Housing component for a housing of a vehicle

Abstract

The invention relates to a housing component (10) for a housing (50) of a vehicle (100), comprising at least one first shaped plate element (1) and a second shaped plate element (2) inseparably connected thereto, the at least two shaped plate elements (1, 2) forming walls for a cavity volume (3) formed at least partially therebetween.

Description

[0001] ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23

[0002] Housing component for a vehicle housing

[0003] The invention relates to a housing component for a vehicle body. Furthermore, the invention relates to a housing for a transmission and / or for a drive unit of a vehicle, as well as a vehicle with such a housing.

[0004] Gearbox components, especially gearbox covers, such as a gearbox housing cover, can be designed to support and guide gearbox shafts. The housing cover forms a closed unit with the rest of the housing. Bearings can be integrated into the housing cover to rotatably support and guide the gearbox shafts.

[0005] Common housing components and housings for gearboxes and drive units are typically made of gray cast iron. Alternatively, graphite cast iron and cast steel are used. Light metal casting alloys are frequently employed in vehicle transmissions. Furthermore, housing components are known to feature ribbing to ensure a sufficiently stable design for bearing applications. This ribbing is also generally produced by primary forming. Ribbing is a structural design in which ribs or reinforcing elements are applied to the surface of a component.

[0006] The object of the present invention is to provide an alternative housing component that can be manufactured cost-effectively and in an environmentally friendly manner, and is lightweight and resistant to deformation. This object is achieved by the features of independent claim 1. Advantageous embodiments are the subject of the dependent claims, the following description, and the figures.

[0007] According to a first aspect, a housing component for a vehicle housing is provided, comprising at least one first formed plate element and a second formed plate element inseparably connected to it, wherein the at least two formed plate elements create walls for a cavity volume formed at least partially between them. Thus, the at least two plate elements do not lie completely against each other, but form a double-walled housing component, whereby the cavity volume is continuous and closed. For example, the cavity volume is filled with air. Alternatively, the cavity volume can be filled with a foamed material. The cavity volume between the two plate elements makes the housing component particularly lightweight.The cavity volume extends, for example, over at least 50% and at most 95% of the overlap area of ​​the at least two plate elements. This provides sufficient stiffening of the plate elements to support a bearing element. In particular, sufficiently high deformation resistance and stability are achieved to prevent tilting of a bearing with line contact, such as a roller or tapered roller bearing. This prevents so-called edge bearing. The risk of tilting is particularly high with flat housing parts or housing covers, as these exhibit unfavorable leverage.

[0008] According to one embodiment, the housing component is designed as a housing cover. In particular, the housing component is ribless, i.e., without ribbing. Specifically, the housing component is designed as a gearbox cover for an electric drive comprising an electric motor and a gearbox. The housing component is understood as a structural unit consisting of at least two formed plate elements. The housing component thus functions as a single component. A formed plate element is understood to be a disc made of a metal, in particular a metal sheet, a polymer material, or a composite material, which is formed into its final shape by forming. This process saves material and weight, as well as CO2 emissions during manufacturing, compared to manufacturing by primary forming.

[0009] According to one embodiment, at least one of the plate elements is made of a steel sheet, an aluminum alloy, a polymer material, or a composite material. For example, the composite material is reinforced by fibers or particles. Alternatively, both plate elements are made of a steel sheet, an aluminum alloy, a polymer material, or a composite material. Alternatively, both plate elements are made of the same material (ZF Friedrichshafen AG File 303499, Friedrichshafen, 2024-09-23). ​​Finally, both plate elements are made of different materials.

[0010] According to one embodiment, at least one of the plate elements is formed at least partially by deep drawing, hydroforming, and / or forging. For example, both plate elements are manufactured at least partially or completely by deep drawing, hydroforming, and / or forging, i.e., also by a combination of these processes.

[0011] According to one embodiment, the at least two formed plate elements are permanently joined together by welding, bonding, and / or riveting. A non-destructive, permanently inseparable connection is thus achieved by welding, bonding, and / or riveting, or by a combination of these methods.

[0012] According to one embodiment, the housing component has an opening designed to receive a bearing component. In particular, a bearing component is arranged in the opening of the housing component. For example, the bearing component is designed as a bearing ring, preferably as the outer ring of a roller bearing or tapered roller bearing. The double-walled structure with a cavity is sufficiently stable so that roller bearings or tapered roller bearings can be used. Compared to ball bearings, forces can be absorbed more effectively by the "line contact" of a roller bearing or tapered roller bearing. The use of a roller bearing or tapered roller bearing therefore enables extremely efficient bearing arrangement. In particular, the opening is designed as a central opening in the housing component and is thus formed in the at least two plate elements.For example, the at least two plate elements are designed as ring discs, with the opening being produced, for example, by a separation process.

[0013] According to one embodiment, the cavity volume is formed at least partially around the opening in the circumferential direction. In particular, the cavity volume is formed completely around the opening in the circumferential direction. Thus, the cavity volume is formed in an annular shape. This enables efficient and homogeneous support of the bearing element arranged in the opening, since the double wall is formed in the area of ​​the cavity volume.

[0014] According to one embodiment, the first formed plate element is essentially cup-shaped and has a first circumferential collar section for guiding a shaft and receiving the bearing component, and a second circumferential collar section for end-face contact with the housing. For example, the first collar section is essentially perpendicular to the second collar section. "Essentially perpendicular" includes angular deviations of up to 10 degrees. In particular, the bearing component bears radially against the first circumferential collar section. Furthermore, the first collar section is configured to center the second plate element on the first plate element, with the second collar section being configured to axially support the second plate element on the first plate element. For example, bores for guiding screws and fastening to a housing are arranged in the second collar section.

[0015] According to one embodiment, the second formed plate element is essentially star-shaped and has an inner circumferential surface that abuts the first collar section, with radial end sections of the second formed plate element abutting at least partially against the second collar section. In particular, the radial end sections of the second formed plate element are formed radially outwards such that they abut axially over a surface area against the second collar section. According to one embodiment, the second plate element abuts axially against the first plate element with a circumferentially formed outer contour. This creates a large contact area with a simultaneously large cavity volume.

[0016] According to a second aspect, a housing for a transmission and / or for a drive unit of a vehicle is provided, comprising a housing component according to the first aspect. For example, the housing component is designed as a housing cover. For example, the housing has two such housing components. ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23

[0017] According to a third aspect, a vehicle is provided with a housing according to the second aspect. The above definitions, as well as explanations of the technical effects, advantages, and advantageous embodiments of the housing component, also apply analogously to the housing and the vehicle. For example, the vehicle is designed as an electric motor vehicle.

[0018] Advantageous embodiments of the invention, which are explained below, are illustrated in the drawings, wherein identical or similar elements are designated with the same reference numeral. They show:

[0019] Fig. 1 shows a schematic perspective section view of a housing component;

[0020] Fig. 2 is a schematic perspective section view of the housing component according to Fig. 1 in a mounted state on a housing;

[0021] Fig. 3 is a highly schematic representation of a housing with two housing components according to Fig. 1 and

[0022] Fig. 4 shows a vehicle with a housing according to Fig. 3.

[0023] Fig. 1 shows a housing component 10, which is formed from a first formed plate element 1 and a second formed plate element 2, which is permanently and non-destructively connected to it. The housing component 10 has an opening 4 in which a bearing component 5, designed as a bearing ring, is arranged. The two plate elements 1, 2 can be made of different materials. In this case, the two plate elements 1, 2 are made of steel sheets and form walls for a cavity volume 3 formed at least partially between them. The cavity volume 3 is closed and, in particular, filled with air, with the second plate element 2 bearing against the first plate element 1 by means of an inner circumferential surface and a circumferential outer circumferential section, which is accordingly formed and designed to form a flat contact surface with the first plate element 1.Therefore, the two plate elements 1, 2 do not lie completely against each other, but form a double-walled housing component 10, whereby the cavity volume 3 is continuous and closed.

[0024] The cavity volume 3 and the corresponding shaping of the first and second plate elements 1, 2 form a housing component 10 that is particularly lightweight and sufficiently rigid to serve as a bearing housing. The housing component 10 has a flat yet stable design, exhibiting high structural integrity and high resistance to deformation and mechanical loads. Furthermore, it is advantageous that ribbing can be omitted, thus simplifying manufacturing and saving material and costs. In this case, the two plate elements 1, 2 are manufactured by deep drawing steel sheet discs and joining these steel sheet discs, for example by bonding or welding. This saves material and weight as well as CO2 emissions during manufacturing compared to manufacturing by primary forming.

[0025] The first formed plate element 1 is essentially cup-shaped and has a first circumferential collar section 6 for the passage of a shaft 21, which is shown in Fig. 2, and a second circumferential collar section 7 for end-face contact with the housing 50, which is shown in Fig. 2. The first collar section 6 is essentially perpendicular to the second collar section 7. In particular, an outer surface of the first collar section 6 radially receives the second plate element 2. The second collar section 7 axially supports the second plate element 2 with a uniform circumferential distribution.

[0026] The second formed plate element 2 is essentially star-shaped and comprises an inner circumferential surface 8 that radially abuts the first collar section 6, as well as radial end sections 9 that are correspondingly formed and abut the second collar section 7. The cavity volume 3 extends circumferentially around the opening 4 and runs through each support arm of the star-shaped second plate element 2. Thus, the two plate elements 1, 2 abut both along the entire inner contour of the second plate element 2 and along the entire ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23

[0027] The outer contour of the second plate element 2 abuts each other. This creates a particularly rigid structure. Furthermore, in the second collar section 7, a bore 11 for the passage of screws (not shown) is formed circumferentially between two support arms of the second plate element 2, whereby the housing component 10, designed as a housing cover, is fixed to the housing 50 according to Fig. 2 via the screws.

[0028] Fig. 2 shows the housing component 10 according to Fig. 1 in an assembled state on a housing 50, which is only partially shown. For the design of the housing component 10, reference is made to Fig. 1. A gearbox 20 is arranged in the housing 50, of which only one output gear 22 is shown here. This gear is effectively connected via a differential 23 to output shafts, of which only one output shaft 21 is shown here. A tapered roller bearing is arranged between the first circumferential collar section 6 and the output shaft 21. Only the bearing component 5, designed as an outer ring, is shown here. The tapered rollers are arranged spatially between the bearing component 5 and a differential component 24, through which the output shaft 21 is guided.Housing component 10 is designed as a housing cover and is suitable for stable support and efficient tapered roller bearing arrangement. Efficient tapered roller bearing arrangement refers to the way tapered roller bearings are arranged in a gearbox to ensure optimal performance and efficiency and to resist tilting. Efficient tapered roller bearing arrangement minimizes friction losses and energy losses in the gearbox. This contributes to the overall efficiency of the gearbox. Tapered roller bearings are rolling bearings specifically designed to absorb radial and axial forces in a rotating application. They consist of an inner ring, an outer ring, tapered rollers, and a cage.

[0029] Fig. 3 shows a highly simplified representation of the housing 50 with two housing components designed as housing covers, as shown in Figs. 1 and 2. The housing 50 encloses a drive device 30 designed as an electric machine and a gearbox 20. ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23

[0030] Fig. 4 shows a vehicle 100 with a first axle 101 with two wheels R1, R2 and a second axle 102 with two wheels R3, R4. In this case, the first axle 101 is designed as the rear drive axle of the vehicle 100 and is equipped with a drive unit. The drive unit comprises a drive device, designed as an electric machine and configured to generate drive power, and a transmission 20 with a differential for distributing the drive power to the two wheels R1, R2 of the first axle 101. The drive device 30 and the transmission 20 are arranged together in a housing 50 as shown in Fig. 3. The vehicle 100 is designed as an electric vehicle.

[0031] ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23

[0032] Reference mark

[0033] 1 first transformed plate element

[0034] 2 second transformed plate element

[0035] 3 cavity volume

[0036] 4 Opening

[0037] 5 Bearing component

[0038] 6 first continuous collar section

[0039] 7 second circumferential collar section

[0040] 8 Inner perimeter area

[0041] 9 radial end section

[0042] 10 Housing component

[0043] 11 bore

[0044] 20 gearboxes

[0045] 21 Output shaft

[0046] 22 Output gear

[0047] 23 Differential

[0048] 24 Differential component

[0049] 30 Drive device

[0050] 50 cases

[0051] 100 vehicles

[0052] 101 first axis

[0053] 102 second axis

[0054] R1 wheel

[0055] R2 wheel

[0056] R3 wheel

[0057] R4 wheel

Claims

ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23 Patent claims 1. Housing component (10) for a housing (50) of a vehicle (100), comprising at least a first formed plate element (1 ) and a second formed plate element (2) inseparably connected thereto, wherein the at least two formed plate elements (1 , 2) form walls for a cavity volume (3) formed at least partially between them.

2. Housing component (10) according to claim 1, wherein at least one of the plate elements (1 , 2) is made of a sheet steel, an aluminium alloy, a polymer material or a composite material.

3. Housing component (10) according to one of the preceding claims, wherein at least one of the plate elements (1 , 2) is formed at least partially by deep drawing, hydroforming and / or forging.

4. Housing component (10) according to one of the preceding claims, wherein the at least two formed plate elements (1 , 2) are inseparably joined together by welding, gluing and / or riveting.

5. Housing component (10) according to one of the preceding claims, comprising an opening (4) designed to receive a bearing component (5).

6. Housing component (10) according to claim 5, wherein the cavity volume (3) is formed at least partially in the circumferential direction around the opening (4).

7. Housing component (10) according to claim 5 or 6, wherein the first formed plate element (1 ) is essentially cup-shaped and has a first circumferential collar section (6) for receiving the bearing component (5) and a second circumferential collar section (7) for end-face contact with the housing (50).

8. Housing component (1) according to claim 7, wherein the second formed plate element (2) is essentially star-shaped and has an inner circumferential surface ZF Friedrichshafen AG File 303499 Friedrichshafen 2024-09-23 (8), which comes into contact with the first collar section (6), wherein radial end sections (9) of the second formed plate element (2) come into contact at least partially with the second collar section (7).

9. Housing (50) for a transmission (20) and / or a drive device (30) of a vehicle (100) comprising a housing component (10) according to one of the preceding claims.

10. Vehicle (100) with a housing (50) according to claim 9.

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