IP Library Granted Patent US 11,654,970
Granted Patent B2
US 11,654,970 · App. 17/956,176 · Granted May 23, 2023

Land vehicles incorporating monocoques and modular mold systems for making the same

Inventor: Robert Willison (Lebanon, OH)
Assignee: Workhorse Group Inc.
B62D23/00B29C69/02B29C70/28B60K1/02B62D23/005B62D25/20B62D29/02B62D29/043B62D29/046B62D33/06B62D65/10B29K2309/08B29K2311/14B29L2031/30B29L2031/3055
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Quick Facts
Patent No.
US 11,654,970
App. No.
17/956,176
Granted
May 23, 2023
Kind
B2
Abstract

Land vehicles, modular systems for forming monocoques of land vehicles, and methods of forming monocoques of land vehicles using modular systems are envisioned. In certain embodiments, the land vehicles are provided as delivery vehicles and/or utility vehicles. A land vehicle includes a monocoque supporting a plurality of wheels to permit movement of the vehicle relative to an underlying surface in use of the land vehicle.

Claims (33)

1. A method of producing an electric vehicle, the method comprising:

forming a monocoque supporting a plurality of wheels of the vehicle,

wherein forming the monocoque includes forming (i) a front cage defining an operator cabin, (ii) a rear floor, (iii) an intermediate section disposed between the front cage and the rear floor, and (iv) a stowage compartment at least partially defined by the intermediate section and the rear floor.

2. The method of claim 1 , wherein forming the stowage compartment includes defining an interior space closed off from outside the vehicle.

3. The method of claim 1 , wherein forming the intermediate section includes forming a section having a single fixed length.

4. The method of claim 1 , wherein forming the stowage compartment includes forming a plurality of sidewalls each devoid of an opening extending therethrough.

5. The method of claim 4 , wherein forming the stowage compartment includes forming a ceiling devoid of an opening extending therethrough.

6. The method of claim 1 , wherein forming the monocoque includes forming the front cage, the rear floor, the intermediate section, and the stowage compartment from one or more composite materials.

7. The method of claim 6 , wherein forming the monocoque includes forming the front cage, the rear floor, the intermediate section, and the stowage compartment without using metallic material.

8. The method of claim 1 , wherein forming the monocoque includes forming a core and a shell that at least partially surrounds the core.

9. The method of claim 8 , wherein:

the core includes balsa wood and one or more of the following: fiberglass, polyparaphenylene terephthalamide, carbon fiber, or plastic, and

the shell is formed from resin and fiberglass.

10. A method of producing an electric vehicle, the method comprising:

forming a monocoque supporting a plurality of wheels of the vehicle; and

coupling at least one electric motor to the monocoque,

wherein forming the monocoque includes forming (i) a front cage defining an operator cabin, (ii) a rear floor, (iii) an intermediate section disposed between the front cage and the rear floor, and (iv) a stowage compartment at least partially defined by the intermediate section and the rear floor.

11. The method of claim 10 , wherein forming the stowage compartment includes forming a plurality of sidewalls each devoid of an opening extending therethrough.

12. The method of claim 10 , wherein forming the monocoque includes defining an interior space of the stowage compartment that is closed off from outside the vehicle.

13. The method of claim 12 , wherein defining the interior space of the stowage compartment includes at least partially defining the interior space with a plurality of sidewalls of the stowage compartment each devoid of an opening extending therethrough.

14. The method of claim 13 , wherein defining the interior space of the stowage compartment includes at least partially defining the interior space with a ceiling of the stowage compartment that is devoid of an opening extending therethrough.

15. The method of claim 10 , wherein forming the intermediate section includes forming a section having a single fixed length.

16. A method of producing an electric vehicle, the method comprising:

forming a monocoque supporting a plurality of wheels of the vehicle; and

coupling at least one electric motor to the monocoque,

wherein forming the monocoque includes forming (i) a front cage defining an operator cabin, (ii) a rear floor, (iii) an intermediate section disposed between the front cage and the rear floor, and (iv) a stowage compartment at least partially defined by the intermediate section and the rear floor, and

wherein forming the monocoque includes enclosing an interior space of the stowage compartment such that the interior space is closed off from outside the vehicle.

17. The method of claim 16 , wherein enclosing the interior space of the stowage compartment includes at least partially defining the interior space with a plurality of sidewalls of the stowage compartment each devoid of an opening extending therethrough.

18. The method of claim 17 , wherein enclosing the interior space of the stowage compartment includes at least partially defining the interior space with a ceiling of the stowage compartment that is devoid of an opening extending therethrough.

19. The method of claim 16 , wherein forming the intermediate section includes forming a section having a single fixed length.

20. The method of claim 16 , wherein forming the monocoque comprises:

forming the front cage, the rear floor, the intermediate section, and the stowage compartment from one or more composite materials; and

forming the front cage, the rear floor, the intermediate section, and the stowage compartment without using metallic material.

Assignments (6)
SECURITY INTEREST Recorded Dec 17, 2025
From: WORKHORSE GROUP INC.; WORKHORSE TECHNOLOGIES INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; STABLES & STALLS LLC; STABLES & STALLS REAL ESTATE I LLC; ROUTEHORSE LLC; OMAHA INTERMEDIATE, INC.; OMAHA INTERMEDIATE 2, INC.; ESG LOGISTICS CORP.; WORKHORSE MOTOR WORKS INC.; MOTIV POWER SYSTEMS, INC.
To: MOTIVE GM HOLDINGS II LLC
Reel/Frame 074006/0682 →
SECURITY INTEREST Recorded Aug 15, 2025
From: WORKHORSE GROUP INC.; WORKHORSE TECHNOLOGIES INC.; WORKHORSE MOTOR WORKS INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; STABLES & STALLS LLC; STABLES & STALLS REAL ESTATE I LLC; ROUTEHORSE LLC; ESG LOGISTICS CORP.; OMAHA MERGER SUBSIDIARY, INC.; OMAHA INTERMEDIATE, INC.; OMAHA INTERMEDIATE 2, INC.
To: MOTIVE GM HOLDINGS II LLC
Reel/Frame 072489/0426 →
RELEASE OF SECURITY INTEREST Recorded Mar 19, 2024
From: HIGH TRAIL SPECIAL SITUATIONS LLC
To: WORKHORSE GROUP, INC.; WORKHORSE TECHNOLOGIES, INC.; WORKHORSE MOTOR WORKS, INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; ESG LOGISTICS CORP.; STABLES & STALLS LLC; ROUTEHORSE LLC; STABLES & STALLS REAL ESTATE I LLC
Reel/Frame 066832/0728 →
SECURITY INTEREST Recorded Mar 18, 2024
From: WORKHORSE GROUP, INC.; WORKHORSE TECHNOLOGIES, INC.; WORKHORSE MOTOR WORKS, INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; ESG LOGISTICS CORP.; STABLES & STALLS LLC; ROUTEHORSE LLC; STABLES & STALLS REAL ESTATE I LLC
To: HORSEPOWER MANAGEMENT LLC
Reel/Frame 066816/0076 →
SECURITY INTEREST Recorded Dec 27, 2023
From: WORKHORSE GROUP INC.
To: HIGH TRAIL SPECIAL SITUATIONS LLC
Reel/Frame 066130/0303 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 29, 2022
From: WILLISON, ROBERT
To: WORKHORSE GROUP INC.
Reel/Frame 061570/0619 →
Continuity (5)
Continuation 17716687 · Apr 8, 2022
Continuation 17552718 · Dec 16, 2021
Continuation 17142766 · Jan 6, 2021
Provisional Application 62957577 · Jan 6, 2020
Related Publication 20230020434A1 · Jan 19, 2023