Integrated cast motorcycle chassis and motor housing
This invention comprises a frame for an electric motorcycle. Electric motorcycles have vastly different component requirements compared to internal combustion engine motorcycles, and, therefore, require a radical redesign of the frame in order to maximize the efficiency of the system.
1. An electric motorcycle frame comprising:
a headstock configured to connect a front suspension to the electric motorcycle frame;
a first side structure connected to the headstock;
a second side structure connected to the headstock;
a fully stressed motor housing connecting the first side structure and the second side structure, the motor housing configured to house an electric motor and also functioning as a first water jacket to contain cooling fluid between the electric motor and the first water jacket.
2. The electric motorcycle of claim 1 , wherein the electric motorcycle frame is cast in multiple pieces.
3. The electric motorcycle frame of claim 1 , wherein the first side structure includes a first opening and the second side structure includes a first opening; and
wherein the fully stressed motor housing includes a first end and a second end, the first end of the fully stressed motor housing connected to the first opening of the first side structure and the second end of the first water jacket connected to the first opening of the second side structure.
4. The electric motorcycle frame of claim 3 , wherein the first end of the fully stressed motor housing extends beyond the first opening of the first side structure and wherein the second end of the fully stressed motor housing extends beyond the first opening of the second side structure.
5. The electric motorcycle frame of claim 3 , wherein the first end of the fully stressed motor housing is connected to the first opening of the first side structure by being inserted into the first opening and wherein the second end of the fully stressed motor housing is connected to the first opening of the second side structure by being inserted into the first opening of the second side structure.
6. The electric motorcycle frame of claim 3 , wherein the first side structure includes a second opening and the second side structure includes a second opening.
7. The electric motorcycle frame of claim 6 , further comprising:
a torsion tube configured to house an output shaft, the torsion tube including a first end and a second end, wherein the first end of the second torsion tube is connected to the second opening of the first side structure and the second end of the second torsion tube is connected to the second opening of the second side structure.
8. The electric motorcycle frame of claim 7 , wherein the torsion tube further houses an oil sump shaped to contain lubricant for the output shaft.
9. The electric motorcycle frame of claim 1 , wherein the fully stressed motor housing includes a plurality of coolant ports that circulate the cooling fluid between the fully stressed motor housing and the electric motor.
10. The electric motorcycle of claim 1 , wherein the fully stressed motor housing includes an opening configured to pass wiring through the electrical motorcycle frame, the wiring connected to the electric motor.
11. The electric motorcycle of claim 10 , further comprising:
a seal between the fully stressed motor housing and the electric motor, the seal preventing the cooling fluid from flowing into the opening configured to pass the wiring through the electrical motorcycle frame.
12. The electric motorcycle frame of claim 1 , further comprising:
a structural rib coupling together the first side structure and the second side structure.
13. The electric motorcycle frame of claim 12 , wherein the first water jacket is positioned in the electric motorcycle frame between a position of the headstock and a position of the swing arm pivot mount.
14. The electric motorcycle frame of claim 1 , wherein the first side structure includes a subframe mount and the second side structure includes a subframe mount.
15. The electric motorcycle frame of claim 14 , further comprising:
a subframe connected to the subframe mount of the first side structure and the subframe mount of the second side structure.
16. The electric motorcycle frame of claim 1 , further comprising:
a swing arm pivot mount positioned between the first side structure and the second side structure.
17. The electric motorcycle frame of claim 1 , wherein the first side structure includes at least one battery box mount and the second side structure includes at least one battery box mount and wherein the electric motorcycle frame further comprises:
a battery box connected to the battery box mount of the first side structure and the battery box mount of the second side structure.