Abstract:
A bicycle frame including a head tube, a bottom bracket adapted to support a crankset, and a tubular frame member that defines a compartment. The bicycle frame also includes a battery pack disposed in the compartment and a chargeport coupled to the tubular frame member. The chargeport includes an electrical contact that is accessible from outside the tubular frame member and that is electrically coupled to the battery pack. A chargeport cover is magnetically coupled to the chargeport to enclose the electrical contact, and is further engageable with the tubular frame member when the chargeport cover is removed from the chargeport.

Description:
BACKGROUND 
       [0001]    The present invention relates generally to bicycles, and more specifically to bicycles including a chargeport. 
         [0002]    Bicycles commonly have a main frame and a front fork pivotally secured to the main frame. The main frame typically includes a top tube, a down tube, a seat tube, and a rear wheel mount for receiving a rear wheel axle. The front fork typically includes a front wheel mount for receiving a front wheel axle. Steering control of the bicycle is provided by a handlebar that is usually secured to the front fork via a handlebar stem. Some bicycles also include a power source, such as a battery, to provide power to components on the bicycle, and in some cases, to provide motive power to the bicycle. 
       SUMMARY 
       [0003]    The present invention provides a bicycle frame including a head tube, a bottom bracket adapted to support a crankset, and a tubular frame member that defines a compartment. The bicycle frame also includes a battery pack disposed in the compartment and a chargeport coupled to the tubular frame member. The chargeport includes an electrical contact that is accessible from outside the tubular frame member and that is electrically coupled to the battery pack. A chargeport cover is magnetically coupled to the chargeport to enclose the electrical contact, and is further engageable with the tubular frame member when the chargeport cover is removed from the chargeport. 
         [0004]    In another construction, the present invention provides a bicycle frame including a head tube, a bottom bracket adapted to support a crankset, and a tubular frame member coupled to the head tube. A battery pack is coupled to the tubular frame member. The bicycle frame also includes a chargeport housing that is coupled to the tubular frame member, and a chargeport that is attached to the chargeport housing. The chargeport has an electrical contact accessible from outside the tubular frame member and electrically connected to the battery pack. A chargeport cover is magnetically coupled to the chargeport to enclose the electrical contact, and the tubular frame member defines a storage location for the chargeport cover near the chargeport for storing the chargeport cover on the tubular frame member upon removal from the chargeport. 
         [0005]    In another construction, the present invention provides a method of storing a chargeport cover on a bicycle frame that includes a tubular frame member and a chargeport electrically connected to a battery pack supported by the bicycle frame. The method includes engaging a chargeport cover with the chargeport, and storing the chargeport cover on the tubular frame member upon removal of the chargeport cover from the chargeport. 
         [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 including a frame embodying the present invention. 
           [0008]      FIG. 2  is a perspective view of a portion of a down tube of the frame illustrated in  FIG. 1 , including a chargeport housing and a chargeport cover. 
           [0009]      FIG. 3 . is an exploded view of the down tube of  FIG. 2 , illustrating the chargeport housing, the chargeport cover, a chargeport, and a chargeport cover storage feature. 
           [0010]      FIG. 4  is a cross-section of the down tube taken along line  4 - 4  in  FIG. 2 , illustrating the chargeport cover connected to the chargeport within the chargeport housing. 
           [0011]      FIG. 5  is another cross-section of the down tube illustrating the chargeport cover coupled to the chargeport housing over the chargeport cover storage feature. 
       
    
    
       [0012]    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. 
       DETAILED DESCRIPTION 
       [0013]      FIG. 1  shows a bicycle  10  that includes a front wheel  15 , a rear wheel  20 , and a frame  25 . The frame  25  has a head tube  30  and a front fork  35  that is rotationally supported by the head tube  30  and that secures the front wheel  15  to the frame  25 . A handlebar assembly  40  is coupled to the head tube  30  and is secured to the front fork  35  by a stem assembly  45  such that movement of the handlebar  40  results in movement of the stem assembly  45  and the fork  35 . 
         [0014]    The frame  25  also has a top tube  50  connected to and extending rearward from the head tube  30 , and a down tube  55  connected to the head tube  30  below the top tube  50  and extending generally downward toward a drive train  60 . A seat tube  65  is connected to the top tube  50  and the down tube  55 , and a seat  70  is supported by the seat tube  65 . 
         [0015]    The frame  25  also has a top tube  50  connected to and extending rearward from the head tube  30 , and a down tube  55  connected to the head tube  30  below the top tube  50  and extending generally downward toward and connected to a bottom bracket  60  of the frame  25 . With reference to  FIG. 2 , the illustrated down tube  55  has an oblong or rounded trapezoidal cross-sectional profile. A seat tube  65  extends upward from the bottom bracket  60  and is connected to the top tube  50 , and a seat  70  is supported by the seat tube  65 . The illustrated frame  25  is formed from non-magnetic material (e.g., aluminum, composite, etc.). 
         [0016]    The bicycle  10  also can include a motor (not shown) that is drivingly coupled to a rear sprocket assembly  75  to selectively provide motive force for the bicycle  10  and/or to act as a generator for an electrical circuit (not shown) of the bicycle  10 . The motor is electrically connected to a power source or battery pack  80 , which may also serve as a controller for the motor and/or other electrical accessories on the bicycle  10 . In some constructions, the motor may be excluded from the bicycle  10 . 
         [0017]    With reference to  FIGS. 1 and 2 , the battery pack  80  is disposed in a compartment  85  of the down tube  55 , although the battery pack  80  can be disposed in another tubular frame member (e.g., the top tube  50 , the seat tube  65 , etc.).  FIGS. 2 and 3  show a chargeport housing or receiver  90  that is disposed in the down tube  55  adjacent and in communication with the compartment  85 . More specifically, the chargeport housing  90  is enclosed within the down tube  55  and has an exterior wall  95  that substantially conforms to the inner hollow profile of the down tube  55 . The chargeport housing  90  also includes an axially aligned first recessed area or tapered socket  100  that is coupled with the battery pack  80 , and a second recessed area or socket  105  that is accessible from the exterior wall  95  and orthogonal to the first recessed area  100 . 
         [0018]    A chargeport  110  is attached to the chargeport housing  90  within the second recessed area  105  so that an outer surface  115  of the chargeport  110  is substantially flush with the exterior wall  95 . Fasteners  120  secure the chargeport  110  to the chargeport housing  90 . As illustrated, when the chargeport housing  90  is placed in the down tube  55 , the chargeport  110  is accessible from outside the down tube  55  via a hole  125 . The chargeport  110  includes an electrical contact  130  that is electrically connected on the back end to the battery pack  80  via wires (not shown) extending between the battery pack  80  and the chargeport housing  90 . As illustrated, the chargeport  110  has a cylindrical recess  135  via which the electrical contact  130  is exposed on the front end. The electrical contact  130  illustrated in  FIGS. 3 and 5  takes the form of a pin-type electrical connector, although other types of electrical connectors are possible. Also, the chargeport can be directly coupled to the down tube  55  (or another tubular frame member) in the absence of the chargeport housing  90 . 
         [0019]    With reference to  FIGS. 2-4 , the chargeport  110  is covered or enclosed by a chargeport cover  140  to protect the electrical contact  130  from debris, fluids, and other material to which the down tube  55  may be exposed. Without the cover  140 , the chargeport  110  is exposed to the environment. The chargeport cover  140  is defined by a flange  145  and cylindrical body  150  that conforms to and fits within the cylindrical recess  135 . The flange  145  has a bridge or gripping portion  155  so that the chargeport cover  140  can be installed on and removed from the chargeport  110 . 
         [0020]    The cylinder body  150  has a blind hole (not shown) that receives the electrical contact  130 . Also, the chargeport  110  includes pins or protrusions  160  (two protrusions  160  illustrated in  FIG. 4 ) that surround the electrical contact  130  and that are received in sleeves  165  on the distal end of the cylindrical body  150 . The protrusions  160  are magnetized and cooperate with first magnets  170  (two shown) disposed in the chargeport cover  140  to align and attach the chargeport cover  140  to the chargeport  110 . As illustrated, the magnets  170  are located near the distal end of the cylindrical body  150  and have a polarity that is opposite the polarity of the magnetized protrusions  160 . 
         [0021]    Referring to  FIG. 3 , a second magnet  175  is coupled to the exterior wall  95  of the chargeport housing  90  and cooperates with the first magnets  170  to store the chargeport cover  140  upon removal of the chargeport cover  140  from the chargeport  110 . The second magnet  175  is recessed in the exterior wall  95  and is enclosed by the down tube  55  when the chargeport housing  90  is installed in the down tube  55 . As illustrated, an optional non-magnetized plate  180  is positioned over the second magnet  175  to hold the magnet  175  in place on the chargeport housing  90 . In other constructions, the second magnet  175  can be attached to the chargeport housing  90  without the plate  180 , directly attached to the inside surface of the down tube  55 , to the outside surface of the down tube  55 , or attached to another component in the down tube  55  (or another frame member) for securing the chargeport cover  140  to the corresponding frame member. 
         [0022]    The orientation and location of the second magnet  175  relative to the down tube defines a storage location  185  on the down tube  55  for the chargeport cover  140  when the chargeport cover  140  is removed from the chargeport  110  (e.g., when the battery pack  80  is being charged). With reference to  FIG. 3 , the down tube  55  can have indicia  190  (e.g., a decal, a recessed area, a scribed area, etc.) that aligns with or overlays the second magnet  175  to identify the storage location  185 . The illustrated storage location  185  (and corresponding location of the second magnet  175 ) is relatively close to or near the chargeport  110  (e.g., less than two inches from the chargeport  110 ) so the storage location  185  is easily identifiable by a user of the bicycle  10 . Generally, the storage location  185  can be anywhere on the down tube  55 , although locating the storage location  185  within four inches of the chargeport  110  is preferable. 
         [0023]    As illustrated in  FIG. 4 , the chargeport cover  140  is coupled to the chargeport  110  during operation of the bicycle  10  to protect the electrical contact  130  from the environment. As illustrated in  FIG. 5 , when access to the electrical contact  130  is necessary (e.g., when the battery pack  80  is being charged), the chargeport cover  140  is removed from the chargeport  110  and placed on the storage location  185 . The first and second magnets  170 ,  175  magnetically engage each other through the down tube  55  so that the chargeport cover  140  is not lost or damaged after the chargeport cover  140  is removed from the chargeport  110 . The close proximity of the storage location  185  to the chargeport  110  and the optional indicia  190  on the down tube  55  provides the user with an easily identifiable location on the bicycle  10  for storing the chargeport cover  140  when the cover  140  is not being used. 
         [0024]    Various features and advantages of the invention are set forth in the following claims.