Injection-Molded Damping Unit for Electric Motor Vibration
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Solution Overview
Problem
Existing damping units for electric motors are ineffective in reducing longitudinal armature vibrations and associated operating noise, particularly in electric motors used for heating and air-conditioning fans, due to inadequate vibration damping mechanisms.
Innovation Solution
A damping unit comprising elastically deformable cavities within injection-molded elements, featuring a positive coupling between first and second injection-molded elements, preferably with a toothed configuration and ultrasonic processing, to convert vibrations into thermal energy, thereby reducing noise and enhancing damping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional damping units are used for electric motors, then the structure is simple, but the vibration damping effectiveness is insufficient
Solution Approach 1:
The damping unit is divided into multiple injection-molded elements (first and second elements) that can be separately manufactured and then assembled together. Each element contains cavities that provide vibration damping, and the segmented structure allows for better damping effectiveness while maintaining manufacturing simplicity through modular production
Solution Approach 2:
The damping unit employs composite construction by combining multiple injection-molded elements with different cavity configurations into a single damping assembly. This composite approach enhances vibration damping effectiveness by creating a multi-layered damping structure that addresses different vibration frequencies and directions
2Reliability
If the damping unit uses multiple injection-molded elements, then the vibration damping improves, but the connection reliability between elements may be insufficient
Solution Approach 1:
The injection-molded elements are designed with pre-formed coupling features (such as integrated attachment points or interlocking geometries) that are created during the molding process itself. This preliminary preparation ensures strong and reliable connections between elements when assembled, eliminating the need for additional fastening operations and ensuring consistent connection strength
Solution Approach 2:
The coupling features are merged directly into the injection-molded elements during manufacturing, creating an integrated design where the connection structures are part of the main body. This merging ensures that the connection strength is inherent to the design rather than added separately, improving both connection reliability and manufacturing efficiency
3Reliability
If cavities are added to the injection-molded elements, then vibration damping effectiveness increases, but the manufacturing complexity increases
Solution Approach 1:
The cavities are designed to be self-formed during the injection molding process itself, utilizing the molding cavity geometry to create the damping cavities without requiring separate machining or post-processing steps. The injection molding process automatically creates the required cavity structures as part of the basic forming operation, maintaining manufacturing simplicity while achieving effective vibration damping
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed damping unit effectively reduces armature longitudinal vibrations and operating noise in electric motors by converting kinetic energy into thermal energy, achieving a secure and reliable connection and compact configuration, thus improving motor performance and noise reduction.
Implementation Method 1
at least one cavity, which is provided for damping the at least one longitudinal armature vibration of the electric motor in at least one operating state
Implementation Method 2
elastically deformable cavity for damping the at least one longitudinal armature vibration
Implementation Method 3
at least one toothed element, which is at least partially provided for a form-fitting coupling between the one first injection-molded element and the one second injection-molded element
Data Source
Figure 1
Figure 2
Figure 3a~4
AI summary
The invention proceeds from a damping unit having at least one run-on element (12) which is intended to damp at least one armature longitudinal vibration of an electric motor in at least one operating state, and which has at least one hollow space (14) for damping the at least one armature longitudinal vibration of the electric motor in at least one operating state and at least one first injection-moulded element (16) and at least one second injection-moulded element (18). It is proposed that the at least one hollow space (14) is arranged at least substantially in the at least one first injection-moulded element (16) or in the at least one second injection-moulded element (18).