P2 hybrid module for electric vehicles

Abstract

A hybrid module for a vehicle is provided. The hybrid module includes an electric motor comprising a stator and a rotor. The hybrid module also includes a torque converter that is operatively coupled to the electric motor. The inner diameter of the stator in a radial direction is larger than the outer diameter of the torque converter in the radial direction.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims the provisional US patent application serial no. 63 / 676,119, filed on July 26, 2024, the entire contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION

[0002] The present disclosure relates to technologies for hybrid electric vehicles (EVs) and in particular a P2 hybrid module that supports improved installation, expansion and operational efficiency for electric vehicles and hybrid electric vehicles. BRIEF DESCRIPTION OF THE INVENTION

[0003] Embodiments of the present disclosure relate to a hybrid module for a vehicle comprising: an electric motor comprising a stator and a rotor; and a torque converter operatively coupled to the electric motor, wherein an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction.

[0004] Embodiments of the present disclosure also relate to a device assembly comprising: an electric motor comprising a stator and a rotor; a torque converter operatively coupled to the electric motor, wherein an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction.

[0005] Embodiments of the present disclosure also relate to a hybrid module for a vehicle comprising: an electric motor comprising: a stator; and a rotor comprising a rotor hub; and a torque converter operatively coupled to the electric motor, wherein the torque converter is removably coupled to the rotor hub; wherein: an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction; an outer diameter of a rotor hub foot of the rotor hub is dimensioned in the radial direction such that the rotor hub foot does not overlap magnets of the rotor.

[0006] Further aspects supported by the present disclosure and features of the exemplary embodiments are illustrated in the accompanying drawings and / or described in the following descriptions. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The following descriptions should not be considered restrictive in any way. With reference to the accompanying drawings, identical elements are numbered the same: Fig. 1A and Fig. Figure 1B illustrates perspective views of a device for an electric vehicle according to one or more embodiments of the present disclosure. Fig. Figure 1C illustrates a cross-sectional view of the device according to one or more embodiments of the present disclosure. The Fig. 2A and Fig. 2B illustrate exemplary system operating modes of the device and associated torque current between a P2 module, a torque converter and a dry damper according to one or more embodiments of the present disclosure. Fig.Figure 3 illustrates an exemplary overview of a hydraulic fluid distribution in the device according to one or more embodiments of the present disclosure. Fig. 4 illustrates aspects of the device according to one or more embodiments of the present disclosure. Fig. Figure 5 illustrates exemplary aspects of an axial length of the device according to one or more embodiments of the present disclosure. Fig. Figure 6 illustrates aspects of a K0 clutch (K0 release clutch) of the device according to one or more embodiments of the present disclosure. Fig. 7A illustrates aspects of the device and an inverter according to one or more embodiments of the present disclosure. Fig. 7B illustrates aspects of attaching the device according to one or more embodiments of the present disclosure. Fig. Figure 8 illustrates an example of a ring mounting of the torque converter. Fig. Figure 9 illustrates an exemplary flowchart of a process according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] According to one or more embodiments of the present disclosure, a P2 hybrid module is provided which supports improved installation, removal and improved operating efficiency in electric vehicles and hybrid electric vehicles.

[0009] Several powertrain architectures exist for hybrid vehicles and are known as P1, P2, P3, and P4 configurations. In a P2 configuration, an electric motor is located between an internal combustion engine and a transmission, and the P2 configuration allows the internal combustion engine to be separated from the transmission. The P2 configuration supports the integration of hybrid technology into an existing internal combustion engine powertrain with minimal modifications to the existing powertrain.

[0010] Fig. 1A and Fig. Figure 1B illustrates perspective views of a device 100 for an electric vehicle according to one or more embodiments of the present disclosure. Fig.Figure 1C illustrates a cross-sectional view of the device 100 according to one or more embodiments of the present disclosure. The device 100 may herein be referred to as a P2 hybrid module, a P2 hybrid module assembly, a hybrid module, or a device assembly according to a P2 configuration. Exemplary aspects of the internal configuration, assembly features, and serviceability features of the device 100 are described herein.

[0011] The device 100 is positioned according to a P2 configuration. The device 100 is positioned between a drive motor 101 and a transmission 102 of a motorized vehicle (not illustrated). Non-restrictive examples of the motorized vehicle include a motor vehicle or other self-propelled vehicles.

[0012] Aspects of the drive motor 101 and the gearbox 102 are not illustrated in detail. Instead, the drive motor 101 and the gearbox 102 are shown coupled to respective rotary input and output components of the device 100, which are configured to rotate about a central axis x. The drive motor 101 can be an internal combustion engine, but embodiments of the present disclosure are not limited to this.

[0013] The device 100 includes a P2 module 105 (hereinafter also referred to as a hybrid module) and a torque converter 125.

[0014] The P2 module 105 includes an electric motor 110, a rotor hub 130 having a rotor hub base 131, a cover plate 135 (hereinafter also referred to as a plate structure), a K0 coupling 140, a resolver 145, a coupling pack 150, a coupling basket 152, and a transmission input shaft 155. The P2 module 105 further includes a support element 142 and an element 165.

[0015] The electric motor 110 comprises a rotor 115 and a stator 120. The electric motor 110 is drivenly coupled to the K0 coupling 140 and to the torque converter 125. In some aspects, the electric motor 110 is drivenly coupled to the torque converter 125 via a splined engagement. Both the rotor 115 and the stator 120 can contain magnets. The rotor 115 can, for example, contain magnets 116. To avoid cluttering the figure, a single magnet 116 is shown.

[0016] The rotor hub 130 can serve as a structure to which the torque converter 125 can be removably coupled. According to one or more embodiments of the present disclosure, the device 100 supports a relatively simpler detachment or decoupling of the torque converter 125 from the rotor hub 130 compared to other approaches.

[0017] The K0 coupling 140 can be a hydraulic or wet coupling. The K0 coupling 140 can engage the drive motor 101 and the electric motor 110 with the torque converter 125 such that the torque converter 125 is disengaged from the drive motor 101 and the electric motor 110 (e.g., according to an internal combustion engine-plus-electric motor drive mode (ICE-plus-electric motor drive mode), which is described below with reference to Fig.2B), is driven. The K0 coupling 140 can engage the electric motor 110 with the torque converter 125 and disengage the drive motor 101 from the torque converter 125 such that the torque converter 125 is driven exclusively by the electric motor 110 (e.g., an all-electric drive mode, which is described below with reference to Fig. 2A is described).

[0018] In some aspects, one or more components of the P2 module 105 can be supported within a housing that is rigidly mounted to the drive motor 101 or another fixed structure of the vehicle.

[0019] The device 100 supports improved installation, removal and improved operating efficiency compared to other approaches, exemplary aspects of which are described herein with reference to the figures.

[0020] The features of the device 100 described herein support, for example, adaptable installation procedures, such as providing and shipping the P2 module 105 as an assembly or subsystem separate from the torque converter 125.

[0021] According to one or more embodiments of the present disclosure, with reference to Fig. 1A and Fig. 1C The inner diameter of the stator lamination 120 (e.g., in the z-direction) is larger than the outer diameter (e.g., in the z-direction) of the torque converter 125, which can facilitate easier installation and removal compared to other approaches. With reference to Fig.1C indicates one end of the inner diameter of the stator lamination of stator 120 by line 124, and one end of the outer diameter of torque converter 125 by line 126. The dimensioning of the inner diameter of stator 120 and the outer diameter of torque converter 125 can facilitate the removal of the stator assembly (i.e., the complete structure of stator 120, including the core and windings) by a user, thereby allowing access to the rotor hub foot 131 and the area corresponding to the rotor hub foot 131.

[0022] In the area corresponding to the rotor hub base 131, the torque converter 125 can be pried off the device 100, for example, using a tool. Detaching the torque converter 125 from the device 100 can provide access to the K0 coupling 140.

[0023] In some embodiments, separate angled sections forming a portion of the rotor hub base 131 can serve as points that facilitate the detachment (i.e., levering off) of the torque converter 125 from the rotor hub base 131 and consequently from the device 100. In some aspects, the angled sections can be formed non-continuously or at predetermined intervals on respective sections of the rotor hub base 131. In other aspects, the angled sections can be formed continuously (i.e., over a full 360 degrees) of the rotor hub base 131.

[0024] In another embodiment, a pin 180 (below in Fig.(7B illustrated) into a hole in the rotor hub base 131 and into the torque converter 125. The pin 180 can lock the torque converter 125 in the rotational position. In an example of removing the device 100 after removing the stator 120, the torque converter 125 can be unlocked from the device 100 by removing (pulling or pressing) the pin 180.

[0025] Additionally or alternatively, the torque converter 125 can be detached from the device 100 by a combination of prying and pin removal as described herein.

[0026] In some aspects, features of the rotor hub foot 131 can support oil flow from the coupling area corresponding to the coupling 140 through the rotor hub foot 131 and onto the end windings of the stator 120, and the oil flow can cool the stator 120.

[0027] In an example where the angled sections of the rotor hub foot 131 are not continuous (i.e., the non-continuous rotor hub foot 131), oil can flow from the coupling area through spaces defined by the angled sections of the rotor hub foot 131. Additionally or alternatively, the rotor hub foot 131 can include holes 175 (in Fig. 4 illustrated), which allow the oil flow through the rotor hub base 131. Additionally or alternatively, the rotor hub 130 can include holes 175 (in Fig. 4 illustrated), which enable the oil flow through the rotor hub 130.

[0028] In some aspects, the device 100 may include a ring 185 on the endplate 135, configured to guide the outer diameter of the stator lamination of the stator 120. The ring 185 can assist in positioning the stator 120. Additionally or alternatively, the device 100 may include pins (not illustrated) on the endplate 135, and the pins may be used to position the stator.

[0029] In some aspects, the stator lamination of stator 120 can be described with reference to the Fig.The stator 120 has eyelets 122, 1A to 1C. In one example, the stator 120 can be removably coupled to the end plate 135 by inserting bolts 123 (hereinafter also referred to as stator bolts) through holes defined in the eyelets 122 and tightening the bolts 123 to the end plate 135. The described implementations of the ring 185, the pins, eyelets 122, and bolts 123 facilitate the removal and installation of the stator 120 with respect to the device 100 and the electric motor 110.

[0030] Embodiments of the present disclosure facilitate the detachment of the torque converter 125 from the device 100 (e.g., the removal of the torque converter 125 for maintenance). In some examples, the torque converter 125 can be attached to the rotor hub 130 by a snap ring (not illustrated), by press fit, heat fit, knurling, key, pin 180 (as previously mentioned), or another similar device.

[0031] In an exemplary implementation using a snap ring, the rotor hub 130 or the torque converter 125 can include a snap ring pocket (not illustrated). The snap ring pocket (not illustrated) can be chamfered or beveled on the right-hand side (e.g., in the x-direction), allowing for easier removal of the torque converter 125. The snap ring pocket can be formed as a groove configured to receive the snap ring.

[0032] In the Fig.In the illustrated example 1C, the rotor hub foot 131 is located on the right side of the figure. In one example, one side (e.g., the side facing the negative x-direction) of the rotor hub foot 131 can act as an axial stop for the rotor 115, and another side (e.g., facing in the x-direction) of the rotor hub foot 131 can act as a stop for the torque converter 125.

[0033] Features of the rotor hub base 131 can prevent flux leakage. For example, the outer diameter of the rotor hub base 131 can be dimensioned such that the rotor hub base 131 does not cover the magnets on the rotor 115.

[0034] Features of the rotor hub base 131 can shield the torque converter 125 from the magnetic flux of the rotor 115. In a non-restrictive example, the thickness of the rotor hub base 131 can be greater than 3 mm, which can provide effective shielding of the magnetic flux. In some aspects, the thickness (e.g., greater than 3 mm) of the rotor hub base 131 can also provide effective resistance to thrust / bulging of the torque converter 125.

[0035] In some aspects, by including the closure plate 135 in the device 100, the device 100 can be formed separately from the gearbox 102. For example, the device 100 can be mounted in or onto the gearbox 102 after the device 100 has been assembled.

[0036] According to one or more embodiments of the present disclosure, the stator end windings on the left side of the stator 120 may be less than about 24 mm, and the surface of the closure plate 135 facing the stator 120 may be flat.

[0037] In some aspects, the stator end windings on the right side of the stator 120 may be relatively longer compared to the stator end windings on the left side due to the fact that the torque converter 125 has a smaller diameter than the inner diameter of the stator lamination of the stator 120.

[0038] Lines 121 of the stator 120 are removable and can be connected to an inverter 700 (see below). Fig.(7A illustrated), connectable. In one exemplary aspect, the leads 121 are mounted on the right side of the stator 120 (and consequently the device 100) to accommodate a case where the conductor area has a busbar (not illustrated) or series connection extending higher than the stator end windings of the stator 120. Since the surface of the cover plate 135 facing the stator 120 is flat, the clearance on the right side of the cover plate 135 may not be sufficient for a busbar or series connection.

[0039] In some cases, a hairpin stator can typically have longer end windings on the weld side of the hairpins. Therefore, in an exemplary embodiment where the stator 120 is a hairpin-type stator, the welds are located on the right side of the stator 120. Consequently, the leads 121 can extend, for example, from the weld side of the hairpins. In an alternative exemplary embodiment, the stator 120 can be a through-winding hairpin stator, wherein the stator 120 has no weld end.

[0040] According to one or more embodiments of the present disclosure, the device 100 may include a dry damper 170. The dry damper 170 may serve to reduce torsional vibrations within the drive train (e.g., vibrations generated by the drive motor 101 and the electric motor 110). Exemplary aspects of the dry damper 170 are illustrated below and with reference to the Fig. 2A, Fig. 2B, Fig. 5 and Fig. 7A described.

[0041] The device 100 can include a ring 185 on the closure plate 135. In one example, the ring 185 is a sealing component that separates the wet oil cavity from the dry damper 170. The ring 185 can, for example, be made of any material suitable for providing the sealing functionality described herein. The dry damper 170 can be located to the left of the closure plate 135.

[0042] The Fig. 2A and Fig. Figure 2B illustrates exemplary system operating modes of the device 100 and the associated torque current between the P2 module, 105, the torque converter 125, and the dry damper 170 according to one or more embodiments of the present disclosure. The device 100 can support an e-machine-only drive mode and an internal combustion engine plus e-machine drive mode (ICE plus e-machine drive mode).

[0043] With reference to Fig. In the e-machine-only drive mode, the rotor 115, the rotor hub 130 (including the rotor hub base 131), the torque converter 125, the transmission input shaft 155, and sections of the K0 clutch 140 (e.g., friction plates 141-a) carry torque, as indicated by shaded areas “CT”. Furthermore, in the e-machine-only drive mode, the friction plates 141-b, a support element 142, the element 165, and the dry damper 170 do not carry torque, as indicated by shaded areas “NCT”. The direction of the torque is determined by the Fig. 2A illustrated arrows.

[0044] With reference to Fig. 2B carries in the ICE-plus-e machine drive mode the rotor 115, the rotor hub 130 (including the rotor hub foot 131), the torque converter 125, the transmission input shaft 155 and the same sections of the K0 coupling 140, which with reference to Fig.2A, torque, as indicated by shaded areas “CT”. Additionally, the friction plates 141-b, the support element 142, the element 165 and the dry damper 170 carry torque, as indicated by shaded areas “CT”. The direction of the torque is determined by the Fig. 2B illustrated arrows.

[0045] Fig. Figure 3 illustrates an exemplary overview of a hydraulic fluid distribution in the device 100 according to one or more embodiments of the present disclosure.

[0046] With reference to Fig. 3. The torque converter 125 may include a torque converter clutch 127 (hereinafter also referred to as a torque converter lock-up clutch or TCC). The clutch 140 may further include a piston assembly 190 (including pistons) and a centrifugal compensator 195.

[0047] According to one or more embodiments of the present disclosure, the device 100 can distribute hydraulic fluid (hydraulic outputs 305) received by the transmission 102 to components of the device 100 via the transmission input shaft 155. The device 100 can distribute the hydraulic fluid via feeds 310 (hereinafter also referred to as TCC feed), feed 315 (hereinafter also referred to as centrifugal compensator / clutch pack / stator feed), and feed 320 (hereinafter also referred to as K0 pressure feed or K0 high-pressure feed).

[0048] The feeds 310 are high-pressure feeds coming from the gearbox 102. The feeds 310 control the torque converter clutch 127 within the torque converter 125.

[0049] Supply 315 is a low-pressure supply that provides lubrication. Supply 315 is supplied to the centrifugal compensator 195, which is located downstream of the piston assembly 190. Supply 315 also provides cooling 317 (K0 lubrication / cooling) to the clutch pack of the clutch 140. Supply 315 is then routed externally and provides cooling 318 to the end windings (i.e., stator windings) of the P2 module 105.

[0050] The feed 320 is a high-pressure feed supplied by the gearbox 102. The feed 320 controls the actuation of the hydraulic pistons of the piston assembly 190.

[0051] Consequently, the device 100 supports, for example, the supply of the hydraulic outputs 305 (i.e., feeds 310, feed 315, feed 320) through the cross-section of the transmission input shaft 155 and via rotating components to various components of the clutch 140 and the torque converter clutch 127.

[0052] Fig. Figure 4 illustrates aspects of the device 100 according to one or more embodiments of the present disclosure. In the example of the Fig. 4. The locations of the holes 175 allow oil to flow onto the right stator end winding of the stator 120. Each of the rotor hub 130 and rotor hub base 131 can contain respective holes 175 that allow the oil flow.

[0053] With reference to Fig.4 The clutch basket 152 can have holes 176 which allow oil to escape from the clutch basket 152 (e.g. due to centrifugal pressure), enter the main engine cavity and cool the clutch 140, the rotor 115 and finally the stator 120.

[0054] Fig. Figure 5 illustrates exemplary aspects of an axial length 500 of the device 100 according to one or more embodiments of the present disclosure.

[0055] In a non-restrictive example, the axial length 500 from a motor mounting surface 505 of the device 100 to a rear surface 510 of the torque converter 125 can be 221.5 mm. According to one or more embodiments of the present disclosure, the features of the device 100 described herein provide an axial length 500 that is relatively shorter than the respective axial lengths of comparable assemblies comprising a P2 module, a dry damper, a motor (including a rotor and a stator), and a torque converter.

[0056] Fig. Figure 6 illustrates aspects of a K0 clutch 140 (K0 release clutch) of the device 100 according to one or more embodiments of the present disclosure. Aspects of the K0 clutch 140 with reference to the display box 600 are provided in Table 1 below. Table 1 Clutch parameters comment Friction Outer diameter 215 mm Friction inner diameter 195 mm Friction material BW4390 Friction plates per package 4 double-sided (8 friction surfaces) Potential to reduce to 4 or 6 friction surfaces for improved efficiency Torque capacity 780 Nm @ 1200 kPa Target: 780 Nm (Max), 720 Nm (Nom) at 1200 kPa

[0057] Fig.Figure 7A illustrates aspects of the device 100 and an inverter 700 according to one or more embodiments of the present disclosure.

[0058] In one example, the device 100 and the inverter 700 can be included and installed in a vehicle (not illustrated). The inverter 700 is electrically connected to the stator 120 of the electric motor 110, which is part of the device 100. The inverter 700 can convert direct current (DC) power from the vehicle's battery into alternating current (AC) power, and the vehicle can use the AC power to drive the stator windings of the stator 120 and operate the electric motor 110. In some aspects, the inverter 700 can facilitate regenerative braking by converting AC power generated by the electric motor 110 back into DC power, and the vehicle can recharge the battery using the DC power. The detachable connection of the wires to the inverter 700 also facilitates the ease of installation, removal, and maintenance of the device 100.

[0059] According to one or more embodiments of this disclosure, the bolts 123 for securing the electric motor 110 to the cover plate 135 of the module 105 can be positioned according to a motor bolt pattern. Based on the motor bolt pattern, sections 136 (bumps) of the cover plate 135 can extend beyond the diameter of the dry damper 170. The sections 136 (bumps) can serve as a reference for thread engagement, and embodiments of this disclosure are not limited to the exemplary sizes, shapes, and positions illustrated herein. For example, embodiments of this disclosure may involve modifying the motor bolt pattern such that the sections 136 (bumps) are enlarged without interfering with the operation of the device 100.

[0060] Fig.Figure 7B illustrates aspects of attaching the device 100 according to one or more embodiments of the present disclosure. With reference to Fig. 7B the pin 180 can be removed and inserted into a hole in the rotor hub foot 131 and in the torque converter 125, locking the torque converter 125 in the rotation position.

[0061] Fig. Figure 8 illustrates an example of a ring mounting of the torque converter 125.

[0062] In one example, a weld 129 on the torque converter 125 can connect the torque converter 125 to the rotor hub 130. In some aspects, the weld 129 can be a relatively simple ring (e.g., a snap ring) connected to the outer or inner diameter of the rotor hub base 131. In some embodiments, the weld 129 on the torque converter 125 can be attached via a fastening mechanism 182. Non-limiting examples of the fastening mechanism 182 include a pin, a screw, a setscrew, or the like.

[0063] Fig. Figure 9 illustrates an exemplary flowchart of a method 900 according to one or more embodiments of the present disclosure. The method 900 is described with reference to the device 100 described herein.

[0064] Method 900 supports a process for accessing the clutch basket of device 100, which allows a user to maintain or repair the clutch basket.

[0065] For block 905, procedure 900 involves removing bolts 123.

[0066] For block 910, procedure 900 involves removing the stator assembly (i.e., the complete structure of the stator 120, including the core and windings).

[0067] In block 915, procedure 900 involves separating the torque converter 125 from the rotor hub 130.

[0068] In some embodiments, separating the torque converter 125 from the rotor hub 130 may initially require the removal of a pin 180 (as described with reference to Fig. 7B) or an attachment mechanism 182 (as described with reference to Fig.8 described) and then include separating the torque converter 125 from the rotor hub 130.

[0069] Additionally or alternatively, separating the torque converter 125 from the rotor hub 130 may involve prying the torque converter 125 off the rotor hub 130 using a tool as described herein.

[0070] Embodiments of the present disclosure support the reassembly of the device 100 in a reverse order to the method 900 described herein.

[0071] As described herein, embodiments of the present disclosure can provide a P2 module 105 in which an included component (e.g., a defective component) can be removed from the P2 module 105 and replaced within the P2 module 105 without replacing other components of the P2 module 105. Aspects of the P2 module 105 support the removal of any or all of the included components and, similarly, the reassembly of any or all of the same removed components back into the P2 module 105.

[0072] For some other P2 modules, for example, if one component fails (e.g., a faulty torque converter, stator, or clutch), the entire assembly is replaced. Therefore, for some other P2 modules, the electric motor (which includes the stator and rotor assemblies), the torque converter, and the clutch are a permanently attached set of components, and failure of any one component would necessitate assembling a completely new P2 module from permanently attached components.

[0073] As described herein, according to one or more embodiments of the present disclosure, a device 100 is provided which includes a P2 module 105 for a vehicle.

[0074] The P2 module 105 includes: an electric motor 110, which includes a stator 120 and a rotor 115; and a torque converter 125, which is operatively coupled to the electric motor 110, wherein an inner diameter of the stator 120 in a radial direction is larger than an outer diameter of the torque converter 125 in the radial direction.

[0075] In some aspects, the stator 120 can be removed from the P2 module 105 in an axial direction without removing the torque converter 125 from the P2 module 105.

[0076] The P2 module 105 can further include a plate structure located at a first axial end of the P2 module 105, wherein: the stator 120 is detachably mounted on the plate structure; and the torque converter 125 is located at a second axial end of the P2 module 105.

[0077] In some aspects, the surface of the plate structure associated with the stator 120 is flat.

[0078] The P2 module 105 can also include a rotor hub 130, wherein the torque converter 125 is removablely coupled to the rotor hub 130.

[0079] In some aspects, removing the stator 120 from the P2 module 105 exposes at least a section of the rotor hub 130 and at least a section of the torque converter 125; and the torque converter 125 is removable from the P2 module 105 in a state in which at least a section of the rotor hub 130 and at least a section of the torque converter 125 are exposed.

[0080] In some aspects, the rotor hub 130 includes a rotor hub foot 131; a hole defined in the rotor hub foot 131 penetrates the rotor hub foot 131 and a section of the torque converter 125; and the torque converter 125 is removably coupled to the rotor hub foot 131 by a pin 180 or a screw which is removably inserted into the hole.

[0081] In some aspects, the torque converter 125 is removablely coupled to the rotor hub 130 by a snap ring 185; and the snap ring 185 is radially compressible and is radially received in a groove formed in the torque converter 125 or the rotor hub 130.

[0082] In some aspects, the rotor hub 130 includes a rotor hub foot 131 defined by one or more angular segments; the torque converter 125 is in removable contact with the rotor hub foot 131 at the one or more angular segments; and the torque converter 125 is removable from the rotor hub foot 131 based on the pressure applied to one or more lever points corresponding to the one or more angular segments.

[0083] In some aspects, the hybrid module 105 can include a clutch 140 containing oil and configured to selectively engage the electric motor 110 with the torque converter 125, wherein at least part of the oil flows from the clutch 140 to the stator 120 of the electric motor 110 through one or more openings defined by the one or more angular section segments.

[0084] The P2 module 105 can further include a clutch 140 containing oil and configured to selectively engage the electric motor 110 with the torque converter 125, wherein: the rotor hub 130 includes one or more holes penetrating the rotor hub 130; and at least a portion of the oil flows from the clutch 140 to the stator 120 of the electric motor 110 through the one or more holes.

[0085] In some aspects, the rotor hub 130 includes a rotor hub foot 131 that extends outwards in a radial direction perpendicular to an axial direction of the P2 module 105; the rotor hub foot 131 is configured to prevent movement of the rotor 115 in the axial direction; and the rotor hub foot 131 is configured to prevent movement of the torque converter 125 in a direction opposite to the axial direction.

[0086] In some aspects, the rotor hub 130 includes a rotor hub foot 131; and the outer diameter of the rotor hub foot 131 in the radial direction is dimensioned such that the rotor hub foot 131 does not overlap the magnets 116 of the rotor 115.

[0087] In some aspects, the stator 120 includes a first set of end windings and a second set of end windings; the second set of end windings is closer to the torque converter 125 compared to the first set of end windings; and the second set of end windings is relatively longer in an axial direction of the P2 module 105 compared to the first set of end windings.

[0088] In some aspects, the stator 120 includes a first set of end windings and a second set of end windings; the first set of end windings is relatively farther away from the torque converter 125 compared to the second set of end windings; and the length of each end winding of the first set of end windings is less than 24 mm.

[0089] The P2 module 105 can further include a busbar which is electrically coupled to lines 121 of the stator 120, wherein the lines 121, the busbar or both are located on an axial side of the P2 module 105 which is associated with the torque converter 125.

[0090] The P2 module 105 may further include: a clutch 140 configured to selectively engage the torque converter 125 with one or more of the electric motor 110 and a drive motor 101 of the vehicle; and an input shaft 155 of the transmission 102 operatively coupled to the clutch 140, the torque converter 125 and a transmission 102 of the vehicle, wherein the P2 module 105 is configured to distribute hydraulic fluid from the transmission 102 to one or more of the electric motor 110, the clutch 140 and the torque converter 125 via the input shaft 155 of the transmission 102.

[0091] The P2 module 105 may further comprise: a fixture assembly, wherein the electric motor 110 and a rotor hub 130 form a section of the fixture assembly and are coupled together; and a dry damper 170, which is operatively coupled to the fixture assembly and a drive motor 101 of the vehicle, wherein: the fixture arrangement is located between the dry damper 170 and the torque converter 125 in an axial direction of the P2 module 105; a motor mounting surface 505 of the P2 module 105 is defined by an end of the dry damper 170 that faces away from the fixture assembly; a rear surface 510 of the P2 module 105 is defined by an end of the torque converter 125 that faces away from the fixture assembly; and an axial length of 500 from the motor mounting surface 505 to the rear surface 510 fulfills a target area.

[0092] The P2 module 105 can further include a clutch 140 configured to selectively engage the torque converter 125 with one or more of the electric motor 110 and a drive motor 101 of the vehicle, wherein the P2 module 105 is configured to transmit power to a transmission 102 of the vehicle via the torque converter 125 based on the selective engagement of the torque converter 125 with one or more of the electric motor 110 and the drive motor 101.

[0093] In the descriptions of the flowcharts herein, operations may be performed in a different order than shown, or the operations may be performed in different orders or at different times. Certain operations may also be omitted from the flowcharts, one or more operations may be repeated, or other operations may be added to the flowcharts.

[0094] Some embodiments of the above disclosure are set forth below.

[0095] Embodiment 1. A hybrid module for a vehicle comprising: an electric motor comprising a stator and a rotor; and a torque converter operatively coupled to the electric motor, wherein an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction.

[0096] Embodiment 2. The hybrid module according to a previous embodiment, wherein the stator can be removed from the hybrid module in an axial direction without removing the torque converter from the hybrid module.

[0097] Embodiment 3. Hybrid module according to a previous embodiment, further comprising a plate structure located at a first axial end of the hybrid module, wherein: the stator is detachably mounted to the plate structure; and the torque converter is located at a second axial end of the hybrid module.

[0098] Embodiment 4. Hybrid module according to claim 3, wherein a surface of the plate structure facing the stator is flat.

[0099] Embodiment 5. Hybrid module according to a previous embodiment, further comprising a rotor hub, wherein the torque converter is removably coupled to the rotor hub.

[0100] Embodiment 6. Hybrid module according to a previous embodiment, wherein: removing the stator from the hybrid module exposes at least a section of the rotor hub and at least a section of the torque converter; and the torque converter is removable from the hybrid module in a state in which at least the section of the rotor hub and at least the section of the torque converter are exposed.

[0101] Embodiment 7. Hybrid module according to a previous embodiment, wherein: the rotor hub comprises a rotor hub foot; a hole defined in the rotor hub foot penetrates the rotor hub foot and a section of the torque converter; and the torque converter is removably coupled to the rotor hub foot by a pin or screw removably inserted into the hole.

[0102] Embodiment 8. Hybrid module according to a previous embodiment, wherein: the torque converter is removably coupled to the rotor hub by a snap ring; and the snap ring is radially compressible and is radially received within a groove formed in the torque converter or the rotor hub.

[0103] Embodiment 9. Hybrid module according to a previous embodiment, wherein: the rotor hub comprises a rotor hub foot defined by one or more angular segments; the torque converter is in removable contact with the rotor hub foot at one or more angular segments; and the torque converter is removable from the rotor hub foot based on pressure applied to one or more release points corresponding to the one or more angular segments.

[0104] Embodiment 10. Hybrid module according to claim 9, further comprising: a coupling comprising oil and configured to selectively engage the electric motor with the torque converter, wherein at least a portion of the oil flows from the coupling to the stator of the electric motor through one or more openings defined by the one or more angular segments.

[0105] Embodiment 11. Hybrid module according to a previous embodiment, further comprising: a clutch comprising oil and configured to selectively engage the electric motor with the torque converter, wherein: the rotor hub comprises one or more holes penetrating the rotor hub; and at least a portion of the oil flows from the clutch to the stator of the electric motor through the one or more holes.

[0106] Embodiment 12. Hybrid module according to a previous embodiment, wherein: the rotor hub comprises a rotor hub foot extending outwards in a radial direction perpendicular to an axial direction of the hybrid module; the rotor hub foot is configured to prevent movement of the rotor in the axial direction; and the rotor hub foot is configured to prevent movement of the torque converter in a direction opposite to the axial direction.

[0107] Embodiment 13. Hybrid module according to a previous embodiment, wherein: the rotor hub comprises a rotor hub foot; and an outer diameter of the rotor hub foot is dimensioned in the radial direction such that the rotor hub foot does not overlap magnets of the rotor.

[0108] Embodiment 14. Hybrid module according to a previous embodiment, wherein: the stator comprises a first set of end windings and a second set of end windings; the second set of end windings is located relatively closer to the torque converter compared to the first set of end windings; and the second set of end windings of the hybrid module is relatively longer compared to the first set of end windings.

[0109] Embodiment 15. Hybrid module according to a previous embodiment, wherein: the stator comprises a first set of end windings and a second set of end windings; the first set of end windings is relatively farther away from the torque converter compared to the second set of end windings; and the length of each end winding of the first set of end windings is less than 24 mm.

[0110] Embodiment 16. Hybrid module according to a previous embodiment, further comprising a busbar electrically coupled to lines of the stator, wherein the lines, the busbar or both are located on an axial side of the hybrid module associated with the torque converter.

[0111] Embodiment 17. Hybrid module according to a previous embodiment, further comprising: a clutch configured to selectively engage the torque converter with one or more of the electric motors and a drive motor of the vehicle; and a transmission input shaft operatively coupled to the clutch, the torque converter and a transmission of the vehicle, wherein the hybrid module is configured to distribute hydraulic fluid from the transmission to one or more of the electric motors, the clutch and the torque converter via the transmission input shaft.

[0112] Embodiment 18. Hybrid module according to a previous embodiment, further comprising: a device assembly, wherein the electric motor and a rotor hub form a section of the device assembly and are coupled to each other; and a dry damper, which is operatively coupled to the device assembly and a drive motor of the vehicle, wherein: the device assembly is located between the dry damper and the torque converter in an axial direction of the hybrid module; a motor mounting surface of the hybrid module is defined by an end of the dry damper facing away from the device assembly; a rear surface of the hybrid module is defined by an end of the torque converter facing away from the device assembly; and an axial length from the motor mounting surface to the rear surface fulfills a target area.

[0113] Embodiment 19. Hybrid module according to a previous embodiment, further comprising a clutch configured to selectively engage the torque converter with one or more of the electric motors and a drive motor of the vehicle, wherein the hybrid module is configured to transmit power to a transmission of the vehicle via the torque converter based on the selective engagement of the torque converter with one or more of the electric motors and the drive motor.

[0114] Embodiment 20 Device assembly comprising: an electric motor comprising a stator and a rotor; a torque converter coupled to the electric motor, wherein an inner diameter of the stator is larger in a radial direction than an outer diameter of the torque converter in the radial direction.

[0115] Embodiment 21. Hybrid module for a vehicle comprising: an electric motor comprising: a stator; and a rotor comprising a rotor hub; and a torque converter operatively coupled to the electric motor, wherein the torque converter is removably coupled to the rotor hub; wherein: an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction; an outer diameter of a rotor hub foot of the rotor hub in the radial direction is dimensioned such that the rotor hub foot does not overlap magnets of the rotor.

[0116] The use of the terms "a" and "the" and similar references in the description of the invention (particularly in the context of the following claims) must be interpreted as covering both the singular and the plural, unless otherwise stated herein or the plain text clearly contradicts this. Furthermore, it should be noted that the terms "first," "second," and the like do not denote any order, quantity, or significance herein, but are instead used to distinguish one element from another. The terms "about," "essentially," and "generally" are intended to encompass the degree of error associated with measurements of the specified quantity based on equipment available at the filing date of the application. For example, "about" and / or "essentially" and / or "generally" may encompass a range of ± 8% of a given value.

[0117] The teachings of this disclosure can be applied in a variety of well operations. These operations may involve the use of one or more treatment agents to treat a formation, fluids present in a formation, a well, and / or equipment in the well, such as casing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents may include, but are not limited to, fracking fluids, acids, steam, water, brine, corrosion inhibitors, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers, etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acid treatment, steam injection, water flooding, cementing, etc.

[0118] Although the invention has been described with reference to a preferred embodiment or embodiments, the person skilled in the art understands that various modifications can be made and equivalents for its elements can be used without departing from the scope of protection of the invention. Furthermore, many modifications can be made to adapt the teachings of the invention to a particular situation or material without deviating from its essential scope. The invention is therefore not intended to be limited by the particular embodiment considered to be the best way of carrying out this invention, but rather includes all embodiments that fall within the scope of the claims.The drawings and description also disclose exemplary embodiments of the invention and, although specific terms may have been used, unless otherwise stated, they are used only in a generic and descriptive sense and not for the purpose of limitation, so that the scope of protection of the invention is not limited in this way.

[0119] The term "approximately" is intended to encompass the degree of error associated with measurements of the specified quantity based on equipment available at the time of filing the application. For example, "approximately" may encompass a range of ± 8% of a given value.

Claims

[1] Hybrid module for a vehicle comprising: an electric motor comprising a stator and a rotor; and a torque converter that is operatively coupled to the electric motor, where the inner diameter of the stator is larger in a radial direction than the outer diameter of the torque converter in the radial direction. [2] Hybrid module according to claim 1, wherein the stator can be removed from the hybrid module in an axial direction without removing the torque converter from the hybrid module. [3] Hybrid module according to claim 1, further comprising a plate structure located at a first axial end of the hybrid module, wherein: the stator is removable and mounted to the plate structure; and the torque converter is located at a second axial end of the hybrid module. [4] Hybrid module according to claim 3, wherein a surface of the plate structure facing the stator is flat. [5] Hybrid module according to claim 1, further comprising a rotor hub, wherein the torque converter is removably coupled to the rotor hub. [6] Hybrid module according to claim 5, wherein: Removing the stator from the hybrid module exposes at least a section of the rotor hub and at least a section of the torque converter; and the torque converter is removable from the hybrid module in a state in which at least the section of the rotor hub and at least the section of the torque converter is exposed. [7] Hybrid module according to claim 5, wherein: the rotor hub includes a rotor hub foot; a hole defined in the rotor hub base, penetrating the rotor hub base and a section of the torque converter; and The torque converter is removablely coupled to the rotor hub base by a pin or screw that is removablely inserted into the hole. [8] Hybrid module according to claim 5, wherein: the torque converter is removablely coupled to the rotor hub by a snap ring; and the snap ring is radially compressible and radially within a groove formed in the torque converter or rotor hub, has been recorded. [9] Hybrid module according to claim 5, wherein: the rotor hub includes a rotor hub foot, which is formed by one or is defined by several angle segments; the torque converter is in removable contact with the rotor hub base at one or more angular sections; and The torque converter is applied to the rotor hub base based on pressure that can be removed at one or more lever points corresponding to one or more angular segments. [10] Hybrid module according to claim 9, further comprising: a coupling comprising oil and configured to selectively engage the electric motor with the torque converter, wherein at least a portion of the oil flows from the coupling to the stator of the electric motor through one or more openings defined by the one or more angular subsections. [11] Hybrid module according to claim 5, further comprising: a clutch that includes oil and is configured to selectively engage the electric motor with the torque converter, where: the rotor hub includes one or more holes that penetrate the rotor hub; and at least some of the oil flows from the clutch to the stator of the electric motor through one or more holes. [12] Hybrid module according to claim 5, wherein: the rotor hub includes a rotor hub foot that extends outwards in a radial direction perpendicular to an axial direction of the hybrid module; the rotor hub foot is configured to prevent movement of the rotor in the axial direction; and the rotor hub foot is configured to prevent movement of the torque converter that is opposite to the axial direction. [13] Hybrid module according to claim 5, wherein: the rotor hub includes a rotor hub foot; and The outer diameter of the rotor hub foot is dimensioned in the radial direction such that the rotor hub foot does not overlap the magnets of the rotor. [14] Hybrid module according to claim 1, wherein: the stator comprises a first set of terminal windings and a second set of terminal windings; the second set of end windings is relatively closer to the torque converter compared to the first set of end windings; and The second set of end windings in an axial direction of the hybrid module is relatively longer compared to the first set of end windings. [15] Hybrid module according to claim 1, wherein: the stator comprises a first set of terminal windings and a second set of terminal windings; the second set of end windings is relatively farther away from the torque converter compared to the first set of end windings; and a length of each end turn of the first set of end turns is less than 24 mm. [16] Hybrid module according to claim 1, further comprising a busbar electrically coupled to lines of the stator, wherein the lines, the busbar or both are located on an axial side of the hybrid module which is associated with the torque converter. [17] Hybrid module according to claim 1, further comprising: a clutch configured to selectively engage the torque converter with one or more of the vehicle's electric motors and a drive motor; and a transmission input shaft that is operatively coupled to the clutch, torque converter and transmission of the vehicle, the hybrid module is configured to supply hydraulic fluid from the transmission to one or more of the electric motors, the clutch and to distribute the torque converter via the transmission input shaft. [18] Hybrid module according to claim 1, further comprising: a device assembly, wherein the electric motor and a rotor hub form a section of the device assembly and are coupled to each other; and a dry damper that is operatively coupled to the device assembly and a drive motor of the vehicle, where: the device assembly between the dry damper and the torque converter is located in an axial direction of the hybrid module; a motor mounting surface of the hybrid module is defined by an end of the dry damper that is facing away from the fixture assembly; a rear surface of the hybrid module is defined by an end of the torque converter facing away from the fixture assembly; and An axial length from the motor mounting surface to the rear surface fulfills a target area. [19] Hybrid module according to claim 1, further comprising a clutch configured to selectively engage the torque converter with one or more of the electric motors and a drive motor of the vehicle, wherein the hybrid module is configured to transfer power to a transmission of the vehicle via the torque converter based on the selective engagement of the torque converter with one or more of the electric motors and the drive motor. [20] Drive assembly comprising the following: an electric motor comprising a stator and a rotor; a torque converter that is operatively coupled to the electric motor, where the inner diameter of the stator is larger in a radial direction than the outer diameter of the torque converter in the radial direction. [21] Hybrid module for a vehicle comprising the following: an electric motor that includes the following: a stator; and a rotor that includes a rotor hub; and a torque converter which is operatively coupled to the electric motor, wherein the torque converter is removablely coupled to the rotor hub; where: an inner diameter of the stator in a radial direction is larger than an outer diameter of the torque converter in the radial direction; The outer diameter of a rotor hub foot of the rotor hub is dimensioned in the radial direction such that the rotor hub foot does not overlap the magnets of the rotor.

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