Compound transmission housing

Abstract

A composite transmission housing (7) for a transmission of a drive train of a vehicle. The transmission housing (7) is configured for sealingly enclosing a set of drive shafts (8, 9) and gears (15, 16, 3, 14) and a lubricant fluid within an interior space of the housing (7) and comprises a first carbon fiber skeleton part (41) having a first attachment area, a second carbon fiber skeleton part (42) having a first attachment area, a first sealing cover part (51) made of a plastic material and having a first sealing surface, and a second sealing cover part (52) made of a plastic material and having a second sealing surface. The first attachment areas (43, 44) of the first and second carbon fiber skeleton parts (41, 42) are connected to each other for providing a rigid structural frame defining the interior space (35), and the first and second sealing surfaces (53, 54) of the first and second sealing cover parts (51, 52) are pressed together or against corresponding sealing surfaces associated with the first and second carbon fiber skeleton parts (41, 42) for providing a sealed enclosure around the interior space (35).

Description

Technical Field

[0001] This disclosure relates to a composite transmission housing for a transmission system in a vehicle, and a method for manufacturing such a composite transmission housing. The transmission housing may include, for example, a multi-speed transmission, a single-speed transmission, a continuously variable transmission (CVT), a differential transmission, and so on.

[0002] While the description of the composite transmission housing according to this disclosure is primarily directed at automobiles, the transmission housing is not limited to that particular vehicle, but may alternatively be installed or implemented in other types of vehicles, such as trucks, buses, rail vehicles, aircraft, marine vessels, work vehicles, motorcycles, and so on. Background Technology

[0003] In the field of transportation engineering, there is a need to further improve weight reduction characteristics, as weight reduction typically improves fuel efficiency or energy efficiency and enhances vehicle driving performance. For example, as known from the document US 2018 / 0245681 A1, a transmission housing with a polymer composite body and reinforcing fiber materials, replacing conventional metal materials, is provided to achieve weight reduction.

[0004] However, despite some activity in this field, further improvements are still needed in terms of lower weight, higher strength, and lower thermal expansion of transmission housings. Summary of the Invention

[0005] One object of this disclosure is to provide a composite transmission housing for a vehicle drivetrain, and a corresponding method of manufacturing thereof, which further improves upon the aforementioned aspects (such as low weight, high strength, and low thermal expansion characteristics). This object is achieved, at least in part, by the features of the independent claims.

[0006] According to a first aspect of this disclosure, a composite transmission housing for a transmission in a vehicle drivetrain is provided. The transmission housing is configured to hermetically enclose a set of drive shafts and gears, as well as a lubricant fluid, within an internal space of the housing. The housing includes: a first carbon fiber skeleton member having a first attachment region; a second carbon fiber skeleton member having a first attachment region; a first sealing cap member made of a plastic material and having a first sealing surface; and a second sealing cap member made of a plastic material and having a second sealing surface. The first attachment regions of the first and second carbon fiber skeleton members are interconnected to provide a rigid structural frame defining the internal space. Furthermore, the first and second sealing surfaces of the first and second sealing cap members are pressed together or against corresponding sealing surfaces associated with the first and second carbon fiber skeleton members to provide a sealed outer shell surrounding the internal space.

[0007] According to a second aspect of this disclosure, a method is provided for manufacturing a composite transmission housing for a transmission system of a vehicle. The transmission housing is configured to hermetically enclose a set of drive shafts and gears, as well as a lubricant fluid, within an internal space of the housing. The method includes: manufacturing a first carbon fiber skeleton member having a first attachment region, a second carbon fiber skeleton member having a first attachment region, a first sealing cap member made of a plastic material and having a first sealing surface, and a second sealing cap member made of a plastic material and having a second sealing surface; and assembling the first carbon fiber skeleton member and the second carbon fiber skeleton member, as well as the first sealing cap member and the second sealing cap member, such that the first attachment regions of the first carbon fiber skeleton member and the second carbon fiber skeleton member are interconnected and define a rigid structural frame defining the internal space, and such that the first sealing surfaces and the second sealing surfaces of the first sealing cap member and the second sealing cap member are pressed together or against corresponding sealing surfaces associated with the first carbon fiber skeleton member and the second carbon fiber skeleton member to provide a sealed outer shell surrounding the internal space.

[0008] In this way, a transmission housing that is very robust and has high strength, yet remains sealed and lightweight, was achieved.

[0009] In particular, the advantages of each structure can be utilized by dividing the housing into two main parts: a high-strength yet very lightweight rigid structural frame and a dedicated sealing cap. For example, by connecting the first and second carbon fiber skeleton components to create the rigid structural frame, a very high-strength and lightweight frame is formed, while still enabling a cost-effective and highly automated carbon fiber tow winding manufacturing process. Furthermore, to enable proper fluid lubrication of the gears within the housing, a leak-proof and lightweight sealing shell of plastic material surrounding the gears is provided by sealingly attaching the first and second sealing cap components to the outside or inside of the rigid frame. Moreover, manufacturing each of the rigid structural frame and the sealing shell from at least two components connected during the assembly of the transmission housing simplifies the manufacturing of the individual components of the frame and the sealing shell, as the geometry is less complex and the characteristics are less compromised. Furthermore, the design of the first and second carbon fiber skeleton components forming the rigid structural frame can be chosen with less consideration for issues related to the assembly of gears and shafts, because such a device can be assembled into a portion of the frame before, if necessary, the first and second carbon fiber skeleton components are connected to each other.

[0010] Other advantages can be achieved by implementing one or more features of the dependent claims.

[0011] In some exemplary embodiments, each of the first and second carbon fiber skeleton components is manufactured by winding a continuous towed carbon fiber filament along a pattern of multiple posts or attachment inserts surrounding a clamp or mold, and subsequently curing the wound continuous carbon fiber filament towed. This provides cost-effective manufacturing and a high-strength final frame structure with a low level of material waste.

[0012] In some exemplary embodiments, the positions of the multiple pillars or attachment inserts of the clamp or mold, as well as the winding pattern (i.e., line type or pattern) of the continuous filament carbon fiber bundle, are selected based on stress- and / or strain-based topology optimization or generative design of the transmission housing. This allows for further optimization in terms of strength and stiffness while minimizing weight, materials, and cost.

[0013] In some exemplary embodiments, the first skeleton component has a first set of attachment inserts secured thereto in a first attachment region by means of continuous carbon fiber filaments wound thereon, and the second skeleton component has a second set of attachment inserts secured thereto in the first attachment region by means of continuous carbon fiber filaments wound thereon, and the first and second carbon fiber skeleton components are interconnected by fastening the first set of attachment inserts to the second set of attachment inserts. The attachment inserts provide well-defined contact surfaces and also enable machining to achieve high tolerance levels. The attachment inserts also simplify the operation of separating the cured carbon fiber frame from the clamp or mold.

[0014] In some exemplary embodiments, at least one, and particularly both, of the first and second carbon fiber skeleton components has a bearing insert fixed thereto by means of continuous carbon fiber filaments wound thereon, wherein a bearing supporting the drive shaft is secured within the bearing insert. The bearing insert provides a well-defined contact surface and also enables machining to achieve high tolerance levels. The bearing insert also simplifies the operation of separating the cured carbon fiber frame from a fixture or mold.

[0015] In some exemplary embodiments, the attachment inserts and / or bearing inserts of the first and second carbon fiber skeleton components are provided with internally threaded holes for attaching the sealing cap component thereto. This reduces the risk of relative movement between the skeleton and the sealing cap, thereby also reducing the risk of noise, vibration, and wear.

[0016] In some exemplary embodiments, at least one of the first carbon fiber skeleton component and the second carbon fiber skeleton component, as well as the first sealing cap component and the second sealing cap component, is provided with a fixing device positioned in the space between the rigid structural frame and the sealing housing, and configured to secure or guide a device installed in the space between the rigid structural frame and the sealing housing. This simplifies the securing, guiding, and arrangement of devices such as cables or pipes within the transmission housing, and also provides slight protection for these devices through their positioning between the skeleton and the sealing cap component.

[0017] In some exemplary embodiments, the first carbon fiber skeleton component and the second carbon fiber skeleton component, as well as the first sealing cap component and the second sealing cap component, are connected together by a set of common fasteners, each of which extends through all the components and presses them together. This results in fewer fasteners required overall.

[0018] In some exemplary embodiments, the first sealing cover component and the second sealing cover component are separate components that are respectively attached to the first carbon fiber skeleton component and the second carbon fiber skeleton component during the assembly of the composite transmission housing. This simplifies the manufacturing of the sealing cover component and the carbon fiber skeleton component.

[0019] In some exemplary embodiments, the first sealing cap component and the second sealing cap component are respectively overmolded (overmolded) on the outside or inside of the first carbon fiber skeleton component and the second carbon fiber skeleton component. This allows for simplified housing assembly because fewer individual components must be handled and assembled.

[0020] In some exemplary embodiments, the attachment inserts and / or bearing inserts have a spool shape. This allows carbon fiber bundles to be easily wound around the inserts.

[0021] In some exemplary embodiments, the first and second sealing cap components are made of thermosetting plastic materials or other similar low-creep plastic materials. This reduces the risk of leakage from the sealing housing due to long-term creep.

[0022] In some exemplary embodiments, the first sealing device is disposed between the first sealing cover component and the second sealing surface of the second sealing cover component. This achieves improved and more reliable sealing performance.

[0023] In some exemplary embodiments, a first sealing device is disposed between a first sealing surface of a first sealing cap component and a corresponding sealing surface associated with a first carbon fiber skeleton component, and between a second sealing surface of a second sealing cap component and a corresponding sealing surface associated with a second carbon fiber skeleton component. This achieves improved and more reliable sealing performance.

[0024] In some exemplary embodiments, each of the first carbon fiber skeleton component and the second carbon fiber skeleton component, as well as the first sealing cap component and the second sealing cap component, is bowl-shaped and includes an inner side, an outer side, and an edge for connection or sealing with the other of the components. This provides a relatively large internal space for the internal transmission gear assembly.

[0025] In some exemplary embodiments, the housing also includes an elongated driveshaft having an elongated extension in the axial direction of the transmission housing, and the first attachment area is assembled together by fasteners extending in the axial direction. Thus, a complete and integrated bearing support for the driveshaft can be formed in each of the first and second carbon fiber skeleton components, without the need to separate the bearing support into multiple components.

[0026] In some exemplary embodiments, the sealing shell formed by the first sealing cap component and the second sealing cap component substantially completely covers the rigid structural frame. This provides a high level of sealing security.

[0027] In some exemplary embodiments, the continuous filament carbon fiber tow is made of at least 75%, particularly at least 90%, and even more particularly at least 97% carbon fiber material. This provides high strength and low weight.

[0028] In some exemplary embodiments, a continuous filament carbon fiber tow comprises approximately 1,000-200,000 twisted or untwisted continuous carbon filaments per tow.

[0029] In some exemplary embodiments, the steps of manufacturing a first carbon fiber skeleton component and a second carbon fiber skeleton component include: providing a first fixture or mold having a plurality of posts or attachment inserts, and providing a second fixture or mold having a plurality of posts or attachment inserts; winding a continuous tow of long filament carbon fiber filaments along a pattern surrounding the plurality of posts or attachment inserts of the first fixture or mold to produce a first intermediate component, and winding a continuous tow of long filament carbon fiber filaments along a pattern surrounding the plurality of posts or attachment inserts of the second fixture or mold to produce a second intermediate component; and curing the wound continuous tow of long filament carbon fiber filaments of the first and second intermediate components to provide a first rigid carbon fiber skeleton component and a second rigid carbon fiber skeleton component. This process provides cost-effective manufacturing.

[0030] In some exemplary embodiments, the steps of manufacturing each of the first carbon fiber skeleton component and the second carbon fiber skeleton component include: mounting a first set of attachment inserts on a first fixture or mold and mounting a second set of attachment inserts on a second fixture or mold; winding a continuous tow of long filament carbon fiber filaments along a pattern surrounding the first set of attachment inserts of the first fixture or mold for the production of the first intermediate component, and winding a continuous tow of long filament carbon fiber filaments along a pattern surrounding the second set of attachment inserts of the second fixture or mold for the production of the second intermediate component; curing the wound continuous tow of long filament carbon fiber filaments of the first intermediate component and the second intermediate component for providing the first rigid carbon fiber skeleton component and the second rigid carbon fiber skeleton component; and assembling the first carbon fiber skeleton component and the second carbon fiber skeleton component by fastening the first set of attachment inserts to the second set of attachment inserts.

[0031] In some exemplary embodiments, the method further includes: determining an optimized structural design of the rigid structural frame of the transmission housing by performing stress- and / or strain-based topology optimization or generative design of the transmission housing; and based thereon, selecting a design for a clamp or mold, selecting the position and number of posts and / or attachment inserts on the clamp or mold, and selecting a winding model of a continuous bundle of long filament carbon fiber filaments surrounding a plurality of posts or attachment inserts of the clamp or mold, the winding model producing a structure of the rigid structural frame corresponding to the determined optimized structural design, particularly in terms of size, shape and / or topology.

[0032] In some exemplary embodiments, the steps of manufacturing each of the first carbon fiber skeleton component and the second carbon fiber skeleton component include: mounting at least one bearing insert onto at least one of a first jig or mold and a second jig or mold; winding a continuous filament carbon fiber bundle along a pattern surrounding the at least one bearing insert to produce a first intermediate component and / or a second intermediate component; curing the wound continuous filament carbon fiber bundle of the first intermediate component and the second intermediate component to provide a first rigid carbon fiber skeleton component and a second rigid carbon fiber skeleton component; and installing a bearing for supporting a drive shaft in the bearing insert.

[0033] In some exemplary embodiments, the step of assembling the first carbon fiber skeleton component and the second carbon fiber skeleton component, as well as the first sealing cap component and the second sealing cap component, includes installing a set of common fasteners, each of which extends through the first carbon fiber skeleton component and the second carbon fiber skeleton component, as well as the first sealing cap component and the second sealing cap component, and pressing them together to connect the first carbon fiber skeleton component and the second carbon fiber skeleton component to each other and to provide a sealed housing around the internal space by means of the first sealing cap component and the second sealing cap component.

[0034] Other features and advantages of the invention will become apparent when examined in light of the appended claims and the following description. Those skilled in the art will recognize that different features of this disclosure can be combined to create other embodiments besides those explicitly described above and below without departing from the scope of this disclosure. Attached Figure Description

[0035] The present disclosure will now be described in detail with reference to the accompanying drawings, in which...

[0036] Figure 1 A vehicle may be provided with a composite transmission housing according to this disclosure, as schematically shown.

[0037] Figure 2 An exemplary layout of a vehicle transmission that may include a composite transmission housing according to this disclosure is schematically shown.

[0038] Figure 3-4 schematically shows two different side views of an exemplary embodiment of the transmission housing.

[0039] Figure 5 A cross-sectional view of an exemplary embodiment of the transmission housing is schematically shown.

[0040] Figure 6 schematically shown Figure 5 Exploded view of the shell,

[0041] Figures 7A-7B schematically shown Figure 5 and Figure 6 First sealing cap component and second sealing cap component,

[0042] Figures 8A-8B schematically shown Figure 5 and Figure 6 The first carbon fiber skeleton component and the second carbon fiber skeleton component,

[0043] Figure 9 An exemplary embodiment of a clamp used for manufacturing a skeleton is schematically shown.

[0044] Figure 10 , 13 Figures 1 and 14 schematically illustrate different solutions for constructing carbon fiber frames.

[0045] Figure 11A-11B Two different exemplary embodiments of the attachment insert are schematically illustrated.

[0046] Figure 12 The diagram schematically shows a spool with carbon fiber filaments wound around it.

[0047] Figure 15A-18 The various manufacturing steps of the carbon fiber frame are shown.

[0048] Figure 19 Details of another embodiment of the transmission housing are schematically shown.

[0049] Figure 20-21 Two different exemplary embodiments of the bearing insert are schematically shown.

[0050] Figure 22-23 Two other exemplary embodiments of the composite transmission housing are shown, and

[0051] Figure 24-29 The basic steps of some alternative embodiments of a method for manufacturing a composite transmission housing are shown. Detailed Implementation

[0052] Various aspects of this disclosure will now be described in conjunction with the accompanying drawings, in order to illustrate and not limit the disclosure, wherein similar reference numerals denote similar elements, and variations of the described aspects are not limited to the embodiments specifically shown, but are other variations that can be applied to the disclosure.

[0053] To describe in more detail and better in some exemplary embodiments of the composite transmission housing of the transmission unit of a vehicle drivetrain according to this disclosure, and to set the environment of the composite transmission housing, reference is first made to... Figure 1 , Figure 1 An exemplary embodiment of a vehicle in the form of an automobile 1, having wheels 2 and a body 3 with a passenger compartment 4, is shown. The automobile 1 has a vehicle transmission system 5 for providing the propulsion necessary to drive the automobile 1.

[0054] Figure 2 schematically shown Figure 1 This is a non-limiting example embodiment of the drivetrain 5 of vehicle 1. In this exemplary embodiment, the drivetrain includes a propulsion power source 6 (such as an electric motor or internal combustion engine) which is drivably connected to the drive wheels 2 of the vehicle via a transmission unit. The transmission unit includes, for example, a transmission unit 17 having a first driveshaft 8 drivably connected to the propulsion power source 6 and a second driveshaft 9 drivably connected to one or more wheels 2, for example via a differential gear transmission 10 and / or a drive shaft. The transmission unit 17 may, for example, include a transmission housing 7 that holds a multi-speed transmission, a single-speed transmission, a continuously variable transmission, etc., for providing a desired gear ratio between the first driveshaft 8 and the second driveshaft 9.

[0055] exist Figure 2 In an exemplary embodiment, the transmission unit 17 includes a multi-speed transmission, i.e., a transmission with multiple discrete gears, wherein each gear has a unique gear ratio. Clearly, the composite transmission housing 7 according to this disclosure and the associated methods for manufacturing such a housing 7 are not limited to this type of transmission unit 17, and this type of transmission unit 17 should only be considered as a non-limiting example used to describe the housing in an exemplary context.

[0056] Figure 2 A schematic diagram of an electric drive system 5 is shown, comprising an electric propulsion motor 6, a transmission unit 17, a differential gearbox, and a set of drive wheels 2. The transmission unit 17 includes a housing 17 and a two-speed automatic-manual transmission (ATM). According to this exemplary embodiment, the transmission unit 17 has a first gear 11 with a first gear ratio and a second gear 12 with a second gear ratio.

[0057] The first gear 11 includes a first gear 13 that rotates freely due to inertia. This first gear 13 is arranged on the first drive shaft 8 and is rotatable relative to the first drive shaft 8, and is constantly meshed with a second gear 14 that is rotatably fixed to the second drive shaft 9. The second gear 12 includes a third gear 15 that rotates due to inertia. This third gear 15 is arranged on the first drive shaft 8 and is rotatable relative to the first drive shaft 8, and is constantly meshed with a fourth gear 16 that is rotatably fixed to the second drive shaft 9.

[0058] A shift sleeve 18, which is axially movable and arranged on and rotatably fixed to the first drive shaft 8 via a bushing 19, includes a set of sleeve teeth (also called dog teeth). This set of sleeve teeth can be axially moved in two directions along the shift axis 25 by means of a shift actuator 28 and a shift arm 30 to engage corresponding teeth or dog teeth 26, 27 of the associated first gear 13 and third gear 15, respectively, thereby enabling the selection of a suitable gear ratio between the first drive shaft 8 and the second drive shaft 9 as appropriate.

[0059] An electronic control system 20 is provided for controlling the operation of the transmission unit 17, particularly for controlling the operation of the shift actuator 28. For example... Figure 2 As shown, the electronic control system 20 can also be arranged to control the operation of an electric power converter 21 (such as, for example, an inverter), which is arranged to control the voltage and current supplied to the motor 6 from the high-voltage fuel cell and / or high-voltage power storage system 22 (such as a battery). The electronic control system 20 can be implemented as a distributed system with multiple individual electronic controllers controlling smaller units, or by means of a more centralized control system that controls a system comprising multiple smaller units.

[0060] As described above, the two-speed transmission unit 17 shown is merely one example of many possible and optional layouts, and the composite transmission housing according to this disclosure can be implemented or used in many other types of transmission units 17, such as single-speed transmissions, three-speed transmission units with up to but not limited to nine-speed transmissions, or even, for example, up to 25-speed transmission units, and the transmission unit can be implemented, for example, as conventional and hybrid dual-clutch transmissions (DCT and DCTH) or automatic manual transmissions (AMT).

[0061] Furthermore, the transmission housing according to this disclosure can also be implemented in transmission units of many different types of transmission systems, such as conventional combustion power transmission systems with a combustion engine as the main power source, or hybrid power systems with a combustion engine and an electric motor as the power source for propelling the vehicle.

[0062] Figure 3 schematically shows an external side view perpendicular to the axial direction AD of a portion of an exemplary drive system 5 including a propulsion motor 6 drivably connected to a transmission unit 17, and Figure 4 schematically shows an axial external side view of the same drive system 5.

[0063] Figure 5 The cross-section along tangent AA in Figure 4 schematically shows the same transmission system 5 as in Figure 3, except that it is a cross-sectional view. The output shaft 23 of the transmission unit can be driven to, for example, a differential gearbox or a separate drive wheel.

[0064] The exemplary design and function of the first and second gears of the transmission unit 17 in Figure 4 include a shift sleeve 18 capable of axial displacement controlled by a shift actuator 28, as referenced above. Figure 2 The description is the same, so it will not be repeated here. See also: Figure 2 And related descriptive paragraphs concerning gears and changes in transmission ratio.

[0065] For example, the motor 6 can be directly bolted to the outer surface of the transmission housing 7 using multiple bolts 29, which engage in corresponding threaded attachment holes 34 in the housing 7. Alternatively, the propulsion power source can be positioned further away from the housing 7 and driven only onto the first drive shaft 8. The motor 6 typically includes a stationary stator 31 and a rotating rotor 32 arranged on a central torque output shaft 33.

[0066] The transmission housing 7 of this transmission unit 17 is a composite transmission housing because it is composed of several parts made of different types of materials.

[0067] Specifically, the composite transmission housing is configured to hermetically enclose a set of drive shafts 8, 9 and gears 13-16, along with lubricant fluid, within the internal space 35 of the composite transmission housing 7. Furthermore, the composite transmission housing 7 includes a first carbon fiber skeleton member 41 having a first attachment region 43, a second carbon fiber skeleton member 42 having a first attachment region 44, a first sealing cover member 51 made of plastic material and having a first sealing surface 53, and a second sealing cover member 52 made of plastic material and having a second sealing surface 54. The first attachment regions 43, 44 of the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42 are interconnected to provide a rigid structural frame defining the internal space 35, and the first sealing surface 53 of the first sealing cover member 51 and the second sealing surface 54 of the second sealing cover member 52 are pressed together to provide a sealed outer shell surrounding the internal space.

[0068] In other words, the first sealing surface 53 of the first sealing cap component 51 and the second sealing surface 54 of the second sealing cap component 52 can be pressed together to directly contact each other to provide a sealed housing surrounding the internal space. Alternatively, the first sealing surface 53 of the first sealing cap component 51 and the second sealing surface 54 of the second sealing cap component 52 can be pressed together while having an intermediate sealing gasket disposed between the first sealing surface 53 and the second sealing surface 54 to provide a sealed housing surrounding the internal space.

[0069] To describe the design and composition of the composite shell in Figure 3-5 in more detail, the following is provided: Figure 6 , Figure 6 schematically shown Figure 5 An exploded view of the cross-section of the composite housing, but drive shafts 8 and 9, gears 13-16 and shifting device are not shown here.

[0070] Similarly, it provides Figure 7A and 7B , Figure 7A and 7B The diagrams illustrate the following: Figure 6 An axial side view of the inner surfaces of the first sealing cap 51 and the second sealing cap 52 of BB and CC is provided. Additionally, an axial side view of the inner surfaces of BB and CC is provided. Figure 8A and 8B , Figure 8A and 8B The diagrams illustrate the following: Figure 6 Axial side view of the inner surfaces of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 of DD and EE.

[0071] like Figure 5As shown, the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cap component 51 and the second sealing cap component 52, can all be connected together by a common set of fasteners 45 (particularly screws), each of which extends through all said components 41, 42, 51, 52 and presses them together. In other words, attachment holes 46 arranged along the periphery of the first sealing cap component 51 and the second sealing cap component 52 mate with attachment holes 47 arranged along the periphery of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, such that when installed in the proper mounting position, the attachment holes 46 of the sealing cap components 51, 52 are aligned with the attachment holes 47 of the carbon fiber skeleton components. Therefore, each of the fasteners 45 used to assemble the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cap component 51 and the second sealing cap component 52, into a single structure (piece) can be inserted through all said components when properly aligned and used to clamp all said components together to the final transmission housing. As a result, fewer fasteners are needed, thus saving weight and cost, and fewer fasteners need to be tightened, thus providing a more cost-effective manufacturing method.

[0072] like Figure 5 , 6 As shown in 7A and 7B, in the composite transmission housing according to any of the preceding claims, wherein, according to some exemplary embodiments of the composite transmission housing 7, the first sealing cap component 51 and the second sealing cap component 52 may be separate (independent) components that are respectively attached to or assembled with the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 during the assembly of the composite transmission housing. In other words, the first sealing cap component 51 and the second sealing cap component 52 may be manufactured separately from the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, and all these components may subsequently be assembled together by fasteners 45 to form the finished composite transmission housing 7. Therefore, the assembled housing 7 can generally also be disassembled again by removing the fasteners 45.

[0073] However, according to some other exemplary embodiments, alternatively, the first sealing cap component 51 and the second sealing cap component 52 may be overmolded on the outside or inside of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, respectively. This typically results in a high-strength bond between the first sealing cap component 51 and the second sealing cap component 52 and the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, thereby preventing the sealing cap components 51, 52 from being removed from or disintegrating from the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 after the molding process is completed. An advantage of overmolding the first sealing cap component 51 and the second sealing cap component 52 onto the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 is a reduced risk of noise and vibration caused by relative movement between the first sealing cap component 51 and the second sealing cap component 52 and the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. On the other hand, an advantage of manufacturing the first sealing cap component 51 and the second sealing cap component 52 separately is that the manufacturing process is less complex, as overmolding is a relatively complex manufacturing process.

[0074] like Figure 5 , 6 As shown in Figures 7A-7B, the sealing housing formed by the first sealing cover component 51 and the second sealing cover component 52 substantially completely covers the rigid structural frame. This results in a more leak-proof housing and reduces the risk of dust or moisture entering the transmission housing. However, some openings in the sealing housing are generally unavoidable, such as in interface areas, i.e., areas where the drive shafts 8, 9 interact with external components, or areas where the clutch shift arm enters the sealing housing, etc.

[0075] exist Figure 5 In an exemplary embodiment, the first elongated drive shaft and the second elongated drive shafts 8 and 9 extend along the axial direction AD of the transmission housing, and fasteners 45 for connecting at least the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42 to each other also extend along the axial direction AD. Therefore, the housing includes elongated drive shafts 8 and 9 having elongated extensions in the axial direction AD of the transmission housing, and the first attachment regions 43 and 44 are assembled together by fasteners 45 extending along the axial direction AD. This simplifies the assembly of the first drive shaft 8 and the second drive shaft 9, on which gears are mounted.

[0076] The first drive shaft 8 is rotatably connected (e.g., via a suitable torque transmission connection) to the output shaft of the motor 6. Figure 5 In an exemplary embodiment, the first drive shaft 8 is telescopically and rotatably connected to the output shaft of the motor 6.

[0077] As described above, each of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 has first attachment regions 43, 44, and the first attachment regions 43, 44 are interconnected to provide a rigid structural carbon fiber frame. According to some exemplary embodiments, as shown in FIG3-8B, the first attachment regions 43, 44 of each of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 include a plurality of attachment holes 47 distributed around the first attachment regions 43, 44, i.e., along the contact periphery between the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 in FIG3-8B.

[0078] The attachment holes 47 of the first attachment regions 43 and 44 may, for example, be provided in the peripheral flanges 50 of the first sealing cover component 51 and the second sealing cover component 52.

[0079] In other words, each of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 may, for example, have a basic bowl shape and include an inner side, an outer side, and an edge for connection with the other of the components 41, 42, wherein a plurality of attachment holes 47 are distributed around the edges of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 for interconnection of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 by means of fasteners 45.

[0080] These attachment holes 47 can be directly disposed in the carbon fiber structure of the first attachment regions 43, 44 of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. Alternatively, certain types of inserts (especially attachment inserts 48) can be fastened to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 and used to connect the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 to each other.

[0081] The insert (such as the attachment insert 48) is advantageous in that it can be machined after the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 have cured. Here, machining refers to processes such as material removal, such as milling, drilling, grinding, etc., and the material of the insert 48 can be a metal such as aluminum alloy, steel, etc., or a plastic material such as polyurethane. Machining the insert 48 after final curing provides the advantage of achieving a perfectly flat contact surface between the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, and perfectly aligned attachment holes 47 within the first attachment regions 43, 44, due to the correct final positioning of the attachment holes 47 or the insert 48 (if used) within the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 during manufacturing and curing. Furthermore, the metal insert 48 is generally more suitable for withstanding the high compressive forces generated by the fastener 45, thereby reducing the risk or damage to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0082] like Figure 6 As shown, the attachment insert 48 typically has a flat front surface 55, that is, the attachment insert 48 faces the adjacent surface of other carbon fiber skeleton components to achieve a flat contact surface between the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0083] The rigid structural frame of the transmission housing 7 may include additional attachment holes, attachment areas, and / or attachment inserts for various purposes. For example, one or both of the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42 may include additional attachment holes disposed directly in the carbon fiber skeleton or disposed in one or more attachment inserts to improve the attachment of the first sealing cap member 51 and the second sealing cap member 52 to the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42. In particular, in order to reduce the risk of undesirable vibration interference between the first sealing cap member 51 and the second sealing cap member 52 and the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42, the first sealing cap member 51 and the second sealing cap member 52 may be appropriately secured at more locations in addition to those locations disposed at the peripheral flanges 50 of the first sealing cap member 51 and the second sealing cap member 52.

[0084] For example, in some exemplary embodiments, additional attachment holes may be appropriately provided, which are disposed directly in the first carbon fiber skeleton member 41 or the second carbon fiber skeleton member 42, or disposed in one or more attachment inserts fixed to the first carbon fiber skeleton member 41 or the second carbon fiber skeleton member 42, wherein these additional attachment holes are disposed in the bottom region of the bowl-shaped first carbon fiber skeleton member 41 or the second carbon fiber skeleton member 42, i.e., at a position away from the first attachment regions 43, 44 of the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42, as supplementary attachment.

[0085] For example, these additional attachment holes are threaded to simplify the attachment of the first sealing cap component 51 and the second sealing cap component 52 to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0086] Furthermore, in exemplary embodiments, such as where the power propulsion source 6 (e.g., an electric motor) is fastened to the transmission housing 7, the rigid structural frame of the transmission housing 7 may include additional attachment holes, attachment areas, and / or attachment inserts for this purpose.

[0087] For example, such as Figure 5 , 6 As schematically shown in 8B, one of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 may include a second attachment region 57 having a plurality of attachment inserts 58 for attaching the motor 6 to the transmission housing 7. As described above, the motor 6 can then be directly bolted to the outer surface of the transmission housing 7, for example, via a plurality of threaded bolts 29 that engage in corresponding threaded attachment holes 34 of the attachment inserts 58 of the first carbon fiber skeleton component 41 or the second carbon fiber skeleton component 42.

[0088] In addition, such as Figure 5 , 6 As schematically shown in 8B, at least one, and especially both, of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 has a bearing 59 (such as a roller bearing) fixed thereto, wherein the bearing 59 rotatably supports one of the first drive shaft 8 and the second drive shaft 9 mounted within the bearing. The bearing 59, for example, made of plastic or metal, can be installed in a hole provided in the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. For example, the bearing 59 can be interference-fitted into or otherwise secured to a pre-made hole (pre-manufactured hole) in the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0089] Alternatively, the bearing 59 can be secured to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 by winding a continuous carbon fiber bundle around the bearing during the manufacture of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, and then curing the carbon fiber bundle to rigidly attach the bearing to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0090] According to another alternative, one or both of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 have a bearing insert 60 fixed thereto, wherein the bearing 59 is fastened within the bearing insert 60. The bearing insert 60 provides the advantage of allowing machining of the bearing insert 60 after the carbon fiber structure has cured to ensure proper alignment of the bearings 59 on the common shafts 8, 9, and proper lateral distance between the first drive shaft 8 and the second drive shaft 9 for providing correct gear meshing characteristics. The bearing insert 60 can be, for example, fixed to the carbon fiber structure by winding a continuous bundle of carbon fiber filaments around the bearing 59 during the manufacture of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, and then curing the carbon fiber filaments to rigidly attach the bearing insert 60 to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0091] Specifically, the annular outer surface of the bearing 59 can be interference-fitted into or fixed to the annular inner hole 61 of the bearing insert 60.

[0092] Referring to Figures 4, 5, 7A-7B, and 8A-8B, the bearing insert 60 may, for example, have a spool shape, i.e., an annular shape with a left flange and a right flange, to hold and secure the wound carbon fiber bundle to the bearing insert 60.

[0093] In an exemplary embodiment of the transmission housing shown in Figures 3-7B, the first sealing cover component 51 and the second sealing cover component 52 together provide a peripheral sealing container surrounding a rigid structural frame.

[0094] Each of the first sealing cap component 51 and the second sealing cap component 52 may have a bowl-shaped shape, including an inner side, an outer side, and an edge for sealing contact with the other of the components. Therefore, the first sealing surface 53 and the second sealing surface 54 are disposed at the edges of the respective components, particularly in the region of the peripheral flange 50 of the first sealing cap component 51 and the second sealing cap component 52.

[0095] In addition to the aforementioned attachment holes 46 provided along the periphery of the first sealing cap component 51 and the second sealing cap component 52 for securing the sealing cap components 51, 52 to each other and / or to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, the first sealing cap component 51 and the second sealing cap component 52 may be secured to the associated first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 at additional locations. For example, the rigid structural frame of the transmission housing 7 may include additional attachment holes, attachment areas, and / or attachment inserts for various purposes. For example, one or both of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 may include additional attachment holes disposed directly in the carbon fiber skeleton or disposed in one or more attachment inserts to improve the attachment of the first sealing cap component 51 and the second sealing cap component 52 to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. In particular, in order to reduce the risk of undesirable vibration interference between the first sealing cap component 51 and the second sealing cap component 52 and the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, the first sealing cap component 51 and the second sealing cap component 52 may be properly secured at more locations in addition to those locations arranged at the peripheral flanges 50 of the first sealing cap component 51 and the second sealing cap component 52.

[0096] For example, as schematically shown in Figures 4, 5, 7A-7B and 8A-8B, one or more bearing inserts 60 of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 may be provided with one or more internally threaded holes 62 configured to attach the first sealing cap component 51 and the second sealing cap component 52 thereto via threaded fasteners 87 extending through dedicated attachment holes 63 in the first sealing cap component 51 and the second sealing cap component 52.

[0097] exist Figure 7A In this configuration, an additional hole 64 is provided for the outlet channel of the second drive shaft 9 to transmit propulsion torque to the drive wheel. Furthermore, in... Figure 7B An additional hole 65 is provided for attaching the motor 6 to the transmission housing 7.

[0098] The first sealing cap component 51 and the second sealing cap component 52 may be made, for example, of thermosetting plastic or polymeric materials or similar low viscoelastic and / or low creep polymeric materials. For example, the first sealing cap component 51 and the second sealing cap component 52 may be made of non-fiber-reinforced epoxy resin or other materials having similar low creep properties, such as having at least 75% (particularly at least 90%) of the creep resistance of epoxy resin. Phenolic resins, amino resins, polyester resins, silicone resins, epoxy resins, and polyurethanes are some examples of thermosetting polymeric materials that can be used to manufacture the first sealing cap component 51 and the second sealing cap component 52. Alternatively, the first sealing cap component 51 and the second sealing cap component 52 may be made of fiber-reinforced thermosetting polymeric materials.

[0099] Figure 8A and 8B The inner sides of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 are shown respectively. The positions of the plurality of attachment inserts 48, 58 and the design or pattern of the carbon fiber skeleton are preferably selected to provide a high-strength, rigid, and reliable rigid structural frame after the first component 41 and the second component 42 are connected. For example, the selected design or pattern can be calculated or determined by performing topology optimization or generative design based on three-dimensional stress and / or strain of the transmission housing. Stress and / or strain-based topology optimization can be performed, for example, using the finite element method (FEM) (i.e., finite element analysis).

[0100] Generally, size, shape, and topology optimization, as well as generative design, involve identifying different aspects of the optimal (optimal) design. Size optimization involves finding the optimal thickness for the cross-sectional area of ​​a component, shape optimization involves finding the optimal shape within a given design domain, and topology optimization involves identifying the optimal material distribution within a predefined design domain.

[0101] Topology optimization methods are typically based on finite elements (FEMs) and may include sensitivity analysis. These methods generally utilize individual finite elements within an FEM mesh, with each element designated as a design variable, such as the material density of the element. By calculating stress and strain levels for each iteration, the parameter values ​​(e.g., material density) of each element can be iteratively updated to achieve the optimal design.

[0102] Therefore, an exemplary strategy for performing stress- and / or strain-based topology optimization may include first preparing an initial design of the transmission housing with certain design constraints, such as external space, connection interfaces with the propulsion power source and drive shaft of the drive wheels, space for internal gears, etc. The walls of the initial transmission housing design may, for example, be solid walls. Subsequently, when certain forces / torques are applied to the transmission housing and / or shaft to simulate the use of the transmission housing, the resulting stress and / or strain levels are calculated. Regions of the transmission housing with low stress and / or low strain levels are then removed from the design, and a new iteration is performed, including the calculation of new stress and / or strain levels and the resulting material removal. This (iteration) is then continued until a stopping criterion is met, such as the lowest and / or highest stress and / or strain levels exceeding a certain threshold. The resulting pattern can then be used to determine the positions of multiple attachment inserts 48, 58 and the design or pattern of the carbon fiber skeleton.

[0103] For example, the carbon fiber structure of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 can then have a pattern corresponding to the stress vector of the transmission housing derived by finite element analysis.

[0104] Not only can the topology of the frame be optimized, but aspects such as the material thickness and dimensions of various parts of the transmission housing can also be optimized using finite element analysis, i.e., structural optimization of the transmission housing.

[0105] The first carbon fiber skeleton component 41 or the second carbon fiber skeleton component 42 can be manufactured using various alternative methods. Figure 9 A 3D view of a fixture or mold 66 is schematically shown for an exemplary method of manufacturing a first carbon fiber skeleton component 41 or a second carbon fiber skeleton component 42. This method involves producing a carbon fiber structure by first winding a carbon fiber tow around a set of pillars or other objects (objects) of the fixture or mold until the desired thickness of a single connecting arm or segment is achieved. For example, the carbon fiber tow can be pre-impregnated during the manufacturing process of a carbon fiber tow manufacturer, so that no additional impregnation is required when performing the winding operation. Alternatively, the carbon fiber tow can be impregnated with resin before being wound onto the fixture or mold, for example, by introducing a continuous carbon fiber tow downwards into an impregnation tank (container) or a coating tank (container).

[0106] Figure 12 A continuous bundle of carbon fiber filaments is schematically shown wound on a spool and prepared for manufacturing the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0107] After the final winding process, the clamp or mold with the wound carbon fiber structure is cured to provide the final rigidity of the first carbon fiber skeleton component 41 or the second carbon fiber skeleton component 42.

[0108] Figure 9 A clamp or mold 66 can be used to manufacture, for example, a first carbon fiber skeleton component 41, which has a bottom surface 67 and a top surface 68. Two annular protrusions 69 or the like can be provided on the bottom surface and arranged to receive bearing attachments 60. In addition, a plurality of posts 70 are provided in certain locations to enable the continuous carbon fiber towed around the various components of the first carbon fiber skeleton component 41.

[0109] If it is necessary to attach inserts 48 and 58, then they can be attached as follows: Figure 10 As shown, it is installed on the column 70. Figure 10 A cross-section of a clamp or mold passing through two separate posts 70 is shown. Specifically, in this exemplary design, an attachment insert 48 of the first attachment region 43 is mounted on a post located on the top surface 68, and a post without any inserts is positioned at the bottom surface 67. A continuous carbon fiber tow is schematically shown, which is wound around the attachment insert 48 and the post 70 at the bottom surface 67 to form a carbon fiber arm or segment 71. After the carbon fiber structure has cured, it can be lifted and separated from the clamp or mold, which is used to manufacture new carbon fiber skeleton components.

[0110] Figure 10 The attachment insert 48 has a spool shape (i.e., an annular shape with a left flange and a right flange 73) for holding and securing the wound carbon fiber bundle to the attachment insert 48.

[0111] Figure 11A A top view schematically illustrates an exemplary embodiment of an attachment insert having an internal central annular spool 74 with an internal attachment hole 47, and a left and right flange 73 for holding and securing a wound carbon fiber bundle to the attachment insert 48.

[0112] Figure 11B A top view schematically illustrates another exemplary embodiment of the attachment insert, which has an internal central annular spool 74 with an internal attachment hole 47, and left and right flanges 73 for holding and securing the wound carbon fiber bundle to the attachment insert 48. Furthermore, the circular section 75 of the lower flange 73 is omitted to simplify the winding of the continuous filament carbon fiber bundle around the attachment insert.

[0113] The winding process can be automated and performed using industrial robots. Therefore, the manufacturing process of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 can be highly automated and cost-effective, and the winding manufacturing process generates virtually no waste (material waste).

[0114] like Figure 13 As schematically illustrated, during manufacturing, to simplify the winding process, some type of end stop 72 can be temporarily mounted on the post 70. This is because the desired three-dimensional form of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 reduces the risk of the continuous carbon fiber tow loops slipping prematurely from the post. Furthermore, the removable end stop 72 also allows for simplified separation of the carbon fiber structure from the clamp 66. Alternatively, other types of inserts can be mounted on the post to simplify the winding and / or removal of the carbon fiber structure.

[0115] Figure 14 A schematic diagram is shown of a series of columns 70 for manufacturing a clamp or mold 66 with a specific shape of elongated carbon fiber structure, wherein a continuous bundle of carbon fiber filaments is independently wound around each of the columns 70.

[0116] The following reference Figure 15A-18 A method for manufacturing, for example, a first carbon fiber skeleton component 41 is described, wherein Figure 15A and 15B Indicates the first state. Figure 16A and 16B Indicates the subsequent second state. Figure 17A and 17B This indicates a near-complete state, and Figure 17 shows the final separation state.

[0117] Figure 15A A first clamp or mold 66 is schematically shown, having a plurality of posts 70 permanently connected (fixedly connected) to the clamp or mold, and two annular protrusions 69 permanently connected to the bottom surface of the clamp or mold.

[0118] The positions of the multiple pillars 70 of the fixture or mold are selected to achieve a winding model for a continuous long-filament carbon fiber bundle, such that the resulting carbon fiber structure has a pattern corresponding to the stress vector obtained through stress- and / or strain-based topology optimization of the transmission housing. Additionally, two annular protrusions 69 are provided for receiving the bearing insert 60.

[0119] Figure 15B Schematic illustration along Figure 15A The cross section FF passes through the cross section of the fixture or mold 66.

[0120] Figure 16A It shows the relationship with Figure 15A The same but now in a subsequent state, clamp or mold 66, wherein a set of attachment inserts 48 have been installed on some pillars 70, while some other pillars 70 still have no inserts, and two bearing inserts 60 have been installed on two annular protrusions 69.

[0121] Figure 16B Schematic illustration along Figure 16A The cross section GG passes through the cross section of the fixture or mold 66.

[0122] Figure 17A It shows the relationship with Figure 16A The same, but still in a further subsequent stage, fixture or mold 66, wherein one or more rolls of continuous long-filament carbon fiber tow have been wound along a pattern surrounding multiple posts, attachment inserts 48, and bearing inserts 60 for the production of a first intermediate component. The selected winding pattern of the continuous long-filament carbon fiber tow, for example, results in a carbon fiber structure having a pattern corresponding to the stress vector obtained through stress- and / or strain-based topology optimization of the transmission housing. Winding continues until the individual carbon fiber arms or segments 71 of the carbon fiber structure reach the desired thickness. Winding can be performed manually, but a robotic winding process is preferred.

[0123] Figure 17B Schematic illustration along Figure 17A The cross section HH passes through the cross section of the fixture or mold 66.

[0124] For example, just before winding, the continuous filament carbon fiber bundle is pre-impregnated or impregnated in an impregnation tank, for example.

[0125] The continuous filament carbon fiber tow is made of, for example, at least 75% (especially at least 90%, more especially at least 97%) carbon fiber material.

[0126] In addition, continuous filament carbon fiber bundles include, for example, approximately 1,000-200,000 twisted or untwisted continuous carbon filaments per bundle, specifically approximately 5,000-50,000 twisted or untwisted continuous carbon fiber filaments per bundle.

[0127] Subsequently, the first intermediate carbon fiber skeleton component 41 is cured to provide the first final rigid carbon fiber skeleton component 41. Typical curing processes are autoclave treatment or heating in an oven, but other curing processes may also be used.

[0128] After curing, such as Figure 18 The diagram schematically illustrates the separation of the rigid final carbon fiber skeleton component 41 from the fixture or mold. The second carbon fiber skeleton component 42 is manufactured in a corresponding manner.

[0129] Each of the first sealing cap component 51 and the second sealing cap component 52 can be manufactured individually, for example by injection molding or similar methods.

[0130] The first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cap component 51 and the second sealing cap component 52, can then be ultimately connected together by a set of common fasteners 45, each of which is as follows: Figure 5 It extends through all the components as shown and presses them together.

[0131] In other words, the resulting first skeleton component 41 has a first set of attachment inserts 48 fixed thereto in the first attachment region 43 by means of continuous carbon fiber filaments wound thereon, and the second skeleton component 42 has a second set of attachment inserts 48 fixed thereto in the first attachment region 44 by means of continuous carbon fiber filaments wound thereon, and the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 are connected to each other by fastening the first set of attachment inserts 48 and the second set of attachment inserts 48 together. Furthermore, the first sealing cap component and the second sealing cap component are separate (independent) components that are respectively attached to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 when assembling the composite transmission housing 7.

[0132] Figure 19 schematically shown Figure 5 An enlarged view of the first region 76. According to some exemplary embodiments, at least one of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, and the first sealing cap component 51 and the second sealing cap component 52, may be provided with a fixing device 77, such as a clip, retainer, clamp, channel, or guide, etc., located in a space 78 between the rigid structural frame and the sealing housing, and configured to fix or guide a device 79 (such as, for example, a pipe, hose, conductive wire, sensor, actuator, etc.) installed in the space 78 between the rigid structural frame and the sealing housing. By arranging or retaining the device 79 within the space 78 enclosed by the rigid structural frame and the sealing housing, the device 79 is better protected to some extent, thereby avoiding contact with rotating parts of the transmission housing 7 or objects arranged outside the transmission housing 7. Furthermore, the arrangement and installation of such a device 79 can be simplified and is more cost-effective.

[0133] Figure 19 The enlarged schematic diagram also shows that, after the winding around the column, attachment inserts 48, 58 and / or bearing insert 60 is completed, the carbon fiber structure is configured to fill the space between the flanges 73 of each attachment insert 48 to form a high-strength and robust carbon fiber structure.

[0134] Figure 19 It is also shown that a first sealing device 80 may be disposed between a first sealing surface 53 of the first sealing cover component 51 and a second sealing surface 54 of the second sealing cover component 52. This first sealing device 80 can help ensure the leak-proof nature of the sealing housing and reduce noise and vibration.

[0135] According to some exemplary embodiments, the second sealing device 81 may be disposed between the fastener 45 and the first sealing cover component 51 and the second sealing cover component 52 to reduce noise and vibration.

[0136] Furthermore, despite Figure 19 Not shown, but a third sealing device may be disposed between each of the first attachment inserts 48 and the first sealing cap component 51 and the second sealing cap component 52 for the purpose of reducing noise and vibration, and / or a fourth sealing device may be disposed between two adjacent first attachment inserts 48 for the purpose of reducing noise and vibration.

[0137] Figure 20 schematically shown Figure 5 An enlarged view of the second region 83 shows details of parts such as the bearing insert 60. More specifically, some of the bearing inserts 60 of the first carbon fiber skeleton component 41 may be provided with one or more internally threaded holes configured for attaching the first sealing cap component 51 thereto via threaded fasteners 87. An annular sealing device 84 may be provided in the region of the outlet passage of the second drive shaft 9.

[0138] also, Figure 20 It is also clearly shown that the bearing insert 60 may have a spool-shaped core region with a left flange and a right flange 73 for holding and securing the wound carbon fiber bundle to the bearing insert 60.

[0139] Figure 21 An alternative exemplary embodiment of the bearing insert 60 is schematically shown, which has an additional flange 85 for improving the attachment of the bearing 59 within the bearing insert 60, since the bearing 59 can thus be axially supported by the additional flange 85 of the bearing insert 60.

[0140] Figure 22Another exemplary embodiment of a transmission housing 7 is shown, which has a sealed outer shell made of a first sealing cover member 51 and a second sealing cover member 52 disposed within a first carbon fiber skeleton member 41 and a second carbon fiber skeleton member 42. Therefore, attachment holes 46 provided in the peripheral flanges 50 of the first sealing cover member 51 and the second sealing cover member 52 are sandwiched between attachment holes 47 disposed along the periphery of the first carbon fiber skeleton member 41 and the second carbon fiber skeleton member 42, and are connected by a common fastener 45.

[0141] In addition to the attachment location of the peripheral flange 50, the first sealing cap component 51 and the second sealing cap component 52 can also be attached to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 at other locations. For example, such as Figure 22 As shown, the first sealing cap component 51 and the second sealing cap component 52 can be attached to the bearing insert 60 of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. Furthermore, the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 may be provided with dedicated attachment inserts 86 configured to connect the first sealing cap component 51 and the second sealing cap component 52 to the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 by means of fasteners 87.

[0142] Figure 23 Another exemplary embodiment of the composite transmission housing 7 is shown, wherein the first sealing cover component 51 and the second sealing cover component 52 are arranged outside the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. However, in this exemplary embodiment, the sealing surfaces 53 and 54 of the first sealing cover component 51 and the second sealing cover component 52 do not directly contact each other, but are sealed to the outer surfaces of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42.

[0143] In other words, the first sealing surface 53 of the first sealing cap component 51 and the second sealing surface 54 of the second sealing cap component 52 are pressed against the corresponding sealing surfaces associated with the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 to provide a sealed outer shell around the internal space.

[0144] Therefore, the first sealing device can be disposed between the first sealing surface 53 of the first sealing cap component 51 and the corresponding sealing surface associated with the first carbon fiber skeleton component 41. Similarly, the first sealing device can be disposed between the second sealing surface 54 of the second sealing cap component 52 and the corresponding sealing surface associated with the second carbon fiber skeleton component 42.

[0145] This arrangement may be advantageous in some embodiments, such as when each of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes a metal-based first attachment region 43, 44 for interconnection, thus eliminating the need to completely enclose the outer surface of the internal rigid structure.

[0146] The following will refer to Figure 24 The basic steps of a method for manufacturing a composite transmission housing 7 for a vehicle powertrain are described. The method includes a first step of manufacturing a first carbon fiber skeleton component 41 having a first attachment region 43, a second carbon fiber skeleton component 42 having a first attachment region 44, a first sealing cover component 51 made of plastic material and having a first sealing surface 53, and a second sealing cover component 52 made of plastic material and having a second sealing surface 54.

[0147] When all these components are available, the method includes a second step S20: assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cap component 51 and the second sealing cap component 52, such that the first attachment regions 43, 44 of the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 are interconnected and define a rigid structural frame defining an internal space 35, and such that the first sealing surface 53 of the first sealing cap component 51 and the second sealing surface 54 of the second sealing cap component 52 are pressed together or pressed against (aggregated against) the corresponding sealing surfaces associated with the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 to provide a sealed housing surrounding the internal space 35.

[0148] Clearly, the second step S20 of assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cover component 51 and the second sealing cover component 52, may also include installing the transmission assembly within the transmission housing before closing and sealing the housing, wherein the transmission assembly includes various combinations of drive shafts and gears, etc.

[0149] The first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 can be manufactured in various ways, and references are made to... Figure 25 One such method will be described in more detail. Thus, according to some exemplary embodiments, the first step S10 of manufacturing the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes the sub-step S13 of providing a first clamp or mold 66 having a plurality of posts 70 and / or attachment inserts 48, 58 and providing a second clamp or mold having a plurality of posts and / or attachment inserts.

[0150] The first step S10 of manufacturing the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 further includes a second sub-step S17, which involves winding a continuous long filament carbon fiber bundle along the pattern of the plurality of posts 70 or attachment inserts 48, 58 surrounding the first clamp 66 or mold to produce the first intermediate component, and winding a continuous long filament carbon fiber bundle along the pattern of the plurality of posts or attachment inserts surrounding the second clamp or mold to produce the second intermediate component.

[0151] Finally, the first step S10 of manufacturing the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 also includes a third sub-step S19, which solidifies the wound continuous filament carbon fiber bundles of the first intermediate component and the second intermediate component to provide the first rigid carbon fiber skeleton component 41 and the second rigid carbon fiber skeleton component 42.

[0152] According to some exemplary embodiments, the first step S10 of manufacturing the first carbon fiber skeleton component and the second carbon fiber skeleton component includes using an attachment insert. Therefore, referring to... Figure 26 A slightly alternative first step S10 is described for manufacturing the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42. Here, the main first step S10 includes: a first sub-step S13, providing a first clamp or mold 66 having a plurality of posts 70 and providing a second clamp or mold having a plurality of posts; and a subsequent sub-step S14, installing a first set of attachment inserts on the first clamp or mold and installing a second set of attachment inserts on the second clamp or mold.

[0153] Similar to a reference Figure 25 The described method steps further include: a subsequent sub-step S17, winding a continuous filament carbon fiber bundle along a model of the first set of attachment inserts surrounding the first clamp or mold for the production of the first intermediate component, and winding a continuous filament carbon fiber bundle along a model of the second set of attachment inserts surrounding the second clamp or mold for the production of the second intermediate component, and a subsequent step S19 as described above, curing the wound continuous filament carbon fiber bundles of the first and second intermediate components.

[0154] Furthermore, according to this exemplary embodiment, the second main step S20 of assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes fastening the first set of attachment inserts 48 to the second set of attachment inserts 48.

[0155] Furthermore, according to some exemplary embodiments, the aforementioned first sub-step S13, which provides a first clamp or mold 66 having a plurality of posts 70 and / or attachment inserts 48, 58 and a second clamp or mold having a plurality of posts and / or attachment inserts, may include: a first additional sub-step S13a, determining an optimized structural design of the rigid structural frame of the transmission housing by performing stress- and / or strain-based topology optimization of the transmission housing; and a subsequent second additional sub-step S13b, based on which, selecting the design of the clamp or mold, selecting the position and number of posts and / or attachment inserts on the clamp or mold, and selecting a winding model of a continuous filament carbon fiber bundle surrounding the plurality of posts or attachment inserts of the clamp or mold, the winding model producing a structure of the rigid structural frame corresponding to the determined optimized structural design, particularly in terms of size, shape, and / or topology.

[0156] Furthermore, according to some exemplary embodiments, the following references Figure 28 Another alternative method for manufacturing a transmission housing is described, wherein a first step S10 includes: a first sub-step S13, providing a first clamp or mold 66 having a plurality of posts 70 and providing a second clamp or mold having a plurality of posts; an additional sub-step S15, mounting at least one bearing insert 60 onto at least one of the first clamp or mold and the second clamp or mold; and a subsequent sub-step S18, winding a continuous filament carbon fiber tow along a pattern surrounding the at least one bearing insert 60 for producing the first intermediate component and / or the second intermediate component. The method then includes a subsequent sub-step S19 as described above, curing the wound continuous filament carbon fiber tow of the first intermediate component and the second intermediate component. Furthermore, according to this exemplary embodiment, a second main step S20 of assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes mounting a bearing 59 for supporting a drive shaft in the bearing insert 60.

[0157] refer to Figure 26 and 28 The described methods can also be combined, meaning that both the attachment insert and one or more bearing inserts can be installed. (See reference...) Figure 29 This method is illustrated in the following manner: a first step S10 includes a first sub-step S13, providing a first clamp or mold 66 having a plurality of posts 70 and providing a second clamp or mold having a plurality of posts; and an additional sub-step S14*, installing a first set of attachment inserts on the first clamp or mold, installing a second set of attachment inserts on the second clamp or mold, and installing at least one bearing insert 60 on the first clamp or mold and the second clamp or mold.

[0158] The main first step S10 also includes a subsequent sub-step S17*, winding a continuous filament carbon fiber bundle along a model of a first set of attachment inserts surrounding a first fixture or mold, winding a continuous filament carbon fiber bundle along a model of a second set of attachment inserts surrounding a second fixture or mold, and winding a continuous filament carbon fiber bundle along a model of at least one bearing insert 60, for the production of a first intermediate component and a second intermediate component.

[0159] Subsequently, the method includes the following follow-up sub-step S19 as described above, to solidify the wound continuous carbon fiber tow of the first intermediate component and the second intermediate component. Furthermore, according to this exemplary embodiment, the second main step S20 of assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes installing a bearing 59 for supporting the drive shaft in the bearing insert 60, and fastening the first set of attachment inserts 48 to the second set of attachment inserts 48.

[0160] Furthermore, according to some exemplary embodiments, the second main step S20 of assembling the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42 includes: installing a set of common fasteners 45, each of which extends through the first carbon fiber skeleton component 41 and the second carbon fiber skeleton component 42, as well as the first sealing cap component 51 and the second sealing cap component 52, and pressing them together for connecting the first carbon fiber skeleton component and the second carbon fiber skeleton component to each other, and for providing a sealed housing around the internal space by means of the first sealing cap component 51 and the second sealing cap component 52.

[0161] It should be understood that the above description is merely exemplary in nature and is not intended to limit the scope of this disclosure or its application or use. Although specific examples have been described in the specification and illustrated in the drawings, those skilled in the art will understand that various modifications can be made and equivalents can be substituted for their elements without departing from the scope of this disclosure as defined in the claims. Furthermore, modifications can be made to adapt specific situations or materials to the teachings of this disclosure without departing from its essential scope. Although the above discussion has been conducted through… Figure 24-29 The flowchart describes the method, but it should be understood that, within the scope of the concept of the appended claims and the methods described herein, one or more operations may be performed in an order other than that expressly described thereafter, and this is not necessarily intended to limit them to the order expressly provided herein. For example, refer to... Figure 27 The methods and steps discussed can also be found in the reference. Figure 25 , 26 The methods described in 28 or 29 shall be implemented. Therefore, the methods discussed are merely one embodiment of the contemplated content of this disclosure, and although not explicitly described, the steps may be combined with other steps.

[0162] Therefore, this disclosure is not intended to limit itself to specific examples disclosed as the best practices currently conceived for carrying out the teachings of this disclosure, which are illustrated in the drawings and described in the specification. Rather, the scope of this disclosure shall include any implementation falling within the scope of the foregoing description and the appended claims. Reference numerals used in the claims should not be construed as limiting the scope of the subject matter protected by the claims; their sole purpose is to facilitate the understanding of the claims.

Claims

1. A composite transmission housing (7) for a transmission system of a vehicle, the transmission housing (7) being configured to hermetically enclose a set of drive shafts (8, 9), gears (15, 16, 3, 14) and lubricant fluid within an internal space of the housing (7), and comprising: A first carbon fiber skeleton component (41) having a first attachment area; A second carbon fiber skeleton component (42) having a first attachment area; The first sealing cap component (51) is made of plastic material and has a first sealing surface; as well as The second sealing cap component (52) is made of plastic material and has a second sealing surface. The first attachment regions (43, 44) of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) are interconnected to provide a rigid structural frame defining the internal space (35); and The first sealing surface (53) of the first sealing cover component (51) and the second sealing surface (54) of the second sealing cover component (52) are pressed together or against the corresponding sealing surfaces associated with the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) to provide a sealed shell around the interior space (35).

2. The composite transmission housing according to claim 1, wherein, Each of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) is manufactured by winding a continuous filament carbon fiber bundle along a pattern of multiple posts (70) or attachment inserts (48, 58) surrounding a clamp or mold (66), and subsequently curing the wound continuous filament carbon fiber bundle.

3. The composite transmission housing according to claim 2, wherein, The positions of the plurality of pillars (70) or attachment inserts (48, 58) of the clamp or mold (66) and the winding model of the continuous filament carbon fiber bundle are selected based on stress- and / or strain-based topology optimization or generative design of the transmission housing (7).

4. The composite transmission housing according to claim 1, wherein, The first carbon fiber skeleton component (41) has a first set of attachment inserts (48) fixed thereon in the first attachment region (43) by means of continuous carbon fiber filaments wound thereon, wherein the second carbon fiber skeleton component (42) has a second set of attachment inserts (48) fixed thereon in the first attachment region (44) by means of continuous carbon fiber filaments wound thereon, and wherein the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) are connected to each other by fastening the first set of attachment inserts (48) and the second set of attachment inserts (48).

5. The composite transmission housing according to claim 1, wherein, One or both of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) have a bearing insert (60) fixed thereon by means of a continuous filament carbon fiber wound thereon, and wherein the bearing (59) supporting the drive shaft (8, 9) is fastened in the bearing insert (60).

6. The composite transmission housing according to claim 1, wherein, The attachment inserts (48, 58) and / or bearing inserts (60) of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) are provided with internal threaded holes (34, 62) for attaching the sealing cap components (51, 52) thereon.

7. The composite transmission housing according to claim 1, wherein, At least one of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42), as well as the first sealing cap component (51) and the second sealing cap component (52), is provided with a fixing device (77) located in the space between the rigid structural frame and the sealing shell, and is configured to fix or guide a device (79) installed in the space between the rigid structural frame and the sealing shell.

8. The composite transmission housing according to claim 1, wherein, The first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42), as well as the first sealing cap component (51) and the second sealing cap component (52), are connected together by a set of common fasteners (45), each of which extends through all the components and presses them together.

9. The composite transmission housing according to claim 1, wherein, The first sealing cover component (51) and the second sealing cover component (52) are separate components that are respectively attached to the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) when assembling the composite transmission housing (7); or The first sealing cap component (51) and the second sealing cap component (52) are respectively injection molded on the outer or inner side of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42).

10. The composite transmission housing according to any one of claims 1-9, wherein, The attachment inserts (48, 58) and / or bearing inserts (60) have a roll shape.

11. The composite transmission housing according to any one of claims 1-9, wherein, The first sealing cap component (51) and the second sealing cap component (52) are made of thermosetting plastic material or other types of low creep plastic material.

12. A method for manufacturing a composite transmission housing for a transmission system in a vehicle, wherein, The transmission housing (7) is configured to hermetically enclose a set of drive shafts (8, 9) and gears (13-16) and lubricant fluid within the internal space (35) of the housing (7), the method comprising: Manufacture a first carbon fiber skeleton component (41) having a first attachment area (43), a second carbon fiber skeleton component (42) having a first attachment area (44), a first sealing cap component (51) made of plastic material and having a first sealing surface (53), and a second sealing cap component (52) made of plastic material and having a second sealing surface (54); Assemble the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42), as well as the first sealing cap component (51) and the second sealing cap component (52), such that the first attachment regions (43, 44) of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) are interconnected and define a rigid structural frame that defines the interior space (35), and such that the first sealing surface (53) of the first sealing cap component (51) and the second sealing surface (54) of the second sealing cap component (52) are pressed together or against corresponding sealing surfaces associated with the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) to provide a sealed shell surrounding the interior space (35).

13. The method for manufacturing a composite transmission housing according to claim 12, wherein, The steps for manufacturing the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) include: A first clamp or mold (66) having multiple posts (70) or attachment inserts (48, 58) is provided, as well as a second clamp or mold having multiple posts or attachment inserts; A continuous tow of long-filament carbon fiber is wound along the pattern of the plurality of posts (70) or attachment inserts (48, 58) surrounding the first clamp or mold (66) for the production of a first intermediate component, and a continuous tow of long-filament carbon fiber is wound along the pattern of the plurality of posts or attachment inserts surrounding the second clamp or mold for the production of a second intermediate component; and The wound continuous carbon fiber bundles of the first intermediate component and the second intermediate component are cured to provide a rigid first carbon fiber skeleton component (41) and a rigid second carbon fiber skeleton component (42).

14. The method for manufacturing a composite transmission housing according to claim 13, wherein, The steps for manufacturing each of the first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) include: Install a first set of attachment inserts (48, 58) on the first clamp or mold (66), and install a second set of attachment inserts on the second clamp or mold; and A continuous tow of long filament carbon fiber is wound along the pattern of the first set of attachment inserts (48, 58) surrounding the first clamp or mold (66) for the production of the first intermediate component, and a continuous tow of long filament carbon fiber is wound along the pattern of the second set of attachment inserts surrounding the second clamp or mold for the production of the second intermediate component. The wound continuous carbon fiber tows of the first and second intermediate components are cured to provide a rigid first carbon fiber skeleton component (41) and a rigid second carbon fiber skeleton component (42); and The first carbon fiber skeleton component (41) and the second carbon fiber skeleton component (42) are assembled by fastening the first set of attachment inserts (48) to the second set of attachment inserts (48).

15. The method for manufacturing a composite transmission housing according to claim 13 or 14, further comprising: By performing stress- and / or strain-based topology optimization or generative design of the transmission housing (7), the optimized structural design of the rigid structural frame of the transmission housing (7) is determined; Based on this, the design of the clamp or mold (66) is selected, the placement and number of the posts (70) and / or attachment inserts (48, 58) on the clamp or mold (66) are selected, and a winding model of a continuous filament carbon fiber bundle around the clamp or mold (66) is selected, which produces a rigid structural frame structure corresponding to the determined optimized structural design in terms of size, shape and / or topology.

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