Abstract:
The present invention provides a bicycle comprising a motor mounted to a motor mount of the bicycle frame. The motor mount includes a down tube mount coupled to a down tube, a chainstay mount coupled to a chainstay, and a side brace secured to the down tube mount and wrapping around one side of the motor to the chainstay mount. Preferably, when viewed from the side, the side brace extends directly from the down tube mount to the chainstay mount. Preferably, the motor mount further comprises a lower support secured to the down tube mount and wrapped around a bottom of the motor to the chainstay mount. The motor mount can further include an upper support connecting the seat tube mount to the down tube mount. This upper support can include an upper flange secured to the motor.

Description:
BACKGROUND 
       [0001]    The present invention relates to bicycle frames and specifically to a bicycle frame that is adapted to support an electric motor. 
         [0002]    It is known to provide a bicycle with an electric motor and battery in order to supplement the pedaling power provided by the user. Such electric motors can be secured to or incorporated into the bicycle frame or wheel hubs. 
       SUMMARY 
       [0003]    The present invention provides a bicycle comprising a front wheel and a rear wheel cooperatively defining a central plane and forward and rearward directions, a front fork supported by the front wheel, and a frame supported by the front fork and the rear wheel. The frame includes a head tube rotationally coupled to the front fork, a down tube extending downward and rearward from the head tube, a motor mount coupled to and extending from the down tube, and a chainstay coupled between the motor mount and the rear wheel. A motor is mounted to the motor mount. The motor mount includes a down tube mount coupled to the down tube, a chainstay mount (e.g., a pivot mount) coupled to the chainstay, and a side brace secured to the down tube mount and wrapping around one side of the motor to the chainstay mount. A side of the motor mount opposite the side brace includes an opening large enough to facilitate insertion and removal of the motor. Preferably, when viewed from the side, the side brace extends directly from the down tube mount to the pivot mount. 
         [0004]    Preferably, the motor mount further comprises a lower support secured to the down tube mount and wrapped around a bottom of the motor to the chainstay mount. For example, the lower support can be substantially aligned with the central plane. In one embodiment, the lower support comprises a lower flange secured to the motor. 
         [0005]    The frame can further include a seat tube, and the motor mount can further include a seat tube mount coupled to the seat tube. Preferably, the motor mount further includes an upper support connecting the seat tube mount to the down tube mount. This upper support can include an upper flange secured to the motor. The motor mount can further include a rear support connecting the seat tube mount to the chainstay mount. 
         [0006]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a side view of a bicycle incorporating features of the present invention. 
           [0008]      FIG. 2  is a perspective view of a bicycle frame assembly of the bicycle shown in  FIG. 1 . 
           [0009]      FIG. 3  is a partially exploded view of the bicycle frame assembly of  FIG. 2 . 
           [0010]      FIG. 4  is an enlarged perspective view of a lower portion of a frame of the bicycle of  FIG. 1 . 
           [0011]      FIG. 5  is a right side view of a lower portion of the frame of  FIG. 4 . 
           [0012]      FIG. 6  is a section view taken along line  6 - 6  in  FIG. 4 . 
           [0013]      FIG. 7  is a perspective view of the battery in a partially-attached position. 
           [0014]      FIG. 8  is a perspective view of the battery in a fully-attached position. 
           [0015]      FIG. 9  is a section view taken along line  9 - 9  of  FIG. 7  showing the lower battery mount engaged with the lower frame mount with the battery in the partially-attached position of  FIG. 7 . 
           [0016]      FIG. 10  is a section view taken along line  10 - 10  of  FIG. 8  with the battery in the fully-attached position of  FIG. 8 . 
           [0017]      FIG. 11  is an enlarged perspective view of an upper frame mount prior to installation of the battery. 
           [0018]      FIG. 12  is the perspective view of  FIG. 11  with the battery in the fully-attached position of  FIG. 8 . 
           [0019]      FIG. 13  is an enlarged view of a battery control panel on the battery. 
           [0020]      FIG. 14  is an enlarged perspective view of a battery connector on the battery. 
           [0021]      FIG. 15  is an enlarged perspective view of a speed sensor. 
           [0022]      FIG. 16  is an exploded view of a right motor cover with an integrated cable channel. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0024]      FIGS. 1-3  illustrate a bicycle  20  embodying the present invention. The illustrated bicycle  20  includes a front wheel  22  and a rear wheel  24  that cooperatively define a central plane  26  and forward and rearward directions. A front fork  28  is supported by the front wheel  22 , and a frame  30  is supported by the front fork  28  and the rear wheel  24 . The illustrated frame  30  includes a head tube  32  rotationally coupled to the front fork  28 , a down tube  34  extending downward and rearward from the head tube  32 , a top tube  36  extending rearward from the head tube  32 , a seat tube  38  extending downward from the top tube  36 , and a motor mount  40  connecting the down tube  34  and the seat tube  38 . The frame  30  further comprises a rear suspension assembly  42  including chainstays  44 , rear wheel mounts  46 , seat stays  48 , and a rear shock  50 , the functions of which are well known in the art. 
         [0025]    The illustrated bicycle  20  further includes an electric motor  52  adapted to provide power to the bicycle  20 . The illustrated electric motor  52  includes three mounting studs  54  for securing the electric motor  52  to the frame  30  via mounting nuts  55 . The electric motor  52  further includes a drive shaft  56  connected to left and right cranks  58  that are adapted to receive corresponding pedals  59  that facilitate pedaling of the bicycle  20  by a user. Power is provided to the electric motor  52  via a battery  60  mounted within a tube recess  62  in the down tube  34 , as explained below in more detail. 
         [0026]    As best seen in  FIG. 4 , the motor mount  40  includes a down tube mount  64  coupled to the down tube  34 , a seat tube mount  66  coupled to the seat tube  38 , and a chainstay mount  68  coupled to the chainstays  44 . The illustrated down tube mount  64  and seat tube mount  66  are welded to the down tube  34  and seat tube  38 , respectively, but any suitable connection (e.g., bonding, fastening, or unitary construction) will suffice. The illustrated chainstay mount  68  comprises a pivot mount  70  for pivotally connecting the motor mount  40  to the chainstays  44  using a pivot shaft  72 . 
         [0027]    The motor mount  40  further includes a side brace  74  connecting the down tube mount  64  to the chainstay mount  68  along the left side of the electric motor  52 . As best shown in  FIGS. 3-4 , the side brace  74  is positioned to structurally and visually extend from the down tube  34  directly toward the chainstay mount  68 . As shown in  FIG. 5 , the right side of the motor mount  40  does not include a side brace  74  and is completely open to facilitate insertion and removal of the electric motor  52  from the motor mount  40 . 
         [0028]    Referring to  FIGS. 3 and 4 , the motor mount  40  further includes an upper support  76  connecting the down tube mount  64  with the seat tube mount  66 , a rear support  78  connecting the seat tube mount  66  with the chainstay mount  68 , and a lower support  80  connecting the down tube mount  64  with the chainstay mount  68 . As illustrated in  FIGS. 3, 4, and 6 , the upper support  76  includes an upper flange  82  aligned with the central plane  26  and including a flange opening  84  adapted to receive one of the mounting studs  54  in order to facilitate attachment of the electric motor  52  to the motor mount  40  by the mounting nuts  55 . Similarly, the lower support  80  includes a lower flange  85  aligned with the central plane  26  and including two flange openings  84  adapted to receive two of the mounting studs  54  in order to facilitate attachment of the electric motor  52  to the motor mount  40 . As explained above and illustrated in the drawings, the combination of the down tube mount  64 , the upper support  76  the seat tube mount  66 , the rear support  78 , the chainstay mount  68 , and the lower support  80  provides complete enclosure of the electric motor  52  along the central plane  26  of the bicycle  20 . This arrangement provides structural integrity to the bicycle frame  30  and also helps to protect the electric motor  52  from damage that could be caused by impact of the bicycle  20  with other objects (e.g., rocks or logs). This arrangement also utilizes the electric motor  52  as a stressed member to further improve the strength and rigidity of the bicycle frame  30 . 
         [0029]    As illustrated in  FIGS. 3-5  and further explained above, the structural arrangement of the motor mount  40  results in an upper left opening  86 , a lower left opening  88 , and a right opening  90 . These openings are fitted with an upper left cover  92 , a lower left cover  94  and a right cover  96 , respectively. Each of the upper support  76 , lower support  80 , and rear support  78  includes threaded openings  98  for receiving threaded fasteners  100  that attach the covers to the motor mount  40 . The covers protect the electric motor  52  from damage and debris infiltrating the electric motor  52 . 
         [0030]    Referring to  FIG. 3 , the illustrated battery  60  includes an upper battery mount  102  and a lower battery mount  104  that facilitates securing the battery  60  to the bicycle frame  30  at an upper frame mount  106  and a lower frame mount  108 , respectively. When attaching the battery  60  to the frame  30 , the lower battery mount  104  is first engaged with the lower frame mount  108  with the battery  60  in a partially attached position, as shown in  FIG. 7 . The battery  60  is then pivoted upwardly toward the frame  30  to a fully attached position, as shown in  FIG. 8  and described below in more detail. 
         [0031]    The lower battery mount  104  and lower frame mount  108  define a pivot interface between the battery  60  and the frame  30 . In the illustrated embodiment, the lower battery mount  104  comprises an eccentric boss  110  adapted to engage the lower frame mount  108 . In the embodiment shown in  FIGS. 9 and 10 , the eccentric boss  110  comprises an elongated shaft having a cam profile with a low point  112  defining a first boss width W 1  and a high point  114  defining a second boss width W 2  larger than the first boss width. As the battery  60  is pivoted from the partially attached position of  FIG. 7  to the fully attached position of  FIG. 8 , the cam profile of the eccentric boss  110  will be rotated with the battery  60  to present different profiles of the eccentric boss  110  to the lower frame mount  108 , as described below in more detail. 
         [0032]    The illustrated lower frame mount  108  defines a depression in the form of a slot  116  that is dimensioned to receive the eccentric boss  110 . With specific reference to  FIGS. 9 and 10 , the slot  116  has a width that is dimensioned to easily receive the first boss width W 1  of the eccentric boss  110 . This is the orientation of the eccentric boss  110  that will be presented to the lower frame mount  108  when the battery  60  is in the partially attached position of  FIGS. 7 and 9 . As the battery  60  is rotated to the fully attached position, the cam profile of the eccentric boss  110  is rotated such that the second boss width W 2  of the eccentric boss  110  is presented to the slot  116  of the lower frame mount  108 , thereby wedging the eccentric boss  110  in the lower frame mount  108 , as shown in  FIGS. 8 and 10 . In order to facilitate this interference fit, the lower frame mount  108  is resilient (e.g., made from a resilient material such as polyurethane or resiliently mounted, such as spring-biased). By virtue of this arrangement, the lower battery mount  104  will be held securely to the lower frame mount  108  with reduced likelihood of any rattling occurring due to shocks or vibrations. In addition, the resilient slot  116  configuration of the lower frame mount  108  will inherently accommodate slight differences in battery  60  lengths. It should be understood that the positions of the eccentric boss  110  and depression could be reversed (i.e., the depression could be positioned on the battery  60  and the eccentric boss  110  could be positioned on the frame  30 ). In addition, the eccentric boss  110  could be made of a resilient material instead of or in addition to the lower frame mount  108 . 
         [0033]    As best seen in  FIGS. 7-8 and 11-12 , the upper battery mount  102  comprises a battery hole  118  extending all the way through the battery  60 , and the upper frame mount  106  includes tube holes  120  through the left and right walls of the down tube  34  adjacent an upper end of the tube recess  62 . With the battery  60  in the fully attached position of  FIG. 8 , the battery hole  118  of the upper battery mount  102  will be aligned with the tube holes  120  of the upper frame mount  106 , and a battery mounting pin  122  can be inserted through the aligned tube holes  120  and battery hole  118  to secure the battery  60  in the fully attached position. In the illustrated embodiment, one of the tube holes  120  is threaded and an end of the battery mounting pin  122  is similarly threaded to secure the mounting pin in place. 
         [0034]    With specific reference to  FIGS. 3, 7 and 8 , the illustrated bicycle  20  further includes a rock guard  124  secured to and removable from a lower end of the battery  60 . The rock guard  124  includes a forked end  126  adapted to fit on opposing sides of the lower battery mount  104 . In the illustrated embodiment, the forked end  126  of the rock guard  124  is secured to the battery  60  by the same battery fastener  128  that secures the eccentric boss  110  to the battery  60 , as best shown in  FIG. 3 . The rock guard  124  further includes two threaded openings (not shown) facing the battery  60  and adapted to receive fasteners (not shown) that can be inserted through holes in the battery  60  and threaded into the threaded openings  98  in the rock guard  124  to further secure the rock guard  124  to the battery  30 . By virtue of this arrangement, the rock guard  124  provides protection to the lower end of the battery  60  and can be easily replaced if damaged. 
         [0035]    The battery  60  further includes a battery control panel  130  that facilitates control of the operation of the battery  60 , best seen in  FIG. 13 . Specifically, the battery control panel  130  includes a power button  132 , a plus button  134  and a minus button  136 . These buttons can be used to power the battery  60  on and off and also to select different modes of the battery  60 . The battery control panel  130  further includes a series of perimeter lights  138  that indicate the battery charge. 
         [0036]    Referring to  FIG. 14 , the battery  60  further includes a battery connector  140  on the left side of the battery  60  near the lower battery mount  104 . The illustrated battery connector  140  can be used both to charge the battery  60  (e.g., with an appropriate charger, not shown) and also to provide connection to the electric motor  52  via a motor connector  142  wired to the electric motor  52 . The illustrated motor connector  142  includes an overmolded housing  144  that fits into and is flush with the surrounding surfaces. 
         [0037]    The illustrated bicycle  20  further includes a speed sensor  146  secured to an inner face  148  of the left rear wheel  24  support, as illustrated in  FIG. 15 . The speed sensor senses the rotation of the rear wheel  24 , and this information can be used to calculate the speed of the bicycle  20 . By virtue of this positioning, the speed sensor  146  is protected from damage and is further not visible from the left side of the bicycle  20 , thus improving aesthetics of the bicycle  20 . 
         [0038]    Referring to  FIG. 16 , the inside surface of the right cover  96  includes an integral cable channel  150  that facilities routing of a cable through the motor mount  40 . More specifically, with the right cover  96  secured to the motor mount  40 , the cable channel  150  will be positioned against the electric motor  52 , thereby creating a substantially enclosed passageway. With this substantially enclosed passage way, a cable or housing can be inserted into the passage way from the down tube  34  (see arrows in  FIG. 16 ) and pushed until it exits adjacent the chainstay mount. This arrangement avoids the need to remove the right cover  96  when threading a new cable or housing through the motor mount  40 . 
         [0039]    Various features and advantages of the invention are set forth in the following claims.