EARLIEST PRIORITY DATE:

This Application claims priority from a Provisional patent application filed in India having Patent Application No. 202241001664, filed on January 12, 2022, and titled “A FRAME FOR A MOTORCYCLE”.

FIELD OF INVENTION

Embodiments of the present disclosure relates to electric vehicle systems and more particularly to a frame for an electric vehicle.

BACKGROUND

Battery module of an electric vehicle is usually placed on a sub-frame and does not help in bearing structural load of the electric vehicle. During installation of the battery module, body frames are built with rigid dimensions to accommodate a single type of battery module only.

The sub-frame acts as a housing to hold the battery module and does not support structural load of the electric vehicle. Similarly, the sub-frame acts as a housing to hold a motor. Motors of different shape and sizes cannot be easily attached to the subframe. Hence, in order to accommodate changes in size of a motor or the battery module of varied ratings, change in the sub-frame is required.

Conventionally, when a user is required to change the motor type or the battery module, the users change the entire sub-frame to accommodate the new type. Further, in some other cases, the change of frame design is highly expensive and un-desirable.

Furthermore, the process of attaching and detaching the sub-frames in such conventional systems is complex and requires multiple sub-components relative to the sub-frame or the frame to be changed. Since, the sub-frames are rigidly connected, skilled manpower is required, and excess time is required to attach the sub-frames to the frame. Also, performing various changes is difficult as it is rigidly connected with help of welding.

Hence, there is a need for an improved frame for an electric vehicle and therefore address the aforementioned issues.

BRIEF DESCRIPTION

In accordance with one embodiment of the disclosure, an electric vehicle frame is disclosed. The electric vehicle frame includes a neck stem. The neck stem is configured to hold steering section of the electric vehicle. The electric vehicle frame also includes a seat support frame. The seat support frame is configured to support seat section of the electric vehicle.

The electric vehicle frame also includes a pre-designed battery holder frame. The predesigned battery holder frame is connected between the neck stem and a proximal frame end of the seat support frame.

The electric vehicle frame also includes a motor mounting unit. The motor mounting unit includes at least two supporting frames on each side of the chassis. The at least two supporting frames is mounted in between the battery holder and the seat support frame using a first pair connector hole and a second pair connector hole. The motor mounting unit also includes a motor mounting bracket. The motor mounting bracket includes a primary mounting point mounted at the middle portion of the second connector hole and a secondary mounting point mounted at the middle portion of a third pair connector hole.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

FIG. 1 is a perspective view of an electric vehicle frame depicting at least two mounting points to hold a battery module, in accordance with an embodiment of the present disclosure;

FIG. 2 is a rear view of the electric vehicle frame depicting a motor mounting unit, in accordance with an embodiment of the present disclosure;

FIG. 3 is a side view of the electric vehicle frame depicting set of mounting points to hold a motor, in accordance with an embodiment of the present disclosure;

FIG. 4 A is a side perspective view depicting the electric vehicle frame holding a battery module, in accordance with an embodiment of the present disclosure;

FIG.4 B is a front perspective view depicting the electric vehicle frame and the battery module before the electric vehicle frame holds the battery module, in accordance with an embodiment of the present disclosure;

FIG. 4 C is a front view depicting the electric vehicle frame holding a battery module, in accordance with an embodiment of the present disclosure;

FIG. 4 D is a top perspective view depicting the electric vehicle frame and the battery module before the frame holds the battery module, in accordance with an embodiment of the present disclosure;

FIG. 5 A is a perspective view depicting a motor mounting bracket present on a frame holding a motor, in accordance with an embodiment of the present disclosure;

FIG. 5 B is an exploded view depicting a frame and a motor before a motor mounting bracket present on the electric vehicle frame holds the motor, in accordance with an embodiment of the present disclosure; and

FIG. 5 C is a sectional view depicting the motor and the motor mounting bracket before the motor mounting bracket is mounted on the electric vehicle frame, in accordance with an embodiment of the present disclosure. Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated online platform, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, subsystems, elements, structures, components, additional devices, additional subsystems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting. In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

FIG. 1 is a perspective view 100 of an electric vehicle frame depicting at least two mounting points to hold a battery module, in accordance with an embodiment of the present disclosure. Electric vehicles are plug-in electric vehicles with two or three wheels, whereby the electricity is stored on board in a rechargeable battery, which drives one or more electric motors.

The electric vehicle frame 100 includes a neck stem 110. The neck stem 110 is configured to hold steering section of the electric vehicle. The steering section helps in providing direction to the electric vehicle during vehicular operation. The electric vehicle frame 100 also includes a seat support frame 114. The seat support frame 114 is configured to support seat section of the electric vehicle.

The electric vehicle frame 100 also includes a pre-designed battery holder frame 112. The pre-designed battery holder frame 112 is connected between the neck stem 110 and a proximal frame end 116 of the seat support frame 114. In one exemplary embodiment, the pre-designed battery holder frame 112 is rectangular in shape.

The pre-designed battery holder frame 112 includes at least two mounting points on each side tube of the pre-designed battery holder frame 112. The at least two mounting points are configured to hold a battery module (not shown in FIG. 1) at a specific inclination. The battery module is inclined guide the air flow through the battery surfaces. In such embodiment, the at least two mounting points is fabricated at edges on each side tube of the pre-designed battery holder frame 112 and affixed with the battery module (not shown in FIG. 1) by a screw mechanism.

In one particular embodiment, the at least two mounting points includes edge mounting points including a first mounting point 102, a second mounting point 104, a third mounting point 106 and a fourth mounting point 108. The first mounting point 102 is similar to the third mounting point 106 in structure. The second mounting point 104 is similar to the fourth mounting point 108 in the structure. The battery module with a metal enclosure is mounted upon these mounting points in a way that the battery module is hanged on the electric vehicle frame 100 with the help of the first mounting point 102, the second mounting point 104, the third mounting point 106 and the fourth mounting point 108. The electric vehicle frame 100 includes a nut and a bolt which is fastened and the material for the battery module outer case may be made of aluminium or any other mild metal sheet to support structural load of the electric vehicle frame 100.

The battery module of various configurations and sizes may be hanged on the electric vehicle frame 100. In one exemplary embodiment, if the battery module of smaller size has to be placed on the electric vehicle frame 100, then the first mounting point 102, the second mounting point 104, the third mounting point 106 and the fourth mounting point 108 are changed according to the size of the battery module to be placed, and the battery module may be placed on the frame.

The battery module becomes a structural member of the electric vehicle frame 100 once the battery module is placed on the frame which supports loading. The electric vehicle frame 100 does not include any sub-frame to hold the battery module. An outer case for the battery module does not have a particular structure at the bottom. The outer case for the battery module is hanged with the help of screws. For example, when a driver or a pillion sits on the electric vehicle, the load of the driver and electric vehicle passed on the electric vehicle frame 100, further, through a bolting structure, the load is passed onto the outer case for the battery module which handles the load. The mountings of the battery module are provided in a manner such that excluded portions of the battery module is mounted on the first mounting point 102, the second mounting point 104, the third mounting point 106 and the fourth mounting point 108 so that the outer case for the battery module may handle the load. In such embodiment, the electric vehicle may include a scooter or a motorcycle.

FIG. 2 is a rear view 200 of the electric vehicle frame depicting a motor mounting unit, in accordance with an embodiment of the present disclosure. The electric vehicle frame 100 also includes a motor mounting unit (201). The motor mounting unit (201) includes at least two supporting frames 202 and 206 on each side of the electric vehicle frame 100. The at least two supporting frames 202 and 206 is mounted in between the battery holder 112 and the seat support frame 114 using a first pair connector hole 504 (shown one side in FIG. 5A) and a second pair connector hole 506 (shown one side in FIG. 5A). The at least two supporting frames 202 and 206 is equivalent to two side plates pointing in downward direction. The two side plates include a left plate 202 and a right plate 206.

The motor mounting unit (201) also includes a motor mounting bracket 204. The motor mounting bracket 204 includes a primary mounting point mounted at the middle portion of the second pair connector hole 506 and a secondary mounting point mounted at the middle portion of a third pair connector hole 508. The motor mounting bracket 204 is attached at the primary mounting point and the secondary mounting point.

Motors of different configurations, motor with different power and sizes may be mounted on the motor mounting bracket 204. In one embodiment, when a new motor has to be installed, the motor mounting bracket 204 is changed accordingly, such that different types of motors such as two-kilowatt rated power motor, three-kilowatt rated power motor or four-kilowatt rated power motor may be placed on the motor mounting bracket 204.

In one of the cases, if the motor of smaller size has to be placed on the motor mounting bracket 204, then the entire frame is not changed. Since the motor mounting bracket 204 is fastened and not rigidly connected by welding, it is easy to change the same by performing structural changes in the motor mounting bracket 204 to accommodate varied size of the motor. The motor mounting bracket 204 may be changed in lateral direction either by changing the design or by providing a bend in the motor mounting bracket 204.

FIG. 3 is a side view 300 of the electric vehicle frame depicting set of mounting points to hold a motor, in accordance with an embodiment of the present disclosure. Motor mounting bracket 204 may be embossed or debossed to accommodate small variations in motor dimensions or power ratings. The motor mounting bracket 204 is coupled onto the electric vehicle frame 100.

A bolt passes through to mount the motor mounting bracket 204 from both sides of the at least two supporting frames 202 and 206. The design of the motor mounting bracket 204 is customisable and is fastened with the help of a nut and the bolt. The distance between mounting points of the motor on the motor mounting bracket 204 plates are changed as per design of the motor to be mounted. The left side plate 202, the motor mounting bracket 204 and the right-side plate 206 may be made of mild steel.

FIG. 4 A is a side perspective view 400 depicting the electric vehicle frame holding a battery module, in accordance with an embodiment of the present disclosure. Specifically, in the FIG. 4 A the first mounting point 102, the second mounting point 104 and the battery module 402 is depicted.

FIG. 4 B is a front perspective view 404 depicting the electric vehicle frame and the battery module before the electric vehicle frame holds the battery module, in accordance with an embodiment of the present disclosure. In the FIG. 4 B, the first mounting point 102, the second mounting point 104 and the battery module 402 is depicted.

FIG. 4 C is a front view 406 depicting the electric vehicle frame holding a battery module, in accordance with an embodiment of the present disclosure. In the FIG. 4 C, a set of screws 408 are used to hold the battery module 402 in position.

FIG. 4D is a top perspective view 410 depicting the electric vehicle frame and the battery module before the frame holds the battery module, in accordance with an embodiment of the present disclosure. The electric vehicle frame 100 includes predesigned battery holder frame 112, whereby a first mounting point 102, a second mounting point 104, a third mounting point 106 and a fourth mounting point 108 is fabricated. The battery module 402 is fixed correctly on the first mounting point 102, the second mounting point 104, the third mounting point 106 and the fourth mounting point 108 with the help of the set of screws 408.

FIG. 5 A is a perspective view 500 depicting a motor mounting bracket present on the electric vehicle frame holding a motor, in accordance with an embodiment of the present disclosure. The motor is hold in position with the help of first axle and second axle (not shown in FIG. 5 A). Further description is provided in FIG. 5 C.

FIG. 5 B is an exploded view 600 depicting the electric vehicle frame 100 and the motor before a motor mounting bracket is mounted on the electric vehicle frame holds the motor, in accordance with an embodiment of the present disclosure. The FIG. 5 B depicts the alignment of the first axle and the second axle. The motor mounting bracket 204 is hold in position with the first axle 514 and the second axle 516.

Specifically, the motor 510 is mounted upon the motor mounting bracket 204 by mechanically coupling a one or more motor frame points with the one or more bracket frame joining points. In one embodiment, the one or more bracket frame joining points includes three frame points on the motor mounting bracket 302, 304 and 306. In another embodiment, the one or more motor frame points comprises four motor joining points 518, 520, 522 and 524. The one or more motor frame points is mechanically screwed by set of screws 534 and 536 (as shown in FIG. 5 c) with the one or more bracket frame joining points.

FIG. 5 C is a sectional view 700 depicting the motor and the motor mounting bracket before the motor mounting bracket is mounted on the electric vehicle frame, in accordance with an embodiment of the present disclosure. The first axle 514 passes through a first set of bracket mounting points for alignment and is locked with a primary bolt 526. The first set of bracket mounting points includes the primary mounting point and the second pair connector hole 506.

The second axle 516 passes through a second set of bracket mounting points for alignment and is locked with a secondary bolt 530. The second set of bracket mounting points includes the secondary mounting point and the third pair connector hole 508.

In one specific embodiment, two outer mounting points 540 and 542 with elongated shafts 502 and 512 is connected with the electric vehicle frame 100. The elongated shafts 502 and 512 also acts as structural support member to restrict bending load on the first axle 514 and the second axle 516. Remaining three mounting points 302, 304 and 306 mount the motor 510 to perform necessary operations. The motor mounting bracket 204 comprises a first elongated shaft 502 passing through the primary mounting point and the second connector hole 506 and 528. The motor mounting bracket 204 comprises a second elongated shaft 512 passing through the secondary mounting point and the third connector hole 508 and 532.

In an embodiment, it is inferred that the first axle 514 passes through the primary mounting point, further passes through the second pair connector hole 506 and 528 of the electric vehicle frame 100 and gets locked with the help of the bolt 526. Similarly, the second axle 516 passes through the secondary mounting point and further passes through the third pair connector hole 508 and 532 and gets locked with the help of another bolt 530. The two outer mounting points 540 and 542 helps rigidly connected the motor mounting bracket 204 with the frame.

The present invention relates to structural electrical vehicle frame whereby the battery module 402 reduces weight of the electric vehicle frame 100 by two percentage. The motor mounting bracket 204 which is part of the electric vehicle frame 100 is designed and assembled in a manner that it supports to accommodate varied size of the motors 510. Battery module 402 and motor 510 acts as structural member of electrical vehicle frame.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependant on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.