Saddle type electric vehicle

Abstract

A saddle type electric vehicle, comprising a frame including at least a front tube (120); at least a pair of cross tubes (130) extending substantially horizontally and rearward of the vehicle connecting at least one front tube (120); and at least plurality of rear tubes (160) extending from the cross tube (130) further rearward of the vehicle; at least a battery pack for providing power to the vehicle; at least a battery casing (190) encapsulating the battery pack; wherein the battery casing (190) is directly attached to the frame detachable from the bottom of the vehicle; at least a floorboard (150) mounted on the cross tubes (130) and wherein the battery pack extends from the front tube (120) below the floorboard (150) and bolted to the cross tube (130) of the frame.

Description

SADDLE TYPE ELECTRIC VEHICLEFIELD OF INVENTON

[0001] The invention relates to an electric vehicle & and more particularly, it relates to mounting of battery packs in a two wheeled electric vehicle.CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This invention takes priority from an earlier filed provisional patent application no. 202421095711 filed on December 04, 2024; which is incorporated herein as reference.BACKGROUND OF THE INVENTION

[0003] Traditionally, two- wheelers are powered by internal combustion engines (ICE) with fuel tanks located under the seat or within the frame. As the industry shifts toward more environmental friendly solutions like electric propulsion, designing efficient two-wheeled vehicle has become a key. Towards this, placement and design of battery packs have become crucial factors. Earlier, electric two-wheelers often had battery packs mounted in ways that compromised space, efficiency and stability. This underscored the necessity for more integrated and effective solutions.

[0004] The mounting of battery packs in two-wheelers, such as electric scooters and motorcycles, presents several challenges that must be addressed to ensure optimal performance, safety and user experience. Small battery packs in electric vehicles (EVs) present several limitations, significantly affecting the vehicle's range and performance. With lower energy storage capacity, these batteries results in a shorter driving range, intensifying "range anxiety" as drivers worry about running out of charge before reaching their destination. This necessitates frequent recharging, which is inconvenient, especially where charging infrastructure is sparse. Additionally, small battery packs often provide less power, leading to reduced acceleration and overall performance, particularly in demanding driving conditions. Longer charging times are another downside, as smaller batteries may not support high-speed charging, increasing vehicle downtime. These drawbacks contribute to higher operating costs and a less practical ownership experience for EV drivers. In addition to that, two-wheelers have limited space compared tolarger vehicles, making it difficult to find an ideal location for mounting large battery pack. The design must optimize space without compromising the vehicle's ergonomics or aesthetics. Proper weight distribution is crucial for the stability and handling of two-wheelers. An improperly placed battery pack can lead to an imbalance. Due to the large size and weight of battery packs, it can adversely affecting the vehicle's center of gravity and making it harder to control.

[0005] Further, battery packs tends to generate heat during operation, requiring effective thermal management to prevent overheating and ensure longevity. In a confined space of a twowheeler, designing an efficient cooling system is challenging. Additionally, two-wheelers are more exposed to impacts in case of accidents or falls. Thus, ensuring that the battery pack is adequately protected from physical damage is critical for safety. Further, battery packs require periodic maintenance or replacement. The design must allow easy access to the battery without requiring extensive disassembly of the vehicle, which can be challenging given the limited space availability.

[0006] Two- wheelers are further subject to significant vibrations and shocks from road irregularities. The battery pack mounting must be designed to absorb these stresses to prevent damage to the battery cells and connections. Also, electric components, including battery packs, need protection from water and dust. The battery pack must integrate seamlessly with other vehicle components, such as the motor, controller, and user interface. Ensuring compatibility and efficient communication between these components adds another layer of complexity. The design and placement of the battery pack should not detract from the vehicle's aesthetic appeal. Thus, achieving a sleek and attractive design while accommodating a sizable battery pack can be challenging.

[0007] One available position for mounting battery packs is under the rider seat, however placing battery packs under the seat of a two-wheeler has several disadvantages, including raising the vehicle's center of gravity, which negatively impacts stability and handling. It also significantly reduces or eliminates under-seat storage space traditionally used for keepingpersonal items. Additionally, this placement can lead to heat accumulation as the confined space under the seat might not allow for adequate cooling, potentially affecting the battery's performance and longevity. Finally, accessing the battery for maintenance or replacement can be more cumbersome compared to other mounting positions.

[0008] In some two wheeled vehicles, battery packs may be mounted on the floorboard, which helps in providing space for packaging of other components under seat, but it also leads to a reduced battery size & moreover, thermal issues due to confined space. So, reduced battery size can limit the vehicle's range and power. Additionally, the confined space can exacerbate thermal issues, as it restricts adequate cooling, potentially leading to overheating and affecting the battery's overall performance and longevity. This placement can also negatively impact the vehicle's stability and handling due to alteration of center of gravity. Further, accessibility problems of removing the battery from top side, including additional covers, unsafe and non- sturdy mounting & connection to frame leads to increase cost and complexity.

[0009] Hence, there is a need to provide a proper battery mounting, to address the aforementioned challenges by providing a novel design for mounting a battery pack under the floorboard of a two- wheeler.OBJECT OF THE INVENTION

[0010] An object of the invention is to provide an improved design for mounting a battery pack in a two-wheeled vehicle.

[0011] Another object of the invention is to enhance overall vehicle performance by incorporating a larger capacity battery pack to ensure longer drive range, safety, and user experience.

[0012] Another object of the invention is to lower the vehicle's center of gravity, thereby enhancing stability and handling characteristics.

[0013] Yet another object of the invention is to maximize the efficient use of available space within the vehicle.

[0014] Yet another object of the invention is to improve thermal management and preventing overheating to ensure optimal performance and longevity.

[0015] Yet another object of the invention is to provide easy access to the battery pack for maintenance or replacement, thus, improving the practicality and user-friendliness of the vehicle.

[0016] Yet another object of the invention is to provide a frame structure for a vehicle that can accommodate at-least a battery pack system which can be easily expanded or contracted to meet varying power and energy requirements for different applications.

[0017] Yet another object of the invention is to ensure sturdy, reliable connections between battery modules while reducing manufacturing and assembly costs.

[0018] Still another object of the invention is to overcome lacunas of existing systems explained in background section.SUMMARY OF THE INVENTION

[0019] With the above objectives in view, the present invention provides a saddle type electric vehicle, comprising: a frame including: a head tube; at least a main tube connected to the head tube and extending downwardly; at least a front tube connected to the main tube and extending laterally in a vehicle width direction; a pair of cross tubes extending substantially horizontally and rearward from the at least one front tube; andat least a pair of long tubes extending rearwardly and upwardly from the cross tubes; at least plurality of rear tubes extending from the long tubes further rearwardly of the vehicle; at least a floorboard mounted on the cross tubes; a battery pack configured to provide power to the vehicle; a battery casing encapsulating the battery; wherein the battery casing is directly attached to the frame below the floorboard and bolted to the cross tubes of the frame to detach from bottom side of the vehicle.

[0020] According to an aspect, the battery casing is directly bolted to the cross tubes of the frame with plurality of brackets supporting the battery.

[0021] The battery pack extends to at least directly below a seat of the vehicle.

[0022] According to another aspect, at least a main tube substantially vertical is connected to a front tube.

[0023] The battery casing is mounted within the frame from the bottom of the vehicle

[0024] The battery casing comprises of a battery assembly and a Battery Management System (BMS) mounted at one end of the casing.

[0025] The battery casing may have a shield bolted to the bottom side of the vehicle on the cross members. The shield preferably a metal or plastic shield to withstand the battery pack from mechanical abrasion or physical damage.

[0026] The shield is attached to the frame structure with the help of bolts.

[0027] The shield attached to the frame structure of the vehicle and has multiple vents or holes to allow air circulation for thermal management.

[0028] The height of the vehicle is 160 mm to 180mm to allow sufficient space at the bottom providing ground clearance and protection of the battery pack. The bottom part of the battery casing ranges from 150 mm to 200 mm above the ground to allow sufficient space at the bottom providing ground clearance and protection to the battery pack.

[0029] According to another aspect, the main tube is surrounded by a plurality of body panels.

[0030] The frame member comprises of rectangular tubes to assist in bracket mounting.

[0031] The space between the main tube and the body panels comprises of a vent path extending along at least a portion of the main tube, the vent path being configured to allow air circulation for thermal management to the shield. This also provides improved aerodynamics for the vehicle.

[0032] The battery casing is attached to the plurality of cross tubes and the rear tubes with at least plurality of brackets. Preferably, four brackets are provided, and the battery casing is connected via plurality of plates using at least two bolts for each plate. The plurality of plates are slidable along the length of the battery casing for ease of attachment of the battery casing comprising battery packs with the frame assembly. The plurality of plates are slidable along length of the battery casing for ease of assembly and disassembly of the battery casing with the frame.

[0033] The long tubes have a horizontally extended seat member along the vehicle plane for provisioning of seat on the vehicle frame. The frame further comprises of at least one support tube connecting the pair of cross tubes along vehicle width direction for provisioning of floorboard attachment from top and provides space for keeping leg.

[0034] The floorboard forms an external structure which is not integral to the battery assembly comprising a battery casing.

[0035] The cross tubes comprises of plurality of brackets at locations for mounting of the battery assembly, and plates provisioned on the battery assembly contain bolts for affixing the battery assembly with the frame and the bolts are unplugged for removing the battery assembly.

[0036] The battery assembly is provided in a battery casing, wherein the battery casing is flat shaped.

[0037] The front tube passes through the main tube providing full mechanical engagement and imparting strength.

[0038] Though bolting is explained as one of the preferred method of making the connection, person skilled in that art may envisage other possible joining or connection means.BRIEF DESCRIPTION OF DRAWINGS:

[0039] The above and other objects, features, and advantages of the present disclosure will be more apparent from the detailed description taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example, only with reference to the accompanied drawings wherein reference numerals represent like elements.

[0040] Fig. 1 illustrates the frame structure of a two- wheeled vehicle accommodating a battery pack under the floorboard, according to an embodiment of the invention;

[0041] Fig. 2 illustrates a top view of the two wheeled vehicle having a floorboard battery pack;

[0042] Fig. 3 illustrates a bottom view of the two wheeled vehicle having a floorboard battery pack;

[0043] Fig. 4 illustrates isometric view of the vehicle comprising exploded view of the battery assembly and a shield underneath frame structure of the vehicle;

[0044] Fig. 5 A & 5B, illustrates a bottom view and an exploded view of the bolting arrangement of the vehicle floorboard in order to mount the battery pack on the frame structure; and

[0045] Fig. 6, illustrates the bottom view & side view of battery assembly with the bolts to be affixed with the frame.DETAILED DESCRIPTION:

[0046] The invention along with preferred embodiments will now be described in detail with reference to the accompanying drawings. The preferred embodiment does not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

[0047] It will be readily understood that components of the present invention, as generally described and illustrated in figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention as represented in the figures is not intended to limit the scope of the invention but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.

[0048] Fig.1, 2 illustrates a side & top view of a two wheeled vehicle according to an embodiment of the present disclosure. A two wheeled vehicle, preferably a moped or a scooter type vehicle, is used as an exemplary embodiment although a motorcycle type frame may also be used. According to this embodiment, a frame comprises of a head tube (100) which forms the base for the handlebar column (not shown) of the vehicle. Although in the presentembodiment, rectangular tube members are used, circular tube members may also be used interchangeably. A single main tube (110) extends downwards from the head tube (100). At least one front tube (120) originates from one end of the main tube (110) and extends laterally in a vehicle width direction. The front tube (120) passes through the main tube (110) providing full mechanical engagement and imparting strength. Thereafter, at least a pair of cross tubes (130) extending linearly connecting the front tubes (120). The cross tube (130) runs parallel to the end of the frame structure substantially horizontally and rearwardly of the vehicle forming the external periphery of the vehicle & provides a mounting provision (250) for a battery casing (190) comprising a battery assembly (140) to be mounted on the frame and under a floorboard (150).

[0049] According to Fig.3, which depicts the bottom view of the vehicle, the floorboard (150) forms the top upper portion above the battery assembly (140), which provides space for resting of feet for a vehicle driver or accommodates goods & luggage to be carried by the driver. The frame further includes at least plurality of rear tubes (160), which extends from the long tubes (170) further rearwardly of the vehicle as shown in Fig.1. The battery assembly (140) comprises at least one battery pack provided for enabling power to the two wheeled vehicle. The frame further comprises of at least a pair of long tubes (170) extending rearwardly and upwardly from the cross tubes (130). The long tubes (170) have a horizontally extended seat member (300) along vehicle plane for provisioning of seat (310) on the vehicle frame. The frame comprises of at least one support tube (180) connecting the plurality of cross tubes (130) for provisioning of the floorboard (150) attachment preferably from top & provides space for keeping leg. The battery assembly (140) can be easily expanded or contracted to meet varying power and energy requirements for different applications.

[0050] In an embodiment, the battery assembly (140) may be provided on at least a battery casing (190) encapsulating one or more battery packs. In other embodiments, the battery packs may be placed directly under the floorboard (150). The battery assembly (140) in the present embodiment is detachable from bottom of the vehicle, offering both convenience and versatility. Encased in a robust, weather-resistant shell, the battery assembly (140) is built towithstand various environmental conditions, ensuring long-term durability. The sleek design allows it to fit seamlessly into the vehicle's floorboard (150), keeping it securely in place during rides. Also, in the present invention, the two wheeled vehicle employs a large battery casing (190) directly attached to the frame, which extends from the front tubes (120) below the floorboard (150) and the seat (not shown) of the vehicle and extends till the rear wheel. This leads to compact mounting of multiple battery packs inside the battery assembly (140) which in turn is placed inside the battery casing (190). This sizable casing is meticulously engineered to house a high-capacity battery and a large battery pack, delivering extended range and consistent performance for daily commuting as well as longer rides. The floorboard (150) placement optimizes the vehicle's weight distribution, providing a lower center of gravity for enhanced stability and smoother handling.

[0051] Fig.4 depicts an exploded view of a battery assembly (140) and a shield (230) underneath the frame of the vehicle according to an embodiment of the invention. The battery assembly (140) comprises of two horizontal battery packs. The battery assembly (140) positioned inside the battery casing (190) has multiple bolts (220) and the brackets (200) which are used for affixing the same with the frame structure and specifically with the cross tubes (130) and the rear tubes (160) at specific points. There are four plates (210) each containing the four bolts (220) respectively to facilitate mounting of the battery assembly (140) with the brackets (200) of the two cross tubes (130) and the two rear tubes (160). The plurality of plates (210) is slidable along the length of the battery casing (190) comprising the battery assembly (140) for ease of attachment of the battery casing (190) with the frame assembly. Each plate (210) is designed to slide smoothly in a linear direction parallel to the battery casing (190) axis, on the cross tubes (130) enabling easy positioning, removal, or replacement of the battery casing (190) without requiring disassembly of other components. This sliding feature facilitates rapid assembly and disassembly, thereby improving maintainability and reducing downtime. Further, the shield (230) is attached at the bottom of the battery assembly (140) to protect the battery assembly (140) from contamination and external abrasion or damage. The shield (230) contains holes for passage of air & thermal management heat dissipation. These openings allow cool air to circulate around the battery pack(s) housed on the shield (230), helping to maintain optimaloperating temperatures. As air passes through the holes, it carries away excess heat generated by the system, ensuring that the internal parts remain cool and function efficiently. Further, the vehicle has a height in the range of 160 mm to 180 mm to allow sufficient space at the bottom providing adequate ground clearance and air movement and protection of the battery assembly (140).

[0052] This ventilation design is particularly important in high-performance or compact systems where heat build-up that could otherwise compromise functionality or reduce lifespan of the components. The holes are carefully sized and positioned to maximize airflow while maintaining the structural integrity and protective function of the shield (230). This combination of protection and efficient heat management ensures that the system operates reliably, even under demanding conditions. There are plurality of mounting points (250), preferably nine mounting points (250) at respective portions of the shield (230) that results in mounting of the shield (230) directly with the frame with the help of bolts (220). Further, there is a hole & vent path at the front part of the vehicle for air circulation along the main tube (110) and the air passes under the floorboard (150) through the vent path out of the shield (230), leading to improved aerodynamics. This further results in providing adequate thermal management for the battery assembly (140) & negates any use of any active cooling through any fan for the battery pack, although in other embodiments liquid cooling or air-cooling through fan may also be incorporated.

[0053] FIG.5 A & 5B illustrates a bottom view and an exploded view of the bolting arrangement of the vehicle floorboard (150) in order to mount the battery pack on the frame structure. The exploded view demonstrates a battery bracket (200) connected to the battery assembly (140) via a plate (210) using the four mounting bolts (220) for each battery bracket (200) respectively. The brackets (200) and the plates (210) can be made from high-strength, corrosion-resistant materials like stainless steel or aluminum to ensure that they can withstand the weight of the battery pack and handle harsh conditions within a vehicle. The mounting plate (210) may be reinforced and equipped with adjustable retainers to accommodate various battery sizes, ensuring a secure fit.

[0054] As shown in FIG. 5A and 5B, the cross tubes (130) comprises of plurality of brackets (200) at locations for mounting of the battery assembly (140), and a plurality of plates (210) provisioned on the battery assembly (140) containing a plurality of bolts (220) for affixing the battery assembly (140) with the frame and the bolts (220) are unplugged for removing the battery assembly (140). According to another embodiment, in order to remove the battery, a simple release mechanism can be integrated into the underside of the vehicle. With a quick unlock feature, the battery pack slides out effortlessly, making it easy to carry for recharging or replacement.

[0055] This two-wheeled vehicle arrangement features a modern, streamlined design, blending functionality with aesthetics. The body of the frame is lightweight yet sturdy, built from high- quality materials including aluminum & steel that offer durability without compromising on style. The most distinctive feature is the floorboard (150), which discreetly houses a powerful, rechargeable battery. This design keeps the battery pack hidden, protecting it from external elements while freeing up space on the vehicle.

[0056] Vibration dampening pads or grommets can be included to protect the battery pack and vehicle components from potential damage caused by road vibrations. In another embodiment, the bracket (200) can feature integrated cable management systems and cooling channels to maintain an organized setup and optimal battery temperature, enhancing both safety and performance. The inclusion of secure fastening mechanisms like bolts (220) or quick-release latches ensures that the battery pack remains securely in place, while also allowing for easy removal and maintenance.

[0057] FIG. 6 depicts a bottom view and a side view of the battery assembly (140) showing the plates (210) and a plurality of mounting holes for the bolts (220) to be affixed with the brackets (200) of the frame member. The battery casing (190) comprises of a Battery management system (BMS) (260) mounted at one end of the casing and all electrical connections are routed to the BMS (260) from a motor, electronic devices and other electronic control units. The strategic placement of the BMS (260) underneath the seat helps in routing the wires with easeto necessary electrical operational features. Moreover, having the maintenance provision being on the topmost portion of the battery pack, the BMS (260) can be easily serviced and supervised.

[0058] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The embodiments described are to be considered in respects as illustrative and not restrictive.

[0059] Within this patent specification, it is crucial to acknowledge the versatility and potential variations of the invention. Other embodiments may incorporate a variety of component units, logical units, and switching units to achieve similar or modified functionalities. These embodiments may involve different arrangements, configurations, or combinations of these units, depending on specific application requirements or design preferences. The scope of the invention encompasses such alternative embodiments, wherein the essential features and principles remain applicable, albeit with potential modifications to suit particular contexts or objectives. Thus, while the embodiments described herein serve as examples, it is understood that numerous other configurations and arrangements are feasible and fall within the scope of the invention as defined by the claims.Reference Numerals:-100 - head tube110 - main tube120 - front tubes130 - cross tubes140 - battery assembly150 - floorboard160 - rear tubes170 - long tubes 180 - support tube 190 - battery casing 200 - brackets210 - plates220 - bolts230 - shield250 - mounting points 260 - Battery management system (BMS)300 - Seat member310 - Seat

Claims

We Claim1. A saddle type electric vehicle, comprising: a frame including: a head tube (100); at least a main tube (110) connected to the head tube (100) and extending downwardly; at least a front tube (120) connected to the main tube (110) and extending laterally in a vehicle width direction; a pair of cross tubes (130) extending substantially horizontally and rearward from the at least one front tube (120); and at least a pair of long tubes (170) extending rearwardly and upwardly from the cross tubes (130); at least plurality of rear tubes (160) extending from the long tubes (170) further rearwardly of the vehicle; at least a floorboard (150) mounted on the cross tubes (130); a battery pack configured to provide power to the vehicle; a battery casing (190) encapsulating the battery; wherein the battery casing (190) is directly attached to the frame below the floorboard (150) and bolted to the cross tubes (130) of the frame to detach from bottom side of the vehicle.

2. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) is directly bolted to the cross tubes (130) of the frame with a plurality of brackets (200) supporting the battery pack.

3. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) extends to at least directly below a seat of the vehicle.

4. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) comprises of a battery assembly (140).

5. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) comprises of a Battery Management System (BMS) (260) mounted at one end of the battery casing (190).

6. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) has a shield (230) bolted to the bottom side of the vehicle on the cross members (130) to protect the battery pack from damage.

7. The saddle type electric vehicle, as claimed in claim 6, wherein the shield (230) attached to the frame of the vehicle has multiple vents or holes to allow air circulation for thermal management.

8. The saddle type electric vehicle, as claimed in claim 1, wherein the bottom part of the battery casing ranges from 150 mm to 200 mm above the ground to allow sufficient space at the bottom providing ground clearance and protection to the battery pack.

9. The saddle type electric vehicle, as claimed in claim 1, wherein the main tube (110) is surrounded by a plurality of body panels.

10. The saddle type electric vehicle, as claimed in claim 9, wherein the space between the main tube and the body panels comprises of a vent path extending along at least a portion of the main tube, the vent path being configured to allow air circulation for thermal management to the shield (230).

11. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) is attached to the rear tubes (160).

12. The saddle type electric vehicle, as claimed in claim 2, wherein the plurality of brackets (200) attach the battery casing (190) to the cross tubes (130) with a plurality of plates (210) and bolts (220).

13. The saddle type electric vehicle, as claimed in claim 12, wherein the plurality of plates (210) are slidable along length of the battery casing (190) for ease of assembly and disassembly of the battery casing (190) with the frame.

14. The saddle type electric vehicle, as claimed in claim 1, wherein the long tubes (170) have a horizontally extended seat member along the vehicle plane for provisioning of seat (310) on the vehicle frame.

15. The saddle type electric vehicle, as claimed in claim 1, wherein the frame further comprises of at least one support tube (180) connecting the pair of cross tubes (130) along vehicle width direction for provisioning of a floor board.

16. The saddle type electric vehicle, as claimed in claim 1, wherein the front tube (120) passes through the main tube (110) providing full mechanical engagement and imparting strength.

17. The saddle type electric vehicle, as claimed in claim 1, wherein the battery casing (190) is flat shaped.

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