Abstract:
A motorcycle is shown comprising a frame comprised of plural cast components coupled together. The frame is comprised of an upper one-piece frame portion having an integrated air tank and an integrated fuel tank therein. The integrated air tank is defined by a forward portion of the upper main frame portion, and a forward open face of the integrated air tank defines an air intake. The fuel tank is defined by a wall separating the upper one-piece frame portion into the two sections. Upper and lower steering post sockets are also integrated into the frame, rearward of the air intake and a steering post extends through the air intake portion of the frame.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a non-provisional of U.S. Provisional Application Ser. No. 61/204,865, filed Jun. 12, 2009, docket PLR-01-23771.02P, the disclosure of which is expressly incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    The subject disclosure relates to a motorcycle. 
         [0003]    Typically, a motorcycle utilizes a tubular frame that cradles an engine and attaches to a front and a rear suspension. The tubes of the tubular frame may be forged and then welded or fastened together. Depending on the tubular frame structure, the frame may be relatively less rigid thus increasing the propensity of the frame to flex. Increased flexing of the frame may enhance vibration and noise. Welding and mechanical fastening of the tubular frame members may increase point-to-point dimensional tolerances. Moreover, for each motorcycle size and or style, a different frame or frame size is required. 
         [0004]    Typically, a plastic and independent air box couples to the engine. The air box filters and directs air into the intake of the engine and is positioned between the tubular frame and the engine. It will be appreciated that one way to increase the structural rigidity of the tubular frame is to enlarge the frame by, for example, increasing the diameter of the tubing. It will also be appreciated that one way to increase airflow through the air box is to increase the volume of the air box. With the above in mind, both the tubular frame and the air box compete for an allocation of space and gross weight on the motorcycle. 
         [0005]    Moreover, a separate steel fuel tank normally sits on top of the frame, forward of the seat. This places a large, as well as variable, amount of mass at a large vertical distance from the ground, which in turn has an effect on the vertical component of the center of gravity. As the center of gravity is raised, the motorcycle becomes more unstable. From a cosmetic standpoint, this also exposes large hoses on the outside of the motorcycle causing exposure to damage as well as detracting from the look of the motorcycle. 
       SUMMARY 
       [0006]    The objects have been accomplished by providing a motorcycle comprising front and rear tires; an engine; and a frame comprising plural cast components coupled together, which encompass the engine from at least the top and bottom thereof. 
         [0007]    In another embodiment, a motorcycle comprises front and rear tires; an engine; and an upper one-piece frame portion having an integrated air tank and an integrated fuel tank therein. 
         [0008]    In still another embodiment, a motorcycle comprises a frame comprising an upper main frame portion; an integrated air tank defined by a forward portion of the upper main frame portion, where a forward open face of the integrated air tank defines an air intake; upper and lower steering post sockets integrated into the frame, rearward of the air intake; a steering post extending through the air intake portion of the frame and positioned in the steering post sockets; and a steering clamp assembly. 
         [0009]    In yet another embodiment, a front steering mechanism is provided for a motorcycle, comprising an upper clamp member having a center aperture for receiving a steering post, and apertures on either side of the center aperture for receiving forks; a lower clamp member having a center aperture for receiving the steering post, and apertures on either side of the center aperture for receiving forks; a top cap receivable over the upper clamp member, the upper clamp member and the top cap being profiled for receiving a handle bar therethrough. 
         [0010]    An embodiment will now be described by way of reference to the following drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of the motorcycle of the subject disclosure; 
           [0012]      FIG. 2  is an underside perspective view of the motorcycle of  FIG. 1 ; 
           [0013]      FIG. 3  is a left side plan view of the motorcycle of  FIGS. 1 and 2 ; 
           [0014]      FIG. 4  is a longitudinal cross-section of the motorcycle of  FIGS. 1-3  less the power train; 
           [0015]      FIG. 5  is an exploded view of the motorcycle frame; 
           [0016]      FIG. 6  is a perspective view of the upper main frame portion; 
           [0017]      FIG. 7  is a left side plan view of the upper main frame portion of  FIG. 6 ; 
           [0018]      FIG. 8  is an underside perspective view of the upper main frame portion of  FIG. 6 ; 
           [0019]      FIG. 9  is a cross-sectional view through lines  9 - 9  of  FIG. 7 ; 
           [0020]      FIG. 10  is a sectional view through lines  10 - 10  of  FIG. 7 ; 
           [0021]      FIG. 11  is a cross-sectional view through lines  11 - 11  of  FIG. 10 ; 
           [0022]      FIGS. 12 and 13  show perspective views of the battery box; 
           [0023]      FIGS. 14 and 15  show perspective views of the hard tails; 
           [0024]      FIG. 16  is a perspective view of the chin fairing; 
           [0025]      FIG. 17  shows a perspective view of the steering assembly; 
           [0026]      FIG. 18  is an exploded view of the steering assembly of  FIG. 16 ; 
           [0027]      FIGS. 19A and 19B  show perspective views of the top triple clamp; 
           [0028]      FIGS. 20A and 20B  show perspective views of the bottom triple clamp; 
           [0029]      FIGS. 21A and 21B  show perspective views of the upper cap; 
           [0030]      FIG. 22  shows a perspective view of the assembly of the frame portion; 
           [0031]      FIG. 23  shows an assembly of a portion of the frame portion with the engine; and 
           [0032]      FIG. 24  shows a perspective view of an exemplary fuel pump for internal mounting within the integrated fuel tank. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    With reference first to  FIGS. 1-3 , a motorcycle is shown at  2  having a frame  4 , steering assembly  6 , power train  8  comprised of an engine  10  and a transmission  12 , front and rear wheels  14 ,  16  and seat  18 . With reference to  FIGS. 4 and 5 , frame  4  is comprised of an upper main frame portion  20 , a lower rear frame portion or battery box  22 , a lower frame portion or chin fairing  24  and frame wheel attachment portions or hard tails  26 ,  28 . 
         [0034]    With reference now to  FIGS. 6-11 , the upper main frame portion  20  will be described in greater detail. As shown best in  FIGS. 6 and 7 , upper main frame portion  20  is comprised of a one piece integrated member having a front section  30 , mid section  32  and a rear section  34 . As described herein, upper main frame portion  20  is a one piece cast aluminum member which has an integrated air box  40  having an air intake at  42 , an integrated fuel tank at  44  including a fuel filler section at  46 , a steering post attachment section at  50 , engine mounting sections  52 ,  54 , a hard tail mounting section at  60 , and a battery box mounting section at  62 . 
         [0035]    With reference now to  FIGS. 8-11 , the integrated air tank  40  and fuel tank  44  will be described in greater detail. As shown in  FIGS. 8 and 9 , a lower cavity  70  is defined beneath the air tank  40  and is comprised of a top wall  72  having an opening at  74 , a rear wall  76 , side walls  78 ,  80  and a front wall  82 . As best shown in  FIGS. 10 and 11 , opening  74  communicates with integrated air box  40  as described herein. Integrated air box  40  is defined within the casting by a wall  90  which is comprised of a rear angled wall portion  92  ( FIG. 10 ) and by a long, exterior wall portion  94  and a front wall portion  96  ( FIGS. 9 and 10 ). Thus it should be appreciated that airflow may enter air inlet  42  and fluidly communicate through air box  40  to opening  74  while remaining separate from integrated fuel tank  44 . 
         [0036]    With reference to  FIGS. 9 and 10 , integrated fuel tank  44  is shown extending towards the front  30  of upper main frame portion  20  and having a side to side separation with air tank by way of wall portion  94 , and a front to back separation with air tank  40  by a wall portions  92 ,  96 . As shown best in  FIGS. 6 and 9 , the fuel filler section  46  is disposed in the laterally forward portion of the fuel tank  44 , but given the general arcuate shape of the upper main frame portion  20 , it should be appreciated that fuel dispensed through the filler section  46  would flow rearwardly into the fuel tank  44 . It should also be appreciated from a review of  FIGS. 8-11  that fuel tank  44  includes an enlarged volume portion  100  which would house a substantial percentage of the overall volume of fuel in tank  44 . It should also be appreciated that the fuel tank  44  would be lined with an inorganic coating, as is known in the art. The tank is prepared by plugging all of the holes, and the coating is measured and poured into the tank. The coating is stirred around to ensure full coverage to all of the surfaces. Other areas, such as around the filler cap may require an extra amount of the coating spray. 
         [0037]    As best shown in  FIGS. 10 and 11 , upper main frame portion  20  also includes a plurality of integrated mounting members. Front end  30  includes steering post attachment section  50  comprised of an upper steering post socket  110  and a lower steering post socket  112  for receiving a steering post and suitable bearings. As mentioned before, integrated engine mounting sections  52 ,  54  extend from an underside of the upper main frame portion  20  as best shown in  FIGS. 8 and 11 . As best shown in  FIGS. 6 and 7 , frame rear section  34 , and more particularly hard tail mounting section  60  has a recessed section  120  as described herein. As also shown best in  FIGS. 8 and 11 , enlarged volume portion  100  is defined by a lower face  130  having integral bosses  132  and threaded apertures  134  extending into the bosses  132  as described herein. Rear section  34  of main frame portion  20  further includes a mounting boss  140  having a threaded aperture  142  as best shown in  FIGS. 7 and 11 . Finally, and with respect to  FIGS. 8 and 11 , the under arcuate surface of the main frame portion includes a recessed groove  150  extending from cavity  70  downwardly and rearwardly, through rear engine mount section  54 . Finally and with respect to  FIG. 11 , rear face of upper main frame portion  20  includes an arcuate surface  160  as further described herein. 
         [0038]    With respect now to  FIGS. 12 and 13 , battery box  22  is generally defined by a front wall  170 , top wall  172 , side walls  174 ,  176  and a lower wall  178 . Front wall  170  includes mounting bosses at  180  with apertures  182  leading to internal counterbores  184 . Top wall  172  includes a top planar mounting surface  186  having a plurality of apertures  188  extending therethrough, with access from the inside of battery box  22 . Side walls  174 ,  176  include mounting extensions  190 ,  192  having mounting bosses  194  having threaded apertures at  196 . Finally, and as best shown in  FIG. 13 , battery box  22  includes a recessed mounting surface  197  having threaded apertures  198  at the corners thereof. 
         [0039]    With respect now to  FIGS. 14 and 15 , hard tails  26 ,  28  will be described in greater detail. As shown, each of the hard tails is a generally angular shaped member having upper arms  200  and lower arms  202 . The free end of arm  202  includes an upper mounting boss portion  204  which is similarly configured as mounting section  60  ( FIG. 7 ) including a mounting protrusion  206  profiled for receipt in recessed section  120  and further comprising mounting through holes at  208 . Mounting standoffs  210  are positioned at the intersection of arms  200 ,  202  and include mounting through holes  212  for receipt of an axle as described herein. A front end of lower arms  202  include mounting bosses  220  having apertures  222 , and standoffs  224  having apertures at  226 . The forward free ends of arms  202  include recessed sections at  228 . 
         [0040]    With reference now to  FIG. 16 , chin fairing  24  is shown in greater detail. Chin fairing  24  includes a front cowl portion  230  having arms  232  attached thereto. Each arm includes a mounting boss  234  where one of the bosses includes an aperture  236 . 
         [0041]    With reference now to  FIGS. 17-21 , steering assembly  6  is shown in greater detail, and is generally comprised of an upper triple clamp  240 , a lower triple clamp  242 , a steering post  244 , and a top cap  246 . As best shown in  FIGS. 18 ,  19 A and  19 B, top triple clamp  240  includes arms  248  forming circular openings  250 . Bosses  252  are positioned adjacent to circular openings  250 . Opposed clamping apertures are provided by apertures  254   a  and threaded apertures  254   b . A central section  256  of upper triple clamp  240  includes an aperture  258  to receive steering post  244  and further comprises a U-shaped recess  260  profiled to receive a handlebar as described herein. With respect to  FIGS. 18 ,  20 A and  20 B, lower triple clamp is similar to upper triple clamp including arms  270  having circular openings at  272  with bosses  274  positioned adjacent to circular openings, having opposed clamping apertures defined at  276   a  and  276   b . A central section  280  includes an aperture  282  for receiving steering post  244 . As best shown in  FIGS. 21A and 21B , top cap  246  includes a U-shaped recess  290  positioned in a complementary manner to U-shaped recess  260 , and includes apertures  292  for receipt of fasteners therethrough. 
         [0042]    With reference now to  FIGS. 22 and 23 , the assembly of the motorcycle as described above will generally be discussed. With reference first to  FIG. 22 , battery box  22  is first positioned with the planar mounting surface  186  against the lower face  130  of the upper main frame portion  20 . Fasteners  400  may be received through apertures  188  ( FIG. 12 ) and received into threaded engagement with threaded apertures  134 , attaching the battery box  22  to the lower portion of the upper main frame portion  20 . Hard tails  26  and  28  may thereafter be positioned against the combination of the upper main frame portion  20  and battery box  22  such that protrusions  206  are received within the recessed sections  120  and fasteners  402  may be received through apertures  208  into threaded engagement with threaded apertures  404  (see  FIG. 7 ). At the same time this positions bosses  220  against bosses  194  of the battery box whereby apertures  222  are aligned with threaded apertures  196 . Fasteners  406  may be received through apertures  222  and brought into threaded engagement with the apertures  196 . 
         [0043]    With reference now to  FIGS. 3 and 23 , power train  8  may now be brought into position against battery box  22  and upper main frame portion  20  whereby cap screws (not shown) may be positioned through counterbores  184  ( FIG. 12 ) and brought into threaded engagement within threaded apertures in bosses  354  ( FIG. 23 ). As shown in both  FIGS. 3 and 23 , engine  10  includes integrated flanges  352 ,  356  which may be connected to engine mounting sections  52  and  54  via clamps (not shown). As shown in  FIG. 23 , engine  10  also includes an air intake system  360  and it should be appreciated that a seal and throttle bodies may be positioned against air intake opening  74  ( FIG. 22 ) to receive incoming air from the integrated air tank. The connection of the engine to the upper main frame portion  20  and the connection of the throttle bodies to the integrated air tank is shown in greater detail in our U.S. Patent Application Publication No. 2008/0190683, the subject of which is incorporated herein by reference. 
         [0044]    At the same time, fasteners  410  ( FIG. 23 ) may be received through apertures  226  of hard tails  26 ,  28  and be received within a threaded aperture of bosses  412  integral with power train  8 . Chin fairing  24  may now be positioned with bosses  234  against integrated bosses  418  of power train  8  as shown in  FIG. 23 , and with lips  238  positioned within corresponding recesses  228  of hard tails  26 ,  28 , whereupon fasteners  416  may be received through apertures  236  and into threaded engagement within a threaded aperture of bosses  418 . 
         [0045]    With respect to the attachment of the wheels and tires, as mentioned above, steering post  244  is received through lower triple clamp  242  into post receiving area  50  within the upper main frame portion  20  and through upper triple clamp  240 , as best shown in  FIG. 22 . Bearings  450  would be positioned within respective recesses  110 ,  112  (see  FIG. 11 ) and a threaded collar  452  maintains post  244  in position. As also mentioned above with respect to  FIGS. 17 and 18 , forks  300  are maintained within apertures  250  by way of fasteners  255  within apertures  254   a ,  254   b  and fasteners  275  within apertures  276   a ,  276   b . A handlebar (not shown) may also be positioned between upper triple clamp  240  and upper cap  246  whereby fasteners  294  may maintain upper cap  246  in clamped retention against the handlebar. As for a rear tire and wheel, the hard tails  26 ,  28 , as shown in  FIG. 23  and as connected to battery box  22  and upper main frame portion  20 , are shown bosses  210  and apertures  212  in position to receive an axle therethrough. 
         [0046]    With respect to the electronics,  FIG. 24  depicts an electronic submersible fuel pump  500  which may be positioned within enlarged tank portion  100 . Pump  500  would include motor  502 , fuel pickup  504 , input power cable  504  and input signal cable  508 . The pump  500  would be inserted into the opening at the bottom of the enlarged tank portion  100 , and then sealed by a plug and retaining ring (not shown). A vent line, water drain line and a fuel rail are routed through portion  62  and through top area  172  of battery box. 
         [0047]    Input signal cable  508  would extend outwardly through enlarged tank  100  at a position adjacent to position  510 , such that control cable (not shown) could be dressed into the groove  150 , and extend to a control panel (not shown) adjacent to a front of the motorcycle. At the same time, the input power cable  506  would extend through a sealed fitting (not shown) through the upper surface  186  of battery box  22 . It should be appreciated that all of the cabling and/or wire harnesses could be run through the groove  150 , and could also run through the air box to and from the front end of the motorcycle. The battery box  22  would house a battery (not shown) which powers the electronics of the motorcycle. 
         [0048]    Once the electronics are completed, a rear access panel  520  ( FIGS. 5 ,  22 ,  23 ) could enclose the battery box  22 , via fasteners  522  received in threaded apertures  198  ( FIG. 13 ). As shown best in  FIG. 4 , the rear face  160  of the upper main frame portion, and the access panel  520  form a complementary arcuate surface spaced for receiving a tire and wheel. 
         [0049]    The seat  18  is also installed to the upper main frame portion  20 . Seat  18  includes seat portions  530  which straddle the upper main frame portion at boss  140  ( FIG. 7 ) where fasteners  532  may be received in threaded apertures  142 . 
         [0050]    It should be appreciated from the foregoing, that the provision of an upper main frame portion having an integrated air box and integrated fuel tank simplifies the manufacturing of the motorcycle, as well as provides an entirely new look. The position of the fuel tank also lowers the center of gravity as discussed above, and allows for a clean look for the electronic cabling. 
         [0051]    Moreover, the provision of an upper main frame portion as discussed herein could be used for a platform of vehicles or for multiple platforms, for example, cruisers or touring motorcycles, with the provision of further multiple optional components, alternate battery boxes, rear wheel frame component with shock absorption systems etc.