Thermal Sprayed Shielding Coatings for Vehicle Drivetrains

Solution Overview

Problem

The electrification of vehicle drivetrains often results in interference between electrical or magnetic fields generated by components, leading to the need for shielding plates that increase costs, weight, and complexity in assembly, while existing solutions fail to efficiently utilize space and reduce errors.

Innovation Solution

A method involving thermal and/or kinetic spraying to apply coating regions directly onto components for targeted magnetic and electrical shielding, allowing for flexible application on complex geometries and reducing the need for shielding plates by simulating and calculating the optimal placement of coatings for individual thicknesses and sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If shielding plates are used to block electromagnetic fields, then shielding effectiveness is improved, but device complexity and assembly difficulty increase

Engineering Contradiction:

Improveelectromagnetic field interferenceVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines the shielding function directly into the housing structure by applying conductive coating regions to specific areas of the housing. This merging of the shielding function into the existing housing eliminates the need for separate shielding plates and reduces assembly complexity, while still providing effective electromagnetic field blocking.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies shielding coating regions only to specific local areas of the housing where electromagnetic field interference occurs, rather than shielding the entire housing. This localized approach provides targeted shielding effectiveness while minimizing the amount of material and complexity required.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If shielding plates are used to block electromagnetic fields, then shielding effectiveness is improved, but weight increases

Engineering Contradiction:

Improveelectromagnetic field interferenceVSAvoidhousing weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent applies shielding coating regions only to specific local areas of the housing where electromagnetic field interference occurs, rather than shielding the entire housing. This localized approach provides targeted shielding effectiveness while minimizing the amount of material and complexity required.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If shielding plates are used to block electromagnetic fields, then shielding effectiveness is improved, but installation space is reduced

Engineering Contradiction:

Improveelectromagnetic field interferenceVSAvoidinstallation space

Core Design Contradiction:

Object-affected harmful factorsVSArea of stationary object

Solution Approach 1:

The patent combines the shielding function directly into the housing structure by applying conductive coating regions to specific areas of the housing. This merging of the shielding function into the existing housing eliminates the need for separate shielding plates and reduces assembly complexity, while still providing effective electromagnetic field blocking.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If thermal and/or kinetic spraying methods are used to apply coating regions, then manufacturing flexibility is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvegeometric adaptabilityVSAvoidcoating application complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical shielding plate assembly with thermal and/or kinetic spraying methods to apply conductive coating regions. This substitution enables the coating to conform to complex geometries and hard-to-reach areas that would be difficult or impossible to access with mechanical assembly, thereby improving geometric adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This approach effectively reduces production and assembly costs, conserves installation space, and minimizes errors by providing customizable shielding that can be applied in hard-to-reach areas, achieving efficient electromagnetic field diversion without additional weight or complexity.

Implementation Method 1

applying to the component at least one coating region, which is designed for shielding from magnetic and/or electrical fields, by means of a thermal and/or kinetic spraying method

Methodology Applied

Scientific EffectThermal spraying:

Implementation Method 2

applying to the component at least one coating region, which is designed for shielding from magnetic and/or electrical fields, by means of a thermal and/or kinetic spraying method

Methodology Applied

Scientific EffectKinetic spraying:

Implementation Method 3

the spraying method is in particular a thermal or kinetic spraying or coating method, such as particularly preferably arc wire spraying

Methodology Applied

Scientific EffectArc wire spraying:

Implementation Method 4

the spraying method is in particular a thermal or kinetic spraying or coating method, such as particularly preferably arc wire spraying, or else cold gas spraying

Methodology Applied

Scientific EffectCold gas spraying:

Implementation Method 5

in the case of high velocity oxygen fuel spraying speeds in a range of 1000 m/s and more are reached

Methodology Applied

Scientific EffectHigh velocity oxygen fuel spraying:

Data Source

PatentUS11596089B2Method for shielding components

Publication Date: 2023.02.28 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for shielding components includes the steps of providing a component and applying at least one coating region, designed to shield from a magnetic and/or an electrical field, to the component by a thermal and/or kinetic spraying method such that a first arrangement space is shielded from a second arrangement space.