Description:TECHNICAL FIELD

[001] The present disclosure generally relates to the field of electric vehicles and more particularly to modular electric vehicles.

BACKGROUND

[002] Electric vehicles, for example electric scooters or e-bikes, have gained significant popularity as a mode of transportation in urban as well as rural areas due to their compact size and eco-friendliness. Electric vehicles are revolutionizing rural and urban mobility and have several noteworthy features including, but not limited to, sustainability, convenience, low operational and maintenance costs, low noise, and rapid technological advancements.

[003] Despite several advantages, electric vehicles have some disadvantages in terms of their limitations, in that it is not amenable to modification or customization of various components or features of the vehicle. Current electric vehicles often lack the ability to be adapted to different user needs and situations, such as different rider heights, different cargo carrying needs, or different terrain. For example:

? For customizing an electric vehicle for different wheel sizes, different wheelbases, different rake angles, and different frames, the entire vehicle layout needs to be changed. That is, for customizing an electric two-wheeler, the packaging of the battery, the motor controller, and the charger needs to be changed. Hence, a manufacturing company needs to maintain different stock keeping units (SKUs) and that involves additional cost and resources to maintain these SKUs across the life of the electric two-wheeler.

? In conventional electric vehicles, components such as the battery, the motor, the motor-controller, and the battery charge controller are assembled in separate housings and are in different parts of the vehicle interconnected with electrical wires and cables. Such arrangements lead to efficiency losses and increased cost of the electric two-wheelers. Further, such arrangements occupy considerable space and hence increase the weight of the electric two-wheelers thus reducing the vehicle’s range of available charge.

? Since the various components are assembled in separate housings, each individual component requires dedicated cooling subsystems. That is, each sub-system requires separate heat dissipation arrangements to handle their individual thermal performance. This may lead to higher weight, cost, and complexity of the system and the electric two-wheelers.

? Such layouts in conventional electric vehicles may impact their aesthetics. That is, riders who wish to change the appearance or style of their electric two-wheelers may have no or limited options for customization.

[004] As described, conventional electric vehicles have various disadvantages as many components cannot be easily upgraded or replaced, a modification to a single structure or component often requires structural modifications to other interconnected structures of the vehicle, and hence, results in additional cost and resources for maintaining the SKUs.

BRIEF SUMMARY

[005] This summary is provided to introduce a selection of concepts in a simple manner that is further described in the detailed description of the disclosure. This summary is not intended to identify key or essential inventive concepts of the subject matter nor is it intended for determining the scope of the disclosure.

[006] To overcome or mitigate at least one of the problems mentioned above, there exists a need for a modular electric vehicle having a housing which enables customization of the electric vehicle.

[007] Thus, disclosed is a modular electric vehicle, wherein the electric vehicle comprises a housing comprising a front portion and a rear portion. The electric vehicle further comprises a front frame, a rear frame, a swing arm, and an electric drive unit. The front frame is detachably coupled to a front wheel and detachably coupled to the front portion of the housing. The rear frame is detachably coupled to the rear portion of the housing. The swing arm comprises a first portion and a second portion, wherein the first portion is detachably coupled to the rear portion of the housing, and the second portion is detachably coupled to a real wheel. The electric drive unit comprises a plurality of components wherein one or more components of the plurality of components are disposed in the housing.

[008] To further clarify advantages and features of the present disclosure, a more particular description of the disclosure will be rendered by reference to specific embodiments thereof, which is illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting of its scope. The disclosure will be described and explained with additional specificity and detail with the accompanying figures.

BRIEF DESCRIPTION OF THE FIGURES

[009] The disclosed method and system will be described and explained with additional specificity and detail with the accompanying figures in which:

[0010] Figure 1A illustrates a side view of an exemplary electric vehicle, in saddle configuration, in which various embodiments of the present disclosure may be seen;

[0011] Figure 1B illustrates a top view of a rectangular shaped elongated housing in accordance with an embodiment of the present disclosure;

[0012] Figure 1C illustrates a cross sectional view of the rectangular shaped elongated housing in accordance with an embodiment of the present disclosure;

[0013] Figure 1D shows the electric vehicle in a motorbike configuration;

[0014] Figure 2A illustrates the coupling of the swing arm with the housing in accordance with an embodiment of the present disclosure;

[0015] Figure 2B illustrates the coupling of the swing arm with the housing in accordance with another embodiment of the present disclosure;

[0016] Figure 3A and 3B illustrate the electric vehicle with two different handlebars in accordance with an embodiment of the present disclosure;

[0017] Figure 4 illustrates an electric vehicle with a customizable front frame in accordance with an embodiment of the present disclosure;

[0018] Figure 5A and 5B illustrate customization of the wheelbase of the electric vehicle in accordance with an embodiment of the present disclosure;

[0019] Figure 6 illustrates an electric vehicle with larger wheels in accordance with an embodiment of the present disclosure;

[0020] Figure 7 illustrates the electric vehicle with a rear suspension in accordance with an embodiment of the present disclosure;

[0021] Figure 8 illustrates the electric vehicle with motor placed at an elevation in accordance with an embodiment of the present disclosure.;

[0022] Figure 9A shows a top view of the housing illustrating a single liquid coolant system in accordance with an embodiment of the present disclosure; and

[0023] Figure 9B and 9C show a bottom view and a side view of the housing with the single liquid coolant system.

[0024] Further, persons skilled in the art to which this disclosure belongs will appreciate that elements in the figures are illustrated for simplicity and may not have been necessarily drawn to scale. Furthermore, in terms of the construction of the joining ring and one or more components of the bearing assembly may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION

[0025] For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.

[0026] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.

[0027] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more…” or “one or more elements is required.”

[0028] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

[0029] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternative embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

[0030] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

[0031] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

[0032] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

[0033] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.

[0034] Embodiments of the present disclosure disclose a modular electric vehicle comprising a housing, wherein the housing houses a plurality of components of a drive unit of the electric vehicle, doubles as a structural element, thermal mass, and enables customization of the electric vehicle by allowing attachment and detachment of various elements. Herein, the term doubles means that it carries out two different functions, namely as a housing for the drive unit components and also as a structural and thermal element. Herein, the term structural element means a portion of the vehicle that is load bearing. The term thermal element means a portion of the vehicle that is used for heat storage and transfer. The electric vehicle (EV) as described herein may include, but not limited to, scooters, mopeds, motorcycles, three-wheelers such as auto-rickshaws, four-wheelers such as cars and other Light Commercial Vehicles (LCVs) and Heavy Commercial Vehicles (HCVs) primarily work on the principle of driving an electric motor using the power from the batteries provided in the EV. Furthermore, the electric vehicle may have at least one wheel which is electrically powered to drive such a vehicle. The term ‘wheel’ may be referred to any ground-engaging member which allows traversal of the electric vehicle over a path. The types of EVs include Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV) and Range Extended Electric Vehicle. However, the subsequent paragraphs pertain to the different elements of two-wheeled electric vehicle and hereinafter referred to as an electric vehicle.

[0035] Figure 1A illustrates a side view of an exemplary electric vehicle, in saddle configuration, in which various embodiments of the present disclosure may be seen. Figure 1B illustrates a top view of a rectangular shaped elongated housing 105 in accordance with an embodiment of the present disclosure As shown, the electric vehicle 100 comprises a housing 105, a front frame 120, a rear frame 130, a swing arm 135, a front wheel 125, a rear wheel 150, and a drive unit 155 comprising a plurality of components 160, 165, 170, 175 and 180, wherein the one or more components of the plurality of components 160, 165, 170, 175 and 180 are disposed in the housing 105.

[0036] The plurality of components 160, 165, 170, 175 and 180 of the drive unit 155 may include, but not be limited to, a battery 160, a battery management system (BMS) 165, a charge and a motor controller module 170, a motor 175, and a gear box 180. The primary function of the above-mentioned elements is detailed in the subsequent paragraphs.

[0037] The battery 160 of the electric vehicle (EV) 100 is re-chargeable in nature and is the primary source of energy required for the operation of the EV 100. The battery 160 is typically charged using Alternating Current (AC) using or Direct Current (DC), wherein in case of AC input, an on-board charger converts the AC power to DC power, after which, the DC power is transmitted to the battery via the BMS 165. In case of DC charging, the current is transmitted without modification to the BMS 165 which charges the battery 160. The battery 160 comprises a plurality of cells made of lithium-ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel-zinc, silver zinc, or other battery configurations. Such cells may be enclosed within a single structure or multi-piece structure.

[0038] The BMS 165 is an electronic system which primarily functions to ensure that the battery 160 is operating efficiently. The BMS 165 continuously monitors different parameters of the battery 160 such as temperature, voltage, current, etc., and communicates these parameters to an Electronic Control Unit (ECU) and a Motor Controller Unit (MCU) of the charger and a motor controller module 170. The BMS 165 typically uses the Controller Area Network (CAN) bus protocol which facilitates the communication between the ECU/MCU and other peripheral elements of the EV 100.

[0039] The charger and a motor controller module 170 comprise the motor controller unit (MCU) and a charge control unit (CCU), wherein the MCU manages the operation of the motor 175, controls the speed, torque, and direction of rotation of the motor, converts the DC from the battery 160 to AC to drive the motor 175, handles regenerative braking, and optimizes efficiency of the motor 175 during variable speed and load conditions. The CCU controls the charging of the battery 160 from external sources, manages different charging modes, regulates current, and volage during charging of the battery 160, etc. When an off-board charger is used to charge the battery 160, the CCU is used for DC charging and when an onboard charger is used to charge the battery 160, the CCU is used for AC charging.

[0040] The gear box 180 facilitates the transfer of the rotary mechanical energy generated by the electric motor 175 to the rear wheel 150. Generally, the gear box 180 uses a single gear ratio, and the motor 175 may deliver power to the rear wheel 150. Alternatively, gear box 180 may have multiple gear ratios and may need a gear shift mechanism to optimize torque and power delivery.

[0041] As described, the plurality of components, the battery 160, the battery management system (BMS) 165, the charge and a motor controller module 170, the motor 175, and the gear box 180, of the drive unit 155 drive the electric vehicle 100. It is to be noted that the electric vehicle 100 may include other elements, including but not limited to, throttle, brakes, display units, chains, belts, locking and unlocking mechanisms, etc. However, only the essential elements are shown, and features and functions of such essential elements are described in the present disclosure.

[0042] In one embodiment of the present disclosure, the one or more components of the plurality of components 160, 165, 170, 175 and 180 are disposed in the housing 105 of the electric vehicle 100. The housing 105 is an elongated enclosure in which one or more components of the plurality of components 160, 165, 170, 175 and 180 are disposed by means of fasteners, for example. In a preferred embodiment, the housing 105 is a rectangular shaped elongated enclosure and the plurality of components 160, 165, 170, 175 and 180 are placed on an inner surface of a bottom plate of the housing 105. Figure 1C illustrates a cross sectional view of the rectangular shaped elongated housing 105 in accordance with an embodiment of the present disclosure. Referring to both the Figures 1A and 1B, the one or more components, such as battery 160, the BMS 165, the charge and motor controller module 170, the motor 175 and the gear box 180, are mounted on the inner surface of a bottom facet 184 of the housing 105. The housing 105 is made of a metal such as aluminum or steel or other materials having properties similar to those of aluminum or steel.

[0043] Referring to Figure 1C, two side facets 182 and 186, and top and bottom facets 188 and 184 along the length of the housing 105 form an enclosure 190 and protects one or more components of the drive unit 155. The other two facets along the width of the housing may have one or more openings for circulating the air and hence for dissipating heat generated by the plurality of components 160, 165, 170, 175 and 180. It is to be noted that the four facets 182, 184, and 186 may be formed by joining, for example by welding, three metal plates. Alternatively, they may be formed by die casting as a single unit to form a U-shaped elongated housing. In either case, the facet 188 may detachably be attached to the U-shaped housing after locating the plurality of components 160, 165, 170, 175 and 180 inside the U-shaped housing. In one embodiment the facet 188 is a rigid sheet metal covering the plurality of components 160, 165, 170, 175 and 180 and may act as a surface on which the riders may rest their feet while riding. Apart from the two methods described above, a person skilled in the art may employ other means of achieving the same results as described and all of which are deemed to fall within the scope of this disclosure. In one embodiment of the present disclosure, the housing 105 acts as a load-bearing structure or load bearing frame of the electric vehicle 100. It serves the dual purpose of accommodating the one or more components of the drive unit 155 and providing structural support for the electric vehicle 100. Referring to Figure 1A, in one embodiment of the present disclosure, the housing 105 forms a horizontal load-bearing structure in the saddle configuration of the electric vehicle 100, providing structural support for vertical loads. Figure 1D shows the electric vehicle in a motorbike configuration. In such a configuration, the housing 105 acts as an inclined load bearing structure of the electric vehicle 100. It is to be noted that the shape of the housing may be a rectangular or cylindrical enclosure with suitable arrangements for housing the one or more components of the drive unit 155. Hence the shape, the material, and the thickness of the housing 105, which accommodates one or more components of the drive unit 155, can vary, allowing for flexibility in configuration. For example, for an electric vehicle of 2 kW to 4 kW power rating, the thickness of the two side facets 182 and 186 may be 4 mm and the thickness of the top and bottom facets 188 and 184 may be 6 mm.

[0044] As described, the housing 105 houses one or more components of the drive unit 155 of the electric vehicle 100 and provides structural support for the electric vehicle 100. Referring to Figure 1A, the housing 105 comprises a front portion 110 and a rear portion 115. Further, one portion of the front frame 120 is detachably coupled to a front wheel 125 of the electric vehicle 100 and the other portion of the front frame 120 is detachably coupled to the front portion 110 of the housing 105, through a bolt for example. The front frame 120 as described herein refers to a front section of the vehicle’s chassis and provides structural integrity. The front frame 120 comprises a front fork or suspension system that allows the front wheel 125 to move up and down, providing shock absorption and control over the vehicle's handling. It is to be noted that the front frame 120 may further include a headstock, handlebar, fender mounting, attachments for display, front lighting, and front braking system, etc.

[0045] In one embodiment of the present disclosure, the rear frame 130 of the electric vehicle 100 is detachably coupled with the rear portion 115 of the housing 105, through a bolt for example. The rear frame 130 as described herein refers to a rear section of the vehicle’s chassis and provides support and structural integrity. It is to be noted that the rear frame 130 may include a mounting point for rear suspension, subframes, seat mounting, rear fender mounting, attachments for rear lighting, etc.

[0046] The swing arm 135 supports the rear wheel 150 of the electric vehicle 100 and allows the rear wheel 150 to move in response to the road conditions, providing smooth ride and handling. Referring to Figure 1A, the swing arm 135 comprises a front portion 140 and a rear portion 145, wherein the front portion 140 is detachably coupled to the rear portion 115 of the housing 105, through a bolt for example. The second portion 145 of the swing arm 135 is detachably attached to the axle of the rear wheel 150 of the vehicle. In one embodiment, the second portion 145 houses a rear axle which secures the rear wheel 150 in place. The axle is inserted through the second portion 145 of the swing arm 135, allowing the rear wheel 150 to pivot while remaining aligned with the swing arm 135, the housing 105 and the front wheel 125. In one embodiment of the present disclosure, the front portion 140 of the swing arm 135 is coupled to the rear portion 115 of the housing 105 through a single bolt. Figure 2A illustrates the coupling of the swing arm 135 with the housing 105 in accordance with an embodiment of the present disclosure. As shown, the front portion 140 of the swing arm 130 is coupled to the rear portion 115 of the housing 105 through a single bolt 205. The single bolt 205 passes through the motor 160 of the drive unit 155 as shown.

[0047] In another embodiment of the present disclosure, the front portion 140 of the swing arm 135 is coupled to the rear portion 115 of the housing 105 through twin bolts. Figure 2B illustrates the coupling of the swing arm 135 with the housing 105 in accordance with another embodiment of the present disclosure. As shown, the front portion 140 of the swing arm 135 is coupled to the rear portion 115 of the housing 105 through twin bolts 210 and 215. The twin bolts 210 and 215 are used either side of the housing 105 and the swing arm 135 as shown and the motor 160 is placed substantially between the twin bolts 210 and 215.

[0048] As described, the front frame 120, the rear frame 130 and the swing arm 135 are detachably coupled to the housing 105 of the electric vehicle 100 and hence makes the electric vehicle modular, that is, the housing 105 enables the customization of the electric vehicle 100. In one embodiment of the present disclosure, the front frame 120 is detachably coupled to the front portion 110 of the housing 105, for enabling use of a handlebar selected from one or more handlebars of different sizes. Figure 3A and 3B illustrate electric vehicles with two different handlebars in accordance with an embodiment of the present disclosure. Referring to both Figures 3A and 3B, the electric vehicle 100 shown in Figure 3A uses a taller handlebar 305 in comparison with the handlebar 310 of the electric vehicle 100 shown in Figure 3B. Hence, without changing the entire structure of the electric vehicle 100, only the front frame 120 is detached from the housing 105 and a new front frame of desired size is coupled to the housing 105. A manufacturer of electric vehicles may use the same housing 105 for providing different variants of the vehicle, for example with short, medium, and long handlebars. Similarly, a front frame having different configurations may be used with the housing 105 of the electric vehicle 100.

[0049] Figure 4 illustrates an electric vehicle with a customizable front frame 120 in accordance with an embodiment of the present disclosure. As shown, the front frame 120 is detachably coupled to the front portion 110 of the housing 105, for enabling use of a handlebars at different rake angles as shown by 405 and 410. For example, a greater positive rake angle, that is, the steering angle inclined backwards, provides stability at high speeds but may reduce maneuverability. On the other hand, a smaller rake angle, that is, the steering angle is inclined forward, makes the vehicle more maneuverable at the cost of stability. Based on the requirement, the front frame 120 may be changed without altering the other structure of the electric vehicle 100 to accommodate handlebars at different rake angles.

[0050] In one embodiment of the present disclosure, the detachable swing arm 135 enables adjustment of the wheelbase of the electric vehicle 100. Figure 5A and 5B illustrate customization of the wheelbase of the electric vehicle in accordance with an embodiment of the present disclosure. Referring to Figure 1A, the front portion 140 of the swing arm 135 is detachably coupled with the rear portion 115 of the housing 105, for enabling use of a swing arm selected from one or more swing arms of different lengths for customizing the wheelbase of the electric vehicle 100. Referring to both Figures 5A and 5B, the electric vehicle 100 shown in Figure 5A comprises a longer swing arm 505 in comparison with a swing arm 510 of the electric vehicle 100 shown in Figure 5B. Hence, without changing the entire structure of the electric vehicle 100, the wheelbase of the electric vehicle 100 may be changed by using a swing arm selected from one or more swing arms 505 and 510 of different lengths. A manufacturer of electric vehicles may use the same housing 105 and swing arms of different lengths for providing different variants of the vehicle having different wheelbase.

[0051] In one embodiment of the present disclosure, the detachable front frame 120, the rear frame 130 and the detachable swing arm 135 enable customization of wheels of the electric vehicle 100. Figure 6 illustrates an electric vehicle with wheels of larger outer diameter than those previously shown, in accordance with an embodiment of the present disclosure. The outer circumferences of the hitherto shown wheels are indicated by white dotted lines, in Figure 6. Similarly, the inner circumferences of the hitherto shown wheels are indicated by black dotted lines. As shown, the electric vehicle 600 comprises wheels of larger diameter 625 and 650 in comparison with the wheels 125 and 150 of the electric vehicle 100 shown in Figure 1A. The wheels of larger diameter 625 and 650 may be incorporated by using a suitable front frame 620, rear frame 130 and a suitable swing arm 635.

[0052] As described, the front portion 140 of the swing arm 135 is detachably coupled to the rear portion 115 of the housing 105 and the rear portion 145 of the swing arm 135 is coupled to the rear wheel 150 of the electric vehicle 100. In one embodiment of the present disclosure, the second portion 145 of swing arm 135 comprises attachment for rear suspension. Figure 7 illustrates the electric vehicle with a rear suspension in accordance with an embodiment of the present disclosure. As shown, a rear suspension 705 is coupled between the rear frame 130 and the second portion 145 of the swing arm 135 using mounting attachments. Such a configuration absorbs and dampens the shocks and vibrations from the road, contributing to rider comfort and stability.

[0053] Referring to Figure 7, in one embodiment of the present disclosure, the axis of the motor 175 is co-axial to a pivot axis 220 (refer Figure 2A) of the swing arm 135, and the mechanical energy generated by the motor 175 is transferred to the rear wheel 150 through the gear box 180 and a timer belt, for example. Such an arrangement provides substantially better transmission durability as the center-to-center distance between gear box 180 and the rear wheel 150 does not change.

[0054] In another embodiment, the axis of the motor is non-co-axial to the pivot axis 220 of the swing arm 135. That is, the motor 175 is placed at an elevation compared to the base of the housing 105. Figure 8 illustrates the electric vehicle with motor 175 placed at an elevation in accordance with an embodiment of the present disclosure. As shown, the motor 175 is placed on an upper surface of the housing 105 and the rear suspension 705 is coupled between the motor 175 and the second end 145 of the swing arm 135. In such a configuration, the motor 175 and the gear box 180 are mounted on the housing 105 through face mounting or foot mounting using bolts, rivets, adhesive bolts, or any other such mounting arrangements and hence accommodates multiple motor construction types and transmissions in the housing 105.

[0055] As described, the housing 105 accommodates one or more components of the plurality of components 160, 165, 170, 175 and 180 and acts as a load-bearing structural member of the electric vehicle 100. For example, in the saddle configuration shown in Figure 7, all the components of the drive unit 155 are housed inside the housing. On the other hand, in the motorbike configuration shown in Figure 1D and the saddle configuration shown in Figure 8, the motor 175 and the gear box 180 are mounted onto the housing 105 of the electric vehicle 100. Hence, the housing 105 accommodates one or more components of the plurality of components 160, 165, 170, 175 and 180.

[0056] In one embodiment of the present disclosure, the housing 105 comprises a single liquid cooling system for dissipating heat from the plurality of components 160, 165, 170, 175 and 180 of the drive unit 155, wherein the single liquid cooling system uses ram air for dissipating the heat from the plurality of components 160, 165, 170, 175 and 180.

[0057] Figure 9A shows a top view of the housing illustrating a single liquid cooling system in accordance with an embodiment of the present disclosure. Figure 9B and 9C show a bottom view and a side view of the housing 105 with the single liquid cooling system. As shown, the liquid cooling system 900 comprises a closed loop cooling tube 905 and a plurality of fins 910, wherein the cooling tube 905 passes through or is in contact with the plurality of components 160, 165, 170, 175 and 180 of the drive unit 155 for collecting the heat from the plurality of components 160, 165, 170, 175 and 180 and dissipates the heat, using ram air, through the plurality of fins 910 on the bottom of the housing 105. It is to be noted that the cooling tube 905 may be in a single loop or in multiple loops to cover the entire length and width of the housing 105, and the cooling tube 905 are in direct contact or adjacent to the one or more components 160, 165, 170, 175 and 180 of the drive unit 155. In one embodiment, a centrifugal pump directly mounted on a rotor shaft of the motor 175 is used for circulating the liquid coolant through the cooling tube 905 from a reservoir. Referring to Figure 9A, the centrifugal pump (not shown) draws the liquid coolant from the reservoir (not shown), through an inlet 915, to circulate the coolant through the cooling tube 905, wherein the liquid coolant, passing through the cooling tube 905, initially collects the heat from the motor 175, and the cooling tube 905 dissipates the heat through natural convection through the plurality of fins 910. Then the cooled liquid coolant passing through the cooling tube 905 collects the heat from the charger and a motor controller module 170, the BMS 165 and the battery 160, the cooling tube 905 dissipates the heat through natural convection through the plurality of fins 910, and the coolant liquid is recirculated to the reservoir through an outlet 920. In one embodiment of the present disclosure, the housing 105 comprises the plurality of fins 910 on an outer surface of the one or more facets 182, 184, 186 and 188 for dissipating heat generated by the plurality of components 160, 165, 170, 175 and 180. For example, referring to Figure 1C, the plurality of fins 910 may be provided on an outer surface of the two side facets 182 and 186, and outer surface of the top and the bottom facets 188 and 184 respectively. Further, the surface of the fins may be grooved or ribbed, matte finished, and so on for better heat dissipation. The liquid coolant may be a mixture of water and antifreeze or a specialized coolant, which is circulated through the cooling tube 905.

[0058] As described, the electric vehicle 100 disclosed in the present disclosure comprises the housing 105, wherein the one or more components of the plurality of components 160, 165, 170, 175 and 180 of the drive unit 155 are disposed in the housing 105. Such housing 105 houses the plurality of components 160, 165, 170, 175 and 180 of the drive unit 155, uses a single liquid cooling system for dissipating heat from all the components, acts as a load-bearing structural support of the electric vehicle 100 and makes the electric vehicle modular, that is, the housing 105 enables the customization of the electric vehicle 100. For example, different vehicle layouts having different wheelbases, different rake angles, and different wheel sizes may be provided using a single housing 105.

[0059] As the plurality of components 160, 165, 170, 175 and 180 of the drive unit 155 are disposed in a single housing 105, this reduces wiring the length and hence the weight and cost of the cable harness, thereby substantially reducing complexity, weight, and cost of the electric vehicle 100. Further, volumetric packaging is substantially higher due to a single integrated housing 105.

[0060] Further, since the one or more components 160, 165, 170, 175 and 180 of the drive unit 155 are disposed in the single housing 105, and the housing 105 acts as a structural element, it eliminates the need for a structural frame in the place of the housing 105, eliminates the need of dedicated housing and cooling subsystems for each component, and hence the complexity, weight, and cost of the electric vehicle 100 in comparison with the complexity, weight, and cost of conventional electric vehicles.

[0061] Furthermore, the placement of housing 105 and the plurality of fins 910 enables passive cooling of the one or more components 160, 165, 170, 175 and 180 of the drive unit 155 by using ram air. Further, the housing 105 also provides substantially higher thermal mass for efficient heat dissipation.

[0062] Furthermore, the housing 105 is configured for continuous and peak power rating across all the components, thereby eliminating the problem of a single component being the bottleneck for the vehicle’s performance.

[0063] Furthermore, the single housing 105 enables sharing of electronics between the BMS 165, and charger and a motor controller module 170, and a single box can be used for assembling all electrical components.

[0064] Furthermore, for customizing the electric vehicle for different wheel sizes, different wheelbases, different rake angles, and different frames, one or more of the from frame 120, the ream frame 130 or the swing arm 135 needs to be replaced. Hence, a manufacturer can maintain a single SKU for multiple variants of the vehicle. Further, same housing 105 may be used for electric vehicle in saddle configuration, motorbike configuration, and go-kart configuration.

[0065] Furthermore, the modular electric vehicle disclosed in the present disclosure provides an opportunity for an end user to customize their electric vehicle by changing one or more of the front frame 120, the rear frame 130, and the swing arm 135.

[0066] As described, the modular electric vehicle allows for easy attachment and detachment of various elements, providing flexibility and customization to the end user. Further, the modular system allows for upgrades and modifications over time, reducing waste and increasing the lifespan of the electric vehicle. Furthermore, the modular system provides sustainable and versatile transportation solutions that may be customized to meet the needs of a wide range of riders.

[0067] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0068] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.

List of reference numerals:
Components
Reference numerals
Electric vehicle 100
Housing 105
Front portion of the housing 110
Rear portion of the housing 115
Front frame 120
Front wheel 125
Rear frame 130
Swing arm 135
First portion of the swing arm 140

Second portion of the swing arm 145
Rear wheel 150
Drive unit 155
Battery 160
Battery Management System (BMS) 165
charger and a motor controller module 170
Motor 175
Gear box 180
two side facets 182 and 186
Top facet 188
Bottom facet 184
Enclosure 190
Single bolt 205
Twin bolts 210 and 215
Handlebars of different sizes 305 and 310
Handlebars at different rake angles 405 and 410
Swing arms of different lengths 505 and 510
Electric vehicle with wheels of larger outer diameter 600
Front frame 620
front wheel of larger diameter 625
rear wheel of larger diameter 650
Swing arm 635
Rear suspension 705
A single liquid coolant system 900
Cooling tube 905
Plurality of fins 910
Inlet 915
Outlet 920

, Claims:1. An electric vehicle (100) comprising:
a housing (105) comprising a front portion (110) and a rear portion (115);
a front frame (120) detachably coupled to a front wheel (125), wherein the front frame (120) is detachably coupled to the front portion (110) of the housing (105);
a rear frame (130) detachably coupled to the rear portion (115) of the housing (105);
a swing arm (135) comprising a first portion (140) and a second portion (145), wherein the first portion (140) is detachably coupled to the rear portion (115) of the housing (105), and the second portion (145) is detachably coupled to a real wheel (150); and
an electric drive unit (155) comprising a plurality of components (160, 165, 170, 175 and 180), wherein one or more components of the plurality of components (160, 165, 170, 175 and 180) are disposed in the housing (105).

2. The electric vehicle (100) as claimed in claim 1, wherein the electric vehicle (100) is in a saddle configuration.

3. The electric vehicle (100) as claimed in claim 1, wherein the electric vehicle (100) is in a motorbike (200) configuration.

4. The electric vehicle (100) as claimed in claim 1, wherein the housing (105) is a horizontal load bearing structure (105) of the electric vehicle (100).

5. The electric vehicle (100) as claimed in claim 1, wherein the housing (105) is an inclined load bearing structure (205) of the electric vehicle (200).

6. The electric vehicle (100) as claimed in claim 1, wherein electric drive unit (155) comprises a battery (160), a battery management system (165), a charger and a motor controller module (170), a motor (175), and a gear box (180).

7. The electric vehicle (100) as claimed in claim 1, wherein the motor (175) and the gear box (180) are mounted onto the housing (105) of the electric vehicle (100).

8. The electric vehicle (100) as claimed in claim 1, wherein the housing (105) comprises a plurality of fins (910) on an outer surface of the one or more facets (182, 184, 186 and 188), for dissipating heat generated by the plurality of components (160, 165, 170, 175 and 180).

9. The electric vehicle (100) as claimed in claim 1, wherein the axis of the motor (175) is co-axial to a pivot axis (220) of the swing arm (135).

10. The electric vehicle (100) as claimed in claim 1, wherein the axis of the motor (175) is non-co-axial to the pivot axis (220) of the swing arm (135).

11. The electric vehicle (100) as claimed in claim 1, wherein the first portion (140) of the swing arm (135) is detachably coupled to the rear portion (115) of the housing (105) using a single bolt (205).

12. The electric vehicle (100) as claimed in claim 1, wherein the first portion (140) of the swing arm (135) is detachably coupled to the rear portion (115) of the housing (105) using twin bolts (210 and 215).

13. The electric vehicle (100) as claimed in claim 1, wherein the housing (105) comprises a single liquid coolant system (900) for dissipating heat from the plurality of components (160, 165, 170, 175 and 180) of the drive unit (155).

14. The electric vehicle (100) as claimed in claim 1, wherein the front frame (120) is detachably coupled to the front portion (110) of the housing (105), for enabling use of a handlebar selected from one or more handlebars (305 and 310) of different sizes.

15. The electric vehicle (100) as claimed in claim 1, wherein the front frame (120) is detachably coupled to the front portion (110) of the housing (105), for enabling use of a handlebar at different rake angles (405 and 410).

16. The electric vehicle (100) as claimed in claim 1 comprising a rear suspension (705) coupled between one of, the rear frame (130) and the swing arm (135), and between the motor (175) and the swing arm (135).

17. The electric vehicle (100) as claimed in claim 1, wherein the first portion (140) of the swing arm (135) is detachably coupled to the rear portion (115) of the housing (105), for enabling use of a swing arm selected from one or more swing arms (505 and 510) of different lengths.