AXLE CARRIER FOR THE DISPOSAL ON AN ELECTRIC MOTOR VEHICLE, AND METHOD FOR THE PRODUCTION OF SAID AXLE CARRIER

Abstract

An axle carrier for an electric motor vehicle and a method of manufacturing thereof is disclosed. The axle carrier has a shell component including an upper shell and a lower shell made from a fiber-composite material, and at least one induction line is integrated in the lower shell.

Claims

1-15. (canceled)

16. An axle carrier for an electric motor vehicle, comprising: an upper shell; a lower shell attached to the upper shell and made from a fiber-composite material; and, at least one induction line integrated in the lower shell.

17. The axle carrier of claim 16, further comprising an organic sheet coupled to the lower shell on a lower side and/or wherein the upper shell is configured from a metallic material.

18. The axle carrier of claim 16, wherein the induction line is embedded in the fiber-composite material and/or an earth lead of the induction line is coupled to the metallic upper shell.

19. The axle carrier of claim 16, wherein the lower shell is produced from fiber composite material by injection-molding, or from electrically non-conducting fiber-composite material, or from a fiber-composite material of electrically isolating fibers.

20. The axle carrier of claim 16, further comprising a ribbed structure comprising a plurality of ribs and disposed between the lower shell and the upper shell, wherein the ribs are produced conjointly with the lower shell and are joined to the upper shell.

21. The axle carrier of claim 20, wherein the lower shell is an impact-extrusion component, wherein the induction line is produced as a flat or planar body or from a metal sheet.

22. The axle carrier of claim 21, wherein the lower shell comprises two half-shells produced in the impact-extruding method, wherein the induction line is incorporated between the two half-shells, and wherein at least one of the two half-shells includes a clearance for receiving the induction line on the internal side thereof.

23. The axle carrier of claim 16, wherein the induction line is made from a wire-shaped or tubular conductor of an endless material as an induction loop, or in that the induction line is produced from one or from a plurality of tiers of a metal sheet.

24. The axle carrier of claim 23, wherein the induction line surrounds or wraps at least partially at least one body from a ferro-magnetic or ferritic material.

25. The axle carrier of claim 24, further comprising a current path that results from the sheet metal and is longer than the shortest spacing between the electric terminals at which the electricity that is induced in the induction line is received from the induction line.

26. The axle carrier of claim 16, wherein the induction line is wound onto the lower shell and covered with an isolation layer, wherein the isolation layer is configured from the matrix material.

27. The axle carrier of claim 26, wherein the induction line is at least partially subjected to a circulating or incident flow by a fluid thermal medium.

28. The axle carrier of claim 16, wherein lower shell comprises multiple tiers, wherein at least one tier is a fiber-composite material, and a second tier is a metallic material, wherein the two tiers are integrally coupled to one another.

29. The axle carrier of claim 28, wherein at least one tier from a fiber-composite material is configured so as to be electrically non-conducting, a shielding tier from a fiber-composite material which has an electrically conducting fibrous material being disposed on that side that is opposite the electrically non-conducting tier.

30. A method of manufacturing the axle carrier of claim 16, comprising: producing a fibrous material blank by a wrapping method, wrapping the induction line in the fibrous material blank, impregnating the fibrous material blank with matrix resin after and/or during the wrapping method.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] For an understanding of embodiments of the disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:

[0028] FIG. 1 is a perspective view of an axle carrier assembly in accordance with an exemplary embodiment;

[0029] FIG. 2 is a sectional view of the axle carrier of FIG. 1 taken along the line B-B;

[0030] FIG. 3 is a longitudinal sectional view of the lower shell of FIG. 1 taken along line B-B;

[0031] FIG. 4 is a longitudinal sectional view of FIG. 3 with two parallel induction lines disposed on top of one another; and,

[0032] FIGS. 5 to 16 are plan views of various forms of induction lines.

[0033] In the figures, the same reference signs are used for identical or similar components, even if a repeated description is dispensed with for reasons of simplicity.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0034] Some embodiments will be now described with reference to the Figures.

[0035] Referring to FIG. 1, an axle carrier 1 is shown. The axle carrier 1 comprises an upper shell 2, a lower shell 3, and a ribbed structure having reinforcing ribs 9 for stiffening the upper shell 2. The reinforcing ribs 9 in FIG. 1 can be seen only through the opening 8 since the reinforcing ribs 9 otherwise are located completely in the cavity 23 of the axle carrier 1. The upper shell 2 in this exemplary embodiment is produced from a fiber-composite material. The lower shell 3 is composed of a fiber-reinforced plastics, wherein the fiber reinforcement preferably includes both long fibers as well as short fibers. The reinforcing ribs 9 are conjointly configured in an integral manner to the lower shell 3 and are composed of a short fiber-reinforced plastics. The fibers herein have a length of up to 10 cm.

[0036] Two attachment towers 4, 5 are attached to the upper shell 2. The attachment towers 4, 5 serve for attaching the axle carrier 1 to the vehicle body. Stiffening portions 6, 7 which protrude into the attachment towers 4, 5 are optionally configured from the lower shell 3. The lower shell 3 is configured as a planar face without clearances and closes off the lower shell 2 across the full area from below. The lower shell 3 can also be configured in an analogous manner to that of the upper shell 2, having longitudinal supports and transverse supports 18, 19. The stiffening portions 6, 7 are angled upward in relation to the planar plane of the lower shell 3, thus so as to point toward the upper shell 2, and in turn terminate the attachment towers 4, 5. Other attachment locations 10 for other suspension parts such as, for example, a stabilizer or control arm, are likewise partially provided with attachment sleeves 11 for reinforcement.

[0037] The bearing 12 represents a further attachment location of a particular configuration. The bearing 12 serves for attaching a torque support of the drive unit and thus for supporting the torques of the drive unit.

[0038] On account of the upper shell 2 being produced according to the invention from fiber-composite material, the attachment towers 4, 5 can be conjointly integrally configured in a materially integral manner. The various attachment locations 10 and/or attachment sleeves 11 can likewise be conjointly cast in the fiber-composite material. The upper shell 2 can have mutually dissimilar wall thicknesses which in particular corresponds to the strength that is in each case predefined in regions.

[0039] FIG. 2 shows a longitudinal section according to the section line B-B of FIG. 1. The reinforcing ribs 9 which in particular at least partially bear on an internal side 13 of the upper shell 2 can be readily seen. An upper end 14 of the reinforcing ribs herein is widened according to the invention, in particular according to the principle of a mushroom head. This is illustrated on the left side in relation to the image plane. First, an upper end 14 of the reinforcing rib 9 is heated, as illustrated by thermal rays 15. The heat can be applied by means of hot air, for example. The reinforcing rib 9 is thereafter pressed onto the internal side 13 of the upper shell 2. The upper end 14 widens according to the principle of a mushroom head. A larger bearing face is thus provided, but at the same time a materially integral connection is also generated.

[0040] Furthermore, mutually dissimilar wall thicknesses W1 and W2 are illustrated in an exemplary manner here on the upper shell 2. The wall thicknesses W1 and W2 of the upper shell 2 and the lower shell 3 can in regions be dimensioned according to the respective stresses. The wall thicknesses W3, W4 of individual reinforcing ribs 9 can also be dissimilar.

[0041] Alternatively or additionally, it is also possible for the upper end 14 of the reinforcing rib 9 to be provided with a V-shaped gap 17 or wedge, respectively, and for the latter here to be likewise fused by thermal rays 15 by way of hot air, for example. On account thereof, a V-shaped splitting of the upper end 14 of the reinforcing rib 9 is supported when the latter is being pressed on.

[0042] FIG. 2 illustrates, on the right side in relation to the image plane, that the upper end 14 of the respective reinforcing rib 9 engages through a clearance 16 of the upper shell 2 and in particular configures an undercut in the manner of a mushroom head. An additional form-fitting coupling is provided on account thereof. This can also be combined with the widening of the upper end 14 on the internal side 13.

[0043] According to the invention it is now provided that an induction line 20 is integrated in the lower shell 3. The induction line 20 is disposed in particular in the region of a lower side 21. An organic sheet 22 can preferably be furthermore disposed below the lower shell 3 and optionally be coupled to the latter. The coupling of the organic sheet 22 and the lower shell 3 herein is also performed in particular in a materially integral manner.

[0044] FIG. 3 shows a longitudinal sectional view through the lower shell 3 produced according to the invention, according to the section line B-B from FIG. 1. Various tiers of fibrous material 24 herein are disposed on top of one another, wherein a lowermost tier is configured as an organic sheet 22, for example. The other fibrous material tiers 24 can be produced from a laminated fiber-composite material or else from organic sheets 22 which are adhesively bonded to one another. The induction line 20 is embedded or enclosed, respectively, therein. The induction line 20 has electric terminals 25 on one side, the electric terminals 25 being illustrated again in FIG. 5 and the following figures and by way of electrical connector lines 26 being connected, for example, to a charging management unit (not illustrated in more detail).

[0045] FIG. 4 shows a longitudinal sectional view in a manner analogous to that of FIG. 3, with the difference that two parallel induction lines 20 are disposed on top of one another in the motor vehicle vertical direction. The two induction lines 20 overall preferably result in an induction line which accordingly enables non-contacting charging.

[0046] FIGS. 5 to 16 show various views of potential induction lines 20, therein referred to as induction conductors, in each case in a plan view.

[0047] FIG. 5 herein shows a plan view and a side view of an induction conductor which as a punch-folded piece is folded from a metal sheet or from a metal foil. The same applies to FIG. 6.

[0048] FIG. 7 and FIG. 8 show in each case induction conductors which as punched pieces are cut from a metal sheet. The induction conductor according to FIG. 8 in particular is wound multiple times.

[0049] FIGS. 9 and 10 show an induction conductor that as a joint-punched piece is produced from a double metal sheet. A thermal medium duct is also integrated in the induction conductor here such that a thermal medium in particular for cooling can be routed through by way of connector pieces. These thermal medial ducts in this instance are likewise incorporated conjointly with the induction conductor in the fiber-composite material

[0050] FIGS. 11 and 12 show in each case an induction conductor as a punched edge-bent piece which is punched from a metal sheet and is subsequently edge-bent.

[0051] FIGS. 13 and 14 show in each case an induction conductor that is bent from a punched bent piece from a metal sheet in the plan view and a side view. It can be seen that the induction conductor has a curved or arcuate, respectively, cross-sectional profile.

[0052] FIGS. 15 and 16 show in each case an induction conductor which as a punched piece is cut from a metal sheet. A magnetic flux collector, in particular an iron core, is disposed in the internal region. The entire induction conductor having the iron core in turn is incorporated in the fiber-composite material.

[0053] The foregoing description of some embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The specifically described embodiments explain the principles and practical applications to enable one ordinarily skilled in the art to utilize various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. Further, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as described by the appended claims.