Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
A8147042CA1 1
ELECTRIC BICYCLE CONVERSION KITS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from US Patent Application Serial No.
17/855,455 filed on June 30, 2022, which is a continuation-in-part of US
Patent
Application Serial No. 17/698,907 filed on March 18, 2022.
TECHNICAL FIELD
The invention relates generally to the field of electric bicycles and, more
particularly, to kits of parts for converting regular bicycles into e-bikes.
BACKGROUND
Electric bicycles, also commonly referred to as "e-bikes", have become
readily available and popular in recent years. Adding battery-assisted power
to
a rider's pedaling power may increase the distances the rider may travel,
shorten the time required to pedal from one location to another, reduce the
rider's fatigue, and increase enjoyment of the bicycling experience. However,
electric bicycles manufactured commercially for public sales are expensive and
may be cost-prohibitive for many consumers.
Consequently, numerous kits comprising batteries and battery-powered
motors, are becoming available for retrofitting regular types of bicycles to
convert them into e-bikes. Use of such e-bike conversion kits typically
require
specialized tools and knowledge of working on bikes and/or bike systems.
Even then, adapting and fitting such kits to regular bikes may be relatively
difficult and time-consuming. These kits may require replacement of certain
bicycle parts such as, for example, front pedal assemblies, gear assemblies,
and wheels. Some prior art e-bike conversion kits may require bypassing
and/or removing a bike's front pedal and/or sprocket assembly, in relatively
complex ways.
Many prior art e-bike conversion kits have components that may be
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bulky and heavy relative to the weight of a regular bicycle that when
installed,
cause an unbalanced weight distribution when in use by a cyclist thereby
creating directional control and balance issues, and other safety concerns
Prior art devices that fail to bypass a bike's pedal system may be
especially bulky and require replacement of the bike's pedal and front
sprocket
assembly in order to provide mid-drive functionality whereby an electric motor
can engage directly with a bike's chain and provide variable-speed
transmission. They may have involved removing a bike's front wheel or rear
wheel, and/or major modifications to the bike's rear sprocket assembly. Prior
art e-bike conversion kits may have been insufficiently compact and may have
failed to provide one or more desired features and/or functionalities.
SUMMARY
The embodiments of the present disclosure generally relate to kits of
parts, components of the kits and systems for converting regular bicycles into
e-bikes wherein some of the motive power transmitted to their rear wheels is
provided by electric power to the pedals by battery components of the kits of
parts. Some embodiments pertain to components comprising the kits of parts.
Such kits of parts may be referred to herein as e-bike conversion kits.
The e-bike conversion kits disclosed herein comprise components that
enable quick and easy conversion of any common bicycle with a rear derailleur
to mid-drive e-bike wherein an electric motive power unit may provide motive
power to the bikes front sprocket assembly, and back again without the need
for specialized tools or technical skills. Installation of an e-bike
conversion kit
disclosed herein does not require the removal of or modification of any of the
regular bike's components. The present e-bike conversion kits comprise
components that may be simply and easily demountably engaged with a bike's
frame element, the front sprocket, and the handlebars. The kits of parts
disclosed herein enable installation of a demountable mid-drive component that
communicates and collaborates with the converted bicycle's rear derailleur
gear assembly to provide a rider with a variable-speed motor transmission for
responding to variable road conditions and inclines while riding.
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For ease of reference hereinafter, regular bike frame assemblies
generally comprise a seat tube element having a bottom bracket for
demountable engagement therethrough with a front sprocket and pedal
assembly, a head tube element configured for rotational engagement with a
front fork element, a top tube element having one end engaged with the top of
the seat tube element and its other end engaged with the top of the head tube
element, a down tube element having one end engaged with the bottom of the
seat tube element and its other end engaged with the bottom of the head tube
element, a seat stay element with one end engaged with the top of the seat
tube element and extending backward and downward therefrom and having a
rear bracket at its other end for demountable engagement therethrough with a
derailleur gear assembly, and a chain stay element engaged at one end with
the bottom bracket of the seat tube element and engaged at its other end with
the rear bracket of the seat stay element. A common feature that most regular
bikes have is a pair of threaded bores provided on the upper-facing topside of
the down tube element for demountable engagement therewith a water bottle
cage.
According to an embodiment of the present disclosure, an example e-
bike conversion kit may comprise a portable electric motive power unit, a
motor
mount bracket configured for demountable engagement with a regular bike's
down tube element and for securely engaging the electric motive power unit
therein a portion of the motor mount bracket, a battery mount bracket
configured
for demountable engagement with a top portion of the motor mount bracket, a
battery configured for demountable engagement with the battery mount
bracket, an on/off switch demountable with the bike's handlebar and in
communication with the electric motive power unit, and a quick-release
throttle
lever assembly configured for demountable engagement with the bike's
handlebar and in communication with the electric motive power unit. According
to one aspect, the e-bike conversion kit may additionally comprise a battery
charging component. According to another aspect, the e-bike conversion kit
may additionally comprise a bearing ring assembly configured for demountable
engagement with the bike's front sprocket assembly.
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According to an embodiment, the electric motive power unit may
comprise a battery-powered electric motor within a housing, a set of drive
gears housed within a housing, and an external freewheeling sprocket gear
assembly in communication with the set of drive gears. According to an aspect,
the gear housing may be directly bolted to the electric motor housing so that
the driveshaft of the motor is in communication with the gear assembly.
According to an aspect, the outermost sprocket of the external freewheeling
sprocket assembly preferably has eight or nine teeth for communication and
cooperation with the sprocket gears of a rear derailleur gear assembly on a
common regular bicycle. It is to be noted that it is preferable that the
outermost
sprocket gear of the external freewheeling sprocket assembly has eight or nine
teeth in order to provide the necessary mechanical advantage to work with a
bike's existing sprocket gears in its rear derailleur to thereby enable lower
electric power motors such as 250W motors, to provide electric motive power
to a regular bike.. A smaller sprocket tooth count also serves to lower the
amount of torque/pulling force that the bracket and bike downtube must handle.
Freewheeling sprocket gears having only eight or nine teeth do not currently
exist on the market for bicycles and can only be made by special modification
to 12-tooth freewheel sprocket gears by welding the 8 or 9 tooth sprocket
gears
onto the end of 12-tooth freewheel sprockets. According to an aspect, the
external sprocket assembly may comprise an outer sprocket gear and inner
sprocket gear, said outer sprocket gear and inner sprocket gear separated and
spaced-apart by a cylindrical roller.
According to another embodiment, the motor mount bracket may be
configured for (a) receiving and demountable engagement of the electric
motive power unit therein whereby the external sprocket assembly extending
outward from the electric motive power unit is disposed sideways from an end
of the motor mount bracket, and (b) demountable engagement with the spaced-
apart pair of threaded bores provided on the topside a regular bike's down
tube
element approximate to the bottom bracket of a bike's frame assembly. When a
motor mount bracket engaged with an electric motive power unit, is
demountably engaged with a regular bike's down tube element, the outward-
extending sprocket assembly of the electric motive power unit is preferably
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disposed below and in front of the bike's front sprocket assembly to allow the
bike's chain 60 to wrap sufficiently around the bike's front sprocket to
prevent
chain slip if a rider pedals without the electric motive power. According to
an
aspect, the motor mount bracket may be adjustably engaged with the bike's
down tube element so that the outward-extending sprocket of the electric
motive power unit preferably is disposed below and in front of the bike's
front
sprocket assembly. According to another aspect, after the motor mount bracket
is demountably engaged with the bike's down tube element, the battery mount
bracket may be demountably engaged with the top portion of the motor mount
after which, the battery may be demountably engaged with the battery mount
bracket.
According to another embodiment, after a motor mount bracket
demountably engaged with an electric motive power unit, is demountably
engaged with regular bike's down tube element, the motor mount bracket may
be twistingly adjusted around the bike's down tube element with bracing and
clamping mounting screws/bolts so that (i) the outermost sprocket gear of the
outward-extending sprocket assembly of the electric motive power unit is
linearly aligned with the outermost sprocket gear of the bike's front sprocket
assembly, and optionally (ii) the cylindrical roller of the outward-extending
sprocket assembly of the electric motive power unit is linearly aligned with
the
middle sprocket gear of the bike's front sprocket assembly.
According to an aspect of the invention, the e-bike conversion kits of
parts disclosed herein may provide three different ways of riding a e-bike
converted with an e-bike conversion kit: (i) as a bike only without engaging
the
battery-powered motor whereby the only motive force provided is by a rider's
pedaling of the front sprocket assembly, (ii) in a pedal-assist mode whereby
supplemental motive is provided by the battery-powered motor in response to
the rider controlling engagement of the throttle lever assembly selectively
rest
their feet on the bicycle pedals and/or to pedal the front sprocket to provide
additional motive power, and/or (iii) as a full e-bike wherein all of the
motive
power is provided by the battery-powered motor with no pedaling required by
the rider.
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According to another embodiment, the motor mount bracket may be
configured for receiving and demountable engagement of the electric motive
power unit, and for demountable and adjustable engagement with the bike's
seat tube element. When the motor mount bracket is engaged with the bike's
seat tube and with the electric motive power unit, the external outward-facing
freewheeling sprocket of the electric motive power unit may be engaged with a
front sprocket gear by the bike's chain to thereby deliver a motive power
thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of the kit and system,
and method according to the present invention, as to their structure,
organization, use, and method of operation, together with further objectives
and
advantages thereof, will be better understood from the following figures in
which one or more presently preferred embodiments of the invention will now
be illustrated by way of example.
FIG. 1 is side view of some example embodiments of assembled
components comprising e-bike conversion kits of parts disclosed herein for
providing electric motive power to regular bicycles, wherein the assembled
components comprise an electric motive power component demountable
engaged with the base of a one-piece motor mount and a battery pack
component demountably engaged with the top of the one-piece motor mount;
FIG. 2 is a perspective view (FIG. 2A) of an example electric motive
power component of an embodiment of the e-bike conversion kits of parts
disclosed herein, while FIG 2B is a side view of the electric motive power
component shown in FIG. 2A;
FIG. 3 is an exploded perspective view of an example battery pack
component of the e-bike conversion kits of parts disclosed herein;
FIG. 4 shows an example off/on switch according to an embodiment of
the e-bike conversion kit of parts disclosed herein, demountably engaged with
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a left side of a handlebar of a regular bicycle (FIG. 4A), and an example
throttle
control assembly according to another embodiment of the e-bike conversion kit
of parts disclosed herein, demountably engaged with the right side of the
handlebar (FIG. 46);
FIG 5 is a perspective view of an example embodiment of a one-piece
motor mount component of the e-bike conversion kits of parts disclosed herein;
FIG. 6 is a perspective front view of the motor mount plate shown in
FIG. 5, the electric motive power component shown in FIG 2, and the battery
pack component shown in FIG 3, demountably engaged with a regular bicycle
frame and the outermost sprocket gear of its front sprocket assembly;
FIG. 7 is a second perspective front view of the motor mount plate
shown in FIG. 5, the electric motive power component shown in FIG 2, and the
battery pack component shown in FIG 3, demountably engaged with a regular
bicycle frame and the middle sprocket gear of its front sprocket assembly;
FIG. 8 shows another example embodiment of a one-piece motor mount
component of the e-bike conversion kits of parts disclosed herein;
FIG. 9 shows another example embodiment of a one-piece motor mount
component of the e-bike conversion kits of parts disclosed herein;
FIG. 10 shows a perspective view an example embodiment of a two-
piece motor mount component of the e-bike conversion kits of parts disclosed
herein;
FIG. 11 is an exploded rear perspective exploded view of the two-piece
motor mount component shown in FIG. 10;
FIG. 12 is a front perspective view of the example embodiment of a
throttle control assembly shown in FIG. 4B;
FIG. 13 is a rear perspective view of the throttle control assembly shown
in FIG. 12;
FIG. 14 is a front perspective exploded view of the throttle control
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assembly shown in FIG. 12;
FIG. 15 shows front perspective views of (i) the throttle base of the
throttle control assembly shown in FIGs. 12, 13, and 14 (FIG. 15A), (ii) the
throttle base left side cover (FIG. 15B), and (iii) a tubular mount member
extending from the inside of the throttle base right side cover (FIG. 15C);
FIG. 16 shows perspective views of the throttle control assembly shown
in FIG. 16 wherein FIG 16A shows the throttle top, FIG. 16B shows the thumb
throttle control, and FIG. 16C shows the throttle shaft;
FIG. 17 shows an example quick-release cam lever (FIG. 17A) and an
example quick-release nut configured for cooperation with the quick-release
cam lever (FIG. 17B);
FIG. 18 is a perspective view of an example bearing ring assembly
configured for demountable engagement with a bicycle front sprocket
assembly;
FIG. 19 is an exploded perspective view of the bearing ring assembly
shown in FIG. 18;
FIG. 20 shows a perspective view of the topside of a sprocket
connection plate shown in FIG. 19 (FIG. 20A), and a perspective view of the
bottom side of a bearing cover plate shown in FIG. 19 (FIG. 20B);
FIG. 21 is a perspective view of the bearing components shown in FIG.
19;
FIG. 22 are perspective views of the bearing clip component shown in
FIG. 18 (FIG. 22A), the clip for attaching the sprocket connection plate to a
bicycle front socket assembly (FIG. 22B), and the clip pull tab (FIG. 22C);
FIG. 23 is a side view of an example embodiment of a bearing ring
assembly shown engaged with a bicycle front sprocket assembly, with an
example electric motive power assembly engaged with the bicycle frame;
FIG. 24 is a perspective front view of the bearing ring assembly shown
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in FIG. 23, wherein a bicycle chain shown demountably engaged with (a) the
outer most sprocket gear of the bicycle front socket assembly, and (b) the
outer
most sprocket gear of the electric motive power unit;
FIG. 25 is a schematic flowchart of a decision tree for processing steps
in an example of a microprocessor for controlling supplementary motive power;
FIG. 26 is a right-side view of an example embodiment of a one-piece
motor mount bracket component configured for engagement with a bike's seat
tube;
FIG. 27 is a left-side view of the one-piece motor mount bracket
.. component shown in FIG. 26;
FIG. 28 is a right-side view of the one-piece motor mount bracket
component shown in FIG. 26, demountably engaged with the electric motive
power component shown in FIG. 2;
FIG. 29 is a left-side view of the one-piece motor mount bracket shown
in FIG. 26, demountably engaged with the electric motive power component
shown in FIG. 2;
FIG. 30 is a right side view of the one-piece motor mount bracket
component shown in FIG. 26, and the battery mount bracket shown in FIG 3,
demountably engaged with the seat tube and the down tube, respectively, of a
regular bicycle frame;
FIG. 31 is a perspective left side view from the rear, of the one-piece
motor mount bracket component shown in FIG. 26 demountably engaged with
the electric motive power component shown in FIG 2, and the battery mount
bracket shown in FIG 3, demountably engaged with the seat tube and the
down tube, respectively, of a regular bicycle frame;
FIG. 32 is a perspective left side view from the front, of the one-piece
motor mount bracket component shown in FIG. 26 demountably engaged with
the electric motive power component shown in FIG 2, and the battery mount
bracket shown in FIG 3, demountably engaged with the seat tube and the
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down tube, respectively, of a regular bicycle frame; and
FIG. 33 is a side view of the one-piece motor mount bracket component
shown in FIG. 26 demountably engaged with the electric motive power
component shown in FIG 2, and the battery pack component shown in FIG 3,
demountably engaged with a regular bicycle frame and the outermost sprocket
gear of its front sprocket assembly.
DETAILED DESCRIPTION
The present disclosure relates to e-bike conversion kits of parts for quick
and easy conversion of common and regular bicycles into e-bikes wherein some
or all of the motive power is provided by a battery-powered electric motive
power
unit included with the kits of parts. The components comprising the e-bike
conversion kits of parts do not require technical skills for their mounting
and
installation onto common and regular bicycles (referred to herein after as
"bikes",
and may be easily installed onto a bike's down tube frame element, front
sprocket assembly, and handlebars. No modifications of regular and common
bicycles are needed, and no bicycle components need to be removed for
installation of the e-bike conversion kits of parts disclosed herein.
Some example embodiments of the present e-bike conversion kits of
parts 100 are illustrated in FIGs. 1 to 16, and generally comprise an electric
motive power unit 110, a one-piece motor mount bracket 150, for the electric
motive power unit 110, a battery pack comprising a rechargeable battery 120, a
battery mount bracket 122 that is demountably engageable with a top portion of
the one-piece motor mount bracket 150, an on/off switch 126 for controllably
turning the electric motive power unit 110, and a quick-release throttle
assembly
300 demountable with a handlebar 70 without need for removal of handlebar
grips 75, 80, for controlling the amount of electric motive power that is
delivered
by the electric motive power unit 110 to a bike's front sprocket assembly. An
optional component that may be included with e-bike conversion kits of parts
100
is a battery charger (not shown) for recharging the battery after the electric
motive power unit 110 has been used to provide electric motive power to a
converted e-bike after it has been ridden.
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For ease of reference hereinafter, regular bike frame assemblies
generally comprise a seat tube element 20 having a bottom bracket for
demountable engagement therethrough with pedals 50 and a front sprocket
assembly comprising one or more front sprocket gears, a head tube element
configured for rotational engagement with a front fork element, a top tube
element having one end engaged with the top of the seat tube element and its
other end engaged with the top of the head tube element, a down tube element
30 having one end engaged with the bottom of the seat tube element 20 and its
other end engaged with the bottom of the head tube element, a seat stay
element with one end engaged with the top of the seat tube element and
extending backward and downward therefrom and having a rear bracket at its
other end for demountable engagement therethrough with a derailleur gear
assembly, and a chain stay element 35 engaged at one end with the bottom
bracket of the seat tube element and engaged at its other end with the rear
bracket of the seat stay element 20. A common feature that most regular bikes
have is a pair of threaded bores provided on the upper-facing topside of the
down tube element for demountable engagement therewith a water bottle cage.
An example of a suitable electric motive power unit 110 is illustrated in
FIGs. 1, 2A, and 2B and in this example, includes a battery-powered motor 112
within a housing, a gear assembly within a housing 114, an external outward-
facing freewheeling sprocket assembly 116, a power cord 118 connected at one
end to the battery-powered motor 112 and provided with a terminal 119 at its
other end, wherein the terminal 119 is demountably engageable with a socket
122a provided therefor on the battery mount bracket 122. Suitable electric
motors for use in the electric motive power units disclosed herein included
brushed DC electric motors and brush less DC electric motors (also commonly
referred to as BLDC motors). As illustrated in FIGs. 2A and 2B,the housing
with
the gear assembly 114 may be directly mounted onto and secured to the
housing for the battery-powered motor 112 whereby the battery-powered
driveshaft may be directly engaged with one end of the housing with the gear
assembly 114. The other end of the housing with the gear assembly 114 is
directly engaged with the external outward-facing freewheeling two-stage
sprocket assembly 116. The freewheeling two-stage sprocket assembly 116
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includes an outermost sprocket gear 116a and an idler roller 116b interposed
the
outermost sprocket gear 116a and the housing with the gear assembly 114. It is
to be noted that freewheeling two-stage sprocket assembly 116 allows a rider
to
provide motive power by pedaling when the electric motive power unit 110 is
turned off. When the electric motive power unit is turned on, the freewheeling
two-stage sprocket assembly 116 will provide electric motive power to the
bicycle chain to assist with the rider's pedaling.
An example of a suitable battery component is shown in FIG. 3 and
comprises a rechargeable battery 120, and a battery mount bracket 122
configured demountable engagement with the rechargeable battery 120 and for
demountable engagement with a one-piece motor mount bracket 150 configured
for receiving and retaining therein the electromotive power unit 110 (FIG. 5).
The
battery mount bracket 122 is provided with a socket 122a for demountably
receiving and engaging therewith the terminal 119 of the power cord 118 (FIG.
3). The battery mount bracket 122 is provided with a first power cord 124
having
approximate to its distal end, an on/off switch 126 with a clamp 128 (FIG. 4A)
for
demountable engagement of the power cord to one side of the handlebar 70 of
the regular bike onto which the components comprising the e-bike conversion
kit
of parts are being installed. The battery mount bracket 122 is provided with a
second power cord 130 having at its distal end quick-release throttle control
assembly 300 (FIG. 4B) that is configured for demountable engagement with a
side of the handlebar of the regular bike onto which the components comprising
the e-bike conversion kit of parts. The battery mount 122 may also be provided
with two or more bores 122b for receiving screw bolts therethrough for
engagement of the battery mount 122 with threaded bores 160a provided
therefor in the top portion 160 of the motor mount bracket 150 (FIG. 5).
An example of a suitable motor mount bracket 150 for demountable
engagement with an electric motive power unit 110 and a regular bike, is
shown in FIG. 5. The example motor mount bracket 150 comprises a base
portion 152, a downward extending side portion 156, an upward-extending side
portion 158, and a top surface portion 160 that is parallel to the base
portion
152. The rearward-facing edge of the downward extending side portion 156 is
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provided with an inward-facing profile 157 that corresponds with the outward-
facing profile of the electric motive power unit 110 (FIG. 2), so that when
the
electric motive power unit 110 is mounted into the motor mount bracket 150
using a pair of motive power clamp assemblies 164 in threadable engagement
with bores 158a and 158b provided in the upward-extending side portion 158,
and bore 154a in yoke 154 provided extending upward from the base portion
152 and opposite bore 158a in the side portion 158, its two-stage sprocket
assembly 116 is projecting rearward from the motor mount bracket 150 as
illustrated in FIG. 1. It is to be noted that the motive power clamp
assemblies
164 comprise a large clamp knob 164a that comfortably fits into a user's hand,
an adjusting screw 164b rotationally engaged at one end with the clamp knob
164a and rotationally engaged at its other end with a wedge-shaped rubber
clamp head 164c, to thereby apply a compressive force against an electric
motive power unit 110 that is being installed into the motor mount bracket 150
whereby the a wedge-shaped rubber clamp head 164c.
The terminal side edge of the top surface portion 160 of the motor mount
bracket 150 is provided with a plurality of equally spaced-apart hook-shaped
slots 162. The motor mount bracket 150 may be demountably engaged with the
topside of a regular bike's down tube element by inserting a pair of retaining
hex
head bolts (not shown) through a selected pair of hook-shaped slots 162 and
then threadably engaging the spaced-apart pair of threaded bores provided on
the topside of a regular bike's down tube element for demountable engagement
with a water bottle cage (FIGs. 6, 7). It is to be noted that the positioning
of the
motor mount bracket 150 may be adjusted upward along the bike's down tube
element by selecting a pair of hook-shaped slots 162 that are closer to the
left-
end edge of the motor mount bracket 150, and may be adjusted downward along
the bike's down tube element by selecting a pair of hook-shaped slots 162 that
are closer to the right-end edge of the motor mount bracket 150. It should be
noted that a pair of slots 162 should be selected so that the outer front
sprocket
gear 116a is positioned such that the bicycle chain 60 is sufficiently wrapped
around a bicycle's front sprocket gear 55a so that the chain 60 will not slip
or
jump the front sprocket teeth 55a if a rider is applying pedal force only
without
electric motive power. After the motor mount bracket 150 has been securely
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mounted to the bike's down tube element 30, the electric motive power unit 110
may be positioned within the motor mount bracket's base portion 152 and
upward-extending side portion 158 so that its outer external sprocket gear
116a
is aligned with the bike's outermost front sprocket gear 55a, and then secured
in
place by threadably engaging first and second clamping bolt assemblies 164
with bores 154a, 158b and 158a.
The battery mount bracket 122 may be secured to the top surface portion
160 of the motor mount bracket 150 by slipping two flat-head machine screws
(not shown) through bores 122b provided therefore through the battery mount
bracket 122 and threadably engaging the two threaded bores 160a in the top
surface portion 160 of the one-piece motor mount bracket 150. After the
rechargeable battery 120 is demountable engaged with the battery mount
bracket 122, it may be locked into place with the battery key 121 thereby
preventing disengagement of rechargeable battery 120 battery from the battery
mount bracket 122, It is to be noted that when the rechargeable battery 120
battery is locked to the battery mount bracket 122, the machine screws
securing
the battery mount bracket to 122 to the top portion 160 of the motor mount
bracket 150 and the hex head bolts securing the top portion 160 of the motor
mount bracket 150 to the bicycle down tube element 30 cannot be accessed for
unauthorized removal.
After demountable engagement of an e-bike conversion kit of parts 100
onto a bike's down tube element 30 and demountable engagement of the clamp
128 for the on/off switch 126 and the throttle control assembly 300 with the
bike's
handlebar 70, the bike's chain 60 can then be placed onto the outermost
sprocket gear 55a of the bike's front sprocket assembly and onto the outer
sprocket gear 116a of the two-stage sprocket assembly 116 of the electric
motive power unit 110 as shown in FIG. 6. A rider is then able to pull the
bike's
chain 60 over the outer front sprocket gear 116a, then mount and pedal the
converted e-bike and provide electric motive power by turning the on/off
switch
126 on and applying throttle power 300 as desired depending on the speed and
power requirements. If the rider wishes to pedal without motor power, they may
do so any time because the two-stage sprocket assembly 116 is a freewheel
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ratchet system. When the user pedals without motor power, the bicycle's rear
chain tensioner/derailleur will freely turn the outer sprocket gear 116a by
pulling
the chain. When electric motive power is provided, the ratchet system will
allow
the electric motor 115 and the housing with the gear assembly 114 to turn the
outer front sprocket gear 116a and supply motive power to the chain 60. If the
rider wishes, they may switch the front sprocket assembly to the middle
sprocket
gear 55b and the chain will disengage from the outer sprocket gear 116a and
move onto an idler roller component 116b. When the user switches back to the
outermost front bicycle sprocket gear the chain will automatically reengage
with
the outer front sprocket gear 116a and make electric motive power available
again at any time. Connecting the two-stage sprocket assembly 116 directly to
a
bike's existing chain 60 allow for gear changes on the bike's rear derailleur
system while riding depending on the amount of incline the bike is traversing.
This makes it a demountable 'mid-drive' kit. Coasting without motor power or
pedal power is also always available since bikes can coast without chain
rotation
because the rear wheel sprockets do not rotate if the chain is not applying
any
force. According to an aspect, the present e-bike conversion kits of parts 100
may be demountably engaged with a down tube element of a bicycle with a
single-gear front sprocket by aligning the outer sprocket gear 116a of the two-
stage sprocket assembly 116 of the electric motive power unit 110 with the
bicycle front sprocket gear and then slipping the bicycle chain around the
outer
sprocket gear 116a.
Another example of a suitable one-piece motor mount bracket 170 for
demountable engagement with an electric motive power unit 110 and a regular
bike, is shown in FIG. 8. The example motor mount bracket 170 comprises a
base portion 172, a downward extending side portion 176, an upward-extending
curvilinear side portion 178, and a top surface portion 180 that is parallel
to the
base portion 172. The rearward-facing edge of the downward-extending side
portion 176 is provided with an inward-facing profile 177 that corresponds
with
.. the outward-facing profile of the electric motive power unit 110 (FIG. 2),
so that
when the electric motive power unit 110 is mounted into the motor mount
bracket
170 using a pair of motive power clamp assemblies 164 in threadable
engagement with bore 178a provided in the upward-extending curvilinear side
Date Recue/Date Received 2023-01-10
A8147042CA1 16
portion 178, and bore 174a in yoke 174 provided extending upward from the
base portion 172 opposite bore 178a, its two-stage sprocket assembly 116 is
projecting rearward from the motor mount bracket 170 as illustrated in FIG. 1.
It
is to be noted that the curvilinear upward-extending curvilinear side portion
178
of the one-piece motor mount bracket 170 terminates in a top surface portion
180 that is parallel to the mounting base portion 172 whereby the base portion
172, the upward-extending curvilinear side portion 178, and the top surface
portion 180 form a cradle for receiving and housing therein the electric
motive
power unit 110 as well as electronic components. The base portion 172 is
provided with an upward-extending yoke 174 with a bore 174a for receiving
therethrough a first clamping bolt assembly 260 (FIG 10). The upward-extending
curvilinear side portion 178 is provided with a bore 178a therethrough a
second
clamping bolt assembly 260 (FIG 10). The bores 174, 178a are positioned about
the same distance from the left edge of the motor mount bracket 170.
The terminal side edge of the top surface portion 180 of the motor mount
bracket 170 is provided with a plurality of equally spaced-apart hook-shaped
slots 182. The motor mount bracket 170 may be dennountably engaged with the
topside of a regular bike's down tube element by inserting a pair of retaining
hex
head bolts (not shown) through a selected pair of hook-shaped slots 182 and
then threadably engaging the spaced-apart pair of threaded bores provided on
the topside of a regular bike's down tube element for demountable engagement
with a water bottle cage as illustrated in FIGs. 6, 7. It is to be noted that
the
positioning of the motor mount bracket 170 may be adjusted upward along the
bike's down tube element by selecting a pair of hook-shaped slots 182 that are
closer to the left-end edge of the motor mount bracket 170, and may be
adjusted
downward along the bike's down tube element by selecting a pair of hook-
shaped slots 182 that are closer to the right-end edge of the motor mount
bracket 150. It should be noted that a pair of slots 182 should be selected so
that
the outer front sprocket gear 116a is positioned such that the bicycle chain
60 is
sufficiently wrapped around a bicycle's front sprocket gear 55a so that the
chain
60 will not slip or jump the front sprocket teeth 55a if a rider is applying
pedal
force only without electric motive power. After the motor mount bracket 170
has
been securely mounted to the bike's down tube element 30, the electric motive
Date Recue/Date Received 2023-01-10
A8147042CA1 17
power unit 110 may be positioned within the mount bracket's base portion 172
and upward-extending side portion 178 so that its outer external sprocket gear
116a is aligned with the bike's outermost front sprocket gear 55a, and then
secured in place by threadably engaging first and second clamping bolt
assemblies 260 with bores 174a and 178a.
The battery mount bracket 122 may be secured to the top surface portion
180 of the motor mount bracket 170 by slipping two flat-head machine screws
(not shown) through bores 122b provided therefore through the battery mount
bracket 122 and threadably engaging two selected threaded bores 180a in the
top surface portion 180 of the one-piece mount bracket. After the rechargeable
battery 120 is demountable engaged with the battery mount bracket 122, it may
be locked into place with the battery key 121 thereby preventing disengagement
of rechargeable battery 120 battery from the battery mount bracket 122, It is
to
be noted that when the rechargeable battery 120 battery is locked to the
battery
mount bracket 122, the machine screws securing the battery mount bracket to
122 to the top portion 160 of the motor mount bracket 170 and the hex head
bolts securing the top portion 160 of the motor mount bracket 170 to the
bicycle
down tube element 30 cannot be accessed for unauthorized removal.
An alternative embodiment for a one-piece mount bracket 200 for the
electric motive power unit 110 is illustrated in FIG. 9. The example motor
mount
bracket 200 comprises a base portion 202, a downward extending side portion
206, an upward-extending curvilinear side portion 208, and a top surface
portion
210 that is parallel to the base portion 202. The rearward-facing edge of the
downward extending side portion 206 is provided with an inward-facing profile
.. 207 that corresponds with the outward-facing profile of the electric motive
power
unit 110 (FIG. 2), so that when the electric motive power unit 110 is mounted
into
the motor mount bracket 200, its two-stage sprocket assembly 116 is projecting
rearward from the motor mount bracket 200 as illustrated in FIG. 1. It is to
be
noted that the curvilinear upward-extending curvilinear side portion 208 of
the
one-piece motor mount bracket 200 terminates in a top surface portion 210 that
is parallel to the mounting base portion 202 whereby the base portion 202, the
upward-extending curvilinear side portion 208, and the top surface portion 210
Date Recue/Date Received 2023-01-10
A8147042CA1 18
form a cradle for receiving and housing therein the electric motive power unit
110. The base portion 202 is provided with an upward-extending yoke 204 with a
bore 204a for receiving therethrough a first clamping bolt assembly 260
illustrated in FIG 11. The upward-extending curvilinear side portion 208 is
provided with a bore 208a therethrough a second clamping bolt assembly 260
illustrated in FIG 11. The bores 204a, 208a are located about the same
distance
from the right edge of the motor mount bracket 200. After an electric motive
power unit 110 is mounted into the motor mount bracket 200, the motor mount
bracket may be demountably clamped into place with the first and second
clamping bolt assemblies 260.
Furthermore, the downward extending side portion 206 is also provided
with a plurality of bores 206a for mounting screws to the electric motive
power
unit 110. An example electric motive power unit 110 may be placed onto the
base portion 202 and secured thereto with mounting screws (not shown) inserted
through the bores 206a provided therefor in the downward extending side
portion
206.
The terminal side edge of the top surface portion 210 of the motor mount
bracket 200 is provided with a plurality of equally spaced-apart hook-shaped
slots 212. The motor mount bracket 200 may be demountably engaged with the
topside of a regular bike's down tube element by inserting a pair of retaining
hex
head bolts (not shown) through a selected pair of hook-shaped slots 212 and
then threadably engaging the spaced-apart pair of threaded bores provided on
the topside of a regular bike's down tube element for demountable engagement
with a water bottle cage as illustrated in FIGs. 6, 7. It is to be noted that
the
positioning of the motor mount bracket 200 may be adjusted upward along the
bike's down tube element by selecting a pair of hook-shaped slots 212 that are
closer to the left-end edge of the motor mount bracket 200, and may be
adjusted
downward along the bike's down tube element by selecting a pair of hook-
shaped slots 212 that are closer to the right-end edge of the motor mount
bracket 200. It is to be noted that the length of the top surface portion 210
is
about a third shorter than the length of the base portion 202 and therefore,
the
range of upward repositioning of the motor mount bracket 200 along the topside
Date Recue/Date Received 2023-01-10
A8147042CA1 19
of a bike's down tube element 30 is smaller than the range downward
positioning
of the motor mount bracket 200 along the topside of a bike's down tube element
30.
The battery mount bracket 122 may be secured to the top surface portion
210 of the motor mount bracket 200 by slipping two flat-head machine screws
(not shown) through bores 122b provided therefore through the battery mount
bracket 122 and threadably engaging the two threaded bores 210a in the top
surface portion 210 of the one-piece mount bracket. After the rechargeable
battery 120 is dennountably engaged with the battery mount bracket 122, it may
be locked into place with the battery key 121 thereby preventing disengagement
of rechargeable battery 120 battery from the battery mount bracket 122, It is
to
be noted that when the rechargeable battery 120 battery is locked to the
battery
mount bracket 122, the machine screws securing the battery mount bracket to
122 to the top portion 210 of the motor mount bracket 200 and the hex head
bolts securing the top portion 210 of the motor mount bracket 200 to the
bicycle
down tube element 30 cannot be accessed for unauthorized removal.
An alternative embodiment for a two-piece motor mount bracket 235 for
the electric motive power unit 110 is illustrated in FIGs. 10, 11. This
example
two-piece motor mount bracket 235 comprises a lower mount bracket 240 and
an upper mount bracket 250. The lower mount bracket 240 comprises a base
portion 242, a downward extending side portion 246, an upward-extending side
portion 248. The rearward-facing edge of the downward extending side portion
246 is provided with an inward-facing profile 247 that corresponds with the
outward-facing profile of the electric motive power unit 110 (FIG. 2), so that
when
the electric motive power unit 110 is mounted into the lower mount bracket
240,
its two-stage sprocket assembly 116 is projecting rearward from the lower
mount
bracket 240 as illustrated in FIG. 1.
The base portion 242 of the lower mount bracket 240 is provided with an
upward-extending yoke 244 with a bore 244a for receiving therethrough a first
clamping bolt assembly 260 (FIG 10). A corresponding bore (not shown) for
receiving a second clamping bolt assembly 260 is provided in the curvilinear
juncture of the base portion 242 and the upward-extending side portion 248.
The
Date Recue/Date Received 2023-01-10
A8147042CA1 20
clamping bolt assemblies 260 comprise a knob 260a, an adjusting screw 260a
rotationally engaged at one end with the knob 260a and at its other end with a
swivel head 260c. A compressible rubber gasket 260d is provided at the end of
the damping bolt assembly 260 for secure engagement with a side of an electric
motive power unit 110.
The upper mount bracket 250 comprises a flat top surface with a front-
facing terminal elongate side edge having opposed outward extending arms 252
with a plurality of equally spaced-apart outward-facing hook-shaped slots 254
provided there between. The rearward-facing terminal elongate side edge is
provided with an arm 255 that is integrally formed with the end edges of upper
mount bracket 250 thereby defining a through-slot 256 that is configured for
sliding communication with the upward-extending side portion 248 of the lower
mount bracket 240. A collar 257 with a threaded bore therethrough is provided
around the rear arm at about the mid-point between the two end edges of the
upper mount bracket 250 for rotational engagement with a two-piece mount
clamping assembly 265 that comprises a knob 265a, an adjusting screw 265a
rotationally engaged at one end with the knob 260a and at its other end with a
swivel head 265c. A compressible rubber gasket 265d is provided at the end of
the clamping bolt assembly 265 to enable a secure engagement of the upper
mount bracket 250 with the upward-extending side portion 248 of the lower
mount bracket 240.
An example electric motive power unit 110 may be placed onto the base
242 of the lower mount bracket 240 and secured thereto with mounting screws
(not shown) inserted through the bores 246a provided therefor in the downward
extending side portion 246. The upper mount bracket 250 is then slidably
engaged with the lower mount bracket 240 by sliding the through-slot 256 over
the upward-extending side portion 248 until the bottom surface of the upper
mount bracket 250 contacts the top surface of the electric motive power unit
110.
Then, the clamping bolt adjusting screw 265b is inserted through the bore in
the
collar 257 by the clamping bolt knob 265a, and engaged with the clamping bolt
swivel head 265c and rubber gasket 265d, and threadably engaged by the
clamping bolt assembly 260 with the threaded bore 257 provided therefor in the
Date Recue/Date Received 2023-01-10
A8147042CA1 21
collar 257 to securely engage the upper mount bracket to the upward-extending
side portion 248. The electric motive power unit 110 may then be securely
engaged within the two-piece motor mount bracket 235 with clamping bolt
assemblies 260 threadably engaged with the bores provided therefor in the yoke
244 on the base portion 242 of the lower mount 240, and the corresponding bore
(not shown) provided therefor in the curvilinear juncture of the base portion
242
and the upward-extending side portion 248.
The plurality of equally spaced-apart hook-shaped slots 254 in the upper
mount bracket 250 may be demountably engaged with the topside of a regular
bike's down tube element by inserting a pair of retaining hex head bolts (not
shown) through a selected pair of hook-shaped slots 254 and then threadably
engaging the spaced-apart pair of threaded bores provided on the topside of a
regular bike's down tube element for demountable engagement with a water
bottle cage (FIGs. 6, 7). The slots 254 also allow the upper mount bracket 250
to
be installed without first removing the retaining hex head bolts (not shown)
from
the bike's down tube element. It is to be noted that the positioning of the
two-
piece motor mount bracket 235 may be adjusted upward along the bike's down
tube element by selecting a pair of hook-shaped slots 254 that are closer to
the
left-end edge of the two-piece motor mount bracket 235, and may be adjusted
downward along the bike's down tube element by selecting a pair of hook-
shaped slots 254 that are closer to the right-end edge of the two-piece motor
mount bracket 235. It is to be noted that the positioning of the two-piece
motor
mount bracket 235 may be adjusted upward along the bike's down tube element
by selecting a pair of hook-shaped slots 254 that are closer to the left-end
edge
of the two-piece motor mount bracket 235, and may be adjusted downward
along the bike's down tube element by selecting a pair of hook-shaped slots
254
that are closer to the right-end edge of the two-piece motor mount bracket
235. It
should be noted that a pair of slots 254 should be selected so that the motor
sprocket gear 116a is positioned such that the bicycle chain 60 is
sufficiently
wrapped around a bicycle's front sprocket gear 55a so that the chain 60 will
not
slip or jump the front sprocket teeth 55a if a rider is applying pedal force
only
without electric motive power.
Date Recue/Date Received 2023-01-10
A8147042CA1 22
The battery mount bracket 122 may be secured to the top surface portion
of the upper mount bracket 250 by slipping two flat-head machine screws (not
shown) through bores 122b provided therefore through the battery mount
bracket 122 and threadably engaging two threaded bores provided therefor in
the top surface portion of the upper mount bracket 250. After the rechargeable
battery 120 is demountable engaged with the battery mount bracket 122, it may
be locked into place with the battery key 121 thereby preventing disengagement
of rechargeable battery 120 battery from the battery mount bracket 122, It is
to
be noted that when the rechargeable battery 120 battery is locked to the
battery
mount bracket 122, the machine screws securing the battery mount bracket to
122 to the top portion 250 of the upper mount bracket 250 and the hex head
bolts securing the top portion 250 of the upper mount bracket 250 to the
bicycle
down tube element 30 cannot be accessed for unauthorized removal.
An example embodiment of a suitable quick-release throttle assembly 300
demountable with a handlebar for controlling the amount of electric motive
power
that is delivered by the electric motive power unit 110 to a bike's front
sprocket
assembly, is illustrated in FIGs. 12 to 17. An example quick-release throttle
assembly 300 generally comprises a throttle base 302 with front hinge fingers
304 and rear upward-extending yokes 306, a throttle top cover 308 with front
downward-extending hinge fingers 309 configured for hinged cooperation with
the throttle base front hinge fingers 304. The upper surface of the throttle
base
302 and the lower surface of the throttle top cover 308 are provided with
matching concave channels 324 that are configured for snug demountable
engagement with a handlebar 70. The throttle base 302 is provided with a first
side cover 310 provided with a plurality of pegs 311 extending outward
therefrom
for demountable engageable with the tubular members 314 provided therefore in
tubular members extending along the vertical and horizontal wall junctures of
the
throttle base 302. The throttle base 302 is provided with a second side cover
310
provided with a plurality of pegs 311 extending outward therefrom for
demountable engageable with the tubular members 314 provided therefore at
the other ends of the tubular members extending along the vertical and
horizontal wall junctures of the throttle base 302. The second side cover 310a
is
provided with a tubular member 312 that extends laterally into the chamber
Date Recue/Date Received 2023-01-10
A8147042CA1 23
defined by the front and back ends, the bottom, and the top of the throttle
base
302. A throttle actuator 340 is provided for sliding and rotational engagement
within the throttle base chamber, with the tubular member 312. The front face
of
the throttle chamber 302 is provided with a vertical slot 318 therethrough.
One
end of a throttle shaft 352 is engaged at one end with a hinge pin inserted
therethrough and through a yoke 340a provided therefore on the throttle
actuator
340. The other end of the throttle shaft 352 is hingedly engaged with a pair
of
yokes 344a extending downward from a throttle thumb control 344. The throttle
thumb control 344 additionally comprises a throttle thumb push bar and a
backward-extending throttle thumb arm 344b having a bore 348c provided at the
distal end of the throttle thumb arm 344b. The throttle top cover 308 is
provided
with upward-extending hinge fingers 330 configured for receiving therein the
distal end of the throttle thumb arm 344b and for hinged cooperation therewith
a
hinge pin inserted through the bores provided therefor in the upward-extending
hinge fingers 330 and bore 344c at the distal end of the throttle thumb push
bar
344b.
According to an example embodiment, the rear-facing ends of the throttle
base 302 and the throttle top 308 may be configured to cooperate with a quick-
release cam lever 360 to enable rapid and easy demountable engagement with
a bike handlebar without a need for removal of the handlebar grips. The top
surface of the rear-facing end of the throttle base 302 is provided with a
pair of
upward-extending yokes 306 with bores therethrough, and with a recessed
cavity 305 between the upward-extending yokes 306. The rear-facing surface on
the throttle top cover 308 is provided with an annular recess 308a with a
vertical
channel 308b extending inward from the rear edge of the throttle top cover
308.
The quick-release cam lever 360 is provided with a downward-extending cam
lever pin 360a with a cam lever base 306b engaged with a proximal end of cam
lever pin 360a at the base of the quick-release cam lever 360. The distal end
of
the cam lever pin 306a is engaged with a center bore 362a of a quick-release
nut 362 having a bore 362a extending laterally therethrough for receiving a
hinge
pin 334 therethrough, said hinge pin 334 engaged with bores 306a provided
therefor in the throttle base rear upward-extending yokes 306.
Date Recue/Date Received 2023-01-10
A8147042CA1 24
In use, the quick-release throttle control assembly 300 may be quickly
demountable engaged with a bike handlebar 70 by operating the quick-release
cam lever 360 to disengage the cam lever base 360b from the rear-facing
annular recess 308a in the throttle top cover 308 whereby the cam lever 306
and cam lever pin 360a can be moved out of the vertical channel 308b to
thereby enable separation of the rear of the throttle top cover 308 from the
throttle base 302. The throttle control assembly may then be slipped around
the handlebar 70 after which, the quick-release cam lever 360 and the cam
lever pin 360a may be moved back through the vertical channel 308b to the
center of the rear-facing annular recess 308a in the throttle top cover 308
after
which, the quick-release cam lever 360 may be operated to clamp the throttle
top cover 308 and the throttle base 302 around the handlebar 70.
According to another example embodiment, power delivered by the electric
motive power unit 110 to the bike's front sprocket assembly, may be controlled
by a rider riding a bicycle equipped with an e-bike conversion kit of parts.
According to one aspect, an off-the-shelf standard DC motor controller 117
(FIGs 6, 7) may be attached to a motor mount bracket 170, 200, 235 for the
electric motive power unit 110 and may be in communication with the quick-
release throttle assembly 300 via communication cable 130. Housed within the
quick-release throttle assembly 300 is a circuit board (not shown) in
communication with the communication cable 130 and a sensor in
communication with the front wheel. The circuit board may be provided with a
microprocessor that when the on/off switch 126 is turned on, constantly
monitors and processes signals communicated from the electric motive power
unit 110 and the sensor in communication with the front wheel. The
microprocessor monitors and processes the rider's speed on the bicycle to
modulate the electric motive power to the bike's front sprocket assembly,
depending on various e-Bike speed regulations, and generally following, for
example, the process steps outlined in the decision tree on the next page. The
circuitry also allows for the dampening of the throttle signal to reduce the
impact of uncontrolled or aggressive throttle application unless it senses an
uphill incline where faster power application is necessary. If so desired, the
microprocessor may also be programmed to monitor and process signals
Date Recue/Date Received 2023-01-10
A8147042CA1 25
received from gear ratio sensors and/or from cadence sensors. A general
overview of the processing steps are shown in FIG. 25.
When a rider wishes for electric power assist while riding a bike
provided with an assembled e-bike conversion kit of parts according to the
present disclosure, they merely have to turn the on/off switch on, switch
their
front sprocket assembly to the outermost sprocket and then operate the thumb
throttle to increase or decrease the magnitude of electric motive power
delivered to the bike's front sprocket assembly.
In use, the quick-release throttle control assembly 300 may be quickly
demountable engaged with a bike handlebar 70 by operating the quick-release
cam lever 360 to disengage the cam lever base 360b from the rear-facing
annular recess 308a in the throttle top cover 308 whereby the cam lever 306
and cam lever pin 360a can be moved out of the vertical channel 308b to
thereby enable separation of the rear of the throttle top cover 308 from the
throttle base 302. The throttle control assembly may then be slipped around a
handlebar after which, the quick-release cam lever 360 and the cam lever pin
360a may be moved back through the vertical channel 308b to the center if the
rear-facing annular recess 308a in the throttle top cover 308 after which, the
quick-release cam lever 360 may be operated to clamp the throttle top cover
308 and the throttle base 302 around the handlebar 70.
Another embodiment of the present disclosure relates to a bearing ring
assembly configured for demountable engagement with a regular bicycle's
front sprocket. An example of a suitable bearing ring assembly 400 is
illustrated in FIGs. 17 to 23, and generally comprises a sprocket connection
plate 410 configured for demountable engagement with the outermost sprocket
gear of the bike's front sprocket assembly, a bearing cover plate 430, and a
plurality of equidistantly spaced-apart roller bearings 420 fitted between the
sprocket connection plate 410 and the bearing cover plate 430.
The sprocket connection plate 410 is provided with four equidistantly
spaced-apart teeth 412 extending perpendicularly outward from the plate 410
(best seen in FIG. 17) for engaging four spaced-apart notches between the
Date Recue/Date Received 2023-01-10
A8147042CA1 26
sprocket teeth on the outermost sprocket gear of a bike's front sprocket
assembly. A pair of opposing notched recesses 410d is provided on the inner
surface 410a of the sprocket connection plate 410 for receiving and seating
therein spring clips 414 provided for demountable engagement of the outward-
facing surface of the sprocket connection plate 410 with the outermost
sprocket
gear on the bike's front sprocket gear. Each spring clip 416 may be locked in
place in cooperation with a spring clip pull tab 416 and a spring clip holder
418.
The inner surface 410a of the sprocket connection plate 410 is provided with a
plurality of equidistantly spaced- apart annular recesses 410c around the axis
of the sprocket connection plate 410. The inner surface 430a of the bearing
cover plate 430 is provided with a plurality of equidistantly spaced- apart
annular recesses 430c around the axis of the bearing cover plate 430 that are
aligned with and match the equidistantly spaced- apart annular recesses 410c
around the axis of the sprocket connection plate 410. Each bearing 420 in the
plurality of bearings 420 is provided with a bearing rod 42 therethrough with
washers/spacers 422 thereon each side of the bearing 420. The ends of each
bearing rod 424 are seated in a selected opposing matching annular recess
410c in the sprocket connection plate 410 and annular recess 430c in the
bearing cover plate 430. The sprocket connection plate 410 and the bearing
cover plate 430 are provided with matching gaps 4lab, 430b in their
circumferences so that when assembled, the bearing ring may be easily
slipped over the bike's right-side pedal and onto the other sprocket gear of
the
front sprocket assembly.
An alternative example of a suitable one-piece motor mount bracket 500
for demountable engagement with an electric motive power unit 110 and a seat
tube of 20 a regular bike is shown in FIGs. 26 to 33.
As shown in FIGs. 26 to 29, the alternative motor mount bracket 500
comprises (1) a seat tube engagement bracket 502 configured for demountable
engagement with a regular bike's seat tube element 20 having a seat tube
upper engagement cradle 502a, seat tube middle engagement cradles 502b
and a seat tube lower engagement cradle 502c for partially encircling a seat
tube. A pair of hose clamps 504 are provided for demountable engagement of
a seat tube 20 to the seat tube clamping element 502. A downward-extending
Date recue/Date received 2023-04-20
A8147042CA1 27
arm 510 interconnects the seat tube clamping element 502 with the upper
surface 512 of the downward-extending motor mount element 516. The
backward and downward-extending motor mount element 516 is provided with
a profile 518 that is configured for mating engagement with the battery-
powered motor housing 112 and the housing with the gear assembly 114 of the
electromotive power unit 110. Three bores are provided therethrough the
downward-extending motor mount element 516 for engagement of the
electromotive power unit 110 thereto with motor mounting bolts 519. The motor
power control box 117 is mounted to inward-facing side to the downward-
extending motor mount element 516 and then secured in place with a cover
117a (both best seen in FIG. 32).
The hose clamps 504 are capable of being opened and closed for
clamping onto the bike's seat tube element 20. Any suitable materials may be
used for the clamps 50 such as for example, plastic, metals, polymeric
materials, and combinations thereof. As shown in FIGs. 26 to 29, the pair of
hose clamps 504 are located at two opposite ends of the seat tube clamping
element 502. In alternative embodiments, one or more hose clamps can be
provided at any various suitable locations along the seat tube clamping
element 502, for example, about the cradle-shaped mid portions 502b.
It is to be noted that the positioning of the motor mount bracket 500 may
be adjusted upward along the bike's seat tube element by clamping the hose
clamps 504 of the engagement bracket 502 closer to the bike's top tube
element 10, and may be adjusted downward along the bike's seat tube element
by clamping the hose clamps 504 of the engagement bracket 502 closer to the
bike's front sprocket assembly.
The engagement bracket 502 may further comprise a plurality of seat
tube engagement cradles 502a to 502c, configured for aiding the demountable
engagement of the upper portion of the motor mount bracket 500 with a regular
bike's seat tube element 20. A seat tube upper engagement cradle 502a, a
seat tube middle engagement cradle 502b, and a seat tube lower engagement
cradle 502c are shown in FIG. 26A. Any suitable materials may be used for the
cradles, such as rubber, plastic, steel, wood, polymeric materials, and metal.
Date recue/Date received 2023-04-20
A8147042CA1 28
The upper surface 512 of the downward-extending motor mount element
516, may optionally further comprise one or more upward-extending detents
therefrom. FIGs. 26-29 illustrate a front detent 514a extending upward from
the
right-side edge of the front-facing end of the upper surface 512. A rear
detent
514b extends upward from the left-side edge of the rear-facing end of the
upper surface 512. After the one-piece motor mount bracket 500 has been
demountably engaged with a bike's seat tube, there will be a first space 514aa
between the front detent 514a and the bike's down tube element 30 into which
a shim 520 may be inserted (FIGs. 30, 33), and a second space 514bb
between the rear detent 514b and the bike's down tube element 30 into which
another shim 520 may be inserted (FIGs. 32). The two shims 520 are provided
to absorb any twisting torque that may be produced by the electric motive
power unit 110 during rapid acceleration and de-acceleration, and serve to
protect from or reduce any potential damage to the motor mount bracket 500
.. and/or to the down tube element 30 caused by the twisting torque. The shims
may be made of any suitable resilient materials such as for example, rubber,
plastics, polymers, and the like.
The rearward-facing edge of the downward extending side portion 516 is
provided with an inward-facing profile 519 that corresponds with the outward-
facing profile of the electric motive power unit 110 (FIG. 2), so that when
the
electric motive power unit 110 is mounted into the motor mount bracket 500,
its
two-stage sprocket assembly 116 is projecting rearward from the mount
bracket as illustrated in FIG. 27A.
The downward extending side portion 516 further comprises a plurality
of bores 517 (FIG. 26) for receiving the motor mounting bolts 518 (FIG. 27).
An
example electric motive power unit 110 may be placed under the mounting
base portion 512 and be mounted and secured thereto with mounting screws
or bolts 518 inserted through the bores 517 provided therefor in the downward
extending side portion 516.
In comparison to the one-piece motor mount brackets 150, 170, 200,
and the two-piece motor mount bracket 235, the one-piece motor mount
bracket 500 is configured for demountable engagement with a regular bike's
Date Recue/Date Received 2023-01-10
A8147042CA1 29
seat tube element 20 instead of the bike's down tube element 30. The motor
mount bracket 500 allows the external outward-facing freewheeling sprocket
assembly 116 of the electric motive power unit 110 to engage with the bike's
front sprocket assembly and allows the bike's chain 60 to wrap sufficiently
around the bike's front sprocket gear 55a, 55b, or 55c to prevent chain
slippage even if a rider pedals hard and/or if the throttle is turned up high
and
delivers a large amount of electric motive power to the bike's front sprocket
gear 55a, 55b, or 55c. This embodiment also serves to lower the amount of
torque/ pulling force that the bracket and bike's front sprocket must handle.
In
particular, when a rider is cycling uphill and is pedaling hard and/or
applying an
aggressive throttle application to increase the amount of electric motive
power
to the bike's front sprocket assembly, the one-piece motor mount bracket 500
serves to prevent the torque from throwing off the bike's chain 60 from the
bike's front sprocket gear 55a, 55b, or 55c.
In further comparison to the one-piece motor mount brackets 150, 170,
200 and the two-piece motor mount bracket 235, the one-piece motor mount
bracket 500 is not configured for threadable engagement with the battery
mount bracket 122 as it does not have a top surface portion with bores for
receiving screws that secure the battery mount bracket 122. Instead, the
battery mount bracket 122 may be threadably engaged with the upper-facing
topside of the bike's down tube element 30 by inserting a pair of bolts/screws
(not shown) through bores 122b provided (FIGs. 30, 31). In another
embodiment, there is provided an additional piece with a plurality of equally
spaced-apart hook-shaped slots (not shown), similar to the top surface portion
160 of the motor mount bracket 150 shown in FIG. 5, positioned in between the
upper-facing topside of the bike's down tube element 30 and the battery mount
bracket 122, thereby allowing the position of the battery mount bracket 122 to
be adjusted along the bike's down tube element.
As used herein, the term "and/or" refers to and encompasses any and all
possible combinations of one or more of the associated listed items (for
example, one or the other, or both), as well as the lack of combinations when
interrupted in the alternative (or).
Date Recue/Date Received 2023-01-10
A8147042CA1 30
In the present disclosure, all terms referred to in singular form are meant
to encompass plural forms of the same unless context clearly dictates
otherwise.
Likewise, all terms referred to in plural form are meant to encompass singular
forms of the same unless context dictates otherwise.
As used herein, the term "about", when referring to a measurable value,
refers to an approximately +/-10% variation from a given value. It is
understood
that such a variation is always included in any given value provided herein,
whether or not it is specifically referred to.
Date Recue/Date Received 2023-01-10
A8147042CA1 31
Number Key 116a outer sprocket gear
top tube element 116b idler roller
seat tube element 117 motor power control box
down tube element 117a cover for the motor power
control box
chain stay element
118 power cord from motor to
50 pedal
the battery mount
55a outermost front sprocket
119 power cord terminal or
gear
engagement with the battery
55b middle front sprocket gear mount bracket socket
55c innermost front sprocket 120 battery
gear
122 battery mount bracket
60 chain
122a socket in battery mount
70 handlebar bracket or demountable
engagement with power
75 left handlebar grip cord terminal 119
80 right handlebar grip 122b bores in battery mount
bracket
100 assembled e-bike
conversion kit of parts 124 power cable from the
electric motor to the on/off
110 electric motive power unit
switch
112 housing with a battery
126 on/off switch
powered motor
128 demountable handlebar
114 housing with a gear
assembly clamp for the on/off switch
116 two-stage sprocket
assembly
Date Recue/Date Received 2023-01-10
A8147042CA1 32
130 communication cable from 162 plurality of mounting slots
the electric motor to the
164 motive power unit clamp
throttle control assembly
assembly
150 1-piece motor mount
164a clamp knob
bracket for electric motive
power unit 164b adjusting screw
152 mounting base portion 164c wedge-shaped rubber clamp
head
153 elongate bore in the
mounting base 170 1-piece motor mount
bracket for electric motive
154 yoke for clamping screw
power unit
154a bore in yoke 154
172 mounting base portion
156 downward-extending side
173 elongate bore in the
portion
mounting base
157 profile in downward-
174 yoke for clamping screw
extending side portion for
engaging the motive power 176 downward-extending side
unit portion
158 upward-extending side 177 profile in downward-
portion extending side portion for
engaging the motive power
158a bore in the side portion 158
unit
for a clamping bolt
178 upward-extending
158b bore in the side portion 158
curvilinear side portion
for a clamping bolt
178a bore in the side portion 158
160 top surface portion
fora clamping bolt
160a threaded bores in the top
180 top surface portion
surface portion
Date Recue/Date Received 2023-01-10
A8147042CA1 33
180a threaded bores in the top 235 2-piece motor mount
surface portion bracket for electric motive
power unit
182 plurality of mounting slots
240 lower mount bracket
200 1-piece motor mount
bracket for the electric 242 base of lower mount
motive power unit
244 yoke for clamping bolt
202 mounting base assembly
204 yoke for clamping 246 downward-extending side
portion
204a bore in yoke 204
246a bores in downward-
206 downward-extending side
extending side portion for
portion
mounting bolts
206a bore in the downward side
247 profile in downward-
portion 186 for mounting
extending side portion for
screws to the electric motive
engaging the motive power
power unit 110
unit
207 profile in downward-
248 upward-extending side
extending side portion for
portion of the lower mount
engaging the motive power
bracket
unit
250 upper mount bracket
208 upward-extending
curvilinear side portion 252 upper mount bracket side
arms
208a bore in side portion 208
254 plurality of mounting slots
210 shortened top portion
255 rear arm of the upper mount
210a threaded bores in the top
bracket
surface portion
212 plurality of mounting slots
Date Recue/Date Received 2023-01-10
A8147042CA1 34
256 through-slot formed by the
rear arm of the upper mount
306 throttle base rear upward-
bracket
extending yokes
257 collar around the rear arm
306a bores through the base rear
with a bore therethrough
hinge fingers for receiving a
260 clamping bolt assembly hinge pin
260a knob 308 throttle top cover
260b adjusting screw 308a rear-facing annular recess in
the throttle top cover 308
260c swivel head
308b vertical channel from the
260d rubber gasket
rear edge of the throttle top
265 clamping bolt assembly for cover 308 to about the
the upper mount bracket center of the annular recess
308a
265a knob
309 throttle top downward-
265b adjusting screw extending hinge fingers
265c swivel head 310 throttle base side covers
265d rubber gasket 311 pegs extending outward
from the throttle base side
300 quick-release throttle control
covers, for demountable
assembly
engagement with the throttle
302 throttle base tubular members 314
304 throttle base front hinge 312 tubular mount member
fingers extending from one base
side cover (310a) for sliding
304a bores through the base front
engagement with the throttle
hinge fingers for receiving a
actuator
hinge pin
Date Recue/Date Received 2023-01-10
A8147042CA1 35
314 tubular members provided 336 hinge pin for the front of the
along three side walls of the throttle assembly
throttle base
340 throttle actuator for sliding
316 bore in the floor of the engagement with the tubular
throttle base mount member extending
from one base side cover
318 vertical slot in the front wall
312
of the throttle base
342 yoke on throttle lever
320 throttle top
344 throttle thumb control
322 throttle top downward-
extending rear hinge fingers 344a yokes extending downward
from throttle thumb control
322a bores through the top rear
hinge fingers for receiving a 344h throttle thumb arm
hinge pin
344c bore through the distal end
324 matching channels molded of the thumb throttle arm
into the throttle based and
352 Throttle shaft for connecting
top for demountably
the thumb throttle with the
engaging a handlebar
throttle lever
326 reinforcing channels on
360 quick-release cam lever for
throttle top
demountable engagement
328 recess in the front face of of the throttle base and the
the throttle top throttle top
330 upward-extending hinge 360a cam lever pin
fingers on the throttle top
360b cam lever base
332 recess at the rear of the
362 Quick-release nut
throttle top
interconnected to the quick-
334 hinge pin for the rear of the release cam lever 360
throttle assembly
Date Recue/Date Received 2023-01-10
A8147042CA1 36
418 spring clip holder
362b bore through the center of
the quick-release nut for 420 roller bearings
providing the cam
422 bearing washers/spacers
movement in response to
manipulation of the thumb 424 bearing rods
throttle
424a ends of the bearing rods
400 bearing ring assembly
430 bearing cover plate
410 sprocket connection plate
430a inner surface of the bearing
410a inner surface of the sprocket plate cover
connection plate
430b gap in the circumference of
410b gap in the circumference of the bearing cover plate
the sprocket connection
430c recesses on inner surface of
plate
bearing cover plate for
410c annular recesses on the seating the ends of the
inner surface of sprocket bearing rods
connection plate for seating
500 1-piece motor mount
the ends of the bearing rods
bracket for the electric
410d opposing notched recesses motive power unit
on the inner surface of the
502 seat tube engagement
sprocket connection plate
bracket
412 teeth on the sprocket
502a seat tube upper
connection plate for
engaging a front sprocket engagement cradle
gear
502b seat tube middle
414 spring clip for attaching the engagement cradles
sprocket connect plate to a
502c seat tube lower engagement
front sprocket assembly cradle
416 spring clip pull tab
Date recue/Date received 2023-04-20
A8147042CA1 37
504 hose clamp
510 arm
512 upper portion
514a front detent
514aa space between the front
detent and the down tube
element (for receiving
shims)
514b rear detent
514bb space between the rear
detent and the down tube
element (for receiving
shims)
516 downward-extending motor
mount element
517 bores for receiving motor
mounting bolts
518 profile in downward-
extending side portion for
engaging the motive power
unit
519 motor mounting bolts
520 wedge-shaped rubber shim
Date recue/Date received 2023-04-20
