阅读说明：本技术 屏蔽元件 (Shielding element ) 是由 克里斯托夫·科菲拉特 托马斯·拉默特 弗里德里克·霍兰德 保罗·舍恩扎特 于 2019-08-19 设计创作，主要内容包括：本发明涉及一种用于特别是电动车辆的机动车辆中的电动马达(2)的隔音隔热囊(1),其包括：多个能够相互连接的隔音隔热囊元件(10)；以及至少一个用于将所述囊(1)紧固至所述电动马达(2)的壳体的紧固元件(20)。(The invention relates to a sound and heat insulating capsule (1) for an electric motor (2) in a motor vehicle, in particular an electric vehicle, comprising: a plurality of mutually connectable sound and heat insulating bladder elements (10); and at least one fastening element (20) for fastening the capsule (1) to a housing of the electric motor (2).)

1. A sound-insulating and heat-insulating capsule (1) for an electric motor (2) of a motor vehicle, in particular an electric vehicle, comprising:

a plurality of mutually connectable sound and heat insulating bladder elements (10); and

at least one fastening element (20) for fastening the capsule (1) to a housing of the electric motor (2).

2. A bladder (1) according to claim 1, wherein the bladder element (10) comprises one or more layers of a flexible, resilient, open-cell polyurethane foam.

3. A capsule (1) according to claim 2, wherein said one or more layers have a layer thickness in the range of 5 to 30 mm.

4. Capsule (1) according to any one of the preceding claims 1 to 3, wherein said capsule element (10) has reinforcing elements (13).

5. A capsule (1) according to any one of the preceding claims 1 to 4, wherein said reinforcing element is configured in the form of an exoskeleton, in particular an injection-molded exoskeleton.

6. Capsule (1) according to any one of the preceding claims 1 to 5, wherein at least one of said capsule elements (10) has a semi-permeable membrane.

7. Capsule (1) according to any one of the preceding claims 1 to 6, wherein at least one of said capsule elements (10) has a height structure (15) arranged in a pattern on an inner surface (11).

8. Capsule (1) according to any one of the preceding claims 1 to 7, wherein at least one of said capsule elements (10) has a notch (16).

9. The capsule (1) according to any of the preceding claims 1 to 8, wherein at least one of said capsule elements (10) has a bending elastic-reforming layer.

10. Capsule (1) according to any one of the preceding claims 1 to 9, wherein said fastening elements (20) are vibration-decoupled.

11. Use of a capsule (1) according to any one of the preceding claims 1 to 10 for acoustic thermal insulation of an electric motor (2) of a motor vehicle, in particular an electric vehicle.

Technical Field

The present invention relates to a sound and heat insulating capsule for an electric motor of a motor vehicle, in particular an electric vehicle. With the sound-insulating and heat-insulating capsule according to the invention, the noise emission from the electric motor known from the prior art can be significantly reduced, wherein at the same time the formation of condensation water is effectively reduced and thus the accumulation of the formed condensation water on the electric motor is avoided.

Background

An electric vehicle is understood in the sense of the present application to be both an electric purely driven motor vehicle and a so-called hybrid variant, i.e. a motor vehicle comprising an internal combustion engine and at least one electric drive motor.

Although electric motors known from the prior art are already many times quieter than internal combustion engines, it is desirable to further reduce the noise emission, in particular in the interior of motor vehicles. For example, WO 99/33156 suggests to manufacture the various components of an electric motor, in particular the stator and the rotor, from composite materials. For this purpose, the individual electrical steel sheets (elektrobech) are replaced by composite materials consisting of two thinner electrical steel sheets joined to one another by polymer layers. Viscoelastic plastics such as elastomers are used as the polymer layer.

Such electric motors exhibit a desired reduction in noise emissions. In practice, however, it has been found that such systems are very sensitive to contact with oils, which may lead to dissolution of the complex system.

Disclosure of Invention

It is therefore an object of the present invention to provide an improved measure compared to the prior art, which not only makes it possible to reduce the noise emission of the electric motors known from the prior art, but at the same time also reduces the formation of condensation water.

This object is achieved by a device having the features of claim 1.

Advantageous embodiments and variants of the invention are given in the dependent claims and in the following description. The features listed individually in the claims can therefore be combined with one another in any technically meaningful way, also with features explained in more detail in the following description, and can represent further advantageous embodiment variants of the invention.

The sound and heat insulating capsule according to the invention comprises a plurality of sound and heat insulating capsule elements which can be connected to one another and at least one fastening element for fastening the capsule to the housing of the electric motor. In particular, acoustic insulation (akustische Wirksamkeit) is to be understood as a reduction of noise emissions or sound suppression. In particular, thermal insulation (therische Wirksamkeit) is to be understood as ensuring a sufficient air exchange or a sufficient convection between the interior space between the capsule and the electric motor and the environment outside the capsule, in particular in order to avoid condensation of moisture in said interior space or on the electric motor.

The noise generated by the electric motor is absorbed to a large extent by the bag surrounding the electric motor and an almost noise-free operation of the electric motor is ensured. This produces a particularly advantageous effect in the interior of the motor vehicle. Furthermore, the electric motor is thermally insulated from the environment by a bag surrounding the electric motor due to its thermal insulation.

Furthermore, the individual bladder elements can be connected to one another, which also provides a simple, inexpensive and retrofittable method for reducing noise emissions, in particular in the interior of a motor vehicle.

To connect the bladder elements to each other, a variety of fastening methods may be used, either methods based on mechanical fasteners, fasteners integrated into the bladder elements, or methods using adhesives. In particular, the bladder elements may be interconnected by plugging and/or adhering. The pluggable connection allows an easy-to-maintain mounting and dismounting of the capsule according to the invention without the need for additional tools. Additionally or alternatively, the bag elements can be connected to one another by means of hook and loop fasteners (Klettband), pull straps (zugbands), tie straps (Riemen), magnetic means or tabs (Lasche), i.e. in particular by means of mechanical fastening means. It should again be noted that the member may be encapsulated (e.g., by foaming)Or foam molding) Directly integrated into the bladder element or may be used in the form of an external fastening member. In this case, it should be noted that the bladder elements may be interconnected such that the bladder elements are arranged at least partially overlapping each other or at least partially spaced apart from each other in the area of the connection. The connection of the bladder element may be adapted to acoustic requirements or to requirements which ensure less condensate formation or an optimized condensate discharge.

Preferably, the bladder element comprises one or more layers made of soft elastic open-cell polyurethane foam. The open cell structure ensures that water vapour can diffuse through the bladder element or bladder. For example, when the temperature rises due to the operation of the electric motor, moisture present in the space enclosed by the bladder may escape, so that the air in the space is dried. If the temperature should drop during further operation, little condensate will condense. This construction avoids undesired damage to the electric motor in the sense of corrosion or moisture-based efflorescence. At the same time, the construction of the bladder element made of one or more layers of a flexible, resilient open-cell polyurethane foam structure according to the invention provides sufficient sound insulation. The density of the polyurethane foam is generally from 60 to 130kg/m³In the meantime.

Higher density polyurethane foams may also be used depending on the application. If the bladder element should first have sound-insulating properties, the density is at least 250kg/m³The polyurethane foams of (2) have proven to be particularly advantageous. However, even in the case of such an embodiment, in particular by means of the other embodiments mentioned in the context of the description of the invention, it is possible to ensure a sufficient drainage of the formed condensate or of such condensate.

The capsule according to the invention preferably consists of 2 to 6, more preferably 4 to 6, individual acoustic and thermal insulating capsule elements which can be connected to one another.

Furthermore, the bladders according to the invention are arranged at defined intervals around the electric motor in order to ensure a sufficient convection of air. A spacing of at least 1500 μm has proved to be particularly advantageous in order to prevent possible capillary action, so that condensed water is absorbed by the foam. In addition, since the air convection is ensured at a certain distance between the bladder and the electric motor, the formed moisture can be dried according to the air convection immediately after the formation of the condensed water, and thus, the defined distance from the bladder can reduce the formation of the condensed water. Furthermore, in terms of acoustic optimization, the distance between the bladder and the electric motor can be adjusted according to specific requirements. Depending on the size or power of the motor, different distances may be required to achieve the same acoustic performance. Thus, the distance can be adapted to the frequency spectrum of the motor.

The pitch is particularly preferably 3 to 12mm, more preferably 6 to 9mm, and most preferably 7 to 8 mm. Even smaller than the specified 3mm pitch, in principle, can provide certain acoustical or thermal advantages.

Preferably, the one or more layers have a layer thickness in the range of 5 to 30 mm.

In an advantageous embodiment, the bladder element comprises a stiffening element for reducing deformation due to its own weight.

The stiffening element may be formed by an insert arranged inside the bladder element and/or a structure having a high compression ratio, and in the form of ribs or grooves arranged inside and/or outside. Thus, a stiffening element arranged inside can be provided, for example, for the drainage of the condensate, so that a directed drainage of the formed condensate is possible.

Preferably, the insert comprises a bending elastic heavy layer (biegeelastische Schwerschicht), wherein the heavy layer is particularly preferably selected from Ethylene Vinyl Acetate (EVA), ethylene propylene diene monomer (EPM), Ethylene Propylene Diene Monomer (EPDM) and/or polyvinyl chloride (PVC) and/or mixtures thereof.

In principle, it should be noted that the stiffening elements (in the form of ribs, grooves, inserts or other structures) may be formed from various materials. The stiffening element may be integrated or molded into the bladder material (e.g., polyurethane foam) (e.g., by foam encapsulation or foam molding) or may be secured to the bladder material (e.g., adhered thereto). They may also be injection-molded polymers or injection-molded heavy-duty layers (injection-molded inserts). In injection moulding, customized reinforcement elements with different reinforcement directions can be produced for each application. Injection molded polyamides may be mentioned as an exemplary material.

According to a particularly advantageous embodiment of the invention, the reinforcing element can be formed in the form of an exoskeleton, for example in the form of an injection-molded exoskeleton, which is integrated in the bladder element or surrounds the bladder element from the outside or from the inside in the sense of a frame structure. Such an exoskeleton may promote the overall rigidity of the bladder, which is composed of bladder elements, but at the same time allow it to have some elasticity. Furthermore, portions of the exoskeleton may act as anchor points for securing the bladder to the electric motor. The shape of the exoskeleton can be adapted to the acoustic and thermal requirements of the bladder. Such an exoskeleton can be produced integrally or in sections by injection molding and can be formed in a separate step by the material of the bladder element by foam encapsulation or foam molding. Here, a form-locking connection and/or a material-engaging connection can be provided between the exoskeleton and the balloon element.

The preferred layer thickness of the heavy layers is 1 to 5 mm.

Structures with high compressibility are characterized by their local thickness being less than the thickness of the bladder elements at other locations surrounding them. Preferably, the structure may be formed by line segments of single or multiple stiffening bladder elements arranged parallel to each other.

In a particularly preferred variant embodiment, at least one of the capsule elements comprises a semi-permeable membrane which improves the moisture exchange between the air in the space enclosed by the capsule and the ambient air. Preferably, a micro-perforated film or an in-mold coating is used as the material for making the film. Materials of the textile industry (e.g. Gore-Tex)^TM) Also suitable for this purpose. In addition, by implementing the semipermeable membrane, condensed water is effectively discharged, and corrosion or weathering of the electric motor is reduced.

Here, the semi-permeable membrane is configured such that moisture can diffuse out of the space enclosed by the capsule, but moisture from the ambient air cannot diffuse into the space enclosed by the capsule.

In order to increase the sound insulation effect, preferably at least one of the cell elements, more preferably 2 to 4 cell elements, has a height structure arranged in a pattern on the inner surface, which height structure is preferably designed in the shape of a pyramid.

According to a particularly preferred embodiment, the region of the height structure facing the electric motor (for example the tip of the pyramid) is flattened such that it forms the contact surface. Furthermore, the contact surface can preferably be provided with a water repellent agent, which is made of, for example, a hydrophobic plastic. The height structure configured in this way thus has the function of both a spacer and a fastening element, in addition to an improved sound insulation effect.

In order to better fix the capsule element configured in this way on the electric motor, the contact surface is preferably provided with an adhesive.

In another preferred embodiment, the fastening element is formed by a pin-shaped element. It has proven to be particularly advantageous to use needle-shaped elements made of foamed plastic (e.g. PUR), since fastening elements configured in this way can be vibration-decoupled.

Other resilient plastics known in the art may also be used as suitable materials for the fastening element. Preferably, these materials are selected from the viscoelastic foam series. For example, BASF corporationA commercially available elastic plastic sold under the product name of (a).

According to a further advantageous embodiment of the capsule according to the present invention, at least one capsule element (preferably the capsule element forming the bottom of the capsule) comprises an opening. For example, the openings may be funnel-shaped, so that an outlet is formed, and thus more standing water concentrated in the bottom area of the capsule according to the invention can flow out through the openings. This also helps to prevent corrosion of the packaged electric motor.

In a further advantageous embodiment, at least one of the capsule elements (preferably the capsule element forming the capsule wall) may comprise one or more preferably slit-shaped openings which ensure the rear ventilation of the capsule according to the invention.

Furthermore, the capsule or at least one capsule element according to the invention comprises a recess for the drive shaft and/or the cable harness.

According to another aspect, the invention relates to the use of a capsule according to the invention for acoustic-thermal insulation of an electric motor of a motor vehicle (in particular, an electric vehicle).

The invention will be explained in more detail below with reference to schematic drawings.

Drawings

Fig. 1 shows a schematic cross-sectional view of a variant embodiment of the acoustic capsule according to the invention.

Fig. 2 shows a schematic perspective view of a variant embodiment of the bladder element.

Detailed Description

Fig. 1 shows a highly simplified cross-sectional view of a variant embodiment of a sound-insulating capsule 1 according to the invention, the sound-insulating capsule 1 being arranged around an electric motor 2 of an electric vehicle (not shown). The electric motor 2 has, in addition to other components not shown in detail herein, a drive shaft 3 and a base plate 4.

In the present variant embodiment, the capsule 1 has a cubic shape and is composed of 6 individual acoustic capsule elements 10 connected to one another. The bladder elements 10 are interconnected, for example, by pins and pin sockets, not shown. In order to establish a connection between the individual bladder elements 10, they are inserted into one another and positioned around the electric motor 2.

The capsule 1 further comprises a fastening element 20, which is also designed in the form of a pin. These fastening elements are integrally connected to the upper capsule element 10 forming a cover and extend from the inner surface 11 of the capsule element 1 to the bottom plate 4 of the electric motor 2. Here, they form a spacing of about 6 mm between the two components. For a better fastening effect, the fastening element 20 can be adhered to the base plate 4.

In the present variant embodiment, the lateral bladder elements 10 comprise pyramidal height structures 15, which have an additional sound-damping effect. Furthermore, as shown in fig. 1, the height structure 15 shown here also forms a fastening element 20 which secures the entire capsule 1 laterally on the electric motor 2. For this purpose, the fastening element 15 has at its top end a contact surface 14 which abuts against the electric motor 2.

A recess 16 is provided in the lower bag element 10 shown in fig. 1, which recess surrounds the drive shaft 3 of the electric motor 2.

Fig. 2 shows a highly simplified perspective view of a variant embodiment of the bladder element 10 with the stiffening element 13. In the present variant embodiment, the reinforcing elements 13 are designed in the form of grooves arranged parallel to one another and are arranged on the outer surface 12 of the bladder element 10.

List of reference numerals

1 Sound-proof bag

2 electric motor

3 drive shaft

4 bottom plate

10 balloon element

11 inner surface

12 outer surface

13 reinforcing element

14 contact surface

15-height structure

16 notches

20 fastening element