Air gap sleeve assembly for an electric drive module

Abstract

A sleeve assembly for an electric drive module of a vehicle includes an elongated tubular sleeve, having an inner diameter and an outer diameter, configured to fit concentrically between a rotor assembly of an electric motor and a stator assembly of the electric motor; a first end cap received at one axial end of the elongated tubular sleeve forming a fluid tight seal between the first end cap and the elongated tubular sleeve; a second end cap received at an opposite axial end of the elongated tubular sleeve forming a fluid tight seal between the second end cap and the elongated tubular sleeve, such that the elongated tubular sleeve comprises a non-electrically conductive material and at least one of the first end cap or the second end cap is formed from a different non-electrically conductive material.

Description

4.561 (8887-3393-003) AIR GAP SLEEVE ASSEMBLY FOR AN ELECTRIC DRIVE MODULE PRIORITY CLAIM

[0001] This application claims priority to U.S. provisional patent applicationnumber 63 / 631,705 filed April 9th, 2024 the contents of which are incorporated by reference in their entirety. BACKGROUND

[0002] Vehicles increasingly rely on electric motors (or rotating electricalmachines) at least partially for propulsion. The electric motors are electrically coupled to a vehicle battery via power electronics that regulate the supply of electrical current to the electric motor. The range and power of the vehicle can vary depending on the efficiency with which these components operate. It would be helpful to configure electric motors to more efficiently convert the electrical current into vehicular motion. SUMMARY

[0003] According to one implementation, a sleeve assembly for an electricdrive module of a vehicle includes an elongated tubular sleeve, having an inner diameter and an outer diameter, configured to fit concentrically between a rotor assembly of an electric motor and a stator assembly of the electric motor; a first end cap received at one axial end of the elongated tubular sleeve forming a fluid tight seal between the first end cap and the elongated tubular sleeve; a second end cap received at an opposite axial end of the elongated tubular sleeve forming a fluid tight seal between the second end cap and the elongated tubular sleeve, such that the elongated tubular sleeve comprises a non-electrically conductive material and at least one of the first end cap or the second end cap is formed from a different non-electrically conductive material.

[0004] According to another implementation, a sleeve assembly for anelectric drive module of a vehicle includes an elongated tubular sleeve, having an inner diameter and an outer diameter, configured to fit concentrically between a4.561 (8887-3393-003) rotor assembly of an electric motor and a stator assembly of the electric motor; a first end cap, removably coupled to the inner diameter or outer diameter of the elongated tubular sleeve via a fluid seal, received at one axial end of the elongated tubular sleeve forming a fluid tight seal between the first end cap and the elongated tubular sleeve; and a second end cap, removably coupled to the inner diameter or outer diameter of the elongated tubular sleeve via a fluid seal, received at an opposite axial end of the elongated tubular sleeve forming a fluid tight seal between the second end cap and the elongated tubular sleeve. DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a cross-sectional view depicting an implementation of anelectric drive module including an air gap sleeve;

[0006] Figure 2 is a cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0007] Figure 3 is a perspective view depicting an implementation of an airgap sleeve;

[0008] Figure 4 is a cross-sectional view depicting an implementation of anelectric drive module including an air gap sleeve;

[0009] Figure 5 is a perspective view depicting a portion of animplementation of an air gap sleeve;

[0010] Figure 6 is perspective view depicting a portion of an implementationof an air gap sleeve;

[0011] Figure 7 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0012] Figure 8 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0013] Figure 9 is cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0014] Figure 10 is cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0015] Figure 11 is a perspective view depicting a portion of animplementation of an air gap sleeve;4.561 (8887-3393-003)

[0016] Figure 12 is a perspective view depicting a portion of animplementation of an air gap sleeve;

[0017] Figure 13 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0018] Figure 14 is cross-sectional view depicting a portion of animplementation of a portion of an air gap sleeve;

[0019] Figure 15 is cross-sectional view depicting a portion of animplementation of a portion of an air gap sleeve;

[0020] Figure 16 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0021] Figure 17 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0022] Figure 18 is a perspective view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0023] Figure 19 is a perspective view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0024] Figure 20 is a cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0025] Figure 21 is a cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0026] Figure 22 is a perspective view depicting an implementation of an airgap sleeve;

[0027] Figure 23 is a cross-sectional view depicting an implementation of anair gap sleeve;

[0028] Figure 24 is a perspective view depicting a portion of animplementation of an air gap sleeve;

[0029] Figure 25 is a perspective view depicting a portion of animplementation of an air gap sleeve;

[0030] Figure 26 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0031] Figure 27 is a perspective view depicting a portion of animplementation of an air gap sleeve;4.561 (8887-3393-003)

[0032] Figure 28 is a perspective view depicting a portion of animplementation of an air gap sleeve;

[0033] Figure 29 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0034] Figure 30 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0035] Figure 31 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve;

[0036] Figure 32 is a cross-sectional view depicting a portion of animplementation of an air gap sleeve in an electric drive module;

[0037] Figure 33 is cross-sectional view depicting a an implementation of anelectric drive module including an air gap sleeve;

[0038] Figure 34 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve;

[0039] Figure 35 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve; and

[0040] Figure 36 is cross-sectional view depicting a portion of animplementation of an electric drive module including an air gap sleeve. DETAILED DESCRIPTION

[0041] An electric drive module can include a rotating electrical machine(also referred to as an electric motor) operatively coupled to a transmission, power electronics that control the rotating electrical machine, and a battery supplying electrical power to the electric drive module. The rotating electrical machine generally comprises a rotor assembly that is received within a stator assembly, and the power electronics can invert direct current (DC) electrical power to induce angular movement of the rotor assembly relative to the stator assembly. The electric drive module can flow lubricating fluid through the assembly to cool and possibly lubricate its components. However, the existence of fluid in space where components move can reduce the efficiency of the module.4.561 (8887-3393-003)

[0042] A sleeve assembly can be positioned within the electric drive moduleto isolate lubricating fluid from the rotor assembly so as the rotor assembly can rotate without unnecessarily pushing fluid within the electric drive module. The sleeve assembly can be positioned concentrically within the stator assembly in between the stator assembly and the rotor assembly, such that the sleeve assembly is radially-outward from the rotor assembly. The sleeve assembly can include an elongated tubular sleeve that receives end caps at each axial end of the elongated tubular sleeve forming a fluid-resistant seal. In one implementation, the elongated tubular sleeve can be formed from one non-electrically-conductive material while the end caps can be formed from a different non-electrically- conductive material. It is possible that the elongated tubular sleeve is bonded to the end caps using an adhesive that permanently affixes the end caps to the elongated tubular sleeve. However, other implementations are possible that include fluid seals positioned between the elongated tubular sleeve and the end caps to facilitate possible disassembly of the sleeve assembly permitting separation of the end caps from the elongated tubular sleeve and reassembly of the end caps with the elongated tubular sleeve. The fluid seals can permit assembly / disassembly while maintaining or re-establishing a fluid-resistant seal between the end caps and the elongated tubular sleeve.

[0043] With reference to Figure 1, an exemplary electric drive moduleconstructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10. The electric drive module 10 can generally include a housing assembly 12, a motor assembly 14, a transmission 16, one or more output members 20 and optionally a differential assembly 22. The motor assembly 14 can include an electric motor 30 and a motor controller 32 that includes an inverter 36. In the example provided, the electric drive module 10 is constructed similar to that which is disclosed in U.S. Patent Application Publication No. 2022 / 0393522 except as noted herein.

[0044] With reference to Figure 2, the electric motor 30 includes a statorassembly 40 and a rotor assembly 42. The stator assembly 40 can have a stator body 50, a plurality of sets of field windings 52 and a plurality of phase leads 54.4.561 (8887-3393-003) The stator body 50 is fixedly coupled to the housing assembly 12 and defines a plurality of stator body cooling channels 60 that extend longitudinally through the stator body 50. In the example shown, each of the stator body cooling channels 60 extends in a straight line between and through the opposite axial ends of the stator body 50, but it will be appreciated that the stator body cooling channels 60 could be configured differently (e.g., to extend helically about the stator body 50 and / or could enter into and / or exit from the stator body 50 in a manner that is different from that which is depicted here). Each of the sets of field windings 52 is wrapped about the stator body 50 such that the opposite axial ends of each set of field windings 52 extends from a corresponding axial end of the stator body 50. A cap 64 can be coupled to the sets of field windings 52 and can shroud or cover the wires that form the sets of field windings 52. The cap 64 is formed of an electrically insulating material but also has relatively good thermally conductive properties. Optionally, the cap 64 can be an encapsulant that is molded onto the wires of the sets of field windings 52.

[0045] The rotor assembly 42 is received in a rotor bore that is formed in thestator assembly 40 and includes a rotor body 70 and a motor output shaft 72. The rotor assembly 42 is rotatable relative to the stator assembly 40 about a motor axis 76. Each of the phase leads 54 is mechanically and electrically coupled to a corresponding one of the sets of field windings 52. Optionally, the phase leads 54 can be sealingly coupled to the cap 64 that covers or shrouds the wires that form the sets of field windings 52. In the example provided, the phase leads 54 are partly encapsulated in the encapsulant material that forms the cap 64.

[0046] Turning to Figures 3-21, an implementation of a sleeve assembly 80used within the electric drive module 10 is shown. The sleeve assembly 80 includes an elongated tubular sleeve 82 with a first end cap 84 permanently bonded to an axial end of the elongated tubular sleeve 82 and a second end cap 86 permanently bonded to an opposite axial end of the elongated tubular sleeve 82. The elongated tubular sleeve 82 can have an inner diameter 88 and an outer diameter 90. The thickness of the elongated tubular sleeve in between the inner diameter 88 and the outer diameter 90 can be relatively small; the thickness can4.561 (8887-3393-003) be an amount permitting the elongated tubular sleeve 82 to fit concentrically between the stator assembly 40 and the rotor assembly 42. The elongated tubular sleeve 82 can be formed from a material that is electrically non-conductive. For instance, the elongated tubular sleeve can be formed from a prepreg composite fiber that is wrapped around a mandrel and cured at an elevated temperature in an autoclave or an oven. After cooling the elongated tubular sleeve, it can be removed from the mandrel and rigidly hold its tubular shape. Elongated tubular sleeves formed from composite fibers can be very light and strong yet also minimize the thickness between the inner diameter and the outer diameter. In other implementations, the elongated tubular sleeve 82 could be formed from fiberglass. An axial length of the elongated tubular sleeve 82 extending along the motor axis 76 can roughly correspond to an axial length of the rotor assembly 42.

[0047] The first end cap 84 can be substantially ring-shaped having an innerdiameter 92 and an outer diameter 94. The first end cap 84 can be formed from an electrically non-conducting material. Given the detailed contours possibly included in the first end cap 84, it may be helpful to form the first end cap 84 from a material that is different than the material used to form the elongated tubular sleeve 82. The different material may facilitate easier fabrication of the first end cap 84 given the surface contours and orifices. For instance, the end caps 84, 86 can be formed from a glass-based material as a solid block that is milled using a vertical milling center having a spindle that cuts the solid block into a final shape of an end cap 84, 86. In one implementation, the end caps 84, 86 can be formed from a fiberglass laminate, such as a glass-based epoxy resin laminate. In this implementation, the outer diameter 94 of the first end cap 84 receives the inner diameter 88 of the elongated tubular sleeve 82. The surfaces of the outer diameter 94 of the first end cap 84 and the inner diameter 88 of the elongated tubular sleeve 82 can directly contact each other and mechanically bond together using an adhesive such as an epoxy-based adhesive. The adhesive can permanently bond the first end cap 84 to the elongated tubular sleeve 82. The inner diameter 92 of the first end cap 84 can be sized to receive a rotor shaft support 74 in such a way to prevent the flow of fluid between the inner diameter 92 of the first end cap 84 and the rotor shaft support 74. In one implementation, a radially-outwardly-4.561 (8887-3393-003) facing surface of the rotor shaft support 74 can include a groove 78 for receiving a fluid seal 116 that engages both the radially-outwardly-facing surface of the rotor shaft support 74 and the inner diameter 92 of the first end cap 84 preventing the flow of lubricating fluid in between the rotor shaft support 74 and the first end cap 84. The fluid seal 116 can be implemented using seals formed from elastomeric materials, such as PVC or natural rubber, such as O-rings. But other types of fluid seals are possible from non-polymeric materials.

[0048] The second end cap 86 can be substantially ring-shaped having aninner diameter 96 and an outer diameter 98 along with one or more fluid orifices 100 located between the inner diameter 96 and the outer diameter 98 permitting fluid to pass through. The fluid orifices 100 can be positioned radially outwardly from the motor axis 76 a sufficient amount that the fluid orifices 100 are axially aligned with stator cooling channels 60 in the stator assembly 40. The second end cap 86 can be formed from an electrically non-conducting material in a similar way as the first end cap 84 can be formed. It may be helpful to form the second end cap 86 from a material that is different than the material used to form the elongated tubular sleeve 82. The second end cap 86 can include a tube-engaging surface 66 along a first axial length of the inner diameter 96 and a housing- engaging surface 68 extending along a second axial length of the inner diameter 96. In this implementation, the tube-engaging surface 66 and the housing- engaging surface 68 face radially-inwardly toward an outer diameter 90 of the elongated tubular sleeve 82 and a radially-outwardly-facing surface of the housing assembly 12, respectively. However, in other implementations, the tube-engaging surface and the housing-engaging surface may be differently oriented.

[0049] In this implementation, the tube-engaging surface 66 receives theouter diameter 90 of the elongated tubular sleeve 82. The tube-engaging surface 66 and the outer diameter 90 of the elongated tubular sleeve 82 can directly contact each other and mechanically bond together using an adhesive, such as an epoxy-based adhesive. The adhesive can permanently bond the second end cap 86 to the elongated tubular sleeve 82. The housing-engaging surface 68 can face a housing groove 56 formed in the housing assembly 12. The housing groove 56 can4.561 (8887-3393-003) be sized and shaped to receive a fluid seal 116 that, when abutting the housing- engaging surface 68 and the housing assembly 12, can prevent the passage of lubricating fluid from the stator assembly 40 past the second end cap 86 and into the elongated tubular sleeve 82. The outer diameter 98 of the second end cap 86 can be sized and shaped to abut a portion of the stator assembly 40 to prevent the flow of fluid between the stator assembly 40 and the inner diameter 88 of the elongated tubular sleeve 82. The outer diameter 98 of the second end cap 86 can include an axially-extending lip 104 that can fit over an outer diameter of the stator assembly 40, or in this implementation, an appendage 58 to the stator assembly 40. The appendage 58 can be an axially-extending ring that abuts a radial face of the stator assembly 40 and the lip 104 to help guide lubricating fluid around end turns 130 of the stator assembly 40.

[0050] The second end cap 86 can also include a drain 106 positionedbetween the inner diameter 96 and the outer diameter 98 to receive any fluid that unintentionally entered the elongated tubular sleeve 82 and deliver it to a fluid sump or the transmission 16. The drain 106 can be in fluid communication with an opening 108 in the housing assembly 12 through which lubricating fluid can pass. In one implementation, the drain 106 can be formed from aluminum. The opening 108 can be covered with a metering thimble 110 that is coupled to the housing assembly 12 and receives the lubricating fluid from the second end cap 86 through the drain 106. The metering thimble 110 can include a fluid reservoir 112 and a fluid orifice 114 for receiving fluid and exhausting fluid from the second end cap 86 at a determined rate of flow.

[0051] The sleeve assembly 80 can be inserted into the stator assembly 40from an axial end of the stator assembly 40 so that the first end cap 84 abuts a radial surface of the stator body 50 and the inner diameter 92 of the first end cap 84 compresses the fluid seal 116 in the groove 78 included with the rotor shaft support 74. The rotor assembly 42 can subsequently be inserted into the sleeve assembly 80 such that the sleeve assembly 80 is concentrically positioned between the stator assembly 40 and the rotor assembly 42. The second end cap 86 can be cabined in between the housing assembly 12 and the stator body 50. The second4.561 (8887-3393-003) end cap 84 can be compressed between the stator body 50 and a portion of the housing assembly 12 so that the fluid seal 116 included in the housing groove 56 is compressed between the housing assembly 12 and the housing-engaging surface 68 of the second end cap 86. The housing assembly 12 can include a plurality of fluid seals 116, that are received in seal grooves 118 formed in a surface of the housing assembly 12, and engage an inner diameter 92 of the first end cap 84 and / or an inner diameter 96 of the second end cap 86. In operation, pressurized lubricating fluid can be supplied from a fluid source (not shown) and received at the first end cap 84. The pressurized fluid can be supplied to a variety of locations, including the stator body 50 included in the electric drive unit 10. The lubricating fluid can flow through the fluid orifices 100 to the stator body 50 and along the outer diameter 90 of the elongated tubular sleeve 82. The stator body 50 can include a plurality of axially-extending stator cooling channels 60 that may be shaped in any one of a variety of ways. The stator cooling channels 60 can extend linearly along the motor axis 76 or can be helically-shaped. In one implementation, fluid passages 120 can be formed between the outer diameter 90 of the elongated tubular sleeve 82 and the stator body 50 as is shown in Figure 21. The second end cap 86 can receive the lubricating fluid from the stator body 50 and direct the lubricating fluid to a sump or the transmission 16.

[0052] Another implementation of a sleeve assembly 80’ used within theelectric drive module 10 is shown in Figures 22-36. The sleeve assembly 80’ includes an elongated tubular sleeve 82 with a first end cap 84’ removably coupled to an axial end of the elongated tubular sleeve 82 and a second end cap 86’ removably coupled to an opposite axial end of the elongated tubular sleeve 82. Fluid seals 122 can be positioned between an inner diameter 88 or outer diameter 90 of the elongated tubular sleeve 82 and an inner diameter 92, 96 or outer diameter 94, 98 of the first and second end caps 84’, 86’. The first end cap 84’, the second end cap 86’, and the elongated tubular sleeve 82 can be axially biased in engagement with each other using a biasing element 124.

[0053] The first end cap 84’ can be substantially ring-shaped having aninner diameter 92 and an outer diameter 94. The first end cap 84’ can be formed4.561 (8887-3393-003) from an electrically non-conducting material. In this implementation, the outer diameter 94 of the first end cap 84’ receives the inner diameter 88 of the elongated tubular sleeve 82. A portion of the surfaces of the outer diameter 94 of the first end cap 84’ and the inner diameter 88 of the elongated tubular sleeve 82 can directly and releasably contact each other. A first cap groove 126 can be positioned along the outer diameter 94 of the first end cap 84’, in between the locations where the first end cap 84’ and the elongated tubular sleeve 82 directly contact each other. The fluid seal 122 can be received within the first cap groove 126 and, when the first end cap 84’ is received by the elongated tubular sleeve 82, forms a fluid resistant seal between the first end cap 84’ and the elongated tubular sleeve 82. The fluid seal 122 can obviate the need to permanently bond an end cap 84, 86 to the elongated tubular sleeve 82. The inner diameter 92 of the first end cap 84’ can be sized to receive a rotor shaft support 74 in such a way to prevent the flow of fluid between the inner diameter 92 of the first end cap 84’ and the rotor shaft support 74. In one implementation, a radially-outwardly-facing surface of the rotor shaft support 74 can include a groove 78 for receiving a fluid seal 116 that engages both the radially-outwardly-facing surface of the rotor shaft support 74 and the inner diameter 92 of the first end cap 84’ preventing the flow of lubricating fluid in between the rotor shaft support 74 and the first end cap 84’.

[0054] The second end cap 86’ can be substantially ring-shaped having aninner diameter 96 and an outer diameter 98 along with one or more fluid orifices 100 located between the inner diameter 96 and the outer diameter 98 permitting fluid to pass through. The fluid orifices 100 can be positioned radially outwardly from the motor axis 76 a sufficient amount that the fluid orifices 100 are axially aligned with stator cooling channels 60 in the stator assembly 40. The second end cap 86’ can be formed from an electrically non-conducting material in a similar way as the first end cap 84’ can be formed. As noted above, it may be helpful to form the first and / or second end caps 84’, 86’ from a material that is different than the material used to form the elongated tubular sleeve 82.

[0055] The second end cap 86’ can include a tube-engaging surface 66 alonga first axial length of the inner diameter 96 and a housing-engaging surface 684.561 (8887-3393-003) extending along a second axial length of the inner diameter 96. In this implementation, the tube-engaging surface 66 and the housing-engaging surface 68 face radially-inwardly toward an outer diameter 90 of the elongated tubular sleeve 82 and a radially-outwardly-facing surface of the housing assembly 12, respectively. However, in other implementations, the tube-engaging surface and the housing-engaging surface may be differently oriented. The second end cap 86’ can include a second cap groove 128 positioned on the tube-engaging surface 66 so that the second cap groove 128 faces radially-inwardly toward the outer diameter 90 of the elongated tubular sleeve 82. The second cap groove 128 can receive a fluid seal 116 that abuts the elongated tubular sleeve 82 and the second end cap 84’. In some implementations of the first cap 84’ and / or the second end cap 86’, the fluid seals 116 can be axially spaced away from the rotor assembly 42 as is shown in Figure 32. This axial spacing may help insulate the fluid seals from heat generated by the electric motor 30.

[0056] In this implementation, the tube-engaging surface 66 receives theouter diameter 90 of the elongated tubular sleeve 82. The tube-engaging surface 66 and the outer diameter 90 of the elongated tubular sleeve 82 can directly contact each other on opposite sides of the second cap groove 128. The housing- engaging surface 68 can face a housing groove 56 formed in the housing assembly 12. The housing groove 56 can be sized and shaped to receive a fluid seal 116 that, when abutting the housing-engaging surface 68 and the housing assembly 12, can prevent the passage of lubricating fluid from the stator assembly 40 past the second end cap 86’ and into the elongated tubular sleeve 82. The outer diameter 98 of the second end cap 86’ can be sized and shaped to abut a portion of the stator assembly 40 to prevent the flow of fluid between the stator assembly 40 and the inner diameter 88 of the elongated tubular sleeve 82. The outer diameter 98 of the second end cap 86’ can include an axially-extending lip 104 that can fit over an outer diameter of the stator assembly 40, or in this implementation, an appendage 58 to the stator assembly 40. The appendage 58 can be an axially- extending ring that abuts a radial face of the stator assembly 40 and the lip 104 to help guide lubricating fluid around the end turns 130 of the stator assembly 40.4.561 (8887-3393-003)

[0057] The second end cap 86’ can also include a drain 106 positionedbetween the inner diameter 96 and the outer diameter 98 to receive lubricating fluid that unintentionally entered the elongated tubular sleeve 82 and deliver it to a fluid sump or transmission 16. The drain 106 can be in fluid communication with an opening 108 in the housing assembly 12 through which lubricating fluid can pass.

[0058] In this implementation having end caps 84’, 86’ with fluid seals 116,122, at least one of the end caps 84’, 86’ can be shaped to closely conform to the end turns exposed outside of the stator body 50. More specifically, the sleeve assembly 80’ can be assembled in situ with the stator assembly 40 after the stator body 50 has received stator windings. The elongated tubular sleeve 82 can be initially positioned concentrically in between the stator assembly 40 and the rotor assembly 42. Subsequently, the end caps 84’, 86’ can be positioned to engage opposite axial ends of the stator body 50 and the stator windings. The first end cap 84’ can abut a portion of the housing assembly 12 such that the housing assembly 12 prevents axial movement of the sleeve assembly 80’ relative to the housing assembly 12. After positioning the first end cap 84’ and second end cap 86’ into engagement with the elongated tubular sleeve 82 as described above, the biasing element 124 can be positioned to abut the second end cap 86’ and another portion of the housing assembly 12 to maintain the first end cap 84’, the elongated tubular sleeve 82, and the second end cap 86’ in an assembled state. Later, if disassembly of the sleeve assembly 80’ is desired, the biasing element 124 can be removed and axial displacement of the components of the sleeve assembly 80’ is possible, permitting removal and disassembly. The term “biasing element” should be viewed broadly to include a mechanical device that creates directional force, such as a spring, Belleville washer, or elastomeric spacer, to name a few. From a claim interpretation standpoint, the term “spring” and “biasing element” can be used interchangeably.

[0059] It is to be understood that the foregoing is a description of one or moreembodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below.4.561 (8887-3393-003) Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

[0060] As used in this specification and claims, the terms "e.g.," “forexample,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open- ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

Claims

4. 561 (8887-3393-003) Claims:

1. A sleeve assembly for an electric drive module of a vehicle, comprising: an elongated tubular sleeve, having an inner diameter and an outer diameter, configured to fit concentrically between a rotor assembly of an electric motor and a stator assembly of the electric motor; a first end cap received at one axial end of the elongated tubular sleeve forming a fluid tight seal between the first end cap and the elongated tubular sleeve; and a second end cap received at an opposite axial end of the elongated tubular sleeve forming a fluid tight seal between the second end cap and the elongated tubular sleeve, wherein the elongated tubular sleeve comprises a non-electrically conductive material and at least one of the first end cap or the second end cap is formed from a different non-electrically conductive material.

2. The sleeve assembly recited in claim 1, wherein the elongated tubular sleeve is formed from a composite fiber.

3. The sleeve assembly recited in claim 1, wherein the first end cap or the second end cap is formed from a fiberglass laminate.

4. The sleeve assembly recited in claim 1, wherein the first end cap and the second end cap are permanently bonded to the elongated tubular sleeve.

5. The sleeve assembly recited in claim 1, wherein the first end cap and the second end cap are removably received by the elongated tubular sleeve.

6. The sleeve assembly recited in claim 5, wherein the first end cap or the second end cap includes a fluid seal that forms a fluid tight seal with the elongated tubular sleeve.

7. The sleeve assembly recited in claim 6, wherein the fluid seal is axially spaced away from the rotor assembly.4.561 (8887-3393-003) 8. The sleeve assembly recited in claim 1, wherein the second end cap further comprises a metering thimble that receives lubricating fluid.

9. The sleeve assembly recited in claim 1, wherein the second end cap further comprises a drain that expels lubricating fluid.

10. The sleeve assembly recited in claim 1, further comprising a fluid seal positioned between the second end cap and a housing of the electric drive module.

11. The sleeve assembly recited in claim 1, further comprising a plurality of fluid passages formed between an outer diameter of the elongated tubular sleeve and the stator assembly.

12. A sleeve assembly for an electric drive module of a vehicle, comprising: an elongated tubular sleeve, having an inner diameter and an outer diameter, configured to fit concentrically between a rotor assembly of an electric motor and a stator assembly of the electric motor; a first end cap, removably coupled to the inner diameter or outer diameter of the elongated tubular sleeve via a fluid seal, received at one axial end of the elongated tubular sleeve forming a fluid tight seal between the first end cap and the elongated tubular sleeve; and a second end cap, removably coupled to the inner diameter or outer diameter of the elongated tubular sleeve via a fluid seal, received at an opposite axial end of the elongated tubular sleeve forming a fluid tight seal between the second end cap and the elongated tubular sleeve.

13. The sleeve assembly recited in claim 12, wherein the elongated tubular sleeve is formed from a non-electrically conductive material and the first end cap or the second end cap is formed from a different non-electrically conductive material.

14. The sleeve assembly recited in claim 12, wherein the elongated tubular sleeve is formed from a composite fiber.4.561 (8887-3393-003) 15. The sleeve assembly recited in claim 12, wherein the first end cap or the second end cap is formed from a fiberglass laminate.

16. The sleeve assembly recited in claim 12, wherein the fluid seal of the first end cap or the fluid seal of the second end cap is axially spaced away from the rotor assembly.

17. The sleeve assembly recited in claim 12, wherein the second end cap further comprises a metering thimble that receives lubricating fluid.

18. The sleeve assembly recited in claim 12, wherein the second end cap further comprises a drain that expels lubricating fluid.

19. The sleeve assembly recited in claim 12, further comprising a fluid seal positioned between the second end cap and a housing of the electric drive module.

20. The sleeve assembly recited in claim 12, further comprising a plurality of fluid passages formed between an outer diameter of the elongated tubular sleeve and the stator assembly.

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