Energy storage unit for an electric bicycle comprising an integrated plug connector component

Abstract

The present invention relates to an energy storage unit (3) for an electric bicycle (1), comprising a housing element (35) on a housing of the energy storage unit (3), wherein a plug connector component (351) is provided on the housing element (35) in order to electrically connect the energy storage unit (3) to a drive system of the electric bicycle (1), which drive system is to be supplied with electric energy. The plug connector component (351) is an integral part of the housing element (35) and is formed in one piece therewith.

Description

[0001] Energy storage unit for an electric bicycle with integrated connector component

[0002] Description

[0003] The proposed solution concerns an energy storage unit for an electric bicycle.

[0004] Electric bicycles are equipped with an energy storage unit to supply the drive system, which typically has one or two electric motors. Such an energy storage unit comprises at least one energy storage device for storing electrical energy, typically in the form of a (rechargeable) battery. The energy storage unit is attached, for example, to a bicycle frame of the electric bicycle, often to a down tube of the bicycle frame.

[0005] A connector component is provided on the energy storage unit for electrical contact. This connector component is plugged into a connector component on the bicycle to supply electrical energy to the electric bicycle's drive system and, if necessary, other consumers, such as one or more lighting devices, via the energy storage unit.

[0006] In conventional energy storage units, the connector component is a separately manufactured component that is mounted to a housing element of the energy storage unit's housing. For example, in this context, a separately manufactured connector component is fixed to a front end cap, for example, by means of a screw connection.

[0007] Based on this, the proposed solution is based on the task of reducing the effort and costs for an energy storage unit for an electric bicycle.

[0008] This object is achieved with an energy storage unit according to claim 1. A proposed energy storage unit for an electric bicycle comprises a housing with a housing element, wherein a connector component is provided on the housing element for electrically connecting the energy storage unit to a drive system of the electric bicycle that is to be supplied with electrical energy. The connector component is an integral part of the housing element and is formed in one piece therewith.

[0009] In the proposed solution, a connector component is molded onto the housing element itself. The housing element thus forms a single, uniform component with the connector component. By integrating the connector component into a housing element of the energy storage unit's housing, the connector component does not need to be separately prefabricated and mounted to the housing. This saves assembly time and costs. Furthermore, by integrating the connector component into a housing element, the tightness of the energy storage unit's housing can be more easily ensured. This means that there is no need for a separate seal between an interface to be provided on the housing element for a separately manufactured connector component that is to be mounted on the housing element. With a connector component integrated into a housing element, less installation space is also required than with a design consisting of at least two parts.

[0010] The housing element can, in principle, be part of the housing of the energy storage unit, within which at least one energy storage device for storing electrical energy is accommodated. In this case, the housing element can, for example, form a wall of the housing.

[0011] Alternatively, the housing element is connected to a housing part of the housing and closes off an interior space in which the at least one energy storage device is accommodated. The housing part thus defines the interior space in which the at least one energy storage device is accommodated and which is closed off by the housing element integrating the connector component.

[0012] In principle, the housing element integrating the connector component can be provided at various locations on the housing. Given the typically elongated design of an energy storage unit in practice and the plug connection typically provided on the bicycle side at a longitudinal end of the energy storage unit, one design variant provides for the housing element integrating the connector component to be provided on one end of the housing.

[0013] For example, the housing element is formed by an end cap provided on the front side of the housing. Such an end cap is connected to a typically elongated housing part of the housing, in the interior of which the at least one energy storage device is accommodated.

[0014] The housing element can, for example, form a recess within which the connector component is located. This can ensure, for example, that the connector component does not protrude beyond a side or end surface defined by the housing element. The connector component can thus be located entirely within the recess formed by the housing element, regardless of whether the connector component is designed as a plug or socket.

[0015] Alternatively or additionally, the housing element can define and form at least one externally accessible attachment point for an electronic component. Such an electronic component can be, for example, a switch or a push-button that is accessible to a user—possibly when the energy storage unit is separated from the electric bicycle. Thus, an attachment point for such an electronic component is formed on the housing element so that the electronic component can be mounted thereon during manufacture of the energy storage unit. For example, the attachment point is formed with a trough-shaped or pocket-shaped recess in the housing element.

[0016] In one embodiment, alternatively or additionally, at least one additional connection opening can be provided on an outer surface of the housing element. Such a connection opening then serves, for example, for the engagement of a positioning or fixing element of a bicycle-side bearing point for the energy storage unit. For example, a web-shaped or pin-shaped positioning or fixing element is provided on a bicycle-side battery compartment in order to fix the energy storage unit in a specific orientation to the battery compartment. Such a web-shaped or pin-shaped positioning or fixing element then engages in a form-fitting manner in a connection opening (of possibly several connection openings) of the housing element when the energy storage unit is attached to the electric bicycle as intended.For a robust and comparatively lightweight design, the housing of the energy storage unit can be made at least partially of aluminum. This particularly includes a design variant in which one housing part is made of aluminum, and the housing element closing the interior of this housing part, with the connector component integrated therein, is made of a plastic material.

[0017] Part of the proposed solution is also an electric bicycle with a variant of a proposed energy storage unit.

[0018] The attached figures illustrate possible embodiments of the proposed solution.

[0019] Here we show:

[0020] Figure 1 shows a partial and partially sectioned view of a

[0021] Energy storage unit for an electric bicycle in the form of a battery unit with an end cap integrating a battery connector;

[0022] Figure 2 shows a detail and perspective view of the battery unit of Figure 1;

[0023] Figure 3 is a partially sectioned view of the battery unit of Figures 1 and 2, looking towards an inner side of the end cap facing the interior of the battery unit;

[0024] Figure 4 shows schematically an electric bicycle having a battery unit of Figures 1 to 3;

[0025] Figure 5 an enlarged section of a down tube of the electric bicycle of the

[0026] Figure 4, where the battery unit is attached.

[0027] Figure 4 shows an electric bicycle 1 with an electric motor drive unit A. The electric bicycle 1 has a frame 10, which here, for example, comprises a top tube 10.1, a down tube 10.2 and a seat tube 10.3 and to which the drive unit A is fastened in the region of an intersection point of the seat tube 10.3 and the down tube 10.2. Part of the drive unit A are control electronics SE and a sensor device 15, for example designed with a torque sensor and a position sensor, for sensorically detecting a torque introduced by muscle power at a drive shaft in the form of a bottom bracket shaft AT of the drive unit A. The sensor device 15 can alternatively or additionally comprise a speed sensor, via which the speed of the bottom bracket shaft AT can be detected.

[0028] An output element of the drive unit A, for example, a hollow output shaft mounted coaxially with the bottom bracket shaft AT, is connected to a rear wheel 12 of the electric bicycle 1 via a belt or chain 13 as a power transmission link in order to drive the electric bicycle 1. A wheel sensor 14 for determining the driving speed of the electric bicycle is assigned to this rear wheel 12, for example. Of course, the wheel sensor 14 can instead be provided on a front wheel 11 of the electric bicycle 1.

[0029] The drive unit A is part of a drive system of the electric bicycle 1, which further comprises an operating part 2. The operating part 2 is fastened in Figure 4, for example, in the area of ​​a handlebar of the electric bicycle 1 and is connected to the control electronics SE of the drive unit A, in this case via several connecting cables of a cable harness 5. A user input can be detected via the operating part 2 and used to control the drive unit A. For example, the operating part 2 further comprises at least one display to inform a user of the electric bicycle 1 about

[0030] - the current operating status of the drive unit A, for example with regard to a set support level,

[0031] - a charge state of an energy storage unit in the form of a battery unit 3 supplying the drive unit A with electrical energy, which contains at least one (rechargeable) battery, in particular a rechargeable battery, as an energy storage device, and / or

[0032] - to inform about a set gear which specifies the ratio with which a drive torque introduced by muscle power at the bottom bracket shaft AT is transmitted to the output element of the drive unit A.

[0033] The connecting cables of the wiring harness 5 are provided for connecting the battery unit 3 to the control unit 2 and for transmitting signals between the control unit 2 and the control electronics SE of the drive unit A. The wiring harness 5 typically also includes several connectors for connecting to the various electronic components of the electric bicycle 1 and the battery unit 3, which is secured to the down tube 10.2 via a battery holding frame 4.

[0034] The battery holding frame 4 is, for example, C-shaped here and accordingly has an elongated central part 402, which is connected at its longitudinal ends to two first and second end pieces 401, 403, each oriented perpendicularly thereto. The battery holding frame 4 defines a mounting location in a battery compartment for the battery unit 3 between the two end pieces 401 and 403, so that the battery unit 3, which is properly attached and locked to the battery holding frame 4, is connected to both end pieces 401, 403. For this purpose, a connection area with the plug 53 is provided on a second end piece 403, for example on a side of the second end piece 403 facing the opposite, first end piece 401. The battery unit 3 can be plugged into this connection area in order to establish an electrical connection between the at least one battery of the battery unit 3 and the cable harness 5.A locking device 42 is provided on the other, first end piece 401. This locking device 42 serves to mechanically lock the battery unit 3, which is mounted as intended on the battery holding frame 4.

[0035] If a battery unit 3, which is designed here as an example to be cuboid-shaped and elongated, is attached and locked to the battery holding frame 4 as intended, the battery unit 3 extends parallel to the elongated central part 402 of the battery holding frame 4.

[0036] Figure 5 shows the state of the battery holding frame 4 mounted on the down tube 10.2. In Figure 5, the battery holding frame 4 is inserted into a battery compartment 1020 of the down tube 10.2 and thus accommodated within a cavity of the down tube 10.2 that is open on one side. The battery unit 3 can be inserted into the battery compartment 1020 via the down tube 10.2, which is open on one side in this case, for example, on an underside. The battery unit 3 is first plugged into the connection area with one end face and then mechanically locked with its opposite end face to the locking device 42.

[0037] For closing and opening the locking device 42, a key 420 is provided, which can be inserted into a lock cylinder of the locking device 42. This lock cylinder is accessible from the outside when the battery holder unit 4 is properly mounted in the down tube 10.2. For the connection to the bicycle-side plug connector component in the form of the plug 53, the battery unit 3 has a corresponding plug connector component in the form of a battery plug 351 at its longitudinal end. According to the illustrations in Figures 1, 2 and 3, the battery plug 351 is an integral part of a housing element of the housing of the battery unit 3, which is designed as a front end cap 35. The end cap 35 of the battery unit 3 thus integrates the plug connector component 351 in that the plug connector component 351 is formed on the end cap 35.The end cap 35 closes an interior of the battery unit 3 defined by a battery housing part 30, in which the at least one battery is accommodated.

[0038] In the illustrated embodiment, the end cap 35 with the integrated battery connector 351 only needs to be attached to the end of the battery housing part 30 in order to, on the one hand, seal the battery housing part 30 at its longitudinal end and, on the other hand, to provide the battery connector 351 on the battery unit 3. No separately manufactured battery connector needs to be mounted on the end cap 35. Instead, the end cap 35 forms a single component with the integrated battery connector 351.

[0039] In this case, the battery connector 351 is formed in a connector recess 350 of the end cap 35. The battery connector 351 is completely located in the connector recess 350, so that the battery connector 351 does not protrude beyond an end surface of the end cap 35.

[0040] For electrically contacting a battery of the battery unit 3 inside the battery housing part 30, contacts for electrical contacting are provided on an outer surface 3510 of the plug recess facing the interior of the battery unit 3 (see Figure 3). Via this, the battery plug 351 is also electrically connected, for example, to a circuit board 33 inside the battery unit 3. Electrical contacts within the battery plug 351 are thus accessible on the inside 3510 of the plug recess 350 in order to connect the contacts of the battery plug 351 to the electronics and the at least one battery of the battery unit 3.

[0041] Also connected to the circuit board 33 is a switch or keypad 32 accessible on the outside of the end cap 35. This switch or keypad 32 can be used, for example, to electrically activate the battery unit 3 or to query the charge level of the battery unit 3 if the battery unit 3 has been removed from the electric bicycle 1. To simplify installation of the switch or keypad 32, the end cap 35 forms an attachment point in the form of a recess or pocket 352 at a distance from the plug recess 35, as shown in Figures 2 or 3. The switch 32 can be inserted into this recess or pocket 352 during installation of the battery unit 3. Electrical contact with the circuit board 33 can be made via through-openings in the base of the recess or pocket 352.

[0042] As can be seen in Figure 3, the recess or pocket 352 for the switch 32 is represented as a projection on the inside facing the interior of the battery unit 3. The same applies to any additional connection openings 353A and 353B provided on the outside and thus on the front of the end cap 35. A positioning or fixing element can engage in this connection opening 353A, 353B, which is provided on the battery compartment 1020 in the region of the bicycle-side plug 53 for a positive engagement in the end cap 35.

[0043] While the end cap 35 with the battery connector 351 integrally formed thereon is made of a plastic material, the battery housing part 30 in this case is made of aluminum.

[0044] List of reference symbols

[0045] 1 electric bike

[0046] 10 bicycle frames

[0047] 10.1 Top tube

[0048] 10.2 Down tube

[0049] 10.3 Seat tube

[0050] 1020 Battery compartment

[0051] 11 Front wheel

[0052] 12 rear wheel

[0053] 13 Belt / Chain

[0054] 14 Wheel sensor

[0055] 15 Sensor device

[0056] 2 Control panel

[0057] 3 Battery unit (energy storage unit)

[0058] 30 Battery housing part

[0059] 32 switches / buttons

[0060] 33 Printed circuit board (electronic component)

[0061] 35 End cap

[0062] 350 plug recess

[0063] 351 Battery connector (connector component)

[0064] 3510 outer surface with contacts

[0065] 352 Trough / pocket (attachment point)

[0066] 353A, 353B connecting opening

[0067] 4 battery holding frame (holding element)

[0068] 401 First end piece

[0069] 402 Middle section

[0070] 403 Second end piece with connection area

[0071] 42 Locking device

[0072] 420 keys

[0073] 5 Wiring harness with connecting cables

[0074] 53 Plug (connector component)

[0075] A drive unit

[0076] AT bottom bracket spindle

[0077] SE control electronics

Claims

Claims 1. Energy storage unit for an electric bicycle (1), with a housing element (35) on a housing of the energy storage unit (3), wherein a plug connector component (351) for electrically connecting the energy storage unit (3) to a drive system of the electric bicycle (1) to be supplied with electrical energy is provided on the housing element (35), characterized in that the plug connector component (351) is an integral part of the housing element (35) and is formed in one piece therewith.

2. Energy storage unit according to claim 1, characterized in that the housing element (35) is part of the housing of the energy storage unit (3), in the interior of which at least one energy storage device for storing electrical energy is accommodated.

3. Energy storage unit according to claim 2, characterized in that the housing element (35) forms a wall of the housing.

4. Energy storage unit according to claim 2, characterized in that the housing element (35) is connected to a housing part (30) of the housing and closes an interior space in which the at least one energy storage device is accommodated.

5. Energy storage unit according to one of the preceding claims, characterized in that the housing element (35) is provided on an end face of the housing.

6. Energy storage unit according to claims 4 and 5, characterized in that the housing element is formed by an end cap (35) provided on the front side of the housing.

7. Energy storage unit according to one of the preceding claims, characterized in that the housing element (35) forms a recess (350) within which the connector component (351) is located.

8. Energy storage unit according to one of the preceding claims, characterized in that the housing element (35) forms at least one externally accessible attachment point (352) for an electronic component, in particular for a switch or button (32).

9. Energy storage unit according to claim 8, characterized in that the attachment point is formed with a recess (352) in the housing element (35).

10. Energy storage unit according to one of the preceding claims, characterized in that the housing consists at least partially of aluminum.

11. Electric bicycle with an energy storage unit according to one of the preceding claims.

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