Bike frame having drive module enclosure

Abstract

The motorcycle includes a longitudinally elongated frame, a front fork rotatably engaged with a front wheel at a front end of the motorcycle, a rear fork rotatably engaged with a rear wheel at a rear end of the motorcycle, a handlebar supported for rotation at the front end of the frame for steering the motorcycle, and a drive module configured to drive the rear wheel of the motorcycle when selectively operated with power. The frame includes a downtube extending downwardly and rearwardly from the front end of the motorcycle, and a drive module enclosure formed at a second end of the downtube. The drive module enclosure defines a drive module receptacle opening along the longitudinal direction of the motorcycle. The drive module receptacle is sized to receive the drive module along the longitudinal direction of the motorcycle.

Description

[Technical field]

[0001] The present disclosure relates to a bike frame having a drive module enclosure. [Background technology]

[0002]

[0001] Running bikes may be used to train children to properly balance and control two-wheeled vehicles, such as bicycles and motorcycles. Running bikes may also include a drive train assembly (e.g., including an electric motor) that powers the running bike. Thus, running bikes allow for the development of children's skills, ranging from initial balancing to the more complex task of combining balance, throttle control, and braking. Summary of the Invention [Means for solving the problem]

[0003] In one aspect, the invention provides a motorcycle including a longitudinally elongated frame, a front fork rotatably engaged with a front wheel at a front end of the motorcycle, a rear fork rotatably engaged with a rear wheel at a rear end of the motorcycle, a handlebar supported by the front fork for rotation at the front end of the frame for steering the motorcycle, and a drive module configured to drive the rear wheel of the motorcycle when selectively operated with power. The frame includes a downtube extending downwardly and rearwardly from the front end of the motorcycle, the downtube having a first end located adjacent the front end of the motorcycle and a second end opposite the first end, and a drive module enclosure formed at the second end of the downtube defining a drive module receptacle opening along the length of the motorcycle, the drive module receptacle sized to receive a drive module along the length of the motorcycle.

[0004] In another aspect, the invention provides a bicycle frame elongated in a front-to-rear direction, the frame including a downtube extending downwardly and rearwardly from a front end of the frame, the downtube having a first end located proximate the front end of the running bike and a second end opposite the first end, a rear fork configured for rotatable engagement with a rear wheel, and a drive module enclosure formed in the second end of the downtube, the drive module enclosure defining a longitudinally opening drive module receptacle.

[0005] In another aspect, the invention provides a method of assembling a bicycle, the method comprising the steps of providing a drive module configured to selectively provide power to the bicycle, providing a longitudinally elongated frame including a downtube extending downwardly and rearwardly from a front end of the frame, the downtube having a first end located proximate the front end of the running bike and a second end opposite the first end, a rear fork configured for rotatable engagement with a rear wheel, and a drive module enclosure formed at the second end of the downtube, the drive module enclosure defining a longitudinally opening drive module receptacle, the method comprising the steps of longitudinally inserting the drive module into the drive module receptacle.

[0006]

[0004] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0007] [Figure 1] 1 is a perspective view of a running bike according to an embodiment of the invention. [Diagram 2] FIG. 2 is a first side view of the running bike of FIG. 1. [Diagram 3] FIG. 2 is a second side view of the running bike of FIG. 1. [Figure 4]FIG. 2 is an exploded perspective view of the running bike of FIG. [Diagram 5] FIG. 2 is another perspective view of the running bike of FIG. 1 with the side panels and chain guard removed to show the drivetrain assembly. [Figure 6] FIG. 2 is a perspective view of a portion of the running bike of FIG. 1 showing a drive module of a drivetrain assembly disposed within a drive module enclosure. [Figure 7] FIG. 2 is a cross-sectional side view of the running bike of FIG. 1 showing the drive module disposed within the drive module enclosure. [Figure 8] 2 is a first side view of the portion of the running bike of FIG. 1 showing a first set of fasteners securing the drive module to the frame in an exploded position. [Figure 9] 2 is a second side view of the portion of the running bike of FIG. 1 showing a second set of fasteners securing the drive module to the frame. [Figure 10] FIG. 10 is a cross-sectional view taken along line 10-10 showing a first set of fasteners and a second set of fasteners that secure the drive module to the frame of the running bike. [Figure 11] FIG. 2 is a perspective view of the frame of the running bike of FIG. 1. [Figure 12] FIG. 2 is a perspective view of the drivetrain assembly and electrical components of the running bike of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008]

[0017] Before describing any embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is susceptible to other embodiments and to being practiced or carried out in various ways.

[0009]

[0018] 1-4 show a bike 10, configured as, for example, a balance bike or running bike, including a longitudinally elongated frame 12. The longitudinal direction can be considered as a front-to-rear direction 14 or vice versa, a rear-to-front direction 15 (FIGS. 2, 3) of the running bike 10. The frame 12 includes a head tube 16, a down tube 20 extending downwardly and rearwardly from the head tube 16, a top tube 22 extending rearwardly from the head tube 16, and a rear fork 24. The area adjacent the head tube 16 defines a front end 18 of the frame 12 and running bike 10. The area adjacent the rear fork 24 defines a rear end 26 of the frame 12 and running bike 10. The head tube 16 is sized to receive and rotatably support a front fork 28 and handlebars 30 for steering the bike 10.

[0010]

[0019] A front wheel 34 is rotatably connected to the front fork 28, and a rear wheel 38 is rotatably connected to the rear fork 24. In the illustrated embodiment, the front fork 28 includes a suspension system and the rear fork 24 is a rigid fork. In other embodiments, the front fork 28 may lack a suspension system or the rear fork 24 may include a rear suspension system. A seat tube 40 is disposed between and coupled to the top tube 22 and the rear fork 24. The seat tube 40 is sized to receive a seat 42 that is adjustable relative to the top tube 22 and configured to support a rider on the bike 10.

[0011]

[0020] In the illustrated embodiment, the head tube 16 defines a cylindrical receptacle that houses a set of bearings (not shown) that rotatably support the front fork 28 and handlebar 30 within the head tube 16. Additionally, a front wheel 34 and a rear wheel 38 are connected to the front fork 28 and rear fork 24, respectively, by conventional bicycle axle hardware, such as nuts, bolts, and bearings, and serve to support the running bike 10 relative to the ground.

[0012]

[0021] The handlebar 30 includes left and right grips 44, 46 that may function as throttle inputs to a drivetrain assembly 50 (FIG. 11), and a brake lever 48 coupled to the handlebar 30 for selectively activating a front or rear braking system. For example, the right grip 46 may be integrated with a throttle sensor 47 such that the rider can twist the grip 46 relative to the handlebar 30 to adjust the amount of power provided to the drivetrain assembly 50. In other embodiments, an alternative throttle, such as a thumb lever throttle or the like, may be used. Although the disclosure is described with respect to a running bike, it should be understood that the frame 12 described herein may be used for other bicycles, such as electric bikes (e.g., E-bikes).

[0013]

[0022] 1-4, the down tube 20 includes a first end 54 connected to the head tube 16 and a second end 58 opposite the first end 54. A drive module enclosure 62 is formed in the second end 58 of the down tube 20. The drive module enclosure 62 defines a drive module receptacle 66 (FIG. 4) that is open longitudinally of the running bike 10. In the illustrated embodiment, the drive module receptacle 66 is open in both the front-to-rear direction 14 and the back-to-front direction 15 (FIGS. 2 and 3). The drive module receptacle 66 is sized to receive a drive module 70 of the drivetrain assembly 50. In the illustrated embodiment, the drive module receptacle 66 is only open longitudinally such that the drive module enclosure 62 does not permit lateral installation of the drive module 70. In the illustrated embodiment, the drive module receptacle is integral with the downtube 20 (e.g., welded together or formed as a single casting) rather than being removably secured via fasteners. In other embodiments, the drive module enclosure 62 may be removably attached to the downtube 20. The drive module enclosure 62 forms a tunnel for receiving at least a portion of the drive module 70 when the drive module 70 is assembled into a usable configuration. The drive module enclosure 62 may be open at both its front and rear ends. The drive module enclosure 62 includes an upper portion coupled to the second end 58 of the downtube 20 and a lower portion coupled to the rear fork 24.

[0014]

[0023] The downtube 20 includes a curved profile that provides additional clearance between the front wheel 34 and the downtube 20 as compared to a straight line between the ends 54, 58. The top tube 22 has a first end 74 that is connected to the head tube 16 and a second end 78 that is coupled to the rear fork 24. In other embodiments, the first end 74 of the top tube 22 may be connected to the downtube 20. In the illustrated embodiment, the downtube 20 and the top tube 22 each have a generally rectangular cross-sectional profile. In other embodiments, the downtube and / or top tube 22 may have alternative geometries (e.g., circular geometries, etc.).

[0015]

[0024] Continuing to refer to FIG. 4, the running bike 10 further includes a footrest 82 supported by the frame 12 adjacent the drive module enclosure 62, a battery pack 86 supported by the frame 12 adjacent the drive module enclosure 62, and a pair of side panels 88, 90. In the illustrated embodiment, the frame 12 includes a support platform 92 extending outwardly from the drive module enclosure 62 that supports the footrest 82. The running bike 10 does not include pedals for manually driving the rear wheel 38. In the illustrated embodiment, the footrest 82 has a generally U-shaped geometric shape that surrounds three sides (e.g., left side, right side, front side) of the drive module enclosure 62. For example, the footrest includes a left portion 94, a right portion 98, and a front portion 102 that connects the left portion 94 to the right portion 98. The left portion 94 and the right portion 98 each include a recess sized to receive a fastener that secures the footrest 82 to the support platform 92. The support platform 92 may form an integral part of the frame 12 .

[0016]

[0025] A pair of side panels 88, 90 are coupled to the frame 12 to enclose the drive module 70 within the drive module enclosure 62 and support an electronic control module 106. In the illustrated embodiment, the pair of side panels 88, 90 includes a left side panel 90 and a right side panel 88 that are connected together. The left and right side panels 90, 88 are coupled to each other and to the footrest 82. The combination of the side panels 88, 90 and the front portion 102 of the footrest 82 forms a battery mount 110 at a front end of each of the side panels 88, 90. The battery mount 110 supports a battery pack 86 that provides electrical power to the drive module 70 of the drivetrain assembly 50. In some configurations, the battery pack 86 is supported (e.g., by a sliding interface) for selective removal from the battery mount 110 to allow the battery pack 86 to be removed for charging or replacement. The battery mount 110 provides both a mechanical interface for the battery pack 86 and an electrical interface for establishing circuitry between the battery pack 86, the drive module 70, and the electronic control module 106, among other components.

[0017]

[0026] 5, 6 and 11, the drivetrain assembly 50 (shown separately in FIG. 11) includes a drive module 70 having a first sprocket 112, a second sprocket 114 coupled to the rear wheel 38 (FIG. 5), and a chain 118 extending between the first sprocket 112 and the second sprocket 114. In the illustrated embodiment, the second sprocket 114 is a freewheel sprocket that freely allows the rear wheel 38 to rotate faster than the second sprocket 114, allowing the running bike 10 to coast when the drive module 70 is not activated. The running bike 10 further includes a chain cover 120 (FIG. 4) that protects the chain 118.

[0018]

[0027] 11, the drive module 70 includes an electric motor 126, a gearbox 130 operably coupled to an output of the electric motor 126, and a first sprocket 112 coupled to an output shaft 131 of the gearbox 130 and driven by the electric motor 126. The drive module 70 can define a longitudinal axis A (FIG. 7), which in some configurations may be a central rotational axis of the electric motor 126 and / or the gearbox 130. In some configurations, the longitudinal axis A may be parallel to a longitudinal axis (e.g., front-to-back direction 14) of the running bike 10. The drive module 70 is electrically connected to the electronic control module 106, the battery pack 86, and a throttle sensor on the grip 46 via electrical cables 132, 134, 136. The electronic control module 106 receives a signal from the throttle 47 that provides power to the electric motor 126. In the illustrated embodiment, the electric motor 126 is a brushless motor. In other embodiments, the motor may be a brushed motor or other motor of equivalent functionality. The gearbox 130 includes a planetary gear reduction and a 90 degree angle drive output shaft 131 coupled to the first sprocket 112. Although the illustrated drive module 70 includes an electric motor 126, a gearbox 130, and a sprocket 112, the drive module 70 may include more or fewer components, or may include similar components in a different arrangement. For example, the drive module 70 may include only the electric motor 126.

[0019]

[0028] 6-8, the drive module enclosure 62 includes an inner surface 140 (FIG. 6) that supports the drive module 70 within the drive module receptacle 66. In the illustrated embodiment, the inner surface 140 is defined by a top surface 141 (FIG. 7), two opposing side surfaces 142 (FIG. 6), and a bottom surface 143 (FIG. 7). The inner surface 140 thus defines the drive module receptacle 66 that is open in a front-to-back direction 14 and a back-to-front direction 15 (specifically, only open in these two opposite directions 14, 15). In the illustrated embodiment, the side surfaces 142 are perpendicular to the adjacent top surface 141 and bottom surface 143. Thus, the drive module receptacle 66 is defined by the inner surface 140 and has a rectangular cross-sectional geometry. The rectangular cross-sectional geometry may include rounded corners between adjacent ones of the surfaces 141, 142, 143. Although the faces 141, 142, 143 are all flat, the inner surface 140 may have other combinations of face portions or may have a continuous face around its periphery. The frame 12 includes a mounting structure 144 spaced rearward of the drive module enclosure 62. During installation of the drive module 70, the drive module 70 is inserted into the drive module receptacle 66 in a front-to-back direction 14 and the drive module 70 is coupled to the mounting structure 144 to secure the drive module 70 within the drive module enclosure 62. The drive module receptacle 66 may partially or completely surround the drive module 70 and aid in positioning the drive module 70 relative to the longitudinal axis A (FIG. 8), although the drive module receptacle 66 may lack mounts or fasteners, leaving at least one degree of freedom for the drive module 70. In some embodiments, the drive module 70 may be inserted rearward in a forward direction 15.

[0020]

[0029] The drive module 70 is secured to the frame 12 of the bike 10 via a first pair of fasteners 154, 155 (FIGS. 6, 9, and 10) located on a first side (e.g., right side) of the bike 10 and a second pair of fasteners 152 (FIGS. 8 and 10) located on a second, opposite side (e.g., left side) of the bike 10. As shown in FIG. 10, the first pair of fasteners 154, 155 extend through openings 159, 161 formed in the drive module 70 and thread into respective threaded recesses 160 formed in the frame 12 (e.g., mounting structure 144). The second pair of fasteners 152 extend through openings 148 formed on the opposite side of the frame 12 (e.g., mounting structure 144) and thread into respective threaded recesses 149 formed in the drive module 70. In the illustrated embodiment, the aperture 161 has a standard "standard" clearance size to receive the first fastener 155 of the first pair of fasteners (e.g., a countersunk head screw such as a flat head machine screw). In the illustrated configuration, the fastener 155 has a conical taper on the underside of its head to mate with a similar complementary conical taper formed on the surface of the aperture 161 on the drive module 70. The remaining apertures 148, 159 are oversized such that the clearance is at least 10 percent greater (e.g., greater than 15 percent) than the standard "standard" clearance for the size of the fastener 152, 154. Standard "standard" fastener clearance diameters are determined by U.S. or international engineering organizations or governing bodies, such as ASME B18.2.8. The oversized configuration of the apertures 148, 159 facilitates longitudinal and vertical alignment of the apertures 148, 159 with the remaining threaded recesses 149, 160 following installation of the countersunk screw 155 into the threaded recess 160. In other words, during assembly of the bicycle 10, the countersunk screw 155 is threaded into the threaded recess 160 prior to installation of the remaining fasteners 152, 154.

[0021]

[0030] In some embodiments, the fasteners 152, 154, 155 may have an M6 nominal thread size. Code "standard" fastener clearance diameters are determined by U.S. or international engineering organizations or governing bodies, such as ASME B18.2.8. For example, according to ASME B18, the standard fastener clearance diameter for fasteners with an M6 nominal thread size is 6.6 millimeters. In other embodiments, the fasteners 152, 154, 155 may include alternative nominal thread sizes. It follows that the code standard clearance size varies by nominal fastener size.

[0022]

[0031] In the illustrated embodiment, the mounting structure 144 (FIGS. 4 and 8) is located at the lower end of the seat tube 40. As shown in FIGS. 8 and 10, the mounting structure 144 includes openings 148, each sized to receive a corresponding fastener 152 of the second pair of fasteners identified above. As shown, the mounting structure 144 may have a substantially flat outer surface and an inner surface that matches the geometry of the drive module 70. Also, the mounting structure 144 may be laterally offset from the illustrated longitudinal axis A. The mounting structure 144 may be in the form of a mounting plate integrated into the frame 12. The fasteners 152, 154, 155 may be oriented at an angle or perpendicular to the longitudinal axis A. As shown in FIG. 10, each of the fasteners 152, 154, 155 extends laterally toward the center of the frame 12 such that all of the fasteners 152, 154, 155 are parallel and extend in different horizontal directions.

[0023]

[0032] 6, 9, and 10, the drive module 70, and more specifically the gearbox 130 in the illustrated embodiment, includes a first fixed structure 158. The first fixed structure 158 includes two openings 159, 161 that are aligned with corresponding threaded recesses 160 formed in the mounting structure 144 and are sized to receive the first pair of fasteners 154, 155. The openings 159 (e.g., lower openings) formed in the first fixed structure 158 include an oversize diameter D1 that is larger than the standard "standard" fastener clearance diameter as determined by ASME B18.2.8 for the corresponding fasteners 154. For example, for an M6 fastener, the standard diameter D2 of the threaded recess 160 is 5 millimeters and the standard clearance diameter is approximately 6.6 millimeters, which is 32% larger than the diameter D2 of the threaded recess 160. In the illustrated embodiment, the oversized diameter D1 of the aperture 159 is at least 50% larger than the diameter D2 of the threaded recess 160. Additionally, the diameter D1 of the aperture 159 is approximately 15% larger than the standard "standard" fastener clearance diameter as determined by ASME B18.28. The oversized diameter configuration improves the ability to align the threaded recess 160 of the mounting structure 144 with the opening 159 of the first fastening structure 158 following engagement of the countersunk screw 155 with the recess 160. Thus, the larger diameter D1 of the aperture 159 relaxes the tolerances required during manufacture of the drive module 70 and the mounting structure 144 and facilitates longitudinal and vertical alignment of the apertures 148, 159 with the recesses 149, 160 during assembly of the running bike.

[0024]

[0033] 8 and 10, the mounting structure 144 includes two openings 148 that align with respective threaded recesses 149 (FIG. 10) formed in a second fixed structure 156 side of the drive module 70, more specifically, the gearbox 130 in the illustrated embodiment. The second fixed structure 156 is on the opposite side (e.g., in a left-to-right direction) from the first fixed structure 158. The openings 148 are elongated in the longitudinal direction of the bike 10 such that the width W1 (FIG. 8) of each opening 148 is greater than its height H1. For example, the width W1 of the openings 148 is at least 10% greater than the height H1 of the openings 148. In the illustrated embodiment, the width W1 of each opening 148 is approximately 15% greater than the height H1. For example, in the illustrated embodiment, the height H1 of each opening 148 is approximately 6.6 millimeters and the width W1 is approximately 7.6 millimeters. The elongated configuration of the aperture 148 facilitates longitudinal alignment of the aperture 148 of the mounting structure 144 with the threaded recess 149 of the drive module 70 such that the fasteners 152 can engage the threaded recesses 149 to secure the drive module 70 to the frame 12. The elongated aperture 148 thus reduces the tolerances required during manufacture of the drive module 70 and the mounting structure 144 and improves the ability to longitudinally align the aperture 148 with the recess 149. In some embodiments, the aperture 159 may be formed in a manner similar to the elongated aperture 148. Additionally, while the illustrated embodiment depicts four fasteners 152, 154, 155, it should be understood that more fasteners (e.g., five, six, etc.) or fewer fasteners (e.g., two or three) may be used to secure the drive module 70 to the frame 12.

[0025]

[0034] 4 and 7, at least one alignment structure 164, 168 is disposed between the drive module 70 and the inner surface 140 of the drive module enclosure 62 for supporting the drive module 70 within the drive module receptacle 66. In the illustrated embodiment, a first alignment structure 164 is integrally formed with the front portion 102 of the footrest 82, and a second alignment structure 168 is disposed opposite the first alignment structure 164. The first alignment structure 164 is sandwiched between a lower side of the drive module 70 and a lower surface 143 of the receptacle 66, and the second alignment structure 168 is sandwiched between an upper side of the drive module 70 and a top surface 141 of the receptacle 66. The first and / or second alignment structures 164, 168 may further include portions that are sandwiched between the drive module 70 and respective sides 142 of the receptacle 66. The configuration of the alignment structures 164, 168 forms a press-fit engagement between the alignment structures 164, 168 and the drive module 70 such that a front portion of the drive module 70 is supported within the drive module receptacle 66 without fasteners. In other words, the drive module receptacle 66 is comprised of walls that are completely devoid of fastener holes. The alignment structures 164, 168 also vertically align the threaded recesses 149, 160 with the openings 148, 159. In the illustrated embodiment, the alignment structures 164, 168 are spacers that are coupled to the foot rest 82 and / or the drive module enclosure 62.

[0026]

[0035] The alignment structures 164, 168 limit lateral (e.g., left to right) and vertical (e.g., up and down) movement of the drive module 70. At the same time, the fasteners 152, 154, 155 limit movement of the drive module 70 along the longitudinal axis of the running bike 10 (e.g., front to back 14 or back to front 15). In alternative embodiments, the alignment structures 164, 168 may be formed as a unitary structure or may be directly coupled to the drive module enclosure 62. In other words, it should be understood that the alignment structures 164, 168 may be formed in a variety of manners that limit lateral and / or vertical movement of the drive module 70.

[0027]

[0036] 6 and 7, the alignment structure 168 further includes a channel 172 disposed between the drive module 70 and the inner surface 140 of the drive module enclosure 62 such that the electrical cables 132, 134 (FIG. 7) can extend through the drive module receptacle 66 to electrically connect the battery pack 86 and the drive module 70 to the electronic control module 106. For example, a first electrical cable 132 extends from the drive module 70 through the channel 172 in the drive module receptacle 66 and connects to the electronic control module 106. A second electrical cable 134 extends from the battery mount 110 through the channel 172 in the drive module receptacle 66 and connects to the electronic control module 106. As a result, the configuration of the drive module enclosure 62 creates a compact arrangement of the drive module 70, the battery pack 86, and the electronic control module 106. Additionally, the drive module 70 and electronic control module 106 are easily accessible and removable from the running bike, improving the serviceability of the running bike.

[0028]

[0037] During assembly of the running bike, the drive module 70 is inserted into the drive module receptacle 66 along the longitudinal direction of the running bike 10. For example, the drive module 70 may be inserted in the front-to-rear direction 14 while moving along the longitudinal axis A of the drive module 70. The alignment structures 164, 168 are disposed between the drive module 70 and the inner surface 140 of the drive module enclosure 62. In the illustrated embodiment, the attachment of the foot rest 82 to the support platform 92 causes the first alignment structure 164 to be disposed between the lower surface 143 and the drive module 70. Following attachment of the foot rest 82, the second alignment structure 168 is disposed between an upper portion of the drive module 70 and the upper surface 141 of the drive module enclosure 62. In the illustrated embodiment, the drive module 70 is press fit until it engages the alignment structures 164, 168 to support the drive module 70 in the drive module receptacle 66 such that the drive module 70 has only a single degree of freedom, the ability to translate along the longitudinal axis A. The drive module 70 is translated in the front-to-back direction 14 along this one degree of freedom until it reaches a longitudinal position where a portion of the drive module 70 is aligned with the mounting structure 144. For example, a first fastening structure 156 of the drive module 70 is secured to the mounting structure 144 via fasteners 154, 155, and a second fastening structure 154 of the drive module 70 is secured to the mounting structure 144 via fastener(s) 152. In the illustrated embodiment, a countersunk head screw 155 is threaded into a threaded recess 160 prior to securing the remaining fasteners 152, 154. Once the drive module 70 is secured, the side panels 88, 90 are secured to the frame 12 (e.g., via engagement with the foot rest 82) to form the battery mount 110. Although the illustrated embodiment has the drive module 70 inserted in the front-to-back direction 14, it should be understood that the drive module could also be inserted in the back-to-forward direction 15. In such an embodiment, a portion of drive module 70 may extend beyond the front end of drive module enclosure 62 in a manner similar to drive module 70 .In other embodiments, the front portion of the drive module enclosure 62 may be partially or fully closed, with the drive module receptacle 66 only opening from the rear in the forward direction 15 .

[0029]

[0038] In some embodiments, for example after the bike 10 is serviced, the drive module 70 may be removed from the drive module enclosure and replaced with a replacement drive module. To remove the drive module 70, the side panels 88, 90 are disconnected from the frame 12 and the fasteners 152, 154, 155 (FIG. 10) are disengaged from the securing structures 156, 158 of the drive module 70. The drive module 70 may be biased out of engagement with the alignment structures 164, 168 to allow the drive module 70 to be removed towards the front end 18 of the running bike 10. Once the drive module 70 has been removed, a replacement drive module may be placed in the drive module enclosure 62 as described above to complete the repair or upgrade of the bike 10.

[0030]

[0039] Various aspects of the invention are set forth in the accompanying claims. [Aspect 1] It is a motorcycle, A long and narrow frame, a front fork rotatably engaged with a front wheel at a front end of the motorcycle; a rear fork rotatably engaged with a rear wheel at a rear end of the motorcycle; a handlebar supported for rotation by the front fork at the front end of the frame for steering the motorcycle; a drive module configured to drive the rear wheel of the bike when selectively activated with power, The frame is a down tube extending downwardly and rearwardly from the front end of the motorcycle, the down tube having a first end disposed adjacent the front end of the motorcycle and a second end opposite the first end; a drive module enclosure formed at the second end of the down tube defining a drive module receptacle opening along the longitudinal direction of the bike, the drive module receptacle sized to receive the drive module along the longitudinal direction of the bike. [Aspect 2] In the motorcycle according to aspect 1, The second end of the down tube terminates at an upper portion of the drive module enclosure and the rear fork extends from a lower portion of the drive module enclosure, such that the second end of the down tube and the rear fork are spaced apart by the drive module enclosure. [Aspect 3] In the motorcycle according to aspect 1, The frame further comprises a mounting structure spaced rearward of the drive module enclosure, the drive module being coupled to the mounting structure to secure the drive module within the drive module receptacle. Aspect 4 4. The bike of claim 3, The bike further comprising a seat tube connected to the top tube, the mounting structure being disposed at a lower end of the seat tube. Aspect 5 4. The bike of claim 3, a threaded recess formed in one of the drive module and the mounting structure; an elongated opening formed in the other of the mounting structure and the drive module, the elongated opening having a width extending in the longitudinal direction of the bike and a height extending in a vertical direction of the bike, the width of the elongated opening being at least 10 percent greater than the height of the elongated opening to facilitate longitudinal alignment of the elongated opening with the threaded recess; a fastener sized to extend through the elongated opening and engage with the threaded recess to secure the drive module to the frame of the bike. Aspect 6 In accordance with aspect 3, the motorcycle further comprises: The drive module includes: An electric motor; a gearbox coupled to the electric motor, the gearbox having an output shaft and secured to the mounting structure via fasteners that secure the drive module to the frame of the motorcycle; a first sprocket coupled to and driven by the output shaft of the gearbox. Aspect 7 4. The bike of claim 3, an opening formed in one of the mounting structure and the drive module, the opening having a first diameter; a threaded recess having a second diameter formed in the other of the mounting structure and the drive module, the first diameter of the opening being at least 50 percent greater than the second diameter of the threaded recess to facilitate longitudinal or vertical alignment of the opening and the threaded recess; a fastener sized to extend through the opening and engage with the threaded recess to secure the drive module to the frame of the bike. Aspect 8 2. The bike of claim 1, a battery mount and a battery selectively received by the battery mount; the battery is configured to selectively provide power to the drive module; The battery mount is disposed adjacent the second end of the down tube and configured to at least partially surround a front end of the drive module receptacle. Aspect 9 9. The bike of claim 8, further comprising: A motorcycle further comprising a left side panel and a right side panel that are integrally connected to form the battery mount at each front end. 〔Aspect 10〕 In the motorcycle according to Aspect 1, the drive module enclosure of the frame has an inner surface defined by an upper surface, a side surface, and a lower surface, and an alignment structure is arranged between the drive module and the inner surface of the drive module enclosure to support the drive module within the drive module receptacle. 〔Aspect 11〕 In the motorcycle according to Aspect 10, the drive module is arranged within the drive module receptacle so as to form a press-fit engagement between the alignment structure and the drive module to support the drive module within the drive module receptacle without fasteners. 〔Aspect 12〕 The motorcycle according to Aspect 10, further comprising an electronic control module arranged behind the downtube, the electronic control module being supported by one or more side panels. 〔Aspect 13〕 The motorcycle according to Aspect 12, further comprising an electrical cable connecting the battery mount to the electronic control module, the electrical cable extending through the drive module receptacle. 〔Aspect 14〕 In the motorcycle according to Aspect 13, the electrical cable extends through a channel formed in the alignment structure. 〔Aspect 15〕 The motorcycle according to Aspect 1, further comprising a footrest connected to and supported by the frame adjacent to the second end of the downtube, the alignment structure being integrally formed with the footrest so as to support the drive module within the drive module enclosure and limit lateral or vertical movement of the drive module. 〔Aspect 16〕 A longitudinally elongated motorcycle frame, the frame comprising a downtube extending downward and rearward from the front end of the frame, the downtube having a first end disposed adjacent to the front end of the motorcycle and a second end opposite the first end, a rear fork configured to be rotatably engaged with a rear wheel, A drive module enclosure formed at the second end of the down tube, the drive module enclosure defining a drive module receptacle that is open in the longitudinal direction, and a frame comprising the drive module enclosure. 〔Aspect 17〕 The frame according to Aspect 16, further comprising a mounting structure that is spaced behind the drive module enclosure and configured to provide a mounting point for a drive module within the drive module receptacle. 〔Aspect 18〕 The frame according to Aspect 17, further comprising a seat tube connected to the top tube, wherein the mounting structure is disposed at a lower end of the seat tube. 〔Aspect 19〕 In the frame according to Aspect 18, the mounting structure includes at least an opening configured to pass a first fastener for mounting the drive module, and the mounting structure includes at least one threaded recess configured to receive a second fastener for mounting the drive module. 〔Aspect 20〕 In the frame according to Aspect 19, the drive module receptacle consists of a wall without any fastener holes. 〔Aspect 21〕 A method of assembling a bicycle, the method comprising: providing a drive module configured to selectively provide power to the bicycle; providing a longitudinally elongated frame, the frame comprising: a down tube extending downward and rearward from a front end of the frame, the down tube having a first end disposed proximate the front end of the bicycle and a second end opposite the first end; a rear fork configured to rotatably engage a rear wheel; and a drive module enclosure formed at the second end of the down tube, the drive module enclosure defining a drive module receptacle that is open in the longitudinal direction, and providing a frame comprising the drive module enclosure; inserting the drive module longitudinally into the drive module receptacle. 〔Aspect 22〕 The method according to Aspect 21, and pressing the drive module into the drive module receptacle until it engages with an alignment structure disposed between the drive module and an inner surface of the drive module enclosure, such that the drive module is supported within the drive module receptacle with only a longitudinal degree of freedom. Aspect 23 22. A method according to embodiment 21, comprising: forming a mounting structure on the frame spaced rearwardly of the drive module enclosure; aligning a portion of the drive module with the mounting structure; and fastening the portion of the drive module to the mounting structure with a first fastener that engages a first threaded recess formed in the drive module. Aspect 24 23. The method of embodiment 22, comprising: following said engagement of said first fastener with said first threaded recess, aligning a second threaded recess formed in one of said drive module and said mounting structure with an elongated opening formed in the other of said mounting structure and said drive module; The method further comprising securing the drive module to the mounting structure with a second fastener sized to extend through the elongated opening and engage the second threaded recess. [Explanation of symbols]

[0031] 10. Bikes 12 Frames 14 Front to back 15 Back to front 16 Head tube 18 Front end of the bike 20 Downtube 22 Top tube 24 Rear fork 26 Rear end of motorcycle 28 Front fork 30 Handlebar 34 Front wheel 38 Rear wheel 40 Seat tube 42 sheets 44 Left Grip 46 Right Grip 47 Throttle Sensor 48 Brake lever 50 Drivetrain Assembly 54 First end of down tube 58 Second end of down tube 62 Drive Module Enclosure 66 Drive Module Receptacle 70 Drive Module 74 First end of top tube 78 Second end of top tube 82 Footrest 86 Battery Pack 88 Right side panel 90 Left side panel 92 Supported Platforms 94 Left part of footrest 98 Right part of the footrest 102 Front part of footrest 106 Electronic Control Module 110 Battery Mount 112 1st sprocket 114 Second sprocket 118 Chain 120 Chain cover 126 Electric Motor 130 Gearbox 131 90 degree angle drive output shaft 132, 134, 136 Cables 140 Inside the drive module enclosure 141 Top surface 142 Side 143 Bottom surface 144 Mounting structure 148 Aperture 149 Depression 152, 154, 155 Fasteners 156 Second fixed structure 158 First fixed structure 159 Aperture 160 Depression 161 Aperture 164 First aligned structure 168 Second alignment structure 172 channels A Longitudinal axis of the drive module D1 Oversized diameter of opening 159 D2 Standard diameter of recess 160 W1 Width of opening 148 H1 Height of opening 148

Claims

1. It is a motorcycle, A long and narrow frame, a front fork rotatably engaged with a front wheel at a front end of the motorcycle; a rear fork rotatably engaged with a rear wheel at a rear end of the motorcycle; a handlebar supported for rotation by the front fork at the front end of the motorcycle for steering the motorcycle; a drive module configured to drive the rear wheel of the bike when selectively activated with power, The frame is a downtube extending downwardly and rearwardly from the front end of the motorcycle, the downtube having a first end disposed adjacent the front end of the motorcycle and a second end opposite the first end; a drive module enclosure formed in the second end of the down tube defining a drive module receptacle open only in the longitudinal direction of the bike, the drive module receptacle sized to receive the drive module along the longitudinal direction of the bike; the drive module enclosure of the frame has an interior surface defined by a top surface, a side surface, and a bottom surface; An alignment structure is disposed between the drive module and the inner surface of the drive module enclosure to support the drive module within the drive module receptacle.

2. 2. The motorcycle according to claim 1, The second end of the down tube terminates at an upper portion of the drive module enclosure and the rear fork extends from a lower portion of the drive module enclosure, such that the second end of the down tube and the rear fork are spaced apart by the drive module enclosure.

3. 2. The motorcycle according to claim 1, The frame further comprises a mounting structure spaced rearward of the drive module enclosure, the drive module being coupled to the mounting structure to secure the drive module within the drive module receptacle.

4. A motorcycle according to claim 3, The bike further comprises a head tube, a top tube extending rearwardly from the head tube, and a seat tube connected to the top tube, the mounting structure being disposed at a lower end of the seat tube.

5. A motorcycle according to claim 3, a threaded recess formed in one of the drive module and the mounting structure; an elongated opening formed in the other of the mounting structure and the drive module, the elongated opening having a width extending in the longitudinal direction of the bike and a height extending in a vertical direction of the bike, the width of the elongated opening being at least 10 percent greater than the height of the elongated opening to facilitate longitudinal alignment of the elongated opening with the threaded recess; a fastener sized to extend through the elongated opening and engage with the threaded recess to secure the drive module to the frame of the bike.

6. A motorcycle according to claim 3, The drive module includes: An electric motor; a gearbox coupled to the electric motor, the gearbox having an output shaft and secured to the mounting structure via fasteners that secure the drive module to the frame of the motorcycle; a first sprocket coupled to and driven by the output shaft of the gearbox.

7. A motorcycle according to claim 3, an opening having a first diameter formed in one of the mounting structure and the drive module; a threaded recess having a second diameter formed in the other of the mounting structure and the drive module, the first diameter of the opening being at least 50 percent greater than the second diameter of the threaded recess to facilitate longitudinal or vertical alignment of the opening and the threaded recess; a fastener sized to extend through the opening and engage with the threaded recess to secure the drive module to the frame of the bike.

8. 2. A motorcycle according to claim 1, a battery mount and a battery selectively received by the battery mount; the battery is configured to selectively provide power to the drive module; The battery mount is disposed adjacent the second end of the down tube and configured to at least partially surround a front end of the drive module receptacle.

9. A motorcycle, A long and narrow frame, a front fork rotatably engaged with a front wheel at a front end of the motorcycle; a rear fork rotatably engaged with a rear wheel at a rear end of the motorcycle; a handlebar supported for rotation by the front fork at the front end of the motorcycle for steering the motorcycle; a drive module configured to drive the rear wheel of the bike when selectively activated with power, The frame is a downtube extending downwardly and rearwardly from the front end of the motorcycle, the downtube having a first end disposed adjacent the front end of the motorcycle and a second end opposite the first end; a drive module enclosure formed in the second end of the down tube defining a drive module receptacle open only in the longitudinal direction of the bike, the drive module receptacle sized to receive the drive module along the longitudinal direction of the bike; a battery mount and a battery selectively received by the battery mount; the battery is configured to selectively provide power to the drive module; the battery mount is disposed adjacent the second end of the downtube and configured to at least partially surround a front end of the drive module receptacle; The bike further includes a left side panel and a right side panel connected together to form the battery mount at a front end of each side panel.

10. 2. The motorcycle according to claim 1, The drive module is disposed within the drive module receptacle to form a press-fit engagement between the alignment structure and the drive module to support the drive module within the drive module receptacle without fasteners.

11. 2. A motorcycle according to claim 1, The bike further comprises an electronic control module disposed rearwardly of the down tube, the electronic control module being supported by one or more side panels.

12. A motorcycle as claimed in claim 11, The motorcycle further comprising an electrical cable connecting a battery mount to the electronic control module, the electrical cable extending through the drive module receptacle.

13. A motorcycle according to claim 12, The electrical cable extends through a channel formed in the alignment structure.

14. 2. A motorcycle according to claim 1, the alignment structure being integrally formed with the footrest to support the drive module within the drive module enclosure and to limit lateral or vertical movement of the drive module.

15. A longitudinally elongated bicycle frame, the frame comprising: a down tube extending downwardly and rearwardly from a front end of the frame, the down tube having a first end disposed adjacent the front end of the frame and a second end opposite the first end; a rear fork configured to be rotatably engaged with the rear wheel; a drive module enclosure formed at the second end of the downtube, the drive module enclosure defining a drive module receptacle open only in the longitudinal direction; The drive module receptacle comprises walls that are devoid of fastener holes and forms a fastener-free press-fit engagement between the drive module and alignment structures for supporting the drive module within the drive module receptacle.

16. 16. A frame according to claim 15, The frame further comprising a mounting structure spaced rearward of the drive module enclosure and configured to provide a mounting point for a drive module in the drive module receptacle.

17. 17. A frame according to claim 16, A frame further comprising a head tube, a top tube extending rearward from the head tube, and a seat tube connected to the top tube, the mounting structure being disposed at a lower end of the seat tube.

18. 18. The frame of claim 17, the mounting structure includes at least an opening configured to pass a first fastener for mounting the drive module, and the mounting structure includes at least one threaded recess configured to receive a second fastener for mounting the drive module.

19. 1. A method of assembling a motorcycle, the method comprising: providing a drive module configured to selectively provide power to the bike; Providing a longitudinally elongated frame, the frame comprising: a downtube extending downwardly and rearwardly from a front end of the frame, the downtube having a first end disposed proximate the front end of the frame and a second end opposite the first end; A rear fork configured to be rotatably engaged with the rear wheel; and providing a frame comprising a drive module enclosure formed at the second end of the downtube, the drive module enclosure defining a drive module receptacle open only in the longitudinal direction; and inserting the drive module into the drive module receptacle in the longitudinal direction, forming a mounting structure on the frame spaced rearwardly of the drive module enclosure; aligning a portion of the drive module with the mounting structure; and fastening the portion of the drive module to the mounting structure with a first fastener that engages a first threaded recess formed in the drive module.

20. 20. The method of claim 19, the drive module enclosure has an interior surface defined by a top surface, a side surface, and a bottom surface; The method further comprises the step of pressing the drive module into engagement with alignment structures disposed between the drive module and the inner surface of the drive module enclosure, such that the drive module is supported within the drive module receptacle with only a longitudinal degree of freedom.

21. 20. The method of claim 19, following said engagement of said first fastener with said first threaded recess, aligning a second threaded recess formed in one of said drive module and said mounting structure with an elongated opening formed in the other of said mounting structure and said drive module; The method further comprising securing the drive module to the mounting structure with a second fastener sized to extend through the elongated opening and engage the second threaded recess.

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