JP2018512539A - Oil pan assembly - Google Patents

Abstract

The oil pan assembly includes a first part formed of a first plastic and a second part formed of a second plastic different from the first plastic. The first part is fixedly connected to the second part. The first plastic can be one of a thermosetting material or a thermoplastic material. The second plastic can be the other of a thermosetting material or a thermoplastic material. [Selection] Figure 1

Description

[Related applications]
This application relates to US Provisional Patent Application No. 62/143970, filed April 7, 2015, entitled “Oil Pan Assembly” and claims the benefit of priority from this application. This application is hereby incorporated by reference in its entirety.

  Embodiments of the present disclosure generally relate to an oil pan assembly that can be used with a vehicle transmission and an internal combustion engine.

  Various vehicles include transmissions and internal combustion engines that include components that are lubricated by oil. Oil pans are often used to hold oil in certain parts of the vehicle when the oil is not circulating in the transmission or engine.

  A known oil pan can be formed of a thermoplastic resin (nylon 6/6 or the like). Other known oil pans can be formed from other materials such as, for example, metals and rubbers that withstand impact and are strong. Some known oil pans incorporate other parts into the pan, such as suction and pressure filters, windage trays and baffles. Examples of oil pans are: Patent Document 1 entitled “Oil Pan Module for Internal Combustion Engines”; Patent Document 2 entitled “Oil Pan”; Patent Document 3 entitled “Oil Pan for an Internal Combustion Engine”; Patent Document 4 entitled “An Internal Combustion Engine”, Patent Document 5 entitled “Oil Pan”, Patent Document 6 entitled “Oil Pan Module for Internal Combustion Engines”, and Patent entitled “Oil Pan Useful for an Internal Combustion Engine” Document 7 describes.

  Plastics may be used to form certain engine and transmission components to reduce mass and improve fuel economy. The corporate average fuel consumption (CAFE) standard is a regulation established to improve the average fuel consumption of vehicles such as automobiles and light trucks manufactured and sold in the United States. The specific CAFE standard of 55 miles per gallon by 2025 encourages manufacturers to aim for lighter vehicles. Note that plastic parts are usually lighter than metal parts. Thus, various vehicle parts may be made of plastic to reduce the total weight of the vehicle. Injection molding N6 / 6 is a common material used to form plastic oil pans.

  On the other hand, some manufacturers make oil pans from press-molded metals such as aluminum because of temperature problems. That is, at higher temperatures, such as in and / or near an operating internal combustion engine and / or exhaust line, the plastic parts may deform. Thus, metals can still withstand higher temperatures, so metals are still used to form various parts. However, as can be appreciated, metals such as aluminum or steel have design limitations on the types of shapes that can be produced and are typically heavier than twice the weight of a plastic pan.

EP 1276974 European Patent No. 1511924 U.S. Pat. No. 4,930,469 US Pat. No. 6,131,543 US Pat. No. 6,584,950 US Pat. No. 6,705,270 US Pat. No. 7,481,196

  There is a need for a lighter oil pan that maintains structural integrity when exposed to elevated temperatures, shocks and / or forces, such as may be caused by operation of the transmission and / or internal combustion engine. There is a need for an oil pan that can be formed in a variety of shapes to accommodate a limited space within a vehicle. Furthermore, there is a need for an oil pan that is less expensive to manufacture.

  In view of these needs, certain embodiments of the present disclosure provide a first portion formed by a first plastic and a second portion formed by a second plastic that is different from the first plastic. An oil pan assembly comprising two parts. The first part is fixedly connected to the second part. The first plastic may be one of a thermosetting material or a thermoplastic material, and the second plastic may be the other of the thermosetting material or the thermoplastic material. it can. In at least one embodiment, the thermosetting material is a sheet molding compound and the thermoplastic material is nylon 6/6.

  The first portion may be configured to be exposed to one or both of a higher temperature or a stronger force than the second portion. In at least one embodiment, the first portion is configured to be positioned near one or more exhaust paths.

  The first part may include a peripheral wall, and the second part may include a flange and a base fixed to the peripheral wall. An oil collection chamber is defined between the base portion and the peripheral wall. The base part may have a thickness that is at least twice the thickness of the peripheral wall.

  The first portion can be formed by compression molding. The second portion can be overmolded over the first portion.

  Certain embodiments of the present disclosure provide a method of forming an oil pan assembly. The method includes forming a first portion of the oil pan assembly from a first plastic, and forming a second portion of the oil pan assembly from a second plastic different from the first plastic. Forming and fixingly connecting the first part to the second part.

1 is a top perspective view of an oil pan assembly according to an embodiment of the present disclosure. It is sectional drawing of the base part connected with the surrounding wall of the oil pan assembly which concerns on one Embodiment of this indication. It is a top perspective view of a peripheral wall concerning one embodiment of this indication. 2 is a flowchart of a method of forming an oil pan assembly according to an embodiment of the present disclosure.

  Before describing embodiments of the present disclosure in detail, it is understood that the present disclosure is not limited in its application to the details of the construction and arrangement of components described in the following description or illustrated in the drawings. I want. The disclosure is capable of other embodiments and of being practiced or carried out in various ways. Also, it should be understood that the expressions and terms used herein are for illustrative purposes and should not be considered limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the members listed above and their equivalents, as well as additional members and their equivalents.

  Embodiments of the present disclosure provide an oil pan assembly that can comprise two different parts, each of which can be formed from a different plastic. In at least one embodiment, the oil pan assembly includes a first portion that can be formed of a thermoplastic material such as nylon 6/6 (N6 / 6) and a thermosetting material such as sheet molding compound (SMC). And a second portion that can be formed of a material. Each plastic has unique properties and different material costs. Thus, two plastics can be used to form the first part and the second part, respectively, and the first part and the second part can be combined to create an adverse environment (eg, an internal combustion engine of a vehicle An oil pan assembly that minimizes or otherwise reduces costs while maximizing or otherwise improving

  Embodiments of the present disclosure typically include a thermosetting material (thermosetting material) in a region that is configured for a strong impact and / or high temperature that exceeds the performance of the thermoplastic material (thermoplastic material). An oil pan assembly is provided. Thermosets are highly cross-linked polymers that have a molecular mesh or network of polymer chains similar to a three-dimensional network. Once cured, the thermosetting material cannot be melted or reshaped and becomes solvent resistant. That is, the thermosetting material is irreversibly cured so that it is permanently cured once molded. Due to the tightly cross-linked structure, the thermosetting material withstands higher temperatures and provides improved structural stability compared to thermoplastic materials.

  A thermoplastic is a type of plastic that becomes flexible or moldable above a certain temperature, has a predetermined melting point, and solidifies upon cooling. The polymer chains of the thermoplastic material are bonded by intermolecular forces, which rapidly weaken with increasing temperature, resulting in a viscous liquid. Accordingly, thermoplastic materials can be reshaped by heating and are typically used to form parts by injection molding, compression molding, calendar molding, extrusion molding, and the like.

  Compared to thermoplastic materials, thermosetting materials have much higher heat resistance (eg, 400-500 degrees Fahrenheit). In contrast, the maximum long-term heat resistance of N6 / 6 or similar derivatives is approximately 300-350 degrees Fahrenheit. However, thermosetting materials, especially carbon fibers, are usually much more expensive than thermoplastic materials. For example, thermoset carbon fibers can currently be in the price range of $ 5 to $ 20 per pound, while thermoplastic high heat resistant derivatives such as N6 / 6 or PPA are currently 1.75 per pound. It can be an average price between $ 3 and $ 3.75.

  Accordingly, certain embodiments of the present disclosure provide an oil pan assembly that includes a first portion formed of a thermoset material and a second portion formed of a thermoplastic material. If desired, the first portion may be formed from a thermoplastic material, while the second portion may be formed from a thermosetting material. The first portion is configured to be at or near an area that may be subjected to high temperatures and / or forces that may be deformed and / or deteriorated with the thermoplastic material. The second portion can be less susceptible to such high temperatures and / or impacts, and thus can be formed of a thermoplastic material to reduce the total cost of the oil pan assembly.

  In at least one embodiment, the oil pan assembly may comprise a thermoset peripheral wall or an annular wall that is coupled to a thermoplastic base. The oil pan assembly may comprise an annular wall and base portion, each formed by a separate plastic material, providing heat resistance and impact resistance while simultaneously impacting and / or lower cost thermoplastics. A unique plastic hybrid design is formed that minimizes or otherwise reduces the total cost when used in areas that are not susceptible to high temperatures.

  The region formed of the thermosetting substance of the oil pan can be molded from thermosetting SMC, for example, in a compression mold. Various shapes and geometric configurations can be used. Compared to steel pans, thermoset SMC pans are deeper drawn and lighter.

  Due to the exhaust path along either side, heat resistance will be required along the sides of the oil pan assembly. Other areas of the oil pan assembly including the bottom and flange can be molded from a thermoplastic material such as N6 / 6. This material allows for the efficient use of lower cost resins and the flexibility to insert mold torque limiters or torque limiters with screw fasteners (bolts). The portions of the oil pan assembly that are not exposed to impact or high temperatures can be overmolded onto the thermoset. For example, the base and / or flange of the oil pan assembly can be formed of injection molded nylon 6/6 33GF.

  Certain embodiments of the present disclosure provide a method of manufacturing an oil pan assembly. The method includes compression molding a thermosetting SMC portion, inserting the thermosetting SMC portion into an injection mold, overmolding N6 / 6 or another thermoplastic material into the SMC portion, Forming a pan assembly.

  Alternatively, if there are other transmission and chassis combination areas that are subject to impact forces and temperatures that exceed the capabilities of thermoplastics, SMC or another thermoset may be used in these areas. . Embodiments of the present disclosure can be used strategically to maximize the benefit from its unique properties.

  FIG. 1 shows a top perspective view of an oil pan assembly 100 according to one embodiment of the present disclosure. The oil pan assembly 100 may include a base portion 102 that is connected to a peripheral wall 104 that extends upward from an outer edge portion of the base portion 102. The upper flange 106 can extend outward from the top edge of the peripheral wall 104. The upper flange 106 can have a plurality of fastener holders 108, each of which is used to secure the oil pan assembly 100 to a portion of the vehicle, such as a metal inner frame. Can be configured to receive a portion of the fasteners that are provided. An oil collection chamber 110 is defined between the upper surface 112 of the base portion 102 and the inner surface 114 of the peripheral wall 104. The oil collection chamber 110 is configured to receive and hold transmission oil or motor oil. As shown, the base portion 102 can be angled upward from the end portion 116 toward the end portion 118 to facilitate the flow of oil from the end portion 118 to the end portion 116 by gravity.

  Alternatively, the oil pan assembly 100 may be a different size and shape than that shown. For example, the oil pan assembly 100 may have a circular shape. The oil pan assembly 100 may have more or fewer fastener holders than shown. In at least one embodiment, the flange 106 may not be continuous across the periphery of the oil pan assembly 100. In at least one other embodiment, the oil pan assembly 100 may not include a flange. Further, the angle from the end 116 to the end 118 may be steeper or looser than that shown.

  The base portion 102 and the peripheral wall 104 can be formed of two different plastics. The base portion 102 (and the flange 106) can be made of a thermoplastic material such as nylon 6/6 (N6 / 6), while the peripheral wall 104 is made of a thermosetting material such as a sheet molding compound (SMC). be able to. The thermoplastic base 102 and the thermoset peripheral wall 104 (and flange 106 if necessary) are combined to form the oil pan assembly 100. The oil pan assembly 100 improves performance in adverse environments (eg, by a thermoset peripheral wall 104 configured to be in close proximity to a hot area) and at the same time (in a place that is not susceptible to high temperatures and / or forces). It is configured to minimize or otherwise reduce the total cost (by using the thermoplastic base 102).

  The peripheral wall 104 is configured to be at or near a location subject to high temperatures and / or impacts that can be deformed and / or deteriorated with the thermoplastic material. The base portion 102 is in a location that is not susceptible to such high temperatures and / or impacts, and thus can be formed of a thermoplastic material to reduce the total cost of the oil pan assembly 100. The oil pan assembly 100 provides heat resistance and impact resistance, while at the same time minimizing the total cost by using lower cost thermoplastics in high temperature and / or less sensitive areas. Provides a unique plastic hybrid design that otherwise reduces.

  In at least one embodiment, the peripheral wall 104 is formed of thermosetting SMC. The peripheral wall 104 can be formed by compression molding. Various shapes and geometric configurations can be used. Thermosetting SMC can be deep-drawn and lighter than various metals.

  Due to the exhaust path 120 along the side 118, heat resistance may be required along the side 118 of the oil pan assembly 100. The exhaust path 120 may generate high temperatures that can deform and / or degrade the thermoplastic. Therefore, the peripheral wall 104 has the side part 118 formed with a thermosetting substance. Other areas of the oil pan assembly 100, such as the base 102 and flange 106, can be formed from a thermoplastic material such as nylon 6/6, thereby allowing for efficient use of lower cost resins, A torque limiter or a torque limiter with a screw fastener (bolt) can be inserted and molded into the fastener holding portion 108 of the flange 106 and the like. That is, areas that are not exposed to high temperatures and / or forces can be overmolded onto the thermoset portion of the oil pan assembly 100.

  Alternatively, various other portions of the oil pan assembly 100 can be formed from a thermoset material or a thermoplastic material. In at least one embodiment, at least a portion of the base portion 102 may be formed of a thermosetting material, depending on where it may be exposed to high temperatures, impacts and / or forces, while at least the peripheral wall 104 A part may be formed of a thermoplastic material.

  FIG. 2 shows a cross-sectional view of the base portion 102 connected to the peripheral wall 104 of the oil pan assembly 100 according to an embodiment of the present disclosure. As shown, the base portion 102 can be a generally flat and planar piece having an outer edge portion 130 that is fixedly connected to the inner edge portion of the base portion connection portion 132 of the peripheral wall 104. The base connection portion 132 can be generally parallel to the base portion 102 and can be connected to the upright rim 134 via a curved transition 136. The upright rim 134 can be approximately perpendicular to the base connection portion 132. The flange 106 extends outward from the upper portion 138 of the upright rim 134.

  As shown, the base portion 102 can have a thickness 140 that is greater than the thickness 142 of the peripheral wall 104. For example, the thickness 140 can be at least twice the thickness 142. The base portion 102 can be thickened as shown to achieve the proper structural strength of the desired molding properties. Alternatively, the thicknesses 140 and 142 may be larger or smaller than those shown.

  FIG. 3 shows a top perspective view of the peripheral wall 104 according to an embodiment of the present disclosure. The peripheral wall 104 can be formed of a thermosetting substance by compression molding or the like. The opening 160 is formed by the peripheral wall 104. The opening 160 is sized and shaped to accommodate the base 102 (shown in FIGS. 1 and 2).

  1 to 3, after the base portion 102, the peripheral wall 104, and the flange 106 are formed, the base portion 102 is disposed in the open portion 160 and connected to the peripheral wall 104 by, for example, bonding, bonding, welding, or the like. . Similarly, the flange 106 is fixed to the peripheral wall 104 by, for example, joining, bonding, welding, or the like. In at least one embodiment, a fully formed peripheral wall 104 can be placed in a mold chamber, and a thermoplastic material is injection molded into the chamber over a portion of the peripheral wall 104 and the base portion. 102 and / or flange 106 may be formed.

  FIG. 4 shows a flowchart of a method of forming an oil pan assembly according to one embodiment of the present disclosure. At 200, a first portion of the oil pan assembly can be formed from a first plastic. The first portion can be a portion configured to be exposed to high temperatures and / or forces. For example, the first portion can be a peripheral wall and the first plastic can be a thermosetting material. In at least one embodiment, the first portion can be formed by compression molding and the first plastic can be a thermoset SMC.

  At 202, a second portion of the oil pan assembly is formed from a second plastic that is different from the first plastic. The second portion can be a portion that is not exposed to high temperatures and / or forces. For example, the second portion can be a base portion and the second plastic can be a thermoplastic material. It should be understood that 202 can be performed simultaneously with 200, before 200, or after 200, as desired.

  At 204, the first portion is connected to the second portion to form an oil pan assembly. For example, the first part can be fixedly connected to the second part by chemical bonding, heating, adhesion, fasteners, welding, or the like. In at least one embodiment, a first portion formed of a first plastic (such as a thermoset SMC) is placed in an injection mold and the second plastic is overlaid on the first portion. Can be molded. For example, the first part can be formed of thermosetting SMC and placed in a mold. A second plastic, such as N6 / 6, can be injection molded into the mold onto the first portion of the thermosetting SMC.

  With reference to FIGS. 1-4, embodiments of the present disclosure provide a hybrid oil pan assembly having portions formed of different plastics. Parts that should be more resistant to temperature, shock and external forces are formed by thermosetting materials, while areas that are not susceptible to high temperatures and / or forces are heated to reduce the total cost of the oil pan assembly. It is formed of a plastic material.

  Accordingly, embodiments of the present disclosure provide a lightweight oil pan assembly (because it is not formed of metal) that maintains structural integrity when exposed to elevated temperatures and / or forces. At the same time, embodiments of the present disclosure provide a lightweight assembly that is efficiently manufactured in a cost effective manner.

  To describe embodiments of the present disclosure, terms relating to various spaces and directions, such as top, bottom, bottom, middle, side, horizontal, vertical, front, etc., may be used, but such terms It is understood that it is only used with respect to the orientation shown in FIG. Their orientation can be reversed, rotated, or otherwise changed such that the upper part is the lower part and vice versa, and the horizontal is vertical.

  Such variations and modifications are within the scope of this disclosure. It is understood that the embodiments disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or apparent from the text and / or drawings. . All of these various combinations constitute various alternative aspects of the disclosure. The embodiments described herein illustrate the best mode known for practicing this disclosure and enable those skilled in the art to make use of this disclosure. The claims should be construed to include alternative embodiments to the extent permitted by the prior art.

  In the scope used in the appended claims, the terms “including” and “in which” are used as synonyms in plain English for the terms “comprising” and “wherein”, respectively. Further, in the scope used in the appended claims, terms such as “first”, “second”, and “third” are merely used as labels, and the terms of these terms It is not intended to impose numerical requirements on things. Furthermore, the limitations of the appended claims are not described in a means plus function format. Such claims are not limited to and unless explicitly used in conjunction with a functional expression that does not describe additional structure, and unless expressly used. It is not intended to be interpreted under paragraph f).

  Various features of the disclosure are set forth in the appended claims.

Claims (20)

A first portion formed of a first plastic;
A second portion formed of a second plastic different from the first plastic;
An oil pan assembly, wherein the first part is fixedly connected to the second part.   The first plastic is one of a thermosetting material or a thermoplastic material, and the second plastic is the other of the thermosetting material or the thermoplastic material. The oil pan assembly as described.   The oil pan assembly of claim 2, wherein the thermosetting material is a sheet molding compound and the thermoplastic material is nylon 6/6.   The oil pan assembly of claim 1, wherein the first portion is configured to be exposed to one or both of a higher temperature, a stronger impact, or a stronger force than the second portion.   The oil pan assembly of claim 4, wherein the first portion is configured to be positioned near one or more exhaust paths.   The first portion includes a peripheral wall, the second portion includes a flange and a base portion fixed to the peripheral wall, and an oil collection chamber is defined between the base portion and the peripheral wall. The oil pan assembly according to claim 1.   The oil pan assembly according to claim 6, wherein the base portion has a thickness at least twice the thickness of the peripheral wall.   The oil pan assembly of claim 1, wherein the first portion is formed by compression molding and the second portion is overmolded over the first portion. A method of forming an oil pan assembly, comprising:
Forming a first portion of the oil pan assembly from a first plastic;
Forming a second portion of the oil pan assembly from a second plastic different from the first plastic;
Fixedly connecting the first part to the second part;
Including a method.   10. The first plastic is one of a thermosetting material or a thermoplastic material, and the second plastic is the other of the thermosetting material or the thermoplastic material. The method described.   11. The method of claim 10, wherein the thermosetting material is a sheet molding compound and the thermoplastic material is nylon 6/6.   The method of claim 9, wherein the first portion is configured to be exposed to one or both of a higher temperature, a stronger impact, or a stronger force than the second portion.   The method of claim 12, wherein the first portion is configured to be positioned near one or more exhaust paths.   The first part includes a peripheral wall, the second part includes a flange and a base part connected to the peripheral wall, and the fixed connection operation is performed between the base part and the peripheral wall. The method of claim 9, comprising defining a collection chamber.   The method of claim 14, further comprising forming the base portion having a thickness that is at least twice the thickness of the peripheral wall.   Forming the first portion includes compression molding the first portion, and the operation of securing and connecting includes overmolding the second portion over the first portion. The method of claim 9, comprising: A peripheral wall formed of a thermosetting substance;
A base and a flange formed of a thermoplastic material;
The peripheral wall is fixedly connected to the base portion and the flange, an oil collection chamber is defined between the base portion and the peripheral wall, and the peripheral wall is hotter than the base portion and the flange. An oil pan assembly configured to be exposed to one or both of a strong impact or a strong force, wherein the peripheral wall is configured to be positioned near one or more exhaust paths.   The oil pan assembly of claim 17, wherein the thermosetting material is a sheet molding compound, and the thermoplastic material is nylon 6/6.   The oil pan assembly of claim 17, wherein the base portion is at least twice the thickness of the peripheral wall.   The oil pan assembly of claim 17, wherein the first portion is formed by compression molding and the second portion is overmolded over the first portion.

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