Frame structure for electric vehicles

Abstract

The present subject matter discloses a frame structure (100) for an electric vehicle (EV) is disclosed. The frame structure comprises a first bracket (102) configured to structurally support at least a handlebar assembly (104), and a second bracket (106) configured to structurally support at least an electric motor (108). A plurality of elongated fasteners (110) connect the first bracket (102) and the second bracket (106) to form a box-shaped enclosure for a battery (118). These fasteners (110) are configured to align with surfaces of the battery's housing (118a). At least one of the elongated fasteners from among the plurality of elongated fasteners (110) directly couples the electric motor (108) to the second bracket (106), providing a compact and robust assembly. integrating the battery as a structural component and providing a compact, rigid, and efficient design.

Description

FRAME STRUCTURE FOR ELECTRIC VEHICLES TECHNICAL FIELD

[0001] The present subject matter relates, in general, to electric vehicles (EVs), and, particularly but not exclusively, to a frame structure for an electric vehicle that incorporates a battery enclosure as a structural component of the frame structure.BACKGROUND

[0002] Electric two-wheeled vehicles, such as electric bicycles and electric scooters, typically include a frame structure. The frame structure may comprise a plurality of interconnected rods or tubes, designed to provide sufficient structural integrity to support a rider and various vehicle components. Beyond structural support, the frame structure commonly serves to house various electrical components and provides mounting points for other essential parts of the vehicle, such as steering mechanisms, suspension systems, and drive train elements.

[0003] An energy storage device, such as a battery pack, is an indispensable component of an electric two-wheeled vehicle. The battery pack supplies power to the electric motor and other electrical systems. The secure integration and positioning of this energy storage device within the vehicle's architecture is critical for overall performance, weight distribution, and rider ergonomics.

[0004] Various configurations exist for securing the battery pack to the electric two-wheeled vehicle. In some designs, the battery pack may be fitted within the confines of the interconnected rods or tubes that form the main frame structure. For example, the battery pack may be strategically situated beneath a foot region, providing a low center of gravity. In some configurations, the battery pack with its housing may be positioned in a rear portion of the vehicle, such as below a pillion area, or integrated into other sections depending on the specific vehicle design and intended use. Thesearrangements aim to balance factors such as space utilization, accessibility, and weight distribution.BRIEF DESCRIPTION OF DRAWINGS

[0005] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.

[0006] Figure. 1A illustrates a perspective view of a frame structure of an electric vehicle without a battery housing, in accordance with an implementation of the present subject matter;

[0007] FIG. 1 B-1 C illustrate exploded views of the frame structure of the electric vehicle without the battery housing, in accordance with an implementation of the present subject matter;

[0008] Figure 1 D illustrates a side view of the frame structure of the electric vehicle without the battery housing, in accordance with another implementation of the present subject matter;

[0009] Figure 2A illustrates a perspective view of the frame structure of the electric vehicle with the battery housing, in accordance with an implementation of the present subject matter;

[0010] Figure 2B illustrates an exploded view of the frame structure of the electric vehicle with the battery housing, in accordance with an implementation of the present subject matter;

[0011] Figure 2C illustrates a cross-sectional view of the frame structure of the electric vehicle with the battery housing, in accordance with an implementation of the present subject matter;

[0012] Figure 2D illustrates a cross-sectional view of the battery housing enclosing a battery pack of the electric vehicle, in accordance with an implementation of the present subject matter;

[0013] Figure 2E illustrates an exploded view of the battery housing enclosing the battery pack of the electric vehicle, in accordance with an implementation of the present subject matter;

[0014] Figure 3A-3D illustrate various views of a second bracket of the frame structure, in accordance with an implementation of the present subject matter;

[0015] Figure 4A-4D illustrates various views of a mounting bracket for a side stand assembly of the frame structure, in accordance with an implementation of the present subject matter;

[0016] Figure 5A-5B illustrate side views of the frame structure, depicting a main stand in extended position, in accordance with an implementation of the present subject matter;

[0017] Figure 6A-6B illustrate perspective views of the frame structure, depicting the main stand in a retracted position and an extended position, respectively, in accordance with an implementation of the present subject matter; and

[0018] Figures 7A-7B illustrate perspective views of the frame structure with the side stand and the main stand in a retracted position and an extended position, respectively, in accordance with an implementation of the present subject matter.DETAILED DESCRIPTION

[0019] The present subject matter relates to a frame structure for an electric vehicle.

[0020] In the rapidly advancing field of electric vehicle (EV) design and manufacturing, particularly the two-wheeler and the three-wheeler electric vehicles, integrating the battery pack and electric motor into the vehicle's structural frame presents multiple challenges. These challenges arise primarily from the intrinsic nature of these components. Electric vehicle (EV) battery packs with their housings typically have substantial mass and volume, while electric motors, though highly efficient, generate significanttorque and vibrations that require robust management. Consequently, designing a structurally rigid and cost-effective vehicle structure becomes a complex task.

[0021] To address the issue of battery integration, it is common industry practice to treat the battery as a distinct, often isolated module within existing frame structures of electric vehicles. This approach usually necessitates a separate, dedicated housing for the battery, which due to the critical need for robust protection adds a significant amount of weight to the electric vehicle. Moreover, this conventional method fails to utilize the inherent structural potential of the battery housing itself. Rather than contributing to the primary load-bearing elements, the battery housing becomes an additional mass that the surrounding frame must support, leading to over-engineered and heavier structural components that reduce overall vehicle weight efficiency of the conventional frame structures.

[0022] In addition, due to numerous elements involved in the assembly of the frame structures, manufacturing them becomes complicated and cost intensive. Furthermore, when such frames are designed to accommodate and support a battery pack with their housing, they typically necessitate the use of excess material. This contributes to a disproportionate increase in vehicle weight without offering commensurate structural or functional benefits. Consequently, this resultant excess mass impacts the vehicle's dynamic performance and also compromises energy efficiency.

[0023] Additionally, existing frame structures often present challenges in efficiently integrating other essential components of electric vehicle, such as the electric motor, handlebar or steering assemblies, and various control units. Mounting these components typically requires additional fasteners, and support structures, which increase the overall part count, manufacturing time, and potential points of failure. Furthermore, providing robust and protected locations for sensitive electrical components, such as the Electrical Control Unit (ECU) within the confined space of electric vehicles remains a significant design hurdle.

[0024] Therefore, there is a need for an improved frame structure for electric vehicles that addresses the above limitations. Specifically, the frame structure should provide superior structural integrity by effectively integrating the battery housing into the primary structural framework, enabling the battery to contribute to the overall structural integrity of the vehicle, and while also simplifying the manufacturing process.

[0025] In accordance with the present subject matter, a frame structure for electric vehicle is provided. In example implementations, the present tire frame structure provides to solve the above-mentioned problems.

[0026] In accordance with an implementation, the frame structure comprises a first bracket to structurally support at least a handlebar assembly, a second bracket configured to structurally support at least an electric motor of the electric vehicle, and a plurality of elongated fasteners to connect the first bracket and the second bracket to form a box-shaped enclosure for a battery of the electric vehicle. The plurality of elongated fasteners are configured to align with surfaces of a housing of the battery, wherein at least one of the plurality of elongated fasteners is to directly couple the electric motor to the second bracket.

[0027] By providing a simple, lightweight, and modular frame structure design for electric vehicle that defines an enclosure for the battery, provides improvement in structural integrity by integrating the battery housing as an essential structural component of the electric vehicle’s frame provides for effective utilization of the components by using the battery unit as a structural element rather than merely a payload, resulting in enhanced overall structural integrity and rigidity, particularly around the vehicle’s heaviest component. Additionally, the integrated and simplified design enables a more cost-effective and less complex manufacturing process by reducing redundant structural elements, lowering overall vehicle weight, and minimizing both labor and material costs compared to conventional multi-component frame and battery integration methods.

[0028] The above-mentioned implementations are further described herein with reference to the accompanying figures. It should be noted that the description and figures relate to exemplary implementations and should not be construed as a limitation to the present subject matter. It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and embodiments of the present subject matter, as well as specific examples, are intended to encompass equivalents thereof.

[0029] Figure 1 A illustrates a perspective view of the frame structure 100 of an electric vehicle (not shown), Figures 1 B and 1 C illustrate exploded views of the frame structure 100, in accordance with an example implementation of the present subject matter. For the sake of explanation, Figures 1A, 1 B, and 1 C are described together below.

[0030] Examples of the electric vehicle may include, but is not limited to, an electric scooter, an electric motorcycle, an electric moped, or a threewheeled electric vehicle. In an example, the frame structure 100 of the electric vehicle comprises a first bracket 102 to structurally support at least a handlebar assembly 104, a second bracket 106 configured to structurally support at least an electric motor 108 of the electric vehicle 100, and a plurality of elongated fasteners 110 to connect the first bracket 102 and the second bracket 106 to form a box-shaped enclosure for a battery (as illustrated in Figure 2A) of the electric vehicle 100, the plurality of elongated fasteners 110 are configured to align with surfaces of a housing 118a of the battery 118, wherein at least one of the plurality of elongated fasteners 110 is configured to directly couple the electric motor 108 to the second bracket 106.

[0031] In an example implementation, the first bracket 102 and the second bracket 106 are substantially rectangular in shape, such that their longitudinal edges are oriented to be perpendicular to the intended direction of movement of the electric vehicle. The interconnection between thesebrackets is achieved through a plurality of elongated fasteners 110 That are oriented in the direction of movement of the electric vehicle.

[0032] In an example, the plurality of fasteners 110 may comprise at least eight elongated fasteners arranged in a configuration. As depicted in Figure 1 B and 1 C, this arrangement may include a first set of fasteners, comprising at least four elongated fasteners 110a, 110d, 110e, and 11 Oh, each positioned to extend between the respective corner edges of the first bracket 102 and the corresponding corner edges of the second bracket 106. Concurrently, a second set of fasteners, also comprising at least four elongated fasteners 110b, 110c, 11 Of, and 110g, is positioned along the upper longitudinal edge and the lower longitudinal edge of both the first bracket 102 and the second bracket 106. The fasteners of the second set are situated between the fasteners of the first set (i.e. , between the corner fasteners along the longitudinal edges). The electric motor 108 is directly coupled to the second bracket 106 utilizing one or more fasteners from this second set of elongated fasteners, thereby integrating the motor mounting directly into the primary frame structure.

[0033] While the preceding description describes an exemplary configuration of the frame stricture 100 utilizing eight elongated fasteners 110 for interconnecting the first bracket 102 and the second bracket 106 with the battery housing 118a, it is imperative to understand that this specific arrangement is not intended as a limitation of the present subject matter. Various other configuration may also be possible that may comprise more than 8 elongated fastener to suit diverse structural requirements, battery sizes, and design objectives. For example, a configuration employing ten elongated fasteners may be possible. In such an alternative embodiment, three elongated fasteners may be positioned along each of the upper and lower edges of both the brackets with the remaining fasteners being distributed along the side edges. This flexibility allows for scalable and adaptable designs across a range of electric vehicle platforms, optimizing structural performance for varied applications.

[0034] In an example, the first bracket 102 may also support, but not limited to, a front wheel assembly (not shown), a front suspension assembly (not shown), and a headlight assembly (not shown). The second bracket 106 may also support, but not limited to, a rear wheel assembly (not shown), a rear suspension assembly (not shown), and components of a pillion (passenger seating). Figure 1 A-1 C also illustrate a side stand assembly 114 and its corresponding mounting bracket 114a and side stand 114b, a main stand assembly 116, and an integrated control board 112, all shown as part of the frame structure 100. Each of these components is described in detail subsequently.

[0035] Figure 1 D illustrates a side view of the frame structure 100 of the electric vehicle without the battery housing, in accordance with another implementation of the present subject matter.

[0036] As depicted, the frame structure 100, defines a box-shaped enclosure for the battery pack 118 and integrates the battery housing 118a. In an example, the housing 118a of the battery 118 may be shaped complementary to, and may be positioned within, the box-shaped enclosure, such that, the first bracket 102 is configured to align with a front opening of the housing 118a and the second bracket 106 is configured to align with a rear opening of the housing 118a.

[0037] In an example, this housing 118a of the battery 118 may include a plurality of hollow tubular structures ( as depicted later in Figure 2D) that align with the elongated fasteners 110. When the fasteners 110 extend from the first bracket 102 to the second bracket 106 (or vice versa), they pass through these tubular structures within the battery housing 118a, thereby clamping the battery housing rigidly between the two brackets. This arrangement ensures the battery pack is not merely a payload but an integral, load-bearing component of the frame structure, significantly enhancing its overall rigidity and structural integrity.

[0038] Furthermore, the design of the elongated fasteners 110 facilitates easy operation, allowing for the selective removal of either the first bracket102 (front) or the second bracket 106 (rear). This enables the convenient extraction of the battery pack 118 from its housing 118a. Such a separable connection is crucial for various practical purposes, including the replacement of the battery , or for conducting necessary repair and maintenance operations on the battery unit or other internal components without requiring extensive disassembly of the entire frame.

[0039] In an example, to further enhance the integration and support of a battery housing (not depicted in this view), the first bracket 102 and the second bracket 106 may each incorporate four inwardly extending portions, such as annular flanges, as depicted by ‘A’, projecting from their respective edges. In the fully assembled state, these inwardly extending portions are configured to facilitate direct and comprehensive support to the battery housing, thereby ensuring its secure and integrated placement within the frame structure 100.

[0040] In an embodiment, the first bracket supports a head tube part 104, 104a, forming a portion of the handlebar assembly. As depicted, the handlebar assembly is structurally supported on the annular flange of the first bracket 102.

[0041] Figure 2A illustrates a perspective view of the frame structure of the electric vehicle with the battery housing 118a, Figure 2B illustrates an exploded view of the same frame structure of the electric vehicle, in accordance with an implementation of the present subject matter. For the sake of explanation, Figures 2A and 2B are described together below.

[0042] As depicted, the frame structure 100, comprising the first bracket 102, the second bracket 106, and the plurality of elongated fasteners 110. The frame structure 100 also comprises a battery pack 118 and its corresponding housing 118a. Examples of the battery pack 118 may include, but are not limited to, a lead-acid battery pack, a lithium-ion battery pack, a nickel metal hydride battery pack, and a solid-state battery pack. All other components of the frame structure 100, as previously described with respect to Figures 1A-1 C, are similarly present.

[0043] In an example, the battery pack 118 may be partially encased within its housing 118a, such that the housing 118a may be open from both its front and rear sidewalls. As explained previously, the housing 118a may be specifically configured to interact with the inwardly extending portions A (e.g., annular flanges) of the first bracket 102 and the second bracket 106. This interaction is designed such that the flanges A precisely align with corresponding features or internal surfaces (not shown) of the battery housing 118a, thereby providing positive engagement and secure support. This structural interaction allows the battery housing 118a to be securely supported within the box-shaped enclosure formed by the interconnected first bracket 102, second bracket 106, and plurality of elongated fasteners.

[0044] In an embodiment, when the first bracket 102, the battery 118 encased within its housing 118a, and the second bracket 106 are interconnected together using the plurality of elongated fasteners 110, the first bracket 102 faces the front opening 118-1 of the housing 118a and the second bracket 106 faces the rear opening 118-2 of the housing 118a, thereby actively closing the open front and rear ends of the battery housing 118a. This may be further facilitated by a first sealing gasket (not shown) disposed between the first bracket 102 and the housing 118a, and a second sealing gasket disposed between the second bracket 106 and the housing 118a. This effective sealing ensures that the battery pack 118 with its housing 118a is fully encapsulated within the box-shaped enclosure defined by the frame structure 100, thereby offering comprehensive protection from the ingress of environmental elements such as moisture, dust, and other contaminants, as well as against external mechanical impacts.

[0045] In an example, the plurality of elongated fasteners 110, by exerting a clamping force that draws the first bracket 102 and second bracket 106 together, firmly secure the battery housing 118a in its designated position. This operational mechanism not only provides superior physical protection but also integrates the battery housing 118a as a critical, load-bearing component of the electric vehicle's structural assembly. Suchintegration inherently enhances the overall frame rigidity of the electric vehicle and significantly contributes to improved occupant safety during vehicle operation.

[0046] In an example, the frame structure 100 also comprises a side stand assembly 114. The side stand assembly 114 comprises a mounting bracket 114a having a pair of through holes provided along a pair of edges to accommodate a pair of elongated fasteners from amongst the first set of fasteners aligned in a vertical direction. The side stand assembly 114 also comprises a side stand 114b, which is mounted on this mounting bracket 114a in a foldable arrangement, allowing it to be stowed when not in use. In an example, the side stand 114b and the mounting bracket 114a may have a plurality of holes through which the side stand 114b and the side bracket 114a can be attached to the battery housing using the plurality of fasteners 110, for example, 110d and 110e (as illustrated in Figure 1 C). The detailed structure of the mounting bracket 114a is explained subsequently with reference to Figures 4A-4D.

[0047] In an example, the frame structure 100 may be designed to be easily assembled and disassembled. This may facilitate maintenance and repair of the electric vehicle, potentially reducing downtime and costs. For instance, the first bracket 102, the second bracket 106, and battery housing 108a may be designed to be easily detached from each other, allowing easy access to the battery pack and other components of the EV. Similarly, the additional components, such as the handlebar assembly, the seat assembly, or the wheel assembly may be designed to be easily attached and detached from the frame structure 100.

[0048] Figure 2C illustrates a cross-sectional view of the frame structure 100, in accordance with an example implementation of the present subject matter.

[0049] As depicted, a battery 118 may be disposed between the first bracket 102 and the second bracket 106 using the plurality of fasteners 110 to form the frame structure 100 of the electric vehicle. The battery 118comprises a housing 118a and a plurality of battery cells 118b arranged therein.

[0050] As explained previously, in an example, each of the first bracket 102 and the second bracket 106 includes an inwardly extending annular flange. These flanges project inwards from the brackets, serving to structurally support various components within the integrated frame. In a further example implementation, the top surface of the inwardly extending annular flange of the first bracket 102 is configured to structurally support a head tube 104a of the handlebar assembly. The head tube 104a is a fundamental and often cylindrical or conical component integrated into the front portion of the vehicle's frame. It serves as the primary bearing housing and pivot point for the front fork assembly, which connects the handlebars, front wheel, and steering mechanism to the main chassis.

[0051] Figure 2D illustrates a cross-sectional view of the battery 118 with its housing 118, of the frame structure 100, in accordance with an example implementation of the present subject matter.

[0052] In an example, the battery housing 118a may be manufactured by an extrusion process, utilizing various materials such as, but not limited to, aluminum, steel, or carbon fiber. The thickness of the extruded housing 118a can be varied according to a desired structural strength and rigidity. Extrusion may offer several advantages in the production of the housing 118a, including high production rates and the ability to work effectively with materials that may be brittle in their normal state. In some cases, the extrusion process may be combined with other manufacturing processes to create more complex parts of the housing.

[0053] As a result of the extrusion process, the housing 118a may include a plurality of longitudinal channels 202. In an example, these longitudinal channels 202 may be integrated on its top surface and side surfaces. These longitudinal channels offer several significant advantages. Primarily, their integrated design inherently enhances the structural rigidity and torsional stiffness of the battery housing 118a itself, contributing directlyto the overall integrity of the frame structure 100. In an example, these channels may also facilitate efficient thermal management for the battery 118 by acting as cooling fins, enabling airflow or serving as passages for liquid cooling, thus aiding in maintaining optimal operating temperatures.

[0054] In an example, the housing 118a may also include a plurality of hollow tubular structures 204 disposed within these longitudinal channels and configured to facilitate the insertion of an elongated fastener from one end, allowing it to be fixed with a complementary fastener at the other end. In an example, the plurality of hollow tubular structures comprises eight hollow tubular structures, depicted as 204a, 204b, 204c, 204d, 204e, 204f, 204g, and 204h. A first set of four tubular structures, comprising 204a, 204d, 204e, and 204h, may be precisely positioned at each corner of the housing 118a. Concurrently, a second set of four tubular structures, comprising 204b, 204c, 204f, and 204g, may be positioned along the remaining longitudinal sections of the housing 118a.

[0055] In this configuration, each elongated fastener 110 is designed to pass through a corresponding hollow tubular structure, such that, fastener 110a may pass through tubular structure 204a, fastener 110b may pass through tubular structure 204b, fastener 110c may pass through tubular structure 204c, fastener 110d may pass through tubular structure 204d, fastener 110e may pass through tubular structure 204e, fastener 110f may pass through tubular structure 204f, fastener 110g may pass through tubular structure 204g, and fastener 110h may pass through tubular structure 204h. Accordingly, this precise design enables the battery housing 118a to be securely and robustly attached between the first bracket 102 and the second bracket 106, thereby ensuring a firm and stable connection within the frame structure 100.

[0056] In an example, the housing 118a may include a compartment 206 for keeping an integrated integrated control board 112 (as shown in Figure 2B) comprising electrical control unit (ECU) of the EV. In an example, theintegrated control board 112 is to align with a pair of elongated fasteners 110d and 110e, from amongst the first set of fasteners.

[0057] In an example, the integrated control board 112 may comprise a printed circuit board (PCB). This PCB may form a central component of a centralized compute platform, which integrates the functionalities of a Battery Management System (BMS), a Vehicle Control Unit (VCU), and a Motor Control Unit (MCU). This centralized compute platform may further include a host or master controller, a series of "slave" control boards (depending on the system topology), various sensors, and proprietary software that collectively facilitate its operation. The primary functions of this centralized compute platform include, but are not limited to, providing comprehensive protection against operational anomalies such as overcharging, over-discharging, high temperatures, low temperatures, and short-circuiting. Beyond protection, the integrated integrated control board 112 may also offer critical monitoring functionality, continuously assessing the state of the battery and individual cells. It also facilitates communication both internally within the battery and externally with other vehicle controllers and systems. Furthermore, the integrated integrated control board 112 is also configured to optimize and maximize battery performance, ensuring efficient power delivery and longevity. This optimization is supported by integrated software calculations that estimate key battery parameters, including the state of health (SOH), the state of charge (SOC), and maximum voltage.

[0058] Figure 2E illustrates an exploded view of the battery 118 with its housing 118a, in accordance with an implementation of the present subject matter.

[0059] The battery housing 118a, for example, manufactured using aluminum, serves as the primary containment structure for the battery's energy storage and management system. Within this, a battery module assembly 206 is provided, which comprises several critical components, such as, but not limited to, a top insulation panel 206a, a bottom insulationpanel 206b, busbars 206c, and a bottom cell holder 206d. The insulation panels 206a, 206b is to provide both electrical isolation to prevent inadvertent short circuits between battery cells 118b and the metallic housing, and effective thermal management by limiting heat transfer, thereby contributing to the overall thermal stability of the battery module and mitigating the risk of thermal runaway propagation between cells. The energy storage device, such as the battery cells 118b, are contained and organized within the dedicated receptacles or spaces defined by the busbars 206c and the bottom cell holder 206d, ensuring their secure positioning. Beyond these primary structural and electrical elements, a battery 118 may also incorporate a range of other essential mechanical, electronic, and thermal components. These may include, but not limited to, multiple sensors for continuous monitoring of parameters such as temperature, voltage, and current; integrated wiring harnesses for power and data transmission; safety devices like fuses and contactors; and advanced thermal management components such as cooling plates, intricate fluid conduits, or integrated fans.

[0060] In an example, the battery cells 118b are the fundamental electrochemical devices responsible for chemically storing and releasing energy, commonly encapsulated within various form factors such as prismatic, pouch, or cylindrical containers. The collective assembly of the top insulation panel 206a, the bottom insulation panel 206b, the busbars 206c, and the bottom cell holder 206d forms an integrated interconnect panel that functions as a cohesive unit within the larger battery housing 118b. In an example, the integrated control board 112 may also be accommodated within the battery housing 118a, further streamlining the overall design.

[0061] Figures 3A-3D illustrate various views of the second bracket 106 of the frame structure 100, in accordance with an example implementation of the present subject matter. Specifically, Figure 3A illustrates a perspective view, Figure 3B illustrates a rear view, Figure 3C illustrates aside view, and Figure 3D illustrates a top view of the second bracket 106. For the sake of explanation, Figures 3A-3D and 1 B-1 C are described together below.

[0062] As depicted, the second bracket 106 is rectangular in shape, having its longitudinal edge oriented perpendicularly to the intended direction of movement of the electric vehicle. Similarly, the first bracket 102 (not explicitly shown in Figures 3A-3D) is also rectangular and similarly oriented. Both the first bracket 102 and the second bracket 106 are provided with a plurality of machined thorough holes, designed to cooperatively accommodate the two sets of elongated fasteners 110 previously described, ensuring precise alignment and robust interconnection. Specifically, to facilitate the passage of the fasteners, the second bracket 106 includes eight designated through-holes: hole 302a is configured to receive fastener 110a, hole 302b is configured for fastener 110b, hole 302c for fastener 110c, hole 302d for fastener 110d, hole 302e for fastener 110e, hole 302f for fastener 110f , hole 302g for fastener 110g, and hole 302h for fastener 11 Oh. Complementary aligned through-holes are also provided on the first bracket 102 for accommodating these respective fasteners.

[0063] In an example, the electric motor 108 may be mechanically coupled to the second bracket 106 of the frame structure utilizing the designated through-holes 302b, 302c, 302f, and 302g, and their respective elongated fasteners 110b, 110c, 11 Of, and 110g. This arrangement of holes on both brackets ensures the proper alignment and secure engagement of all fasteners, forming the integrated frame structure 100 and the enclosed battery compartment.

[0064] As explained previously, in an example, the second bracket 106 includes an inwardly extending annular flange A. This annular flanges are positioned on the inner periphery of the second bracket 106, designed to project towards the central axis of the frame structure when assembled. In one example, this annular flange is formed along both the top and bottom edges of the second bracket 106, exhibiting a 'C shape when viewed froma side perspective (as illustrates in Figure 3C), thereby creating a channel or recess for engagement. Specifically, the inwardly extending annular flange of the second bracket 106 is designed to align with and provide structural support to the rear sidewall of the battery housing 118a. This integrated design, complementing a similar flange on the opposing first bracket (as illustrated in Figure 2A), creates a secure seating mechanism. This mechanism allows the battery housing 118a to be precisely cradled and physically supported, which not only ensures the accurate axial positioning of the battery with its housing within the frame structure but also contributes significantly to the overall structural integrity of the frame structure 100.

[0065] In an example, the second bracket 106 may also comprise one or more integrally formed mounting lugs 304 to mechanically couple a main stand assembly 116 of the electric vehicle to the second bracket 106. The main stand assembly 116 is a deployable support mechanism designed to stabilize the electric vehicle in an upright, stationary position. Unlike a side stand which typically supports the vehicle at an angle, the main stand assembly usually lifts both the front and rear wheels off the ground, providing enhanced stability for parking, routine maintenance, or extended storage.

[0066] In an example, the mounting lugs 304 may be fabricated as integral extensions of the second bracket 106, meaning they are formed as a single, continuous piece with the bracket, often through processes like casting, forging, or precise machining. This integral formation significantly enhances the structural integrity and load-bearing capacity of the mounting points, minimizing potential failure modes associated with separately attached or welded components. In an example, the main stand assembly 116 may be pivotally mounted to these lugs 304 via a robust pivot pin or bolt, allowing the stand to be rotated downwards for deployment and upwards for secure retraction and stowing when the vehicle is in motion.This design ensures a strong, reliable, and durable connection for safely supporting the vehicle's weight.

[0067] In an example, the rear side of the first bracket 102 and the second bracket 106 may also comprise one or more integrated attachment points (not shown) for supporting an external fairings of the electric vehicle. These integrated attachment points may be separate components bolted or welded onto the bracket. The external fairings, which typically consist of body panels that contribute to the vehicle's aerodynamics, aesthetic design, and protection of internal components (such as wiring harnesses, thermal management systems, or even the rider from wind and road debris), are precisely coupled to these points. The mechanical interface at these attachment points may involve various features such as integrated threaded inserts for fastener reception, specialized mounting lugs, or designed snap- fit receptacles, all configured to ensure a secure, durable, and precise connection that can withstand the dynamic forces encountered during vehicle operation.

[0068] Figures 4A-4D illustrate various views of the mounting bracket 114a for the side stand assembly 114 of the frame structure 100, in accordance with an example implementation of the present subject matter. Specifically, Figure 4A illustrates a perspective view, Figure 4B illustrates a side view, Figure 4C illustrates a front view, and Figure 4D illustrates a top view from upside down of the mounting bracket 114a. For the sake of explanation, Figures 4A, 4B, 4C, and 4D are described together below.

[0069] As depicted, the mounting bracket 114a for mounting the side stand assembly 114 features a distinct, folded profile (as best seen in Figure 4B, which resembles a 'V' shape in its side elevation). This bracket 114a is typically fabricated from a durable material such as steel, carbon fiber, or an aluminum alloy, depending on the specific requirements of the electric vehicle. For instance, steel may be used for its robustness and durability, while aluminum may be used for its lightweight and corrosion-resistantproperties. In an example, carbon fiber may be used for its high strength-to- weight ratio and resistance to chemical and thermal damage.

[0070] In an example, the bracket includes a pair of through holes 402a, 402b provided along a pair of edges of the mounting bracket 114a. These holes 402a and 402b are precisely configured to accommodate a pair of elongated fasteners from amongst the first set of fasteners (e.g., fasteners 110a and 11 Oh) that are also utilized for the primary interconnection between the first bracket 102 and the second bracket 106. This ingenious design allows the mounting bracket 114a to be robustly secured directly to the main frame structure 100 by leveraging existing structural fasteners, thereby minimizing additional hardware requirements, simplifying the overall assembly process, and distributing loads efficiently. The fasteners pass through the mounting bracket 114a and into the corresponding receiving holes in the second bracket 106, ensuring a rigid and stable attachment.

[0071] In an example, the structure of the mounting bracket 114a may vary based on the specific two-wheeled electric vehicle and the battery housing 118a it is deployed upon. For instance, the mounting bracket 114a may be engineered to be adjustable or modular, enabling it to be adapted for different sizes and types of battery housings 118a, particularly if the side stand assembly 114 is directly mounted to the battery housing. This provides significant advantages in the overall design and manufacturing process, potentially reducing costs and increasing production efficiency. It is understood that the specific design of the mounting bracket 114a depicted in the present description is exemplary and not limiting; alternative configurations could be employed to effectively facilitate the secure connection of the side stand assembly 114 to the battery housing 118a.

[0072] In an example, the side stand assembly 114 is pivotally mounted on the mounting bracket 114a in a foldable arrangement. This mounting may involve a pivot pin or bolt passing through a designated pivot point (not shown) on the side stand 114b and the pivot points 404a, 404b on themounting bracket 114a. This allows the side stand to swing outwards from its stowed position to support the electric vehicle in a leaned, stationary posture when parked, providing quick and convenient stabilization. When not in use, a spring mechanism typically integrated into the side stand assembly automatically or manually retracts the stand, pulling it upwards and inwards to lie flush against the vehicle's body or frame, thereby preventing interference with vehicle movement or ground clearance during operation. This provides a readily deployable and securely stowable means of parking the electric vehicle, offering stable support on various ground surfaces.

[0073] Figure 5A-5B illustrate side views of the frame structure 100, depicting the main stand 116 in an extended position, in accordance with an implementation of the present subject matter.

[0074] As depicted, the frame structure 100 of the electric vehicle is illustrated with the main stand assembly 116 in its fully extended, deployed position. In this configuration, the main stand assembly 116 engages the ground surface, effectively supporting the electric vehicle in an upright and stable posture, typically by lifting both the front and rear wheels clear of the ground. This deployment demonstrates the robust mechanical coupling of the main stand assembly 116 to the second bracket 106, specifically via the integrally formed mounting lugs 304, as previously described. The extended main stand provides a secure and balanced platform for parking, as well as for conducting various maintenance tasks that require the wheels to be suspended.

[0075] Figure 6A-6B illustrate perspective views of the frame structure 100, depicting the main stand 116 in a retracted position and an extended position, respectively, in accordance with an implementation of the present subject matter.

[0076] As depicted, Figure 6A illustrates the main stand assembly 116 of the electric vehicle's frame structure 100 in its fully retracted and stowed position. The main stand assembly 116 comprise at a main stand 116a,such that, the main stand 116 is be folded upwards and to be secured close to the underside of the frame 100, ensuring maximum ground clearance and preventing any interference during vehicle movement. This configuration is essential for safe driving, as it keeps the stand clear of road obstacles and prevents accidental deployment. Conversely, Figure 6B clearly shows the main stand assembly 116 in its fully extended and deployed position. In this operational state, the main stand 116a is pivoted downwards to contact the ground, lifting the electric vehicle into a stable, upright posture, typically with both wheels elevated off the ground. This extended position is crucial for securely parking the vehicle on various surfaces, as well as for facilitating maintenance procedures that require the wheels to be suspended, such as tire changes or brake inspections. These figures collectively demonstrate the full range of motion and operational states of the integrated main stand 116a.

[0077] Figures 7A-7B illustrate perspective views of the frame structure 100 with both the side stand 114b and the main stand 116a in a retracted position and an extended position, respectively, in accordance with an implementation of the present subject matter.

[0078] As depicted, Figure 7A illustrates a perspective view of the frame structure 100 with both the side stand 114b and the main stand 116a in their fully retracted and stowed positions. In this configuration, both support mechanisms are compactly folded and securely positioned against the frame. Conversely, Figure 7B illustrates the frame structure 100 with both the side stand 114b and the main stand 116a in their fully extended and deployed positions. This view demonstrates the full range of motion and the robust structural integration of both support mechanisms with the frame. In a practical scenario, the main stand 116a would lift both wheels for stable parking and comprehensive maintenance, whereas the side stand 114b would allow the vehicle to be parked in a leaned position for quick, temporary stops. These figures collectively highlight the versatile and comprehensive support system integrated into the frame structure 100,offering various parking and maintenance capabilities. In addition, the integration of the side stand 114b and the main stand assembly 116 may help to distribute the weight of the electric vehicle potentially improving its stability and handling.

[0079] Thus, by providing an innovative frame structure where the battery with its housing is fully integrated as a fundamental, load-bearing component, provides a simple, lightweight, and modular frame structure design. This innovative approach effectively utilizes the battery unit as a critical structural element rather than merely a payload, which significantly enhances the overall structural integrity and rigidity of the vehicle, particularly around its heaviest component. Furthermore, this inherent integration and simplified design enable a more cost-effective and less complex manufacturing process. This is achieved by reducing redundant structural elements, lowering overall vehicle weight, and minimizing both labor and material costs when compared to conventional multi-component frame and battery integration methods.

[0080] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible. As such, the present disclosure should not be limited to the description of the preferred examples and implementations contained therein.

Claims

l / We Claim:1 . A frame structure (100) for an electric vehicle (EV) comprising: a first bracket (102) to structurally support at least a handlebar assembly (104) of the electric vehicle; a second bracket (106) configured to structurally support at least an electric motor (108) of the electric vehicle; and a plurality of elongated fasteners (110) to connect the first bracket (102) and the second bracket (106) to form a box-shaped enclosure for a battery (118) of the electric vehicle, the plurality of elongated fasteners (110) configured to align with surfaces of a housing (118a) of the battery (118), wherein at least one of the plurality of elongated fasteners (110) is to directly couple the electric motor (108) to the second bracket (106).

2. The frame structure (100), as claimed in claim 1 , wherein the housing (118a) of the battery (118) is shaped complementary to, and positioned within, the box-shaped enclosure, wherein the first bracket (102) is configured to align with a front opening of the housing (118a) and the second bracket (106) is configured to align with a rear opening of the housing (118a).

3. The frame structure (100) as claimed in claim 2, wherein the housing (118a) of the battery (118) comprises a plurality of tubular structures (204), extending longitudinally on an outer surface of the housing (118a), to allow insertion of the plurality of elongated fasteners (110).

4. The frame structure (100) as claimed in claim 1 , wherein the first bracket (102) and the second bracket (106) are rectangular having their longitudinal edge perpendicular to the direction of movement of the electric vehicle, and wherein the plurality of elongated fasteners (110) comprise at least eight elongated fasteners arranged such that:a first set of fasteners comprising at least four elongated fasteners (110a, 110d, 110e, 110h) positioned with one elongated fastener each extending between each corner edge of the first bracket (102) and the second bracket (106); and a second set of fasteners comprising at least four elongated fasteners (110b, 110c, 11 Of, 110g) is positioned along an upper and lower longitudinal edge of the first bracket (102) and the second bracket (106), such that second set of fasteners are situated between the first set of fasteners, and wherein the electric motor (108) is directly coupled to the second bracket (106) using the second set of fasteners.

5. The frame structure (100) as claimed in claim 4, wherein each of the first bracket (102) and the second bracket (106) includes an inwardly extending annular flange (A).

6. The frame structure (100) as claimed in claim 1 , further comprising a side stand assembly (114), comprising: a mounting bracket (114a) having a pair of through holes (402a, 402b) provided along a pair of edges to accommodate a pair of elongated fasteners, from amongst the first set of fasteners aligned in a vertical direction; and a side stand (114b), the side stand (114b) being mounted on the mounting bracket (114a) in a foldable arrangement.

7. The frame structure (100) as claimed in claim 1 , wherein upon the battery (118) being placed in the enclosure, an integrated control board (112) comprising electrical control unit (ECU) of the electric vehicle within the housing (118a) of the battery is to align with a pair of elongated fasteners (110a, 110h), from amongst the first set of fasteners, other than the pair of elongated fasteners supporting the mounting bracket (11 Od, 110e).

8. The frame structure (100) as claimed in claim 1 , wherein the second bracket (106) further comprises one or more integrally formed mounting lugs (304) to mechanically couple a main stand assembly (116) of the electric vehicle to the second bracket (106).

9. The frame structure (100) as claimed in claim 8, wherein the second bracket (106) further comprises one or more integrated attachment points for supporting an external fairings of the electric vehicle.

10. The frame structure (100) as claimed in claim 5, wherein a top surface of the inwardly extending annular flange (A) of the first bracket (106) is to structurally support a head tube (104a) of the handlebar assembly (104).

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