E-Bike Frame Layout for Battery Space and Thermal Decoupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric bicycles face space constraints and thermal issues due to the placement of the electronic control unit near the battery, leading to reduced range and increased complexity in design and handling.
Innovation Solution
The electronic control unit is relocated to the seat tube, and the battery unit is placed in the down tube, with thermal decoupling and minimized cable lengths, allowing for a more compact and efficient frame design without the need for special battery housings, and featuring a remote control unit integrated into the handlebar grip with a joystick for intuitive operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the electronic control unit is arranged in the down tube near the battery unit, then the installation space for the control unit is available, but the space for battery cells is reduced and thermal problems occur
Solution Approach 1:
The patent divides the frame into functional zones: the down tube is dedicated to the battery unit while the seat tube is assigned to the electronic control unit. This spatial segmentation allows both components to be optimally positioned without competing for the same space, maximizing battery cell volume while providing adequate installation space for the control unit.
Solution Approach 2:
The control unit is relocated from the vertical down tube area to the vertical seat tube area, utilizing a different spatial dimension within the frame structure. This dimensional relocation resolves the space conflict by distributing components along different vertical zones of the bicycle frame.
2Ease of manufacture
If the electronic control unit is arranged near the battery unit, then installation is simplified, but thermal problems occur due to heat dissipation from both components
Solution Approach 1:
The electronic control unit is extracted from the battery vicinity and relocated to the seat tube. This separation removes the source of thermal conflict, allowing both the battery and control unit to dissipate heat independently without interfering with each other's thermal management.
3Volume of stationary object
If the electronic control unit is arranged in the seat tube, then more space is available for battery cells and thermal decoupling is achieved, but cable length increases
Solution Approach 1:
The cable routing is optimized locally at critical connection points: cables exit the frame at the bottom near the drive unit and are routed efficiently through the frame structure. This localized cable management minimizes overall cable length despite the control unit's relocated position in the seat tube.
4Shape
If the electronic control unit is arranged in the seat tube, then a compact frame shape is achieved, but the control unit may be damaged by a long seat post
Solution Approach 1:
A stop element is预先 installed in the seat tube above the electronic control unit to prevent the seat post from contacting and damaging the control unit. This preliminary protective measure allows the control unit to be positioned optimally in the lower seat tube area while preventing future damage from seat post movement.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electric bicycle (1) with an electronic control unit (38), a drive unit (14), a battery unit (20), a display unit (24) and a remote control unit (26) for the display unit (24), said remote control unit (26) is arranged in the region of a handle grip (28) which is separate from the display unit (24). According to the invention, the electronic control unit (38) is arranged in the seat tube (8) of the bicycle frame (2).