Electric bicycle motor system

Abstract

An electric motor bicycle system having an electric motor drive gear adapted to drive a wheel gear coupled to a bicycle wheel hub. The motor drive gear is coupled to the wheel gear via a chain. The chain may be tensioned with one or more tensioners, which allows for a tighter system geometry. The motor may be supported by a bracket adapted to mount to an industry standard disc brake mounting interface. In some aspects, the motor drive gear is coupled to a disc mounting interface of a wheel hub. In some aspects, the electric motor bicycle system may also have a disc brake system integrated therein.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a continuation-in-part of Saiki's U.S. patent application No. 16 / 541,130, filed on August 14, 2019, which claims priority to Saiki's U.S. provisional patent application No. 62 / 718,921, filed on August 14, 2018, and claims priority to Saiki's U.S. provisional patent application No. 62 / 785,263, filed on December 27, 2018, the entire contents of which are incorporated herein by reference. Background Art Technical Field

[0004] The present invention relates to electric transportation and, more particularly, to electric bicycle motor systems.

[0005] Description of Related Technology

[0006] Driven by environmental, public health, ecological and carbon footprint issues associated with gasoline-powered cars, researchers, governments and society at large have been searching for viable alternatives. Electric bicycles (e-bikes), powered by a combination of pedals and a battery-powered electric motor, are a promising alternative to automobile transportation. Their main advantages include: lower purchase and operating costs compared to cars; the ability to travel greater distances with less physical exertion than conventional bicycles; and zero emissions during operation.

[0007] Regenerative braking is a unique technology used in EVs to capture the energy generated by the vehicle due to its motion, or in other words, the kinetic energy that is wasted when the vehicle is slowing down due to braking. By measuring the initial vehicle speed and the final vehicle speed, the amount of kinetic energy lost due to braking can be calculated.

[0008] Urban driving cycles have considerable acceleration and deceleration times due to traffic control systems around towns, so a lot of energy is lost when decelerating. However, through regenerative braking, this energy can be captured and the "wasted" energy can be utilized and used for vehicle propulsion. Similarly, off-road bikes have considerable acceleration and deceleration demands due to climbing and descending hills. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an isometric view of an electric bicycle motor system according to some embodiments of the present invention.

[0010] Figure 2A is a left side view of a bicycle having an electric bicycle motor system according to some embodiments of the present invention mounted thereon.

[0011] Figure 2Bis a top view of a bicycle having an electric bicycle motor system according to some embodiments of the present invention mounted thereon.

[0012] Figure 3 is a right side view of an electric bicycle motor system according to some embodiments of the present invention.

[0013] Figure 4 is a left side view of an electric bicycle motor system according to some embodiments of the present invention.

[0014] Figure 5 is a side cross-sectional view of an electric bicycle motor system according to some embodiments of the present invention.

[0015] Fig. 6A is an isometric view of a bicycle having an electric bicycle motor system according to some embodiments of the present invention mounted thereon.

[0016] Figure 6B is an isometric view of a bicycle having an electric bicycle motor system according to some embodiments of the present invention mounted thereon.

[0017] Figure 7 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

[0018] Fig. 8A is an exploded isometric view of an electric bicycle motor system according to some embodiments of the present invention.

[0019] Figure 8B is an interior view of a motor housing according to some embodiments of the present invention.

[0020] Fig. 9 is a left side view of a bicycle having an electric bicycle motor system according to some embodiments of the present invention mounted thereon.

[0021] Fig.10 is an isometric view of an electric bicycle motor system according to some embodiments of the present invention.

[0022] Fig.11 is a side cross-sectional view of an electric bicycle motor system according to some embodiments of the present invention.

[0023] Fig.12 is an isometric view of an electric bicycle motor system with disc brakes according to some embodiments of the present invention.

[0024] Fig.13 is a cross-sectional view of an electric bicycle motor system with a disc brake according to some embodiments of the present invention.

[0025] Fig.14is an exploded isometric view of an electric bicycle motor system according to some embodiments of the present invention.

[0026] Fig.15 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

[0027] Fig.16 is an isometric view of a mounting bracket for an electric bicycle motor according to some embodiments of the present invention.

[0028] Fig.17A A stent according to some embodiments of the present invention is shown.

[0029] Fig. 17B A mounting interface according to some embodiments of the present invention is shown.

[0030] Fig.18 is a flow chart of a motor and battery system according to some embodiments of the present invention.

[0031] Fig.19 An electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention is shown.

[0032] Fig. 20 A bicycle frame having an integrated frame mount according to some embodiments of the present invention is shown.

[0033] Fig.21 An interface area of ​​an integral frame mount according to some embodiments of the present invention is shown.

[0034] Fig. 22 An electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention is shown.

[0035] Fig.23 An electric bicycle motor system having an integral composite frame mount according to some embodiments of the present invention is shown.

[0036] Fig.24 A composite bicycle frame having an integral composite frame mount according to some embodiments of the present invention is shown.

[0037] Fig.25 An electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention is shown.

[0038] Fig.26 An interface area of ​​an integral frame mount with a composite frame according to some embodiments of the present invention is shown.

[0039] Fig. 27An interface area of ​​an integral frame mount with a composite frame according to some embodiments of the present invention is shown.

[0040] Fig.28 A frame insert for a frame mount for a composite frame according to some embodiments of the present invention is shown.

[0041] Fig.29 A frame insert for a frame mount for a composite frame according to some embodiments of the present invention is shown.

[0042] Fig.30 An electric bicycle motor system according to some embodiments of the present invention is shown.

[0043] Fig.31 An electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention is shown.

[0044] Fig.32 A bicycle frame having an integrated frame mount according to some embodiments of the present invention is shown.

[0045] Fig.33 A motor housing for an electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention is shown.

[0046] Fig.34 A motor housing retainer for an electric bicycle motor system having an integrated frame mount is shown according to some embodiments of the present invention.

[0047] Fig.35 is a cross-sectional view of a mounting interface for an electric bicycle motor system having an integrated frame mount according to some embodiments of the present invention.

[0048] Fig.36 are views of laminates according to some embodiments of the present invention.

[0049] Fig.37 are views of laminate stacks according to some embodiments of the present invention.

[0050] Fig.38 are views of laminate stacks according to some embodiments of the present invention.

[0051] Fig.39 is a cross-sectional diagram of the thickness of a laminate stack according to some embodiments of the present invention. Summary of the invention

[0052] An electric motor bicycle system having an electric motor drive gear adapted to drive a wheel gear coupled to a bicycle wheel hub. The motor drive gear is coupled to the wheel gear via a chain. The chain may be tensioned with one or more tensioners, which allows for closely spaced system geometries. The motor may be supported by a bracket adapted to mount to an industry standard disc brake mounting interface. In some aspects, the motor drive gear is coupled to a disc mounting interface of a wheel hub. In some aspects, the electric motor bicycle system may also have a disc brake system integrated therein. The electric motor bicycle system may include a regenerative braking system, which may be a fully proportional regenerative braking system. DETAILED DESCRIPTION

[0053] In some embodiments of the present invention, Figure 1 , Figure 3 , Figure 4 as well as Figure 5 As shown, the electric bicycle motor system 100 connects the motor unit 101 to the drive gear 102 via the drive chain 103. The motor unit 101 is connected to the mounting bracket 110, which is suitable for mounting the motor unit 101 on the bicycle. In some aspects, the mounting bracket 110 is suitable for mounting the rear disc brake mounting interface 107 of the bicycle. In some aspects, the mounting bracket 110 is suitable for mounting to an industry standard brake mounting interface. With such a system, a non-electric bicycle can be converted into an electric bicycle. In some aspects, the electric bicycle system is suitable for mounting to a customized mounting interface.

[0054] In an exemplary application, such as Figure 2A and Figure 2BAs shown, the electric bicycle system 100 can be installed on an existing bicycle designed to accommodate a rear disc brake system. The rear wheel assembly on the bicycle can include a rim 106 with a tire 105 mounted thereon. The rim 106 can be coupled to a hub including a disc mounting interface 109. The rear disc brake mounting interface 107 can be located on the rear portion of the frame 104. Instead of mounting a rear disc and rear disc brake mechanism, the mounting interface 119 of the gear 102 can be mounted to the disc interface 109 of the rear hub. A bracket 110 adapted to support the motor unit 101 is mounted on the disc mounting interface 109, and the motor unit 101 is coupled to the bracket 110. In this manner, the electric bicycle system 100 is easily incorporated into an industry standard bicycle without requiring any rework or additional mounting changes or brackets. Using an electric bicycle system as a rear brake braking system eliminates the need for a rear disc brake, allowing the use of a disc and disc brake mechanism mounting interface for the drive gear 102 and motor unit 101 and motor bracket 110. In some aspects, there is no other rear brake mechanism on the bicycle other than the rear brake mechanism of the motor unit used as a brake. In some aspects, the gear 102 is mounted on the wheel hub mounting interface, and the gear interface consists of a six-hole pattern with approximately 5m diameter holes on a 44mm diameter bolt circle.

[0055] The rotation axis 108 of the rear wheel 106, which is coaxial with the rotation axis of the drive gear 102, is marked by a station 153 along the front-rear axis of the bicycle and is Figure 2A 1. In some aspects, the bicycle frame is configured so that the rear wheel will be mounted to a fixed position in the frame so that the frame will have a rear wheel mounting axis that will be coaxial with the rear wheel rotation axis when the bicycle is assembled. The longitudinal axis 156 of the bicycle is used to indicate the position points of the components in the fore-aft direction. The rotation axis of the motor unit 101 is marked by point 152 along the longitudinal axis of the bicycle, which is forward relative to point 153 of the rotation axis of the rear wheel. The forward point of the center of mass of the motor unit relative to the rotation axis of the wheel allows the motor unit to be mounted without suspending the motor behind the rear wheel axis. In some aspects, the forwardmost position 155 of the wheel rim 106 along the longitudinal axis 156 indicates the farthest forward position of the motor rotation axis 112. In some aspects, the motor rotation axis is located at a point along the longitudinal position axis 156 between point 153 of the rotation axis 108 and point 155 of the forwardmost position 155 of the wheel rim 106. In some aspects, the motor's axis of rotation is not only not further forward of the wheel rim 106 than point 155 , but at other points, is also not radially outward of the wheel rim.

[0056] The rear wheel of a bicycle may have a pedal drive side, i.e., where the drive gear is mounted to the crank assembly. Similarly, the side of the bicycle frame on the side having the pedal drive side of the crank may be referred to as the pedal drive side of the frame. In some aspects, a bicycle frame may not be bilaterally symmetrical, for example, this may be due to the presence of a transmission dropout coupled to the frame.

[0057] like Figure 2B As shown, the inner edge of the pedal (not shown) coupled to the crank arm 151 is located at a distance perpendicular to the crank axis that is equal to or more outboard from the outer surface of the motor unit 101. Figure 2B is Figure 2A A top view of the embodiment as seen in the left side view of FIG. Figure 2A As shown, the rotation axis and center of mass of the motor unit 101 can be located in front of the rotation axis of the rear wheel. In addition, the motor unit 101 can extend to the outside no further than the plane of the rotation path of the inner edge of the pedal connected to the crank, which will allow the user's foot to leave the motor unit 101 in practice. In some aspects, the motor unit leaves the outer surface of the crank arm. In some aspects, whether using a wider "Boost" crank or a conventional "non-Boost" crank set, the motor unit will not protrude outside the outer surface of the crank arm. In some aspects, the outermost part of the motor unit will not protrude farther outside than the outer surface of the crank arm, and the innermost surface of the motor unit will be on the outside of any potential interference part of the tire and wheel assembly. In some aspects, the outer surface of the motor unit away from the center plane of the bicycle will be roughly in a straight line with the farthest outer surface of the pedal crank arm or will be inside the farthest outer surface of the pedal crank arm. In some aspects, the innermost surface of the motor unit will be outside the outer surface of the outer side of the wheel rim. In some aspects, the innermost surface of the motor unit will be outside of the outer side surface of the tire.The very thin nature of the motor unit allows the motor unit to be positioned in locations on the bicycle that were previously unavailable.

[0058] Figure 3A rear view of an electric bicycle system 100 is shown according to some embodiments of the present invention. The electric bicycle system 100 includes two tensioning mechanisms 114, 117 that allow a large amount of chain to be wrapped around the pinion 111 and provide dynamic stability of the chain 103 both during power transmission to the rear wheel and during braking of the rear wheel by the motor under braking conditions. The motor unit 101 can have a rotational axis 112 coupled to an external rotor that is coupled to the pinion 111. In some aspects, as further shown in FIG. 8, the motor 101 has an external rotor 135 that is coupled to an inner housing 134 of the motor 101 and rotates about an inner stator 136 that is coupled to an inner stator 136. The first tensioner 114 is coupled to the first mounting pivot interface 115 and provides tension to the chain 103 using the first spring loaded gear 113. The second tensioner 117 is coupled to the second mounting pivot interface 118 and provides tension to the chain 103 using the second spring loaded gear 116. The fixed outer housing 137 of the motor unit 101 is coupled to the mounting bracket 110, which can be attached to the rear disc brake mounting interface of the bicycle by fasteners 120, 121. The drive gear mounting portion 131 is adapted to provide mounting of the drive gear 102 to the mounting interface 119 on the rear wheel hub.

[0059] In some aspects, the center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in the range of 100 mm to 350 mm. This widest range is roughly defined by the smallest center-to-center distance between the two gears and the largest center-to-center distance defined by the bicycle rim radius. In some aspects, the center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in the range of 125 mm to 290 mm. This intermediate range provides better minimal chain wrap and shorter chain length. In some aspects, the center-to-center distance between the rotational axis of the drive gear and the rotational axis of the motor is in the range of 150 mm to 230 mm. This narrower range provides good chain wrap and minimized chain length. In an exemplary embodiment, the center-to-center distance is approximately 187 mm.

[0060] In this illustrative embodiment, the pinion gear has 13 teeth. The number of pinion gear teeth can vary to provide a desired gear ratio between the pinion gear and the drive gear. In some aspects, the number of drive pinion gear teeth has a range of between 9 and 30 teeth. In this illustrative embodiment, the drive gear has 133 teeth. The number of drive gear teeth can vary to provide a desired gear ratio between the pinion gear and the drive gear. In some aspects, the number of drive gear teeth has a range of between 60 and 200 teeth. Typically, the drive gear has more teeth to provide a gear ratio that allows the pinion gear to rotate faster than the drive gear, thereby providing a gear reduction.

[0061] In the exemplary embodiment, the chain has a 1 / 4 inch pitch. This is a standardized chain pitch. In other aspects, there are other smaller or larger standardized chain pitches that will function properly. Chain pitches in English units, metric units, or non-standardized pitches may also be utilized. The approximate diameter of the pinion and drive gears is determined by the number of teeth multiplied by the chain pitch plus some additional diameter for the tooth profile.

[0062] In some embodiments of the present invention, Figure 4 As shown, the motor unit 101 is coupled to the bracket 110 by fasteners 122, 123. The outer motor housing 137 may have a slot 124 adapted to allow some adjustment of the position of the motor unit 101 relative to the bracket 110. Figure 5 The motor unit 101 is shown in cross-section. In this view, the vertical alignment of the teeth of the pinion 111, the chain 103 and the teeth of the drive gear 102 is shown.

[0063] Fig. 6A and Figure 6B Different embodiments of mounting brackets for the motor unit 101 are shown. Fig. 6A A bracket 110 is shown that is coupled to the motor unit and also to the bicycle frame, and in some aspects may be coupled to a disc brake caliper mounting interface. Figure 6B A bracket portion 110a is shown which is part of a bicycle frame.

[0064] Although discussed in the context of a bicycle, in some aspects the invention may be seen in something other than a bicycle, such as a tricycle having two front wheels and a single rear wheel.

[0065] Figure 7 A mounting bracket 110 according to some embodiments of the present invention is shown. The mounting bracket 110 includes through holes 125, 126 that may be sized to mate with an industry standard disc brake mounting interface. Figure 8BAs shown, the groove 131 can accommodate the mating portion 152 of the outer motor housing 137 of the motor unit 101. The fasteners 122, 123 that attach the motor unit to the bracket 110 can be coupled to the receiving holes 127, 128, which in some aspects can be threaded through holes. In some aspects, the bracket 110 can have an extension arm 129 with a coupling pad 130 at its lower end. In some aspects, the coupling pad can be placed against the bicycle frame to provide an additional support point suitable for offsetting the moment load that may be applied to the bracket. In some aspects, the radial load through the pinion may cause some loads that are not in the plane defined by the axes of the two receiving holes 127, 128. In some aspects, the spacer can be combined or otherwise fixed to the bicycle frame to provide a contact fit of the coupling pad 130 of the bracket 110 to the bicycle frame. In some aspects, there may be a single fastener 122 or fastener 123. In some aspects, there may be three or more fasteners.

[0066] Fig. 8A An exploded view of an electric bicycle system 100 according to some embodiments of the present invention is shown. The drive gear 102 is coupled to a drive gear mount 143 by a fastener 132. The drive gear mount 131 can be adapted to engage with an industry standard rear disc mount on a rear wheel hub. A fixed outer motor housing 137 is coupled to an inner stator 136. The inner stator 136 can have windings and winding rods. An outer bearing 139 is located within an outer recess of the outer motor housing 137, and an inner bearing 138 is located within an inner recess of the outer motor housing. The outer bearing 139 and the inner bearing 138 support a motor shaft that is integral with the rotating inner motor housing 134. A retainer 142 is coupled to the shaft of the inner housing 134 and axially constrains the inner housing and the outer housing relative to each other. A removable cover 141 is coupled to the outer housing 137 by a fastener 140 and allows access to the retainer 142 and the outer bearing 139. The motor pinion 111 is mounted directly to an integral joint shaft extending from the inner motor housing 134 and is coupled to the housing by a fastening coupling 133. An outer rotor 135 is coupled to the inner housing 134. The outer housing 137 is coupled to the bracket 110 by fasteners 122, 123 and is located within a slot 131 which allows the bracket to be mounted to the motor unit to some extent along the direction of the major axis of the slot 131. Figure 8BFurther details of the outer housing 137 according to some embodiments of the present invention are shown. The outer housing 137 can include an axial support portion 151 having a bearing receiver portion 150 adapted to support the outer race of the internal bearing 138. A sliding form 152 is adapted to reside within a slot 131 in the bracket 110 or other bracket. The slots 153, 154 in the outer housing 137 allow relative movement relative to the mounting fasteners 122, 123.

[0067] In some aspects, the motor is a brushless DC motor (BLDC). In some aspects, the motor is an outward-turning BLDC motor. In this motor, the motor rotates an external rotor around its windings. This is in contrast to a more typical motor configuration with an external stator and an internal rotor. For a given outer diameter, the outward-turning configuration produces greater torque and delivers the power required in the configuration described herein. There are magnets on the inner lining of the motor housing, and the stator comprises a laminated stack of steel plates, with the motor windings on the teeth. In some aspects, the motor is a disc motor. The motor can be a motor with a low aspect ratio. The aspect ratio of the motor is defined as the ratio of the axial length of the motor housing minus the mounting bracket and hardware to the diameter of the motor housing. A motor with a low aspect ratio is a motor with an aspect ratio less than 2.

[0068] The ratio of laminate stack thickness to laminate stack thickness diameter is one aspect that affects the motor aspect ratio. Figure 36 to Figure 39 Aspects of laminates, laminate stack thickness, and laminate diameter according to some embodiments of the present invention are shown. A single laminate 601 has a groove 602 around its periphery. Laminate 601 has a diameter 604. Laminate stack 606 is composed of multiple laminates 601, and laminate stack 606 has a thickness 605.

[0069] In some embodiments of the present invention, the stator diameter of the motor stator is greater than 2 times the thickness of the laminated stack. In some embodiments of the present invention, the stator diameter of the motor stator is greater than 4 times the thickness of the laminated stack. In some embodiments of the present invention, the stator diameter of the motor stator is greater than 6 times the thickness of the laminated stack. In some embodiments, the stator stack height is less than 30 mm. In some embodiments, the stator stack height is less than 20 mm.

[0070] In some aspects, there is typically no directional clutch in a drive-only electric bicycle system, as shown in Figure 8. Because there may be some motor drag when coasting the bicycle without such a clutch, in order to provide a frictionless feel, the drive electronics may provide a minimal amount of drive power to the motor when the bicycle is coasting.

[0071] In some embodiments of the present invention, Fig. 9As shown, the motor unit is mounted between the rear stay and the chain stay. Similar to other embodiments described herein, the motor rotation axis is forward of the rotation axis of the rear wheel and rearward of the forwardmost portion of the rear rim. In some aspects, as described below, the motor housing is mounted to the inside of a motor mounting flange that is integral with the rear stay or chain stay of the bicycle frame.

[0072] In embodiments of the present invention, the electric bicycle system will further include a battery, a motor controller, and associated wiring harnesses that connect the motor, battery, and motor controller together. In some aspects, the battery is a battery pack composed of lithium-ion cells. These cells provide a large amount of energy storage in a small, lightweight package. In some aspects, other types of energy storage can be utilized, such as lead-acid batteries, fuel cells, or other energy storage devices.

[0073] The motor controller takes energy from the battery and converts it into a controllable form for driving the electric motor. The motor controller may have other functions, such as processing rider input or controlling other functions. The motor controller may also have the ability to take energy produced by the motor and convert it into a form that inputs energy into the battery. These types of motor controllers are often referred to as controllers capable of regeneration or regeneration, but may have many names and types. In some aspects, an electric bicycle system will include a motor controller with regeneration capabilities.

[0074] Fig.18 An electrical subsystem 400 that may be used in conjunction with an electric bicycle system according to some embodiments of the present invention is shown. A battery 401 is coupled to a motor controller / driver 402, which in turn is coupled to a motor 403. In a driving scenario, the battery provides power 404 to the motor controller / driver, which may then modulate the power and provide it 405 to the motor 403. In a regenerative braking scenario, the motor may provide power 407 through the motor driver / controller 402 and to 406 and the battery 401.

[0075] In another exemplary embodiment of the present invention, Fig. 9 As shown, the electric bicycle system is mounted to the bicycle frame in a position below the rear stay. In other embodiments, the location of the motor may also be above or below the chain stay. Other embodiments may have or not have a chain stay or seat stay at all, or may have asymmetric stays that are present or absent only on the left or right side. Many examples of structures that connect the rear wheel to the rest of the bicycle frame are possible.

[0076] In other embodiments, the rear portion of the bicycle frame may be movable to provide suspension. This is sometimes, but not exclusively, referred to as rear suspension.

[0077] In some embodiments of the present invention, Fig.12 As shown, an electric bicycle system 300 includes a disc brake system incorporated into an electric drive system. A motor unit 301 is coupled to the bicycle via a mounting bracket 310. A chain 306 drives a drive gear 302 in a manner similar to the above-described embodiments. A gear mounting bracket 308 supports the drive gear 302 and also supports a brake disc 303. A fastener 305 that attaches the bracket 308 may also attach the disc 303. A disc brake caliper mechanism 304 may also be supported by the bracket 310 and is adapted to provide a clamping force to the disc 303 to provide braking to the wheel. Fig.13 As shown in the cross-sectional view in FIG. , the thin profile of the components, according to the above-described embodiments, allows assembly of the combined motor and disc brake assembly and similarly avoids the tire, wheel, crank and user.

[0078] Fig.14 An exploded view of an electric bicycle system 300 is shown. In some aspects, the motor unit can have a directional clutch 308 that is adapted to allow the motor to transmit torque in a driving direction, but is adapted to rotate freely to allow relative rotational freedom between the motor and the drive gear when the motor is not driving the drive gear. The outer housing 310 is coupled to the inner stator 316, and the inner housing 313 is coupled to the outer rotor 317. The shaft 309 is coupled to the interior of the clutch 309 and supported by bearings 311, 312. The outer shaft is formed in the inner housing 313 and coupled to the exterior of the clutch 309. The outer shaft is supported by bearings 318, 314 to provide support of the inner housing 313 relative to the outer housing 310. The chain 306 drives the drive gear 302 supported by the bracket 308. The disc utilizes the same mounting fasteners as the bracket 308 and is attached to the disc mounting interface of the wheel hub.

[0079] Fig.15 A mounting bracket 170 is shown according to some embodiments of the present invention. This type of mounting bracket is made to facilitate mounting the motor and disc brake caliper to the frame. The mounting bracket 170 includes through holes 171, 172 that can be sized to mate with an industry standard disc brake mounting interface on the frame. Additional holes 173 and 174 are provided to remount the disc brake caliper in an alternate location that can comply with a caliper mounting standard. This standard may be suitable for smaller or larger disc rotors.

[0080] Fig.16 A mounting bracket 180 is shown according to some embodiments of the present invention. This type of mounting bracket is Figure 7A variation of the bracket shown, but including threaded holes 181 and 182. Threaded fasteners such as set screws or screws may be installed in these holes to provide adjustable multiple contact points with the frame.

[0081] In some embodiments of the present invention, Fig.17A and Fig. 17B As shown, an enhanced mounting system is used. The bracket 440 has an interface portion 446 adapted to engage with the motor unit. The first mounting member 441 has a through hole 442 adapted to receive a fastener that can fasten the bracket 440 to the bicycle frame. The second mounting member 443 has a through hole 441 adapted to receive a fastener that can fasten the bracket 440 to the bicycle frame. The mounting pad portion 445 includes an extended interface area that provides increased lateral stability and load distribution when the bracket is mounted to its mating component. The bicycle frame rear portion 450 may include a bracket mounting area having a first mounting interface 451, which has a fastener receiving portion 452. The second mounting interface 453 may include a second mounting interface 453 having an extended interface area 455, which can be paired with the extended interface area of ​​the mounting pad portion 445 of the bracket 440. In some aspects, the interface dimensions other than the extended pad portion are standard dimensions for rear disc brake mounting interfaces.

[0082] In some embodiments of the present invention, Figures 19 to 21 As shown, a very compact electric bicycle motor system 501 has a motor 556 mounted on the inside of a bicycle frame 502. The outer housing 505 of the motor 556 is mounted to an integral mounting flange 503. The frame 502 can have a seat stay 504 and a chain stay 560 that intersect to support the axle of the rear wheel at an axis 555. The seat stay is a structural member that supports the rear axle mounting and can include a portion of the rear axle mounting that connects the elongated structural members. The frame can be metal and have an integral mounting 503. In some aspects, the frame can be made of aluminum, steel, or titanium among various alloys. In some aspects, a motor mounted to a bracket using a disc brake mount may not provide the stiffness, strength, or durability dictated by the design requirements. An integral mounting can overcome these problems.

[0083] Fig.21A view of an interior area of ​​a rear portion of a seat stay 504 having an integrated mount 503 is shown according to some embodiments of the present invention. An interior surface 509 of the integrated mount 503 provides an interface surface for a mating interface surface 510 of a motor housing 505. In some aspects, the interior surface 509 of the integrated mount 503 can be coplanar with the interior surface 508 of the rear portion of the seat stay 504. In some aspects, the interior surface 509 can be offset 3.5 mm from the exterior of the interior surface 508 of the rear portion of the seat stay 504. In other aspects, the interior surface 509 can be located at a predetermined distance relative to the end where the wheel hub intersects the frame. In other aspects, the interior surface 509 can be located at a predetermined distance relative to a plane where the wheel hub will have a disc mounted thereon. The interior surface 509 of the integrated mount 503 can have a groove 506 having parallel sides adapted to provide adjustment of the mating piece on a single axis 530. Two holes 507 provide alignment for mounting fasteners to couple the motor housing 505 to the integral mount 503 .

[0084] Although multiple positions of the inner surface 509 and the hole 507 are possible, there are configurations that are more efficient in structure and may be easier to measure for inspection on a production frame. In some aspects, the alignment of the hole 507 is roughly in line with the rear axle centerline. In some aspects, the alignment of the hole 507 with the rear axle centerline can be in an angular range of 0 degrees to 60 degrees. In some aspects, the radial distance between the axle centerline and the farthest hole 507 is 119mm. In some aspects, the radial distance between the axle centerline and the farthest hole 507 can have a distance that can be in the range of 50mm to 200mm. In some aspects, the distance between the position of the farthest hole 507 and the line connecting the motor rotation axis and the rear axle axis can be 10mm. In some aspects, the distance between the position of the farthest hole 507 and the line between the motor rotation axis and the rear axle axis can be in the range of 0mm to 100mm. In some aspects, the distance between the holes 507 can be 22mm. In some aspects, the distance between holes 507 can have a distance that can be in the range of 6 mm to 100 mm.

[0085] Fig.33Aspects of a mating interface for a motor 505 for mating with an integrated mount 503 are shown according to some embodiments of the present invention. The motor housing has a mating flange 521, which in turn has a mating surface 510, which is adapted to mate to an interface surface 509 of the integrated motor mount 503. A first guide 513 and a second guide 514 are raised above the mating surface 510 and are adapted to fit snugly within a slot 506 in the integrated motor mount 503. The projections 511, 512 on the sides of the guides 513, 514 are adapted to slide snugly with the slot 506 along an axis 531. The mounting slot 514 allows the motor housing 505 to move along the axis 531, which can allow for adjustment of chain tension in an electric bicycle motor system.

[0086] Fig.34 and Fig.35 Other aspects of attaching the motor housing 505 to the integral motor mount 503 are shown according to some aspects of the present invention. The housing retainer 522 allows the fastener 516 to fasten the mounting flange 521 to the motor mount. The housing retainer 522 has a raised portion 524 that expands to an outer width 525 that fits within a slot 530 on the back of the mounting flange 521 of the motor housing. When linear adjustment along the adjustment axis 531 is required, the fastener 516 and the housing retainer 522 remain in the same position while the motor housing moves along the adjustment axis. The dual slot system provides good alignment and rigidity at the mating interface of the motor housing and the motor mount. In some aspects, there can be a single fastener 516 or another number of fasteners 516.

[0087] Fig.30 Aspects of the configuration of a very compact electric bicycle motor system according to some embodiments of the present invention are shown. The laminate stack 606 has a centerline 620 defined as half the thickness of the laminate stack 606. The mounting surface 509 of the integrated motor mount 503 extends to a line 621 representing its lateral point. Even when the mounting surface 509 is on the inside of the seat stay 504, the centerline 602 of the laminate stack 606 is inboard of the mounting surface 509 of the integrated motor mount (closer to the centerline of the bicycle tire).

[0088] Figure 22 to Figure 29A view of a very compact electric bicycle motor system with a composite bicycle frame is shown according to some embodiments of the present invention. The very compact electric bicycle motor system 701 has a motor 556 mounted inside a bicycle frame 702. The outer housing 705 of the motor 556 is mounted to an integral mounting flange 703, which may have a flange mounting insert 720 that is integrally formed with the composite bicycle frame 702. The frame 702 may have a seat stay 704 and a chain stay 760 that intersect to support the axle of the rear wheel at axis 555. The frame may be a composite structure and have an integral mounting 703. In some aspects, the frame may be carbon fiber.

[0089] Fig.24 and Fig.26 A view of a rear portion of a seat stay 704 with an integrated mount 703 is shown according to some embodiments of the present invention. An inner surface 709 of the integrated mount 703 provides an interface surface for the mating interface surface 510 of the motor housing 505. In some aspects, the inner surface 709 of the integrated mount 703 can be coplanar with the inner surface 708 of the rear portion of the seat stay 704. The inner surface 709 of the integrated mount 703 can have a slot 706 with parallel sides adapted to provide adjustment of the mating piece on a single axis 730. Two holes 707 provide alignment for mounting fasteners to couple the motor housing 505 to the integrated mount 703.

[0090] In the case of the composite bicycle frame 702, the flange mounting insert 720 can be incorporated into the composite structure of the frame 702. In some aspects, the flange mounting insert is metal, such as aluminum, an aluminum alloy, steel, or titanium. Fig. 27 As shown in the cross-sectional view in , the flange mounting insert 720 can have a slot 706 and a hole 707 as part of its structure, as well as a counterbore 731 that allows the head of a fastener used to fasten the motor housing 505 to the integral mount 703 to be recessed.

[0091] Fig.31 and Fig.32Another embodiment of a very compact electric bicycle motor system is shown in which the motor is mounted on a chain stay. The chain stay is a structural member that supports a rear wheel axle mounting member connected to an elongated structural member. The chain stay is a structural member that supports the rear wheel axle mounting member and may include a portion of the rear wheel axle mounting member connected to the elongated structural member. In the most common configuration, there will be two stays: a chain stay and a seat stay. The lower stay is the chain stay and the upper stay is the seat stay. Many different embodiments with one, two, three or more stays are possible. In some aspects, the chain stay can be roughly in a straight line from the crank to the rear wheel axle. In other aspects, the chain stay can be raised to a higher position.

[0092] It is apparent from the above description that a wide variety of embodiments can be configured from the description given herein, and additional advantages and modifications will readily occur to those skilled in the art. Therefore, the present invention in its broader aspects is not limited to the specific details and illustrative examples shown and described. Therefore, departures from such details may be made without departing from the spirit or scope of the applicant's overall invention.

Claims

1. An electric bicycle system, comprising: a bicycle frame having a longitudinal axis, the bicycle including a first side and a second side, the bicycle frame including an integrated motor mount on a chain stay or a seat stay on the second side of the bicycle frame, the integrated motor mount having a mounting surface for a motor unit along an inner side surface of the integrated motor mount; A rear wheel coupled to the bicycle frame, the rear wheel comprising: Axis of rotation; a first pedal drive side of the rear wheel coupled to a first side of the bicycle frame; a second side of the rear wheel coupled to a second side of the bicycle frame; a wheel hub including a first end located on the first pedal drive side of the rear wheel and a second end located on the second side of the rear wheel; Wheel rims; a first spoke extending from the first end of the wheel hub to the wheel rim; and a second spoke extending from the second end of the wheel hub to the wheel rim; a motor unit comprising a motor having an axial centerline, the motor unit coupled to an integral motor mount of the bicycle frame, wherein the motor is a BLDC outward-rotating electric motor, the motor comprising a motor stator, and the stator diameter of the motor stator is greater than 2 times the thickness of the laminate stack, wherein a midpoint of the axial centerline of the motor unit is located inboard of a mounting surface of the integral motor mount; an output gear coupled to the motor; and A drive gear is coupled to a second side of the rear wheel, the drive gear being mechanically coupled to an output gear of the motor.

2. The electric bicycle system according to claim 1, wherein: The motor unit is coupled to the second side of the bicycle frame such that the motor's axis of rotation is longitudinally forward of the rear wheel's axis of rotation and within an outer diameter of the rear wheel.

3. The electric bicycle system according to claim 1, wherein: The laminate stack thickness has a stack midpoint along an axial centerline of the motor, and wherein the stack midpoint is located inboard of a mounting surface of the integral motor mount.

4. The electric bicycle system according to claim 2, wherein: The stator diameter of the motor stator is greater than 4 times the thickness of the laminate stack.

5. The electric bicycle system according to claim 1, wherein: The rear wheel includes a brake disc mounting interface along a second side of the rear wheel, and wherein the drive gear is mounted to the brake disc mounting interface.

6. The electric bicycle system of claim 1, further comprising a chain, wherein the drive gear is mechanically coupled to an output gear of the motor via the chain.

7. The electric bicycle system according to claim 1, wherein: The motor unit is suitable for use as a drive motor and as an electric power regenerative brake.

8. The electric bicycle system according to claim 3, wherein: The motor unit is suitable for use as a drive motor and as an electric power regenerative brake.

9. The electric bicycle system according to claim 1, wherein: The rear wheel includes a center hub having a disc brake mounting interface, and wherein the drive gear is mounted to the disc brake mounting interface.

10. The electric bicycle system according to claim 8, further comprising a motor controller and a power supply, wherein: The motor controller is coupled to the power source and the motor unit, the motor controller being adapted to provide power to the motor as a drive motor in a first operating mode and to use the motor for regenerative braking in a second operating mode.

11. The electric bicycle system according to claim 10, further comprising: a first chain tensioner that applies tension to the chain along a first chain portion on a first side of the motor gear; and A second chain tensioner applies tension to the chain along a second chain portion on a second side of the chain.

12. The electric bicycle system according to claim 11, wherein: The first chain tensioner includes a first chain idler sprocket mounted on a spring loaded arm adapted to maintain tension on the chain.

13. The electric bicycle system of claim 12, further comprising a second chain idler sprocket that applies tension to the chain along a second chain portion on a second side of the output gear of the motor.

14. An electric bicycle system, comprising: a bicycle frame having a longitudinal axis, the bicycle frame having a first side and a second side, the bicycle frame including an integrated motor mount on a chain stay or a seat stay on the second side of the bicycle frame, the integrated motor mount having a mounting surface for a motor unit along an inner side surface of the integrated motor mount; A rear wheel coupled to the bicycle frame, the rear wheel comprising: Axis of rotation; a first pedal drive side of the rear wheel coupled to a first side of the bicycle frame; and a second side of the rear wheel coupled to a second side of the bicycle frame; A motor unit, the motor unit comprising a motor, the motor comprising an axial centerline, the motor unit coupled to an integral motor mount of the bicycle frame, wherein the motor is a BLDC outrunner electric motor, the motor comprising a motor stator, and the stator diameter of the motor stator is greater than 2 times the thickness of the laminate stack, wherein the motor mount comprises: a first planar mounting surface; a pair of holes through the mount, wherein centerlines of the pair of holes define a first alignment axis; and a groove in the mounting surface, the groove including sides parallel to the first alignment axis; an output gear coupled to the motor; and A drive gear is coupled to a second side of the rear wheel, the drive gear being mechanically coupled to an output gear of the motor.

15. The electric bicycle system according to claim 14, wherein: The motor unit includes a mounting mating flange coupled to the integrated motor mount, wherein the mounting mating flange includes: a second planar mounting surface; and One or more raised guides, wherein the raised guides are located within the slots, allow adjustment of the position of the motor unit relative to the motor mount along the first alignment axis.

16. The electric bicycle system according to claim 15, wherein: The distance between the first planar mounting surface and the inner surface of the seat stay is in the range of 2.5 mm to 4.5 mm.

17. The electric bicycle system according to claim 15, wherein: The distance between the rotation axis of the rear wheel and the farthest hole of the pair of holes is in the range of 50 mm to 200 mm.

18. The electric bicycle system according to claim 15, wherein: The distance between the rotation axis of the rear wheel and the farthest hole of the pair of holes is in the range of 100 mm to 150 mm.

19. The electric bicycle system according to claim 16, wherein: The distance between the rotation axis of the rear wheel and the farthest hole of the pair of holes is in the range of 50 mm to 200 mm.

20. The electric bicycle system according to claim 15, wherein: The first planar mounting surface and the inner surface of the seat stay are substantially coplanar.

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