Bracket for supporting an electric motor and method for manufacturing the same

Abstract

The present invention relates to a bracket (10) for supporting an electric motor on a vehicle chassis, the bracket (10) comprising a first half shell (12) defining a first half space (20) and a second half shell (14) defining a second half space (22), the first half shell (12) and the second half shell (14) being made of a plastic material, particularly a polymer material, and the first half shell (12) and the second half shell (14) being fixed to each other, preferably by welding, to define a cavity within the bracket (10) that includes the first half space (20) and the second half space (22).

Description

Technical Field

[0001] The present invention relates to a bracket for supporting an electric motor on a vehicle chassis, the bracket being made of a plastic material. The present invention further relates to a method for manufacturing a bracket for supporting an electric motor on a vehicle chassis, the bracket being manufactured from a plastic material.

Background Art

[0002] In recent years, the development of electric vehicles has advanced, and it has become more common to see electric vehicles on the streets. The electric motor, which is the power source of an electric vehicle, exhibits a different vibration range from that of a general internal combustion engine. Therefore, even if they have similar characteristics regarding vibration damping or absorption, the means for supporting an internal combustion engine cannot be adopted for supporting an electric motor. In particular, the vibration generated by an electric motor cannot be reliably damped / absorbed by using an absorber / damper for an internal combustion engine. As a result, a new support for an electric motor, such as that described in German Patent Application Publication No. 10 2013 109 352, has been developed.

[0003] An object of the present invention is to provide a bracket for supporting an electric motor on a vehicle chassis, which can satisfactorily damp / absorb the vibration generated from the electric motor. Further, it is an object to provide a manufacturing method for such a bracket.

[0004] This object is solved not only by the bracket according to claim 1, but also by the method according to claim 12. Preferred embodiments of the present invention are described in the dependent claims.

Summary of the Invention

Problems to be Solved by the Invention

[0005] The bracket for supporting an electric motor on a vehicle chassis includes a first half shell defining a first half space and a second half shell defining a second half space. The first half shell and the second half shell are made of a plastic material, particularly a polymer material. The first half shell and the second half shell are preferably fixed to each other by welding so as to define a cavity including the first half space and the second half space within the bracket.

[0006] A method for manufacturing a bracket for supporting an electric motor on a vehicle chassis includes manufacturing, preferably molding, a first half shell defining a first half space and a second half shell defining a second half space, wherein the first half shell and the second half shell are made of a plastic material, and fixing the first half shell to the second half shell, preferably by welding, so that the first half shell and the second half shell define a cavity including the first half space and the second half space within the bracket.

[0007] The assembly includes the above bracket and an electric motor, and the bracket is attached to the electric motor to support the electric motor.

[0008] The bracket having a hollow body defined by the cavity and made of a plastic material has flexibility or elasticity capable of attenuating and / or absorbing the vibration of the electric motor in the range between 750 Hz and 2000 Hz. As a result, the bracket itself provides attenuation / absorption characteristics in the frequency range between 750 Hz and 2000 Hz due to its selected material and shape. Assuming that the electric motor generates structure-borne sound having frequencies in the range from 1 Hz to 2000 Hz, about half of the generated frequency range can be attenuated and / or absorbed by the bracket itself due to the selected material and shape.

[0009] Furthermore, the bracket can be easily manufactured by manufacturing or molding two half-shells that are fixed to each other. Moreover, the bracket for supporting the electric motor is hollow, thus being lightweight while having sufficient strength to support a considerable weight of the electric motor.

[0010] For manufacturing the bracket, screws or other fixing means are not necessary. As a result, the assembly process of the bracket is significantly simplified, and the number of parts of the bracket can be reduced.

[0011] Also, the bracket for supporting the electric motor on the vehicle chassis can be understood as a support, a mount, or means for supporting the electric motor on the vehicle chassis. Further, the bracket may be configured to receive the torque load generated by the electric motor. The chassis is any component or part of the vehicle that can withstand the weight of the electric motor.

[0012] The vehicle is preferably an electric vehicle or a hybrid vehicle consisting of both an electric motor and an internal combustion engine. An electric vehicle is driven only by the power generated by at least one electric motor. The electric motor is any electric motor capable of converting electrical energy into rotational motion. Any electric motor capable of driving an electric vehicle can be regarded as an electric motor in the understanding of this application. The electric motor can generate (structure-borne) vibrations in the frequency range between 1 Hz and 2000 Hz during operation. The electric motor or electric motors are preferably provided to supply power to the vehicle, that is, to supply power for driving the vehicle.

[0013] The bracket may preferably be composed of only a first half-shell and a second half-shell. The first half-shell defines a first half-space. The first half-space is a space that opens only in one direction. The first half-space may be opened only in one plane so as to be closed by a first surface provided by the first half-space spanning a solid angle of 180°. Similarly, the second half-shell may also be opened only in one direction so that a second half-space is defined by a second surface provided by the second half-shell spanning a solid angle of 180°.

[0014] The bracket is manufactured by bonding the first half-shell and the second half-shell so that the respective openings of the first half-shell and the second half-shell are in contact with each other. This means that when the bracket is completely manufactured, the first half-space and the second half-space communicate with each other, and the cavity provided in the bracket is defined by the first half-shell and the second half-shell. In particular, the first surface of the first half-shell and the second surface of the second half-shell (alone) define a cavity. The first half-shell and / or the second half-shell may exhibit a convex shape.

[0015] The first half-shell and the second half-shell may be identical to each other except for their chirality. That is, the first half-shell and the second half-shell are similar to each other like a right hand and a left hand. Thereby, the molds for forming the first half-shell and the second half-shell can be made similar to each other, and the manufacturing process can be simplified.

[0016] However, the first half shell and the second half shell may have different configurations. For example, the second half shell provides the main structure of the bracket, and the first half shell is basically a lid for closing the second half shell. In this regard, the first half space may be defined by the convex shape of the first half shell.

[0017] The first half shell and the second half shell are preferably fixed to each other along a line surrounding the opening surface of their respective half spaces, that is, a line adjacent to the second half space and the first half space respectively. The first half shell and the second half shell are preferably fixed to each other by welding, particularly hot gas welding, but other means such as adhesion may also be used. Also, the second half space of the second half shell can be defined particularly by the wall surrounding the second half space. The first half shell may be configured such that a planar or convex first surface (excluding the wall as the second half shell) is fixed to the wall of the second half shell.

[0018] The first half shell and the second half shell may each include a contact area surrounding the opening surface of the first half space and the second half space. The first half space and the second half space are fixed to each other in the contact area. The contact area may be linear or strip-shaped, such as the end face of the wall described above, for example.

[0019] The first half shell and / or the second half shell may have an L-shaped configuration, and the bracket also has an L-shaped configuration. However, other shapes may also be used. The shape of the bracket depends on the shapes of the electric motor and the chassis. The shape of the bracket is adapted for optimal support of the electric motor to the chassis.

[0020] The first half-shell and the second half-shell are made of a rigid plastic material. In particular, the first half-shell and the second half-shell are made of the same plastic material. The plastic material may be a polymer-plastic material that can be fiber-reinforced, particularly by short glass fibers. The first half-shell and / or the second half-shell can optionally be made of a thermoplastic material reinforced by short glass fibers or a thermoplastic material reinforced by continuous fibers. The specific material and final shape of the bracket are selected and designed so as to achieve optimal attenuation characteristics of solid-borne sound in the frequency range between 750 Hz and 2000 Hz. The first half-shell and the second half-shell are preferably attached to each other by hot gas welding.

[0021] Preferably, the first half-shell and / or the second half-shell are reinforced by ribs, and preferably, the ribs are integrally formed with the first half-shell and / or the second half-shell.

[0022] The ribs preferably increase the strength and / or rigidity of the assembled bracket. More preferably, the ribs reinforce the first surface and / or the second surface. In particular, since the bracket is a hollow member, the ribs help to provide the necessary strength while minimizing the weight of the bracket. The ribs may partition the first half-space and / or the second half-space into small compartments. The ribs may be arranged only on the first half-shell or the second half-shell, for example, if one of the half-shells is designed as a "lid".

[0023] The ribs preferably extend in a (straight) linear manner. Furthermore, the number, arrangement, thickness and / or direction of the ribs are preferably set such that an optimum strength of the bracket can be achieved for supporting the electric motor on the chassis. As a result, the parameters defining the ribs strongly depend on the shape, weight distribution and / or weight of the electric motor supported on the chassis. The ribs may be determined using a simulation program for calculating the optimum arrangement of the ribs.

[0024] The ribs may be separate elements from the first half-shell and / or the second half-shell. In a preferred embodiment, the ribs are integrally formed with the first half-shell and / or the second half-shell. The ribs are preferably manufactured in the same molding step as the first half-shell and the second half-shell. However, the ribs can also be manufactured in a separate manufacturing step and then attached to the first half-shell and / or the second half-shell, for example by welding. The ribs may be manufactured from the same material as the first half-shell and / or the second half-shell, in particular a thermoplastic material optionally reinforced with short glass fibers. It is preferred that both the first half-shell and the second half-shell are provided with ribs. However, only the first half-shell or only the second half-shell can also be provided with ribs.

[0025] The ribs are preferably arranged only in the respective first half-space and second half-space so as not to protrude in the direction from the first half-shell and the second half-shell towards the other half-shell. For example, the depth of the ribs corresponds to the depth of the first half-shell and / or the second half-shell. The ribs of one half-shell can contact the ribs of the other half-shell when fixing the first half-shell to the second half-shell.

[0026] The bracket preferably includes a damper disposed within the cavity, and more preferably, the damper includes a vibrating mass and a first elastic member attached to the bracket and the vibrating mass.

[0027] Preferably, the damper comprises a vibrating mass and a first elastic member disposed between the bracket and the vibrating mass. More preferably, the damper is provided to absorb / damp the vibrations generated from the electric motor. In particular, the damper is provided to shift or reduce the natural frequency of the bracket induced by the vibrations generated from the electric motor. The damper is preferably provided at the position where the bracket exhibits the highest natural mode amplitude. This position may be calculated by simulation or measured using a prototype bracket. The damper is preferably provided to attenuate / absorb vibrations in the frequency band from 400 Hz to 750 Hz generated from the electric motor.

[0028] The vibrating mass may be a metal part. Generally, the vibrating mass is made of a material heavier than that of the bracket, i.e., a material having a high density. The vibrating mass vibrates relative to the bracket by the first elastic member. The first elastic member is disposed between the vibrating mass and the bracket. For example, the vibrating mass is attached to the bracket by the first elastic member. Thus, the vibrating mass acts as a mass that can vibrate relative to the bracket to absorb the vibrations of the bracket itself or shift the natural frequency.

[0029] The first elastic member is preferably made of an elastic material, and preferably, the first elastic member includes a layer surrounding the vibrating mass.

[0030] The elastic material of the first elastic member may be a thermoplastic elastomer (TPE) and is formed in layers. Preferably, the vibrating mass has a cubic or rectangular parallelepiped shape. More preferably, the first elastic member is disposed on at least two opposite surfaces of the vibrating mass. Preferably, the first elastic member completely surrounds the vibrating mass.

[0031] In a preferred embodiment, the first elastic member has a two-part configuration. The first elastic member may include a first portion and a second portion that is separate from the first portion. The first portion of the elastic member may surround the vibrating mass on all surfaces except one surface. For example, in the case of a cubic vibrating mass, the first portion of the first elastic member covers five surfaces of the cubic vibrating mass.

[0032] The second portion of the first elastic member covers the side surface of the vibrating mass that is not covered by the first portion of the first elastic member. As a result, it becomes possible to insert the vibrating mass into the first portion of the first elastic member. In the second step, the side surface that is not covered by the first elastic member is covered by the second portion of the first elastic member. In this way, the vibrating mass can be held in a shape-fixed manner without being fixed to the first elastic member.

[0033] The first elastic member is disposed between the vibrating mass and a damper wall integrally formed with the first half shell and / or the second half shell, and it is preferable that a part of the first elastic member and the second half shell are manufactured simultaneously by a two-shot injection molding process.

[0034] Among the first elastic members, the portion manufactured simultaneously with the second half shell by the two-shot injection molding process may be the first portion as described above. The second component may be manufactured by another molding process or may be manufactured simultaneously with the first half shell by the two-shot injection molding process. In the latter case, the second portion of the first elastic member is fixed to the first half shell. As a result, the vibrating mass can be positively blocked within the bracket when the first half shell is fixed to the second half shell.

[0035] The damper wall may protrude from the second surface of the second half-shell into the second half-space. That is, the damper wall is disposed within the cavity of the bracket. The damper wall may be configured as a part of the rib. Further, the damper wall may have the same configuration as the rib, but may be disposed separately from or instead of the rib. In a preferred embodiment, the damper wall intersects the straight extension of the rib.

[0036] For example, the damper wall surrounds four surfaces of the vibrating mass, and the second surface of the second half-shell covers the vibrating mass from the fifth surface. Generally, the combination of the damper wall and the second half-shell provides a half-space in which the vibrating mass is disposed. In particular, the vibrating mass can vibrate by the elastic member in the half-space defined by the damper wall and the second surface.

[0037] By disposing the first half-shell on the second half-shell, the sixth surface or the opening surface of the half-space defined by the damper wall and the second surface is closed, and the vibrating mass is held in a shape-fixed manner by the bracket. When the first half-shell is attached to the second half-shell, the second portion of the first elastic member is disposed on the vibrating mass between the vibrating mass and the first half-shell.

[0038] The first half-shell optionally includes a pocket. Similar to the damper wall, the bottom of the pocket defines a space where the damper is positively blocked. The pocket may form a plateau in the first half-space to close the space defined by the damper wall. The second portion of the first elastic member may be attached to the bottom of the pocket. The first half-shell including the pocket and the second portion of the first elastic member may be manufactured by a two-shot injection molding process. The pocket may be omitted, and the first outer surface may function as a wall for positively blocking the damper against the damper wall.

[0039] The bracket preferably comprises at least one insulating bush for attaching the electric motor to the bracket. The insulating bush preferably comprises a body made of a rigid material connected to the electric motor, and a second elastic member surrounding the body. More preferably, the second elastic member is disposed between the body and the inner surface of the first opening of the bracket.

[0040] The insulating bush is provided to attenuate / absorb (structure-borne) vibrations in the frequency band from 100 Hz to 400 Hz. The attenuation / absorption characteristics are achieved by the mass of the electric motor elastically attached to the bracket. As a result, the mass of the electric motor functions as a damper / absorber. Optionally, the bracket is fixed only to the electric motor with the insulating bush interposed therebetween.

[0041] A body made of a rigid material is provided for attaching the electric motor to the bracket. For example, the body may be an elongated member having a through-hole along its axial extension for inserting a bolt or a screw capable of attaching the electric motor to the bracket. In other embodiments, the body may be an elongated member protruding from a bracket to which the electric motor can be attached. The body may have a circular or star shape in cross-section.

[0042] The second elastic member is disposed between the bracket and the body to provide elastic movement therebetween. In particular, at least one first opening is disposed in the bracket, which means that both the first half-shell and the second half-shell constitute respective portions of the first opening at the same position, and the body can be inserted into the first opening through the first half-shell in the same manner as the second half-shell. The body may be made of a metal material, or may be made of the same material as the material of the first half-shell and / or the second half-shell.

[0043] The material of the second elastic member may also be TPE. Further, the second elastic member may be configured as a layer surrounding the body. The second elastic member may be fixedly attached to the inner surface of the first opening. In order to support the electric motor on the bracket, it is preferable to provide two or more first openings and two or more insulating bushes. The first opening may be star-shaped in cross-section, but other shapes are also possible.

[0044] Not only the thickness but also the shape in the cross-sectional view of the body and the second elastic member are provided to achieve optimal damping / absorbing characteristics. Since the weight of the electric motor is applied to the first insulating bush, it is preferable that the rib is connected to the first opening. The inner surface of the first opening may be integral with the first half-shell and / or the second half-shell.

[0045] The second elastic member and the second half-shell are preferably manufactured simultaneously by a double injection molding process.

[0046] Thereby, the manufacturing process can be significantly reduced. Note that the body may be inserted into the opening of the second elastic member after the manufacturing process, or may be inserted after the first half-shell and the second half-shell are fixed to each other. The second elastic member may be a layer disposed on the inner surface of the first opening. The second elastic member may completely surround the inner surface of the first opening, or may be disposed at the corner portion of the inner surface of the first opening.

[0047] In a preferred embodiment, the inner surface of the first opening is provided only by the second half-shell. The wall defining the first opening in the second half-shell may protrude from the second half-shell. In particular, the first opening in the first half-shell does not include a wall structure and is simply a through-hole in the first surface. The wall defining the first opening in the second half-shell may extend to the first surface when the first half-shell is fixed to the second half-shell. In this case, the second elastic member can be completely manufactured by a double injection molding process with the second half-shell.

[0048] The wall of the first opening may be integral with the first half-shell and / or the second half-shell. When the first half-shell is fixed to the second half-shell, the first half-shell and the second half-shell may optionally contact each other at the respective walls of the first opening, such that the walls of the first opening provided by the first half-shell and the second half-shell form a continuous inner surface of the first opening.

[0049] The bracket preferably comprises at least one mounting bush for attaching the bracket to the chassis. The bracket preferably includes a protrusion that is disposed at an axial end of the second opening and extends into the second opening to positively block the mounting bush in the second opening when the first half-shell is fixed to the second half-shell.

[0050] The mounting bush is provided to attenuate (structure-borne) vibrations in the range from 1 Hz to 100 Hz. The mounting bush is also referred to as a rubber bush.

[0051] The mounting bush is used to attach the bracket to the chassis. For this purpose, the bracket includes a second opening in which the mounting bush is disposed. Depending on the shape of the bracket and the weight distribution of the electric motor, two or more mounting bushes and second openings may be provided. Optionally, the bracket is fixed only to the chassis with the mounting bush interposed therebetween.

[0052] The first half-shell and the second half-shell preferably each constitute a part of the second opening. The second opening may be formed by a bush wall that extends along the outer periphery of the second opening. The second opening may be circular in cross-section, but may also have other shapes.

[0053] The bush wall may be integral with the first half shell and / or the second half shell. The bush wall of the first half shell and the bush wall of the second half shell optionally contact each other when the first half shell is fixed to the second half shell such that the bush wall forms a continuous inner surface of the second opening.

[0054] The bush wall may be integral with only the second half shell or the first half shell, which means that the bush wall is provided by only one of the first or second half shells. The other of the first and second half shells may include only through holes at the position of the second opening, and the through holes have an inner surface structure that functions as a protrusion at the axial end in each half shell. For example, the diameter of the inner surface structure may be smaller than the outer diameter of the mounting bush. Also, it is possible that each of the other half shells has a reduced thickness at the position of the second opening. For example, each half space extends around the second opening.

[0055] Note that the protrusions may be arranged at the second openings of both the first half shell and the second half shell. In particular, the protrusions are respectively arranged at the axial ends that can be arranged on the same plane of the first outer surface and the second outer surface. Also, the protrusions can be arranged adjacent to the first and / or second outer surfaces.

[0056] The protrusions may be formed as ribs extending circumferentially along the inner surface of the second opening, or preferably as one or more protrusions distributed equidistantly along the outer circumference. The protrusions may be integral with the first half shell and / or the second half shell. The protrusions extend radially so that the mounting bush cannot move axially over the protrusions. For example, the inner diameter of the protrusions is smaller than the outer diameter of the mounting bush at each position along the outer circumference.

[0057] Since this protrusion is arranged at both axial ends of the second opening of the first half shell and the second half shell, when the first half shell and the second half shell are fixed, the mounting bush will be positively blocked within the second opening. As a result, additional means for fixing the mounting bush to the bracket are unnecessary. In particular, there is no need to use an adhesive or bonding agent to fix the mounting bush to the bracket. However, for example, a bonding agent may be used to fix the mounting bush to the bracket in order to enhance the strength or durability of the connection between the mounting bush and the bracket.

[0058] The mounting bush may be manufactured by a process separate from the molding process of the first half shell and the second half shell. The mounting bush only needs to be inserted into the second opening formed in the first half shell or the second half shell.

[0059] The inner surface of the second opening may have a shape adapted to the shape of the mounting bush, that is, a shape in which the shape of the inner surface in cross-sectional view deviates from a circular shape.

[0060] The mounting bush preferably includes a sleeve connected to the chassis and a rubber member surrounding the sleeve, and it is more preferable that the sleeve is made of a rigid material such as a plastic material.

[0061] The sleeve may be an elongated member and is preferably connected to the chassis. The sleeve may be provided with a through hole extending in the axial direction of the sleeve, and a bolt or screw for fixing the sleeve, and thus the bracket, to the chassis can be inserted into this through hole. The sleeve may be made of a rigid material such as a plastic material and is preferably made of the same plastic material as the bracket. Also, the sleeve may be made of a metal material.

[0062] The rubber member is preferably made of a rubber material. It is also possible that the rubber member is made of TPE and / or that the rubber member is manufactured by a two-shot injection molding process together with the first half shell and / or the second half shell. The rubber member is an elastic part of the mounting bush provided to attenuate / absorb vibrations generated by the electric motor and transmitted to the mounting bush via the bracket.

[0063] The sleeve may have a cylindrical outer peripheral surface. However, sleeves of other shapes are also possible. The rubber member may surround the sleeve over the entire circumference of the sleeve. Also, the rubber member may be attached only to the portion of the sleeve disposed in the second opening. The sleeve may project from the bracket on one or both sides of the bracket. Also, the sleeve may be on the same plane as the first and / or second outer surfaces. The rubber member may be fixed to the sleeve, for example, by vulcanizing the rubber member to the sleeve. The sleeve and the rubber member may be manufactured by separate manufacturing processes.

[0064] The bracket preferably includes at least two mounting bushes disposed in respective second openings, and the at least two mounting bushes preferably differ in shape and / or material.

[0065] Note that the two second openings and the two mounting bushes may be arranged on the opposite surface of the bracket. Due to the weight distribution of the electric motor or the arrangement of the bracket, the loads acting on the two mounting bushes may be different. To cope with this difference in load, the two mounting bushes differ in their configuration, particularly in their shape and / or material. For example, one mounting bush that receives a low load is configured with a lower rigidity, such as a material, compared to the other mounting bush that receives a high load. By adopting such a design, the damping characteristics of both mounting bushes can be made equivalent regardless of the loads acting on both mounting bushes. For example, different materials with different rigidities are used for one of the mounting bushes. It is also possible to ensure equivalent damping / absorbing characteristics by making the thickness and volume of the rubber member different between one mounting bush and the other.

[0066] Preferably, the mounting bush includes at least one arm inserted into a recess extending in the radial direction of the second opening, and preferably, the at least two mounting bushes are different in the orientation of the at least one arm.

[0067] The arm of the mounting bush may project directly from the sleeve, or the sleeve may be completely surrounded by a part of the rubber member in the circumferential direction where the arm projects. Preferably, there are three, four, five or six arms. The arms preferably have the same diameter and length, but different directions. Due to the different directions, the effective rigidity of the mounting bush varies depending on the specific direction. In this way, it is possible to provide two different mounting bushes with different rigidities in a specific direction, whereby the two mounting bushes can have a similar directivity. The presence of the arm and the recess can fix the orientation of the mounting bush within the recess.

[0068] The second opening may be provided with recesses arranged along the inner surface of the second opening in order to receive the respective arms of the mounting bush. In particular, the dimensions of the recesses are adapted to the dimensions of the arms. It is preferred that the arms contact the inner surface of the recesses completely, and the arms extend along their radial direction and / or contact the recesses along their outer circumference. The arms may have a rectangular cross-section such that the recesses exhibit a rectangular cross-section.

[0069] The mounting bush may include an outer sleeve disposed on the radially outer circumference of the rubber member. The outer sleeve may be arranged only at regular intervals along the outer circumference. For example, the outer sleeve can be arranged only at the radially outer end of the arm. Also, the outer sleeve may extend over the entire circumference of the rubber member. A part of the rubber member may be fixed only to the sleeve or the outer sleeve.

[0070] The bracket preferably includes an acoustic insulation cover shaped to surround the electric motor, and the acoustic insulation cover is fixedly attached to the bracket.

[0071] The acoustic insulation cover is preferably provided for reducing airborne sound, while the bracket having the above-described components is preferably provided for blocking structure-borne sound. In particular, the acoustic insulation cover is provided for blocking vibrations or noises having frequencies of 2000 Hz or higher, which are recognized as acoustic noises.

[0072] For this reason, the acoustic insulation cover is shaped to particularly surround the electric motor from all sides. Preferably, the acoustic insulation cover completely surrounds the electric motor in order to reduce airborne sound. However, the acoustic insulation cover may be provided with openings, through-holes, and passages necessary for guiding an axis or a wire from the electric motor to the outside through the acoustic insulation cover. Furthermore, the acoustic insulation cover may be provided with openings for ventilation purposes. These holes may be filled with noise reduction materials for reducing acoustic noise, or may be configured to allow air to pass through.

[0073] The acoustic insulation cover may be configured and formed to follow the outer shape of the electric motor, i.e., such that there is no or almost no gap between the electric motor and the acoustic insulation cover. In particular, the acoustic insulation cover may be arranged in contact with or spaced apart from the electric motor. The acoustic insulation cover may be provided with mechanical means for attenuating or canceling airborne sound.

[0074] The acoustic insulation cover is supported by brackets. For example, two brackets may be provided on the acoustic insulation cover. For example, the acoustic insulation cover may be held only by brackets provided on the chassis. However, additional mounting means / mounting portions may be provided on the acoustic insulation cover to support the acoustic insulation cover.

[0075] In particular, the bracket is fixedly attached to the acoustic insulation cover. The acoustic insulation cover may be mechanically fixed to the bracket by fastening elements such as bolts, screws, etc., or by snap-fit connection. Further, the acoustic insulation cover may be fixedly attached to the bracket by adhesion or welding. In particular, after attaching the bracket to the acoustic insulation cover, this assembly may be an integral part.

[0076] The advantage of fixedly attaching the acoustic insulation cover to the bracket is that, due to the solid-borne sound or vibration attenuation ability of the bracket, the acoustic insulation cover is simultaneously separated from the vibrations generated by the electric motor. Therefore, additional attenuation means for separating the acoustic insulation cover from the electric motor are not required.

[0077] The acoustic insulation cover preferably comprises a first insulating half-shell and a second insulating half-shell. More preferably, the first insulating half-shell and the first half-shell are an integral unit part. Even more preferably, the second insulating half-shell is mechanically fixed to the first insulating half-shell.

[0078] Since the acoustic insulation cover is composed of two or more separate members, such as a first insulation half shell and a second insulation half shell, an electric motor can be arranged inside the acoustic insulation cover. This is achieved by arranging the first insulation cover using brackets in the chassis, attaching the electric motor to the brackets, and then attaching the second insulation half shell to the first insulation half shell.

[0079] In particular, the first insulation half shell and the second insulation half shell are fixed to each other so that air-borne sound does not leak at the contact point between the first insulation half shell and the second insulation half shell. The first insulation half shell may be mechanically fixed to the second insulation half shell, for example, by providing fastening means such as screws, bolts, etc., and / or by snap-fit connection. Furthermore, it is also possible for the first insulation half shell to be fixed to the second insulation half shell by means of adhesion or welding.

[0080] When a fastening element is used to attach the first insulation half shell and the second insulation half shell, one of the first and second insulation half shells may be provided with a tongue-like portion having a hole that protrudes above the other of the first and second insulation half shells, so that a further hole is provided at the same position as the hole in the tongue-like portion for the fastening element to be guided through.

[0081] The first insulation half shell and / or the second insulation half shell may each be of a two-part construction. For example, the first insulation half shell and / or the second insulation half shell may be composed of a support member and an insulation member. The support member is made of a rigid material to provide stability and strength, whereby the insulation member is made of a material capable of absorbing, attenuating or canceling the air-borne sound of the respective support member and / or attenuating or absorbing the vibration of the corresponding support member.

[0082] The support member may be made of a thermoplastic material optionally reinforced with glass fibers. The support member may be manufactured by thermoforming. The insulating member may be made of polypropylene or natural fibers, which has the advantage of making the insulating material recyclable. The support member and the insulating member may have the same shape such that the insulating member is adhered or snap-fitted to the support member. Also, the insulating member can cover only a part of the surface of the support member.

[0083] The insulating member may be disposed on the inner surface (the surface facing the electric motor) and / or the outer surface of the support member. In particular, it is also possible to dispose the insulating member on both sides of the support member.

[0084] The bracket, in particular the first half-shell, and the acoustic insulation cover, in particular the first insulating half-shell, preferably the support member, may be of an integral type. In particular, the first insulating half-shell and the first half-shell of the bracket may be manufactured by the same injection molding process. Thus, the insulating half-shell (in particular the support member) and the half-shell of the bracket may be made of the same material.

[0085] Preferably, the acoustic insulation cover comprises an attachment portion for attaching the acoustic insulation cover to the chassis and / or the electric motor, and more preferably the attachment portion comprises an insulating bush and / or a mounting bush.

[0086] The attachment portion is a different element from one or more brackets attached to the acoustic insulation cover for supporting the acoustic insulation cover on the chassis and / or the electric motor. The attachment portion can be made similar to the bracket in terms of the material used and / or the structural configuration. For example, the attachment portion may include ribs for enhancing the strength of the attachment portion. The attachment portion may be mechanically fixed to the acoustic insulation cover, or the attachment portion may be integrated with the acoustic insulation cover, in particular the first insulating half-shell, more particularly the support member.

[0087] The mounting part may be fixed to the first insulating half-shell and / or the second insulating half-shell. The mounting part may provide a connection between the chassis and the electric motor and at the same time support the acoustic insulation cover. The mounting part may serve to support the torque generated by the electric motor and acting on the bracket.

[0088] Also, the mounting part may comprise means for decoupling the vibrations generated by the electric motor from the chassis. In particular, elements similar to those described in connection with the bracket may be used by the mounting part to decouple the electric motor from the chassis. For example, the mounting part may include insulating bushes as described above and / or mounting parts as described above.

[0089] Also, the mounting part may include a first opening for receiving an insulating bush and / or a second opening for receiving a mounting bush. The shape and / or other configuration of the first and second openings of the mounting part is similar to that of the bracket. The mounting part may not show the two-part configuration of the bracket, which is composed of a first half-shell and a second half-shell. The mounting part may be, for example, a molded integral part manufactured by a single injection molding process.

[0090] All embodiments, preferred configurations and advantages described in connection with the bracket apply equally to the method for manufacturing the bracket.

[0091] Step a) of the method described above includes manufacturing the first elastic member of the damper together with the second half-shell by a double injection molding process, and preferably the vibrating member of the damper is attached to the first elastic member.

[0092] Step a) of the above method includes providing at least one first opening in the first half shell and the second half shell, preferably the inner surface of the first opening is covered by a second elastic member, and more preferably the second elastic member and the second half shell are manufactured by a two-shot injection molding process.

[0093] Prior to step b) of the above method, at least one mounting bush for attaching the bracket to the chassis is inserted into a part of a second opening disposed in the first half shell and / or the second half shell. Preferably, the second opening includes a protrusion disposed at an axial end of the second opening and extending into the second opening for positively blocking the mounting bush within the second opening when fixing the first half shell to the second half shell.

[0094] Preferred embodiments of the present invention will be described with reference to the accompanying drawings.

Brief Description of the Drawings

[0095]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Best Mode for Carrying Out the Invention

[0096] FIG. 1 is a perspective view of a bracket 10 used for attaching an electric motor (not shown) to a chassis (not shown) of a vehicle.

[0097] The bracket 10 includes a first half shell 12 and a second half shell 14. The first half shell 12 and the second half shell 14 are preferably made of the same plastic material, preferably a glass fiber reinforced polymer material, optionally a thermoplastic material reinforced with short glass fibers, or optionally a thermoplastic material reinforced with continuous fibers. The first half shell 12 has a first outer surface 16, and the second half shell 14 has a second outer surface 18. When the first half shell 12 is attached to the second half shell 14, the outer surface of the bracket 10 is defined by the first outer surface 16 and the second outer surface 18.

[0098] As can be seen from FIGS. 2, 3, and 4, the first outer surface 16 of the first half shell 12 defines a first half space 20, and the second outer surface 18 of the second half shell 14 defines a second half space 22. As a result, the bracket 10 includes a cavity formed by the first half space 20 and the second half space 22. The first half space 20 and the second half space 22 are open in planes of the first half shell 12 and the second half shell 14 facing each other.

[0099] Each plane is defined and surrounded by a contact area 24. The first half shell 12 and the second half shell 14 are fixed to each other in the contact area 24, preferably by hot gas welding. The contact area 24 may have a linear shape (as shown in FIGS. 2, 3, and 4) or may be strip-shaped. The contact area 24 may be an end face of the first half shell 12 and / or the second half shell 14.

[0100] The first half shell 12 and / or the second half shell 14 comprises a plurality of ribs 26. The ribs 26 may extend along a straight line. The ribs 26 project from the first outer surface 16 and / or the second outer surface 18 into the first half space 20 and the second half space 22, respectively. The depth of the ribs 26 is such that it does not project from the plane defined by the contact area 24. The ribs 26 may be integral with the first half shell 12 and / or the second half shell 14.

[0101] The number, arrangement, and spread of the ribs 26 are such that the first half shell 12 and / or the second half shell 14 are reinforced. Due to the arrangement of the ribs 26, the bracket 10 can support the weight of the electric motor. Further, the manufacture of the bracket 10 requires no additional screws or bolts since the bracket 10 is preferably made from the first half shell 12 and the second half shell 14 which are fixed to each other, preferably by welding.

[0102] The bracket 10 optionally comprises a damper 28. As can be seen particularly from FIG. 2, the damper 28 comprises a vibration mass 30 and a first elastic member 32. The damper 28 is preferably provided in a cavity of the bracket 10. The vibration mass 30 is attached to the bracket 10 by the first elastic member 32. As a result, the vibration mass 30 can vibrate relative to the bracket 10. The damper 28 is provided at a position of the bracket 10 where the amplitude of the natural mode vibration of the bracket 10 is the largest. This position may be calculated or determined by a test routine. The damper 28 is provided to reduce the natural vibration of the bracket 10 or to shift the frequency of the natural mode of vibration of the bracket 10.

[0103] The first elastic member 32 may include a first portion 34 and a second portion 36 that is different from the first portion 34. The oscillating mass 30 may be positively blocked within the bracket 10. The first elastic member 32 may include a layer surrounding the oscillating mass 30. For example, the first portion 34 surrounds the oscillating mass 30 from five sides. The second portion 36 of the first elastic member 32 may cover the oscillating mass 30 on the sixth side of the oscillating mass 30.

[0104] The oscillating mass 30 may be made of a material that is heavier than the material of the bracket 10. For example, the oscillating mass 30 may be made of metal. Since the first elastic member 32 completely surrounds the oscillating mass 30, the oscillating mass 30 can vibrate in any direction while having damping / absorbing characteristics.

[0105] Note that the oscillating mass 30 may be fixed to the first elastic member 32 by adhesion. However, it is preferable that the oscillating mass 30 is positively blocked within the first elastic member 32. The damper 28 may be attached to the bracket 10 by adhesion or the like. Also, the damper 28 can alternatively or additionally be positively blocked within the bracket 10.

[0106] For example, the second half shell 14 includes a damper wall 38, and / or the first half shell 12 includes a pocket 40. Similar to the damper wall 38, the bottom of the pocket 40 defines a space where the damper 30 is positively blocked. The damper wall 38 may be provided by the rib 26. In this case, the damper wall 38 intersects the rib 26. The damper wall 38 may have the same shape as the rib 26. The pocket 40 may be omitted, and the first outer surface 16 may function as a wall for positively blocking the damper 28 within the damper wall 38.

[0107] The first part 34 of the first elastic member 32 may be manufactured simultaneously with the second half shell 14 by a two-shot molding process. After manufacturing the second half shell 14 and the first part 34 of the first elastic member 32, the vibrating mass 30 may be inserted into the first part 34 of the first elastic member 32. Thereafter, the second part 36 of the first elastic member 32 is arranged on the side of the vibrating mass 30 where the first half shell 12 is attached to the second half shell 14, such that the bottom surface of the pocket 40 presses the second part 36 of the first elastic member 32 against the vibrating mass 30.

[0108] The second part 36 of the first elastic member 32 can also be attached to the bottom surface of the pocket 40, for example, by an adhesive. Also, the second part 36 of the first elastic member 32 can be manufactured by a two-shot molding process of the first half shell 12. The first elastic member 32 may be manufactured from a thermoplastic elastomer (TPE).

[0109] The bracket 10 optionally includes at least one insulating bush 42. In this embodiment, two insulating bushes 42 are provided. The insulating bush 42 provides a connection between the bracket 10 and the electric motor. The insulating bush 42 may include a body 44 and a second elastic member 46. The body 44 can include an elongated member that may be made of a metallic material or a rigid plastic material. The body 44 may have a through hole in its axial direction for inserting a screw or bolt for attaching the electric motor to the bracket 10.

[0110] It is also possible to project the body 44 from the bracket 10 for mounting the electric motor. The body 44 may have a star-shaped outer peripheral surface in a cross-sectional view. However, other shapes are also possible for the shape of the outer peripheral surface in a cross-sectional view.

[0111] The second elastic member 46 is formed as a layer between the main body 44 and the first opening 48 of the bracket 10. Also, the second elastic member 46 may also be made of TPE, and preferably, it is manufactured by a double injection molding process with the first half shell 12 and / or the second half shell 14. In particular, the first opening 48 arranged in the second half shell 14 protrudes from the second half space 22 towards the first half shell 12. Therefore, the inner surface of the first opening 48 is almost or only arranged in the second half shell 14, and is arranged in the second half shell 14 so that the second elastic member 46 can be completely manufactured in the double injection molding process with the second half shell 14. The first half shell 12 may be provided only with an insulating bush 42, particularly a hole into which the main body 44 can be inserted.

[0112] The rib 26 may be formed from the first opening 48 to strengthen the first opening 48 because the weight of the electric motor is introduced into the bracket 10 by the first opening 48. The main body 44 may be inserted into the second elastic member 46 already arranged in the first opening 48. That is, the main body 44 is inserted in a post-process after the manufacture of the second half shell 14 and the second elastic member 46.

[0113] The bracket 10 optionally includes mounting bushes 50. In this embodiment, two mounting bushes 50 are provided. The mounting bushes 50 enable the bracket 10 to be attached to the chassis.

[0114] The mounting bush 50 may include a sleeve 52 and a rubber member 54. It is also possible for the mounting bush 50 to include an outer sleeve 56. The sleeve 52 is an elongated member that may include a through hole extending along its axial direction. The through hole is provided for inserting a bolt or screw for attaching the bracket 10 to the chassis. The sleeve 52 may be manufactured from a metal material or a plastic material.

[0115] The rubber member 54 is made of an elastic material, particularly a rubber material. The rubber member 54 is fixed to the sleeve 52, for example, by vulcanization. As can be best seen from FIG. 4, the rubber member 54 includes at least one arm 58, and in a particular embodiment, four arms 58. The rubber member 54 may completely surround the sleeve 52 in the circumferential direction, whereby the arms 58 project from the portion of the rubber member 54 that is attached to the sleeve 52.

[0116] The outer sleeve 56 may be made of the same material as the sleeve 52, particularly a plastic material. The outer sleeve 56 surrounds the rubber member 54. A part of the rubber member 54 may be attached to the outer sleeve 56 alone, particularly in the region between the arms 58. The tips of the arms 58 may be attached to the outer sleeve 56. The outer sleeve 56 is provided to better insert the mounting bush 50 into the second opening 60 of the bracket 10.

[0117] The bracket 10 has two second openings 60 in the illustrated embodiment. The second openings 60 are provided in both the first half shell 12 and the second half shell 14. However, the entire inner surface of the second opening 60 is provided only in the second half shell 14. The first half shell 12 may exhibit a reduced thickness around the second opening 60 such that the second opening in the first half shell 12 is simply a through hole. Also, the inner surface of the second opening 60 may be provided by the first half shell 12 and the second half shell 14.

[0118] The inner surface of the second opening 60 is provided with a plurality of recesses 62 provided for receiving the arm 58 of the mounting bush 50. The second opening 60 is provided with protrusions 64 at both axial ends thereof. As can be clearly seen from FIG. 5, the protrusions 64 extend radially inward from the inner surface of the second opening 60. In one embodiment, since the inner surface of the second opening 60 is provided only on the second half shell 14, only the second opening 60 of the first half shell 12 is provided with the protrusions 64.

[0119] The protrusion 64 may be configured as a rib extending over the entire inner peripheral surface of the second opening 60. However, the protrusion 64 can also be provided by a plurality of protrusions arranged in the second opening 60. As can be seen from FIG. 5, the protrusions 64 are arranged at both axial ends of the second opening 60. The protrusion 64 protrudes radially inward from the inner surface of the second opening 60 by such a length that the mounting bush 50 is positively blocked within the second opening 60 of the bracket 10 between the protrusions 64.

[0120] The second opening 60 of the second half shell 14 may be provided by a bush wall 66 configured in the same manner as the rib 26. The bush wall 66 may be reinforced by the rib 26, for example, the rib 26 may be a starting point or an end point in the second opening 60, that is, the bush wall 66. The bush wall 66 may be integral with the second half shell 14. As described above, the entire bush wall 66 may be provided by the second half shell 14.

[0121] The second opening 60 of the first half shell 12 may be only a through hole, whereby the protrusion 64 at the axial end in the first half shell 12 can be configured by reducing the diameter of the through hole (see FIG. 6). In particular, the inner diameter of the through hole (the second opening 60 in the first half shell 12) is smaller than the outer diameter of the mounting bush 50.

[0122] The mounting bush 50 may be manufactured by a separate manufacturing process. The mounting bush 50 may be inserted into the second opening 60 of the second half shell 14. Thereafter, the first half shell 12 is fixed to the second half shell 14 such that the mounting bush 50 is positively blocked in the second opening 60 by the protrusion 64. As a result, no adhesive means or further mounting means for fixing the mounting bush 50 to the bracket 10 are required.

[0123] A further embodiment of the bracket 10 will be described in conjunction with FIGS. 6 to 9. This bracket 10 has a configuration similar to that of the bracket 10 described above, except for the following differences. Note that FIGS. 6 to 9 show only the first half shell 12 of the bracket 10. The second half shell 14 (not shown in FIGS. 6 to 9) may be the same as the second half shell 14 of the embodiment shown in FIGS. 1 to 5.

[0124] The bracket 10 includes an acoustic insulation cover 68. In fact, two brackets 10 are attached to the acoustic insulation cover 68. The bracket 10 is fixedly attached to the acoustic insulation cover 68. The acoustic insulation cover 68 is configured to surround an electric motor (not shown) and has a formed shape. The acoustic insulation cover 68 is provided to reduce, attenuate, and / or cancel airborne sound having a frequency of 2000 Hz or higher. The bracket 10 is provided to reduce, attenuate, and / or cancel structure-borne sound having a frequency of 2000 Hz or lower.

[0125] The acoustic insulation cover 68 may be in contact with the electric motor or may be arranged at a distance from the electric motor. Further, the acoustic insulation cover 68 may have a part in contact with the electric motor and a part arranged at a distance from the electric motor. As can be seen from FIGS. 6 to 9, the acoustic insulation cover 68 is formed and shaped along the outer contour of the electric motor. In order to achieve good noise insulation ability, the acoustic insulation cover 68 is preferably formed so as to completely surround the electric motor. However, as can be seen in FIGS. 6 to 9, the acoustic insulation cover 68 may include through holes and / or openings that can be used to guide the axis or wires from the electric motor through the acoustic insulation cover 68. Further, ventilation holes may be provided to release the heat generated from the electric motor.

[0126] The acoustic insulation cover 68 includes a first insulation half shell 70 and a second insulation half shell 72. The first insulation half shell 70 and / or the second insulation half shell 72 can include a support member 74 and an insulation member 76. In the illustrated embodiment, only the first insulation half shell 70 includes the support member 74 and the insulation member 76. The second insulation half shell 72 is composed only of the support member 74.

[0127] Each of the support members 74 gives stability and strength to the acoustic insulation cover 68. The support member 74 can be manufactured from a thermoplastic material reinforced with short glass fibers. The insulation member 76 may be manufactured from polypropylene and is provided to reduce and attenuate not only airborne sound but also structure-borne sound. In particular, the insulation member 76 is formed and shaped in the same manner as the support member 74 of the first insulation half shell 70. The insulation member 76 may completely cover the outer surface (the surface not facing the electric motor) of the support member 74 of the first insulation half shell 70. Further, the insulation member 76 may be fixed to the support member 74 by adhesion. Since the insulation member 76 is a material capable of attenuating vibration, the insulation member 76 can reduce the vibration of the support member 74 and absorb the airborne sound generated from the electric motor.

[0128] The support member 74 of the first insulating half shell 70 is integral with the first half shell 12 of the bracket 10. The support member 74 can be manufactured by injection molding in one piece with the first half shell 12 of the bracket 10. Thereby, the acoustic insulation cover 68 can be supported by the bracket 10, and vibrations generated from the electric motor can be attenuated by the bracket 10 and not transmitted to the acoustic insulation cover 68.

[0129] The support member 74 of the first insulating half shell 70 and the support member 74 of the second insulating half shell 72 are preferably mechanically attached to each other. For this purpose, the support member 74 of the first insulating half shell 70 includes a plurality of tongue-like portions 78 protruding in the direction of the second insulating half shell 72. The tongue-like portions 78 include holes that are coaxially aligned with the holes of the second insulating half shell 72 when the second insulating half shell 72 is attached to the first insulating half shell 70, as shown in FIG. 7.

[0130] The acoustic insulation cover 68 may further include an attachment portion 80. The attachment portion 80 may be integral with the support member 74 of the first insulating half shell 70. The attachment portion 80 is provided for attaching the acoustic insulation cover 68 to the electric motor and / or the chassis.

[0131] In the embodiments shown in FIGS. 6 to 9, the attachment portion 80 is configured to be connected to both the electric motor and the chassis. The attachment of the attachment portion 80 to the electric motor and the chassis is the same as the attachment of the bracket 10. The attachment portion 80 may include a first opening 48 into which an insulating bush 42 is inserted, for example as shown in FIG. 9. The first opening 48 that interacts with the insulating bush 42 enables the attachment of the acoustic insulation cover 68 to the electric motor and at the same time provides noise decoupling between the acoustic insulation cover 68 and the electric motor.

[0132] Further, the second opening 60 of the mounting portion 80 can include a mounting bush 50 not shown in FIGS. 6 to 9. In this way, the mounting portion 80 can be attached to the chassis and at the same time can be detached from the chassis.

[0133] Further, the mounting portion 80 may include ribs 26 (see FIG. 9). Also, the mounting portion 80 is a hollow member reinforced by the ribs 26. However, in contrast to the bracket 10, the mounting portion 80 is a one-piece member that does not exhibit a two-piece configuration like the bracket 10.

[0134] The beneficial aspects of the bracket 10 will be described below. Due to the configuration in which the bracket 10 is made of two half-shells 12, 14 potentially reinforced by ribs 26, the bracket 10 is lightweight while providing sufficient strength to support the electric motor. The lightweight aspect of the bracket 10 is further provided by manufacturing the bracket 10 from a plastic material. The properties of the plastic material and the configuration of the bracket 10 as a hollow member reinforced by ribs 26 make it possible to attenuate / absorb vibrations generated by the electric motor in the frequency band between 750 Hz and 2000 Hz.

[0135] The damper 28 can absorb / attenuate vibrations in the frequency band between 400 Hz and 750 Hz. Since the first elastic member 32 of the damper 28 can be manufactured by a double injection molding process with the first half-shell 12 and / or the second half-shell 14 respectively, the manufacture of the damper 28 is simplified.

[0136] The insulating bush 42 exhibits attenuation / absorption characteristics in the frequency band from 100 Hz to 400 Hz. Therefore, attenuation / absorption characteristics are obtained by the combination of the weight of the electric motor and the rigidity of the second elastic member 46. Here too, the manufacture of the insulating bush 42 is simplified by the double injection molding process with the second half-shell 14 and the second elastic member 46.

[0137] The attenuation / absorption of vibrations in the frequency band from 1 Hz to 400 Hz generated by the electric motor is realized by the mounting bush 50. The attachment of the mounting bush 50 to the bracket 10 is simple because the mounting bush 50 is positively blocked by attaching the first half shell 12 and the second half shell 14. As a result, no additional means for attaching the mounting bush 50 to the bracket 10 are required.

[0138] Overall, the preferred embodiment of the bracket 10 provides complete attenuation / absorption of vibrations generated by the electric motor over the frequency band from 1 Hz to 2000 Hz. Basically, all vibrations generated by the electric motor can be attenuated by the bracket 10 in its preferred embodiment. Furthermore, the half-shell structure of the bracket 10 simplifies the assembly process of the bracket 10 and optional components (damper 28, insulating bush 42 and / or mounting bush 50).

[0139] Hereinafter, the manufacturing process of the bracket 10 according to the preferred embodiment will be described. The first half shell 12 is manufactured by a molding process, whereby preferably the second part 36 of the first elastic member 32 is simultaneously manufactured by a two-shot injection molding process. Similarly, the second half shell 14 is molded, whereby preferably the first elastic member 32 and the second elastic member 46 are simultaneously molded by a two-shot injection molding process.

[0140] After the second half shell 14 is molded, the vibrating mass 30 of the damper 28 is inserted into the first part 34 of the first elastic member 32. Further, the body 44 of the insulating bush 42 is inserted into the second elastic member 46. Finally, the mounting bush 50 is inserted into the second opening 60.

[0141] Thereafter, the first half shell 12 is preferably fixed to the second half shell 14 by hot gas welding. When the first half shell 12 is fixed to the second half shell 14, the vibrating mass 30 is positively blocked within the first elastic member 32, while the mounting bush 50 is also positively blocked in the second opening 60 due to the presence of the protrusion 64. That is, in the assembly process of the bracket 10, no additional screws or other mounting means are required. Therefore, the mounting process is simplified and the number of parts is reduced.

Description of the Reference Numerals

[0142] 10 Bracket 12 First half shell 14 Second half shell 16 First outer surface 18 Second outer surface 20 First half space 22 Second half space 24 Contact area 26 Rib 28 Damper 30 Vibrating mass 32 First elastic member 34 First part 36 Second part 38 Damper wall 40 Pocket 42 Insulating bush 44 Body 46 Second elastic member 48 First opening 50 Mounting bush 52 Sleeve 54 Rubber member 56 Outer sleeve 58 Arm 60 Second opening 62 Recess 64 Protrusion 66 Bush wall 68 Acoustic insulation cover 70 First insulating half shell 72 Second insulating half shell 74 Support member 76 Insulating member 78 Tongue-shaped part 80 Mounting portion

Claims

1. A bracket for supporting an electric motor on a vehicle chassis, comprising: a first half shell (12) defining a first half space (20); and a second half shell (14) defining a second half space (22), wherein the first half shell (12) and the second half shell (14) are made of a polymer material, and the first half shell (12) and the second half shell (14) are fixed to each other by welding so as to define a hollow body having a cavity within a bracket (10) including the first half space (20) and the second half space (22); the bracket further comprising at least one insulating bush (42) for attaching the electric motor to the bracket (10) and at least one mounting bush (50) for attaching the bracket (10) to the chassis.

2. The bracket according to claim 1, wherein the first half shell (12) and / or the second half shell (14) is reinforced by ribs (26), the ribs (26) being integrally formed with the first half shell (12) and / or the second half shell (14).

3. The bracket according to claim 1 or claim 2, wherein a damper (28) is disposed within the cavity, the damper (28) comprising a vibration mass (30) and a first elastic member (32) attached to the bracket (10) and the vibration mass (30).

4. The bracket according to claim 3, wherein the first elastic member (32) is made of an elastic material, the first elastic member (32) comprising a layer surrounding the vibration mass (30).

5. The bracket according to claim 4, wherein the first elastic member (32) is disposed between the vibration mass (30) and a damper wall (38) integrally formed with the first half shell (12) and / or the second half shell (14), a part of the first elastic member (32) and the second half shell (14) being manufactured simultaneously by a two-shot molding process.

6. The insulating bush (42) comprises a body (44) made of a rigid material connected to the electric motor and a second elastic member (46) surrounding the body (44). The second elastic member (46) is disposed between the body (44) and the inner surface of the first opening (48) of the bracket (10), The bracket according to any one of claims 1 to 5, wherein the second elastic member (46) and the second half shell (14) are simultaneously manufactured by a two-shot injection molding process.

7. The bracket (10) includes a second opening (60), and when the first half shell (12) is fixed to the second half shell (14), the mounting bush (50) is positively blocked in the second opening (60). The second opening (60) is disposed at an axial end of the second opening (60) and includes a protrusion (64) extending into the second opening (60). The mounting bush (50) includes a sleeve (52) connected to the chassis and a rubber member (54) surrounding the sleeve (52). The bracket according to any one of claims 1 to 6, wherein the sleeve (52) is made of a plastic material.

8. At least two of the mounting bushes (50) are respectively disposed in each of the second openings (60). The at least two mounting bushes (50) are different in shape and / or material. The mounting bush (50) includes at least one arm (58) inserted into a recess (62) extending in the radial direction of the second opening (60). The bracket according to claim 7, wherein the at least two mounting bushes (50) are different in the orientation of the at least one arm (58).

9. An acoustic insulation cover (68) in a shape surrounding the electric motor is provided. The bracket according to any one of claims 1 to 8, wherein the acoustic insulation cover (68) is fixedly attached to the bracket (10).

10. The acoustic insulation cover (68) includes a first insulation half shell (70) and a second insulation half shell (72). The first insulation half shell (70) and the first half shell (12) are an integral unit component. The bracket according to claim 9, wherein the second insulation half shell (72) is mechanically fixed to the first insulation half shell (70).

11. The acoustic insulation cover (68) includes an attachment portion (80) for attaching the acoustic insulation cover (68) to the chassis and / or the electric motor. The bracket according to claim 9 or claim 10, wherein the attachment portion (80) includes the insulation bush (42) and / or the attachment bush (50).

12. A method for manufacturing a bracket (10) for supporting an electric motor on a vehicle chassis, comprising: a) forming a first half shell (12) defining a first half space (20) and a second half shell (14) defining a second half space (22), wherein the first half shell (12) and the second half shell (14) are made of a plastic material; b) fixing the first half shell (12) to the second half shell (14) by welding so that the first half shell (12) and the second half shell (14) define a hollow body having a cavity within a bracket (10) including the first half space (20) and the second half space (22); forming at least one insulation bush (42) for attaching the electric motor to the bracket (10) and at least one attachment bush (50) for attaching the bracket (10) to the chassis.

13. The method according to claim 12, wherein step a) includes manufacturing a first elastic member (32) of a damper (28) together with the second half shell (14) by a two-shot injection molding process. The method according to claim 12, wherein a vibration mass (30) of the damper (28) is attached to the first elastic member (32).

14. The method according to claim 12, wherein step a) includes providing at least one first opening (48) in the first half shell (12) and the second half shell (14). The inner surface of the first opening (48) is covered by a second elastic member (46). The method according to claim 12 or claim 13, wherein the second elastic member (46) and the second half shell (14) are manufactured by a two-shot injection molding process.

15. Before the said step b), at least one mounting bush (50) for attaching the said bracket (10) to the said chassis is inserted into a part of a second opening (60) arranged in the said first half-shell (12) and / or the said second half-shell (14), The method according to any one of claims 12 to 14, wherein the second opening (60) is provided with a projection (64) arranged at an axial end of the second opening (60) and extending into the second opening (60) for positively blocking the mounting bush (50) in the second opening (60) when the first half-shell (12) is fixed to the second half-shell (14).

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