Hybrid Module Baffle Blade Oil Vortex Disruption

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Solution Overview

Problem

Hybrid motor vehicle drive trains experience drag loss due to oil vortices within the bell housing, which current designs fail to effectively mitigate.

Innovation Solution

Incorporating a hybrid module with baffle blades extending axially from the housing, radially outside the electric motor and torque converter, to disrupt and redirect oil flow, thereby reducing vortex velocity and improving fluid flow back into the transmission sump.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If baffle blades are added to disrupt oil vortex, then drag loss is reduced, but device complexity increases

Engineering Contradiction:

Improvedrag lossVSAvoiddevice complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The baffle is segmented into multiple blades (typically 2-4 blades) spaced circumferentially around the bell housing. Each blade is a separate structural element that collectively disrupts the oil vortex flow pattern, reducing drag loss while maintaining manageable complexity through modular segmentation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The baffle blades serve as an intermediary structure positioned between the oil pump and the transmission sump. These blades mediate the oil flow by disrupting the vortex pattern without directly contacting moving components, reducing drag loss through fluid flow modification

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If baffle blades extend radially outside motor and torque converter, then oil flow is effectively disrupted, but manufacturing complexity increases

Engineering Contradiction:

Improvedrag lossVSAvoidease of manufacture

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The baffle blades are merged with the bell housing structure, forming an integrated component rather than a separate assembly. The blades extend from the bell housing wall radially outward, combining the housing and baffle functions into a single manufacturable part that reduces production steps and assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bell housing structure serves multiple functions: it houses the oil pump, supports the transmission components, and incorporates the baffle blades for vortex disruption. This multi-functionality reduces the number of separate parts needed, simplifying manufacturing while achieving drag loss reduction

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 baffle blades effectively reduce drag loss by interrupting oil vortices, enhancing oil flow efficiency and manufacturability, while maintaining ease of assembly for production.

Implementation Method 1

The torque converter can create a vortex of oil inside the bell housing

Methodology Applied

Scientific EffectVortex: Vortex Ring

Implementation Method 2

which has been linked to a drag loss on the order of 1 Nm

Methodology Applied

Scientific EffectDrag loss: Drag

Data Source

PatentUS10428922B2Hybrid motor vehicle drive train including hybrid module baffle blade

Publication Date: 2019.10.01 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A hybrid module configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine includes a drive unit including an electric motor and a housing, a torque converter connected to the electric motor and at least one baffle blade extending axially from the housing radially outside of the electric motor and the torque converter.