WO2023170464A1

WO2023170464A1 - A dual cradle frame for an electric vehicle

Info

Publication number: WO2023170464A1
Application number: PCT/IB2022/061177
Authority: WO
Inventors: Rohan R. LODAYA; Meet B. THAKKER; Zakirhusen K. Memon
Original assignee: Matter Motor Works Private Limited
Priority date: 2022-03-11
Filing date: 2022-11-19
Publication date: 2023-09-14

Abstract

A dual cradle frame (100) for an electric vehicle has been provided. The frame comprises a head tube (102), a frame cross tube (104) and a multiple vehicle frames which forms first cradle (112) and a second cradle (114). The first cradle houses heavy weight power pack PP and the second cradle houses power train PT such that largest possible heavy weight power pack can be housed along with an high performance power train in the vehicle, without encountering adverse effects of weight and size on motion, rider ergonomics, vehicle speed and efficiency of the vehicle.

Description

A DUAL CRADLE FRAME FOR AN ELECTRIC VEHICLE

FIELD OF INVENTION:

[001] The present disclosure relates generally to a cradle frame for an electric vehicle, more particular to a dual or two cradle frame for the electric vehicle that supports the mounting of a power pack and a power train of the electric vehicle.

Background of the Invention:

[002] Traditionally, automotive vehicles have used internal combustion engines as their power source and petroleum fuels as a source of power to drive the engines. In majority of vehicles with IC engines, power-trains are conventionally supported by using a single cradle design or a double cradle design. In the single cradle design the IC engine is supported on a single metal tube, while in the double cradle design, the engine is supported on a pair of metal tubes. This design is well suited for the IC engine, but it is proven to have limited effectiveness when implemented in electric vehicles.

[003] Typically, an operation of an electric vehicle requires a higher source of electricity, i.e., battery packs containing a plurality of batteries sufficient to drive the power train or electric motor of the electric vehicle. Such battery packs are big in size and have a higher weight demanding a more sturdy design. At the same time, the designer has to spare some room for the accommodation of another bulky and/or heavy essential part of the electric vehicle, i.e., a power train containing an electric motor and gear-box. It is known in the art that designing of the vehicle has ergonomic constraints or limitations in allowable weight and space. The heavy weight and large size of the battery pack and the power train provide a great test for the strength and vehicle designing to design in a manner that avoids adverse effects on the motion, rider ergonomics, and efficiency of the vehicle.

[004] Thus, a cradle frame is highly desirable that can efficiently package high-weight power-pack and power-train of the electric vehicle without affecting the motion, rider ergonomics, vehicle speed, and efficiency of the vehicle.

OBJECT OF THE INVENTION [005] An object of the present disclosure is to provide a dual cradle frame that is capable of housing both of, a power pack and a power train in an electric vehicle.

[006] Another object of the present disclosure is to provide a dual cradle frame that optimizes position of central gravity to increase the dynamic stability of the vehicle.

[007] Yet another object of the present disclosure is to provide a dual cradle frame accommodating the power pack and the power train in the electric vehicle, while improving performance parameters such as speed, range, weight distribution and so forth, of the electric vehicle.

[008] Other objects and advantages of the system of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY OF THE INVENTION

[009] In accordance with an embodiment of the present disclosure, there is provided a dual cradle frame for an electric vehicle. The dual cradle frame comprises a head tube, a frame cross tube, a plurality of vehicle frames tubes. The plurality of vehicle frames tubes comprises a right and a left upper frame tubes extending backward and downward from a top part of the head tube towards the frame cross tube, a right and a left lower frame tubes extending downward from a middle part of the head tube towards the frame cross tube, and a right and a left middle frame tubes connecting the right and a left upper frame tubes with the right and a left lower frame tubes respectively.

[0010] In one embodiment of the invention, a top part of the right and left upper frame tubes and a top part of the right and left lower frame tubes, together with the right and left middle frame tubes form a first cradle. Similarly, the bottom part of the right and left upper frame tubes and a bottom part of the right and a left lower frame tubes together with the right and a left middle frame tubes form a second cradle. [0011 ] In a preferred embodiment of the present disclosure, the first cradle is adapted to support a first component and the second cradle is adapted to support a second component. Here, the first component and the second component are different.

[0012] The frame further comprises a plurality of resting brackets, locating brackets and arresting brackets for supporting the power-pack in the first cradle and a plurality of mounting brackets, for supporting the power-train in the second cradle.

[0013] In a preferred embodiment of the present disclosure, the first component is a Power-Pack and the second component is a power-train of the electric vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 (a) is an enlarged view of a conventional single cradle frame.

[0015] FIG. 1 (b) is an enlarged view of a conventional double cradle frame.

[0016] FIG. 2 is an iso-metric view showing a dual cradle frame according to an embodiment of the present disclosure.

[0017] FIG. 3 is a side inclined view showing a dual cradle frame according to an embodiment of the present disclosure.

[0018] FIG. 4 is an isometric view showing a dual cradle frame accommodating a power pack and a power train according to an embodiment of the present disclosure.

[0019] Common reference numerals are used throughout the drawings and the detailed description to indicate the same elements.

DESCRIPTION

[0020] The detailed description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a dual cradle frame for an electric vehicle and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structure and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the present disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

[0021 ] Referring to attached drawings, embodiments of the present disclosure will be described below, “front”, “rear”, “right”, “left”, “upper” and “lower” denote each position of a vehicle viewed from a rider. The drawings shall be viewed with regard to the reference numbers.

[0022] The term “power pack” is used in this description and in the appended claims also interpreted to include all synonyms used in the art such as battery pack, power box and like energy storage means comprising a one or more cell array adapted to supply electrical energy to the electric vehicle.

[0023] FIG. 1 (a) and 1 (b) show a conventional design of a single cradle frame and a double-cradle frame used in the conventional automotive two-wheel vehicles. Traditionally, the powertrain (IC engine + Gearbox) is accommodated at the bottom and the fuel tank at the top in such a design.

[0024] FIG.2 is an isometric view of a dual cradle frame 100 according to an embodiment of the present disclosure. The dual cradle frame 100 comprises a head tube 102, a frame cross tube 104 and a plurality of vehicle frames arranged inbetween thereof. The plurality of vehicle frames includes a right and a left upper frame tubes 106, 106’ extending backward and downward from a top part of the head tube 102 towards the frame cross tube 104, a right and a left lower frame tube 108, 108’ extending downward from a middle part of the head tube 102 towards the frame cross tube 104, and a right and a left middle frame tubes 110, 110’ connecting the right and a left upper frame tubes 106, 106’ with the right and a left lower frame tubes 108, 108’ respectively. In simple words, the right and left middle frame tubes 1 10, 110’ are adapted to divide the frame 100 to form two numbers of cradles.

[0025] That is, a top part of the right and left upper frame tubes 106, 106’ and a top part of the right and left lower frame tubes 108, 108’, together with the right and left middle frame tubes 110, 110’ form a first cradle 112. Similarly, a bottom part of the right and left upper frame tubes 106, 106’ and a bottom part of the right and a left lower frame tubes 108, 108’ together with the right and a left middle frame tubes 110, 110’ forms a second cradle 1 14.

[0026] Frame 100 further includes a plurality of support tubes 142, 142’ attached to the right and left upper frame tubes 106, 106’ at one end and with a right and left rear frame tube 140, 140’ at a second end thereof.

[0027] The frame 100 further includes a plurality of resting brackets 1 16, 118, 120, locating brackets 122, 124, 126, 128, and arresting brackets 130, 132. In one embodiment of the present disclosure, the resting brackets 116, 118, 120 are provided between the right middle frame 110 and the left middle frame 110’, while the locating brackets 122, 124, 126, 128 are provided on the right and left upper frame tubes 106, 106’. The arresting bracket 130 is provided between the right rear frame tube 140 and left rear frame tube 140’, while the arresting bracket 132 is provided on the support tubes 142, 142’.

[0028] In another embodiment of the present disclosure, the frame further comprises a plurality of mounting brackets 134, 136, 138. The mounting bracket 134 is provided on the lower part of the right and left lower frame tubes 108, 108’, the mounting bracket 136 is provided on the frame cross tube 104, and the mounting bracket 138 is provided on the right and left middle frame tubes 110, 110’.

[0029] In another preferred embodiment of the present disclosure, the first cradle 1 12 and the second cradle 1 14 are adapted to support two different components, namely, a power pack PP and a power train PT. More precisely, the first cradle 1 12 is adapted to support the power pack PP and the second cradle 114 is adapted to support the power train PT of the vehicle. For example, the power pack PP desired to be accommodated within the first cradle 1 12 is disclosed in patent application No IN 202221013223 dated 11th March, 2022 for “A power pack with an integrated active thermal management system for an electric vehicle” filed herewith, the disclosure of which is herein incorporated by reference. Similarly, the power train PT desired to be accommodated within the second cradle 1 14 is disclosed in patent application No IN 202221013387 dated 11 th March, 2022 for A COMPACT POWER-PACK ASSEMBLY FOR AN ELECTRIC VEHICLE, filed herewith, the disclosure of which is herein incorporated by reference. [0030] The power pack PP may comprise a plurality of individual cells which are mechanically and electrically connected in a series and arranged in parallel. More preferably, the power pack PP contains at least 500 cells. The power pack PP may comprises a cooling circuit to cool the heated cells to avoid adverse effects that might happen due to insufficient heat extraction. The power pack PP may further comprise a plurality of controller. These controllers may include, but is not limited thereto, a controller for Drive Traction Unit, cooling controller and/or Battery management system, and so forth. In a more preferred embodiment of the present disclosure, the power pack PP is a high voltage heavy power pack sufficient to drive an electric vehicle. Sad The power train PT is a compact power train comprising a closely packed gearbox and an electric motor. The power train PT may additionally comprise a cooling and lubricating means for the motor and the gear box. In a more preferred embodiment of the present disclosure, the same power pack coolant may be used for cooling the motor as well as to lubricate the gear box. In an embodiment of the present disclosure, the first cradle 112 and the second cradle 1 14 are made from high-strength metal or metal composites, with or without reinforcement, such as carbon fiber. The high- strength metal tubes may produce by any process known in the art. Such processes may include, but is not limited thereto, forging, molding, printing, embossing casting, cutting, composite manufacturing processes, rapid prototyping techniques, etc.

[0031 ] In a preferred embodiment of the present disclosure, each of the first cradle 112 and the second cradle 1 14 are double-cradle type. In other words, the dual cradle frame 100 is an integrated set of two number of double-cradle frames enabling the stacked arrangement of heavy-weight components of an electric vehicle. In an alternative embodiment of the present disclosure, the frame 100 may be a monocoque frame, Trellis Frame, Perimeter frame or a Single Cradle Frame type, etc.

[0032] Referring to FIG. 3 showing a side-inclined view of the frame 100 according to an embodiment of the present disclosure. FIG. 3 provides a clear representation of the plurality of the resting brackets 116, 118, 120, the locating brackets 122, 124, 126, 128, the arresting brackets 130, 132 and the mounting brackets 134, 136, 138 on frame 100. In a preferred embodiment of the present disclosure, the resting brackets 116, 118, 120, the locating brackets 122, 124, 126, 128 and the arresting brackets 130, 132 are adapted to support power pack PP 1 12, while mounting brackets 134, 136, 138 are adapted to support power train PT. The resting brackets 1 16, 118, 120, the locating brackets 122, 124, 126, 128, the arresting brackets 130, 132 and the mounting brackets 134, 136, 138 are provided in association with the arrangement of the power pack PP and power train PT in any of the cradles.

[0033] In another embodiment of the present disclosure, the dual cradle frame 100 as a whole when viewed from a side, i.e., any of a left or right side, has a polygonal shape. The frame 100 is adaptable as per the size of the power pack PP and power train PT that needs to be supported. For example, frame 100 can be modified in terms of shape, size, height, or length of the first cradle 1 12 and the second cradle 1 14 as per the requirement. For example, if the power pack PP has a size longer than the size of the power train, the first cradle is designed to have more length than the second cradle. Similarly, if the power train has a height greater than that of the power pack PP, the second cradle may be designed to have a more height than the power pack PP. For example, as shown in FIG. 3 the second cradle 1 14 has a shorter bottom area and more height than the first cradle 112. This adds a particular advantage when the second cradle is designed to house power train components having higher weight and height, but narrow width and length compared to the power pack PP. In any of the cases, the power pack PP and power train PT will be stacked vertically. This vertical stacking of power pack PP over power train PT helps to optimize the centre of gravity as the weight is restrained vertically rather than horizontally. This improves the dynamic stability and safety of the vehicle.

[0034] In a preferred embodiment of the present disclosure, the power pack PP is supported within the first cradle 1 12, while the power train is supported within the second cradle 1 14. In an alternative embodiment of the present disclosure, the power train may be housed within the first cradle 112, while the power pack PP may be housed within the second cradle 1 14.

[0035] In one embodiment of the present disclosure, the first cradle 1 12 may have, but is not limited thereto, an obtuse triangle shape, while the second cradle 1 14 may have, but is not limited thereto, a trapezoidal shape.

[0036] Thus dual cradle frame design according to the present disclosure enables, the largest possible size of the Power-Pack PP to be implemented for improved vehicle range and performance characteristics while keeping vehicle boundary conditions within the acceptable limits.

[0037] The dual cradle frame 100 enables successful integration of power-pack PP and the high-performance powertrain PT which would cater for making a high- performance electric two-wheeler attainable.

[0038] The high voltage power-pack PP comprises a plurality of individual cells which are in the mechanical and electrical connection with each other in a series that are arranged in parallel, which adds to the length of the power-pack and not height. Besides, the top placement of the battery cells enables a convenient removal of powerpack for purpose of charging, repairing, or replacement by the user and/or a maintenance service provider.

[0039] In a preferred embodiment of the present disclosure, the frame 100 is adapted to be used for an electric vehicle having a battery pack as a sole means for supplying power. In an alternative embodiment of the present disclosure, the frame 100 may be implemented within a vehicle comprising a battery pack along with a combustion engine or other source of energy.

[0040] In another preferred embodiment of the present disclosure, the frame 100 is adapted to be implemented within an electric vehicle having two or three wheels.

[0041 ] FIG. 4 shows an iso-metric view of the dual cradle frame after the power pack PP and the power train PT are housed within the dual cradle frame 100 according to a preferred embodiment of the present disclosure. In a more preferred embodiment of the present disclosure, the powerpack PP is a high voltage high current power pack. In a more preferred embodiment of the present disclosure the power train is a high- performance power train. The vertical arrangement of the power pack PP and Power train PT provides improved dynamic stability to the electric vehicle.

[0042] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

Claims

CLAIM

1 . A dual cradle frame (100) for an electric vehicle comprising: a head tube (102); a frame cross tube (104); and a plurality of vehicle frames comprising a right and a left upper frame tubes (106, 106’) extending backward and downward from a top part of the head tube (102) towards the frame cross tube (104); a right and a left lower frame tubes (108, 108’) extending downward from a middle part of the head tube (102) towards the frame cross tube (104), and a right and a left middle frame tubes (110, 1 10’) connecting the right and a left upper frame tubes (106, 106’) with the right and a left lower frame tubes (108, 108’) respectively, wherein a top part of the right and left upper frame tubes (106, 106’) and a top part of the right and left lower frame tubes (108, 108’), together with the right and left middle frame tubes (110, 11 O’) form a first cradle (112), and wherein the bottom part of the right and left upper frame tubes (106, 106’) and a bottom part of the right and a left lower frame tubes (108, 108’) together with the right and a left middle frame tubes (110, 110’) form a second cradle (114).

2. The frame as claimed in claim 1 , wherein the first cradle (1 12) is adapted to support a first component and the second cradle (114) is adapted to support a second component, wherein the first component and the second component are different.

3. The frame as claimed in claim 2, wherein the first component is a Power-Pack (PP) and the second component is a power-train (PT) of the electric vehicle.

4. The frame as claimed in claim 1 , wherein the frame further comprises a plurality of resting brackets (116, 1 18, 120), locating brackets (122, 124, 126, 128) and arresting brackets (130, 132) for supporting the power-pack (PP) in the first cradle (112).

5. The frame as claimed in claim 1 , wherein the frame further comprises a plurality of mounting brackets (134, 136, 138) for supporting the power-train (PT) in the second cradle (1 14).

6. The frame as claimed in claim 1 , wherein the second cradle (1 14) has a height larger, smaller than, or equal to the height of the first cradle (112), while the first cradle (112) has a length larger, smaller than, or equal to the length of the second cradle (114).

7. The frame as claimed in claim 1 is adapted to be mounted in a 2W or 3W electric vehicle.