.