Motor module comprising electric motor and liquid separator for liquid-air mixture

Abstract

The invention relates to a motor module (12) comprising an electric motor (13) through which a liquid-air mixture (F+L) can flow and a liquid separator (1) for separating liquid (F) from the liquid-air mixture (F+L). The liquid separator (1) is fastened to the motor (13) such that an inlet (2) of the liquid separator (1) is fluidically connected to a motor outlet (16) of the motor (13).

Description

[0001] MOTOR MODULE WITH ELECTRIC MOTOR AND LIQUID SEPARATOR FOR LIQUID-AIR MIXTURE

[0002] The invention relates to a motor module comprising a motor and a liquid separator according to the preamble of claim 1.

[0003] An electric motor can be cooled, for example, with an oil-air mixture. Since the velocity of the oil-air mixture within the electric motor is higher than that of pure oil due to the addition of air, the electric motor can be cooled more effectively. However, after passing through the motor, the oil-air mixture must be separated into its components to prevent a reduction in the performance of other components in the oil circuit, such as the pump and cooler. Oil separators can be used for this purpose, typically utilizing centrifugal and gravitational effects to separate the oil.

[0004] The object of the invention is therefore to provide an improved or at least alternative embodiment for a motor module of the generic type, in which the described disadvantages are overcome.

[0005] This problem is solved according to the invention by the subject matter of independent claim 1. Advantageous embodiments are the subject matter of the dependent claims.

[0006] The present invention is based on the general concept of designing a space-saving motor module and achieving improved separation of liquid from a liquid-air mixture. The motor module according to the invention is intended for or designed for a vehicle. The motor module comprises an electric motor with a cooling path. The cooling path has a motor inlet leading into the motor and a motor outlet leading out of the motor. A liquid-air mixture flows through the motor in the cooling path from the motor inlet to the motor outlet. Furthermore, the motor module has a liquid separator for separating liquid from the liquid-air mixture. The liquid separator has an inlet for the liquid-air mixture, a first outlet for the liquid separated from the liquid-air mixture, and a second outlet for air.The liquid separator comprises at least one separation element for separating the liquid from the liquid-air mixture. According to the invention, the liquid separator is attached to the engine, and the inlet of the liquid separator is fluidically connected to the engine outlet.

[0007] In the motor module according to the invention, the liquid separator is arranged or attached directly to the motor, so that the liquid-air mixture, after flowing through the motor in the cooling path, is directed into the liquid separator and separated there into liquid and air. This allows other components of a cooling circuit – such as the pump and radiator – to be cooled only by the liquid, thus preventing a reduction in the performance of these components. Furthermore, the liquid enters the liquid separator immediately after the motor and has a high velocity component. This eliminates the need for an additional drive, as required in conventional solutions. Moreover, by arranging the liquid separator directly on the motor, a particularly space-saving design of the motor module or the cooling circuit of the electric motor can be achieved.In other words, this reduces the installation space required for the motor module compared to conventional solutions. Furthermore, the liquid separator can also utilize the rotational component generated in the liquid-air mixture by the rotation of the electric motor around an axis of rotation in one direction to separate the liquid, resulting in particularly efficient liquid separation.

[0008] The fluid used to cool the engine can be oil. Therefore, the fluid separator is primarily an oil separator, and the fluid-air mixture is primarily an oil-air mixture.

[0009] The liquid separator can have an interior space and a flow path leading through this interior space. Within the interior space, the flow path extends from the inlet to the second outlet, passing the first outlet. The separation element is positioned within the interior space such that the inlet is fluidically connected to both the first and second outlets exclusively through the separation element.

[0010] In the liquid separator, the liquid-air mixture flows into the inlet and is introduced into the separation element. Within the separation element, the liquid-air mixture is separated into its components – liquid and air. Air flows from the separation element to the second outlet and then out of the liquid separator. The liquid, on the other hand, flows from the separation element to the first outlet and then out of the liquid separator. The separation element is a separate component of the liquid separator and can be adapted to separate the liquid from the liquid-air mixture independently of other boundary conditions. Compared to a conventional liquid separator, which, for example, uses a rigid internal wall to separate the liquid, this significantly improves the separator's performance.In particular, the entire volume of the liquid-air mixture can flow through the separation element in this liquid separator. As a result, compared to the conventional liquid separator described above, the liquid-air mixture cannot bypass the separation element and is separated into its components more effectively.

[0011] The separation element can have an inlet side, wherein the flow path leads from the inlet to the inlet side and terminates there fluidically. Furthermore, the separation element can have a first outlet side oriented transversely or inclined to the inlet side, wherein the first outlet side is fluidically connected to the first outlet. The separation element can also have a second outlet side opposite the inlet side, wherein the flow path leads from the second outlet side to the second outlet and terminates there fluidically. The separation element can, for example, be cuboid in shape. In the case of the cuboid separation element, the inlet side and the second outlet side can be arranged parallel to and spaced apart from each other. The first outlet side, on the other hand, can be oriented perpendicular to the inlet side and the second outlet side.

[0012] As described above, the liquid-air mixture flows from the inlet to the separation element along the flow path and enters the inlet side. From the inlet side, the liquid-air mixture then flows along the flow path from the inlet side to the second outlet side in the direction of flow. Here, the liquid-air mixture is separated into liquid and air. The air continues along the flow path to the second outlet side and then from the second outlet side to the second outlet. The liquid, on the other hand, flows in a secondary flow path branching off from the main flow path to the first outlet side and then on to the first outlet. This design of the separation element allows the flow path – i.e., the interior space from the inlet to the second outlet – to be traversed at high velocity, effectively separating the liquid-air mixture.

[0013] In a properly oriented liquid separator or motor module, the first outlet can be located at the lowest point of the interior, relative to gravity. Since liquid is heavier than air, the separated liquid can then settle towards the first outlet under the influence of gravity and be discharged from the liquid separator to the outside. This allows for more effective separation of the liquid from the liquid-air mixture. Alternatively, in a properly oriented liquid separator or motor module, the second outlet can be located above the first, relative to gravity. In this configuration, air can rise and flow out of the second outlet. Since liquid is heavier than air, this rising air can further purify any remaining liquid.In a properly oriented liquid separator or motor module, the inlet can be positioned above the first outlet with respect to gravity. This allows the liquid-air mixture to flow towards the first outlet under the influence of gravity, and the liquid can be at least partially separated before reaching the separation element. The separation element can have at least one flow channel and at least one impact surface for the liquid-air mixture. The flow channel can partially define or limit the flow path, or be part of the flow path, and the impact surface can partially limit at least one of the flow channels. Each impact surface can also be oriented at an angle greater than zero towards a flow direction extending from the inlet side to the second outlet side of the separation element.In the separation element, the liquid-air mixture can therefore be directed onto the impact surface and the liquid can be separated from the air due to its higher inertia.

[0014] Since the impact surface is oriented at an angle greater than zero to the flow direction of the liquid-air mixture in the flow channels, the liquid can be effectively separated at the impact surface. In contrast to a conventional liquid separator, which, for example, uses a wall in the interior to separate the liquid, here the angle of the impact surface can be adjusted as desired. In principle, the impact surface can have any angle to the flow direction. Preferably, the angle is between 30° and 55°. The number of impact surfaces within the respective flow channel can also be adjusted. This allows the liquid to be effectively separated from the air in the separation element.

[0015] At least one of the impact surfaces can have a collecting groove projecting into the flow channel to collect the liquid deposited at the impact surface. The collecting groove can be closed in the direction of flow and open against the direction of flow. In particular, the collecting groove can extend transversely to the direction of flow and be directed towards the first outlet. The liquid deposited at the impact surface can be collected in the collecting groove and guided along the groove to the first outlet. The collecting groove prevents the liquid deposited at the impact surface from being carried away again by the flowing liquid-air mixture.

[0016] In a properly oriented liquid separator or motor module, the impact surface can be vertically oriented with respect to gravity. This allows the liquid separated at the impact surface to settle downwards more quickly. In a properly oriented liquid separator or motor module, the collection groove can extend from top to bottom with respect to gravity and / or be vertically oriented with respect to gravity. This also allows the liquid within the collection groove to settle downwards towards the first outlet quickly under the influence of gravity. In a properly oriented liquid separator or motor module, the flow channel can be horizontally oriented with respect to gravity.

[0017] In one possible embodiment, at least one of the flow channels can be zigzag-shaped in the direction of flow. Within this zigzag-shaped flow channel, the sections oriented against the flow direction can form the impact surfaces for the liquid-air mixture described above. This allows for multiple impact surfaces to be formed within the single flow channel, thereby improving the separation of the liquid within the flow channel or the separation element. The separation element can have at least two zigzag-shaped walls oriented parallel to each other. The adjacent walls can each form one of the zigzag-shaped flow channels. The respective impact surface can be formed by a section of the wall.It is conceivable that the separation element has several zigzag-shaped walls, and that these walls form several parallel, zigzag-shaped flow channels. This allows the separation element to be designed in a space-saving manner while still enabling effective separation of the liquid from the liquid-air mixture.

[0018] In one possible embodiment of the liquid separator, the interior space can be formed around a central axis, spaced apart along the flow path. This central axis can, for example, correspond to the rotational axis of the motor. The flow path and / or the interior space can then extend from the inlet to the second outlet in the direction of rotation of the motor. In particular, the interior space can be annular. The liquid separator can also have a web, and this web can fluidically separate the interior space with respect to the flow path upstream of the inlet and downstream of the second outlet. In particular, the web can separate the interior space in such a way that the flow path from the inlet to the second outlet passes exclusively through the separation element. This design allows the liquid separator to be particularly compact and the flow path within the interior space to be extended.This allows the liquid-air mixture to be separated into its components more effectively over the longer flow path. Further important features and advantages of the invention will become apparent from the dependent claims, the drawings, and the accompanying description of the figures based on the drawings.

[0019] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified, but also in other combinations or on their own, without leaving the scope of the present invention.

[0020] Preferred embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein identical reference numerals refer to identical or similar or functionally identical components.

[0021] They show, each schematically

[0022] Fig. 1 shows a view of a motor module according to the invention with a motor and a liquid separator;

[0023] Fig. 2 shows a sectional view of the liquid separator in a first embodiment;

[0024] Fig. 3 shows a sectional view of the liquid separator in a second embodiment;

[0025] Fig. 4 shows a top view of a separation element of the liquid separator. Fig. 1 shows a view of a motor module 12 according to the invention with a liquid separator 1 and an electric motor 13. The electric motor 13 has a cooling path 14 with a motor inlet 15 and a motor outlet 16 and is permeable to a liquid-air mixture F+L. Here and subsequently, the flow of the liquid-air mixture F+L is indicated by dashed arrows, the flow of a liquid F separated from the liquid-air mixture F+L is indicated by solid arrows, and the flow of air L separated from the liquid-air mixture F+L is indicated by dotted arrows.

[0026] The liquid separator 1 is attached to or flanged to the motor 13, such that the motor outlet 16 opens directly into an inlet 2 of the liquid separator 1. The liquid separator 1 is advantageously designed such that its central axis MA corresponds to a rotation axis RA of the motor 13, and a flow path SP defined within the liquid separator 1 can be traversed along a rotation direction RR of the motor 13. This allows the rotational component generated by the motor 13 in the liquid-air mixture F+L to be used in the liquid separator 1 for separating the liquid F. Further details regarding the construction of the liquid separator 1 are explained below with reference to Figures 2 to 4.

[0027] Fig. 2 shows a sectional view of the liquid separator 1 in a first embodiment. The liquid separator 1 has the inlet 2 for the liquid-air mixture F+L mentioned above, a first outlet 3 for the liquid F separated from the liquid-air mixture F+L, and a second outlet 4 for air L.

[0028] Furthermore, the liquid separator 1 comprises an interior space 5, wherein the inlet 2 from the motor 13 leads into the interior space 5 and the outlets 3 and 4 lead from the interior space 5 to the outside. The liquid separator 1 also includes the aforementioned flow path SP, which extends within the interior space 5 from the inlet 2 to the second outlet 4, passing the first outlet 3. The interior space 5 is circumferentially shaped around the central axis MA. As explained above, the central axis MA corresponds to the axis of rotation RA of the motor 13. In the first embodiment, the interior space 5 of the liquid separator 1 is annular. The interior space 5 is fluidically divided by a web 6, which is arranged between the inlet 2 and the second outlet 4.

[0029] Furthermore, the liquid separator 1 has a separation element 7 for separating the liquid F from the liquid-air mixture F+L. The separation element 7 is arranged in the interior 5 such that the inlet 2 and the first outlet 3, as well as the inlet 2 and the second outlet 4, are fluidically connected to each other exclusively through the separation element 7. In other words, the liquid-air mixture F+L is forced to flow through the separation element 7 in the liquid separator 1.

[0030] The separation element 7 is shaped separately here, so that the separation of the liquid F from the liquid-air mixture F+L can be adapted independently of other boundary conditions. In this embodiment, the separation element 7 is cuboid and has a total of six sides or side surfaces. Among other things, the separation element 7 has an inlet side 2a, a first outlet side 3a, and a second outlet side 4a. The inlet side 2a and the second outlet side 4a are oriented transversely to the flow path SP, and the first outlet side 3a is oriented parallel to the flow path SP. The separation element 7 is permeable to flow in the flow path SP in a flow direction SR from the inlet side 2a to the outlet side 4a.As explained above, the flow path SP is permeable in the direction of rotation RR of the motor 13, so that the rotational component generated in the liquid-air mixture F+L by the motor 13 can also be used to separate the liquid F in the liquid separator 1. Furthermore, a secondary flow path NSP leads from the separation element 7 to the first outlet 3.

[0031] In Fig. 2, the liquid separator 1 is oriented for operation with respect to the force of gravity G. The inlet 2 and the second outlet 4 are located above the first outlet 3. The first outlet 3 is also located at the lowest point of the interior 5. Under the influence of gravity G, the separated liquid F settles downwards towards the first outlet 3, and the air L rises towards the second outlet 4. This further enhances or intensifies the separation of the liquid F, in addition to the effect of the separation element 7.

[0032] Fig. 3 shows a sectional view of the liquid separator 1 in a second embodiment. In the second embodiment, the interior space 5 is formed as a partial volume between two closely cuboid volumes and is therefore not annular. Here, too, the interior space 5 is fluidically separated by the web 6 between the inlet 2 and the second outlet 4.

[0033] Fig. 4 shows a top view of the separation element 7 of the liquid separator 1. The separation element 7 has zigzag-shaped flow channels 8 oriented in the flow direction SR. Each zigzag-shaped flow channel 8 is formed between two zigzag-shaped walls 9 that are parallel to each other. In the embodiment shown here, the separation element 7 has exactly two flow channels 8, each formed by exactly three walls 9. The flow channels 8 fluidically connect the inlet side 2a and the second outlet side 4a. The flow channels 8 are also open to the first outlet 3 and the first outlet side 3a, respectively, and are aligned parallel to it. Several impact surfaces are located in the flow channel 8.

[0034] The surfaces 10 are shaped and oriented at an angle greater than zero to the flow direction SR. When the liquid F separates from the liquid-air mixture F+L, small droplets of liquid F strike the impact surfaces 10 and, under the influence of gravity G, settle downwards perpendicular to the flow direction SR towards the first outlet side 3a or the first outlet 3. The air L, on the other hand, can continue to flow to the second outlet side 4a or the second outlet 4 in the flow path SP.

[0035] To prevent the liquid F from being carried away from the impact surface 10 in the flow direction SR, each impact surface 10 has a collecting groove.

[0036] The collection groove 11 is oriented transversely to the flow direction SR and leads to the first outlet 3. The liquid F trapped or collected in the collection groove 11 can thus be directed from the impact surface 10 transversely to the flow direction SR to the first outlet side 3a or to the first outlet 3. For this purpose, the collection groove 11 is open against the flow direction SR and closed in the flow direction SR. Referring also to Fig. 1 and Fig. 2, in the properly oriented liquid separator 1, the flow channel 8 is horizontal and the impact surface 10 is vertically oriented. The collection groove 11 then extends from top to bottom.

Claims

Claims 1. Motor module (12) for a vehicle, - wherein the motor module (12) has an electric motor (13) with a cooling path (14), - wherein the cooling path (14) has an engine inlet (15) leading into the engine (13) and an engine outlet (16) leading out of the engine (13), - wherein the motor (12) is permeable by a liquid-air mixture (F+L) in the cooling path (14) from the motor inlet (15) to the motor outlet (16), - wherein the motor module (12) has a liquid separator (1 ) for separating liquid (F) from the liquid-air mixture (F+L), - wherein the liquid separator (1 ) has an inlet (2) for the liquid-air mixture (F+L), a first outlet (3) for the liquid (F) separated from the liquid-air mixture (F+L) and a second outlet (4) for air (L), and - wherein the liquid separator (1 ) has at least one separation element (7) for separating the liquid (F) from the liquid-air mixture (F+L), characterized in that the liquid separator (1 ) is attached to the motor (13) and the inlet (2) of the liquid separator (1 ) is fluidically connected to the motor outlet (16) of the motor (13).

2. Motor module (12) according to claim 1, characterized in that, - that the liquid separator (1 ) has an interior space (5) and a flow path (SP) leading through the interior space (5), - that the flow path (SP) extends within the interior (5) from the inlet (2) to the second outlet (4) past the first outlet (3), and - that the separation element (7) is arranged in the interior (5) such that the inlet (2) is fluidically connected to the first outlet (3) and to the second outlet (4) exclusively through the separation element (7).

3. Motor module (12) according to claim 2, characterized in that, - that the separation element (7) has an inlet side (2a), wherein the flow path (SP) leads from the inlet (2) to the inlet side (2a) and fluidically opens into it, - that the separation element (7) has a first outlet side (3a) oriented transversely or inclined to the inlet side (2a), wherein the first outlet side (3a) is fluidically connected to the first outlet (3), and - that the separation element (7) has a second outlet side (4a) opposite the inlet side (2a), wherein the flow path (SP) leads from the second outlet side (4a) to the second outlet (4) and flows fluidically into it.

4. Motor module (12) according to claim 3, characterized in that, - that the separation element (7) has at least one flow channel (8) which forms the flow path (SP) in certain areas and through which flow can occur, - that the separation element (7) has at least one impact surface (10) for the liquid-air mixture (F+L) and that the impact surface (10) at least one of the flow channels (8) is at least partially limited, and - that each impact surface (10) is oriented at an angle greater than zero to a flow direction (SR) extending from the inlet side (2a) to the second outlet side (4a) of the separation element (7).

5. Motor module (12) according to claim 4, characterized in that, - that at least one of the impact surfaces (10) has a collecting groove (11) projecting into the flow channel (8) to collect the liquid (F) deposited on the impact surface (10), and - that the collecting groove (11 ) is closed in the direction of flow (SR) and open against the direction of flow (SR).

6. Motor module (12) according to claim 4 or 5, characterized in that, - that in the properly aligned liquid separator (1 ) the impact surface (10) is vertically aligned with respect to the force of gravity (G), and / or - that in the properly aligned liquid separator (1 ) the collection groove (11 ) extends from top to bottom with respect to the force of gravity (G), and / or - that in the properly aligned liquid separator (1 ) the flow channel (8) is horizontally aligned with respect to the force of gravity (G).

7. Motor module (12) according to one of claims 4 to 6, characterized in that, that at least one of the flow channels (8) is zigzag-shaped in the direction of flow (SR).

8. Motor module (12) according to claim 7, characterized in that, - that the separation element (7) has at least two zigzag-shaped walls (9) aligned parallel to each other, - that the adjacent walls (9) each form one of the zigzag-shaped flow channels (8), and - that the respective impact surface (10) is formed by a section of the wall (9).

9. Motor module (12) according to one of claims 2 to 8, characterized in that, - that the interior (5) is continuously shaped along the flow path (SP) about a central axis (MA), and - that the liquid separator (1 ) has a bridge (6) and the bridge (6) fluidically separates the interior (5) with respect to the flow path (SP) upstream of the inlet (2) and downstream of the second outlet (4).

10. Motor module (12) according to claim 9, characterized in that the flow path (SP) and / or the interior (5) extend from the inlet (2) to the second outlet (4) in a rotational direction (RR) of the motor (13).

11. Motor module (12) according to one of claims 2 to 10, characterized in that, - that in the properly aligned liquid separator (1 ) the first outlet (3) is located at the lowest point of the interior (5) with respect to the force of gravity (G), and / or - that in the properly aligned liquid separator (1 ) the second outlet (4) is arranged above the first outlet (3) with respect to the force of gravity (G), and / or - that in the properly aligned liquid separator (1 ) the inlet (2) is arranged above the first outlet (3) with respect to the force of gravity (G), and / or - that in the properly aligned liquid separator (1 ) the separation element (7) is arranged above the first outlet (3) with respect to the force of gravity (G).

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