Monocoque Chassis Integrating Battery Housing for Electric Motorcycles
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Solution Overview
Problem
Traditional motorcycle frames are often costly, complex, and heavy, and existing electric motorcycles with integral suspension units may not offer sufficient structural integrity and flexibility for suspension geometry changes without significant modifications.
Innovation Solution
An electric motorcycle with a monocoque chassis that integrates the battery pack housing as a structural element, allowing for reduced mass, cost, and complexity, while enabling adaptable suspension geometries through detachable suspension mounts and using materials like die cast aluminum or magnesium for structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional motorcycle frame construction is used, then structural integrity and rigidity are maintained, but the motorcycle becomes heavier, more complex, and more costly
Solution Approach 1:
The patent combines the battery pack housing with the motorcycle frame into a single integrated monocoque structure. The battery housing serves dual purposes: containing the battery and providing structural support as the motorcycle frame, eliminating the need for a separate frame construction and reducing overall mass while maintaining structural integrity
Solution Approach 2:
The battery pack housing is designed to perform multiple functions simultaneously: it acts as a structural frame element, a battery container, and a mounting platform for suspension components. This multi-functionality reduces the number of separate components needed and decreases overall vehicle weight
2Stability of the object's composition
If a traditional motorcycle frame construction is used, then structural rigidity is ensured, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the frame construction with the battery housing into a single monocoque structure, reducing the number of separate components and assembly steps while maintaining the necessary structural rigidity for motorcycle operation
Solution Approach 2:
The patent changes the structural parameters by using the battery housing walls and internal battery arrangement to provide structural reinforcement, transforming a non-structural container into a load-bearing monocoque structure with appropriate stiffness and strength characteristics
3Weight of moving object
If the battery housing is used as a structural element, then mass and complexity are reduced, but the housing must bear additional loads requiring enhanced design
Solution Approach 1:
The patent modifies the housing design parameters by incorporating internal ribs, strengthening specific load-bearing areas, and optimizing wall thickness distributions to enable the battery housing to withstand motorcycle operational loads while maintaining weight reduction benefits
Solution Approach 2:
The patent employs composite construction techniques combining the battery housing material with structural reinforcement elements, creating a composite monocoque structure that achieves high strength-to-weight ratio suitable for load-bearing applications
4Ease of manufacture
If integral suspension bosses are used in the motor unit, then assembly is simplified, but flexibility for suspension geometry changes is reduced
Solution Approach 1:
The patent segments the suspension mounting system by providing separate, removable suspension mounts that attach to the monocoque at defined fixation points, allowing the suspension geometry to be modified by changing or repositioning these mounts without altering the core motor unit or battery housing structure
Data Source
AI summary
A core of the electric motorcycle includes a monocoque that partially encloses a housing for a motor and gearbox. Separate suspension mounts attach to the core, which permits them to be exchanged for other mounts to provide different suspension geometries. A power electronics unit attaches to the front of the monocoque. The shape of the monocoque allows for the proper positioning of the center of gravity of the motorcycle in order to provide a balanced ride.