Patent ID: 12214398

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

In various aspects, the present disclosure provides a tool for creating a noncircular roll-formed feature, such as a joint. The tool includes at least two rollers that are wide enough to accommodate both the narrowest and widest dimensions of the noncircular feature. The present disclosure also provides a method of roll-forming a noncircular feature and a method of assembling a pump that includes a noncircular joint. Compared to the typical method of following the shape of the noncircular feature with a complex tool, the methods of the present disclosure are quicker, cheaper, and easier to automate.

With reference toFIGS.1-4, a roll-forming tool10according to certain aspects of the present disclosure is provided. The roll-forming tool10may include a central shaft12that extends along a longitudinal axis14. The roll-forming tool10may further include an axle16that extends along a lateral axis18. The lateral axis18of the axle16may extend substantially perpendicular to the longitudinal axis14of the central shaft12. In various aspects, both the central shaft12and the axle16are substantially cylindrical.

The roll-forming tool10may also include first and second wheels or rollers20,22. In various aspects, the first and second rollers20,22may be referred to as “the rollers.” The rollers20,22may be rotatably coupled to the axle16and adapted to rotate with respect to the axle16. More particularly, the rollers20,22may be adapted to rotate about the lateral axis18. The rollers20,22may be radially positioned with respect to the longitudinal axis14. The rollers20,22may be disposed equidistant from the longitudinal axis14of the central shaft12. The rollers20,22may be circumferentially spaced with respect to each other. The first and second rollers20,22may be equally spaced about a circumference of a circle traced by the rollers20,22when the roll-forming tool10is rotated about the longitudinal axis14. In various aspects, the first roller20and the second roller22are substantially identical.

The roll-forming tool10may further include a base24disposed at a distal end26(FIG.1) of the central shaft12. The base24may be laterally centered with respect to the longitudinal axis14. The axle16and the base24may be fixed with respect to the central shaft12. In various aspects, the axle16and the base24are integrally formed with the central shaft12.

The axle16may include a first portion28having a first axis29, and a second portion30having a second axis31. The first axis29and the second axis31are collinear with each other and the lateral axis18. The first and second portions28,30may project from opposing first and second sides32,34of the base24. In various aspects, the first and second portions28,30may be referred to as first and second axles, respectively. The first and second axes29,31may be referred to as first and second lateral axes, respectively.

The first roller20may be rotatably coupled to the first portion28of the axle16. The second roller22may be rotatably coupled to the second portion30of the axle16. The rollers20,22may be laterally fixed to prevent translation along the lateral axis18of the axle16. In various aspects, inward movement (i.e., toward the longitudinal axis14) of the rollers20,22may be at least partially limited by the base24.

The rollers20,22can continuously and concurrently engage a noncircular feature, such as a noncircular lip50. In one example, the lip50is roll-formed around a noncircular plate52(FIG.2) to create a noncircular joint and retain the plate52. The central shaft12can be rotated about the longitudinal axis14in a first rotational direction54(FIG.1). When the rollers20,22engage the noncircular lip50, rotation of the central shaft12about the longitudinal axis14causes the rollers20,22to rotate in a second rotational direction56(FIG.2) about the lateral axis18. A load may be applied in a downward direction58(FIG.1) so that operable engagement of the rollers20,22with the noncircular lip50causes the noncircular lip50to deform.

The rollers20,22may be wide enough parallel to the lateral axis18to bridge a narrowest portion of a profile of the noncircular lip50(see, e.g.,FIG.2), an intermediate portion of the profile of the noncircular lip50(FIG.3), and a widest portion of the profile of the noncircular lip50(see, e.g.,FIG.4). Thus, the longitudinal axis14may remain fixed while the first roller20and the second roller22concurrently engage the noncircular lip50through an entire rotation of the roll-forming tool10(i.e., a 360° rotation of the central shaft12about the longitudinal axis14). Unlike the typical method of following the noncircular profile with a complex tool having a non-stationary longitudinal axis (not shown), the roll-forming tool10of the present disclosure can be used to form a noncircular joint while the longitudinal axis14remains fixed and the rollers20,22have a circular orbit about the longitudinal axis14.

With reference toFIG.3, the noncircular lip50may at least partially define a first dimension70substantially perpendicular to the longitudinal axis14. The noncircular lip may at least partially define a second dimension72substantially perpendicular to the longitudinal axis14. The first dimension70may be greater than the second dimension72. In one example, the first and second dimensions70,72are substantially perpendicular to one another. In various aspects, the first dimension70is a maximum dimension and the second dimension72is a minimum dimension. In various aspects, a ratio of the first dimension70to the second dimension72is greater than 1, optionally greater than or equal to 1.05, optionally greater than or equal to 1.1, optionally greater than or equal to 1.10, optionally greater than or equal to 1.2, optionally greater than or equal to 1.25, optionally greater than or equal to 1.3, optionally greater than or equal to 1.35, optionally greater than or equal to 1.4, optionally greater than or equal to 1.45, and optionally greater than or equal to 1.5.

The rollers20,22may include respective outer surfaces74and inner respective inner surfaces76. The inner surfaces76may be disposed closer to the longitudinal axis14than the outer surfaces74. The outer surfaces74of the roller20,22may be spaced apart by a third dimension78. The inner surfaces76of the rollers20,22may be spaced apart by a fourth dimension80. The third dimension78may be greater than the fourth dimension80. In various aspects, a ratio of the third dimension78to the fourth dimension80is greater than or equal to 1, optionally greater than or equal to 1.1, optionally greater than or equal to 1.2, optionally greater than or equal to 1.3, optionally greater than or equal to 1.4, optionally greater than or equal to 1.5, optionally greater than or equal to 1.6, optionally greater than or equal to 1.7, optionally greater than or equal to 1.8, optionally greater than or equal to 1.9, and optionally greater than or equal to 2.

As described above the rollers20,22are wide enough to bridge both the narrowest and the widest portions of the profile of the noncircular lip50. Thus, the third dimension78of the rollers20,22may be greater than or equal to the first dimension70of the noncircular lip50. The fourth dimension80of the rollers20,22may be less than or equal to the second dimension72of the noncircular lip50.

Profiles of the plate52and noncircular lip50, in a plane substantially perpendicular to the longitudinal axis14, may be symmetric about two perpendicular axes. More particularly the plate52may be symmetric about a first transverse axis substantially parallel to the first dimension70, and a second transverse axis substantially perpendicular to the second dimension72. However, one skilled in the art would appreciate that other profiles are possible. In one example, the plate52and the noncircular lip50have a single axis of symmetry (see, e.g., pump170ofFIG.8). In another example, the plate52and the noncircular lip50do not have any axes of symmetry.

In various aspects, the roll-forming tool10includes exactly two rollers (e.g., the first roller20and the second roller22). However, in alternative variations, a roll-forming tool may include additional rollers. For example, a roll-forming tool may optionally include three rollers, four rollers, or five rollers, each roller being radially positioned with respect to the longitudinal axis and circumferentially spaced with respect to the other rollers (not shown). Each roller may be disposed on a separate axle having a separate lateral axis (e.g., when the roll-forming tool includes three rollers, first, second, and third axles may each extend radially from a central shaft, be disposed at about 120° from one another, and include respective, first, second, and third lateral axes about which the respective first, second, and third rollers can rotate). In another example, additional rollers disposed along the axle at different radii to concurrently roll-form other nested features (not shown).

With reference toFIG.5, a pump90according to certain aspects of the present disclosure is provided. The pump90may include a housing92and a plate or cover94. In one example, the cover94is a rear cover that encloses an electronics assembly (not shown) of the pump90. The housing92may be cast from a molten metal or machined to final shape. The housing92may include a lip96. The lip96may have a noncircular profile. A geometry of the lip96may be cast together with the housing92or subsequently machined into the housing92. The cover94may have a noncircular geometry. In various aspects, the cover94comprises aluminum. The cover94may be stamped or laser cut. Although the cover94is shown as a solid, flat plate, it may include different or additional features. The cover94may not be flat. By way of example, the cover94can include stamped features, such as to increase stiffness. In another example, the cover may include one or more holes, such as for a vent that allows air, but not moisture, to pass in and out of the enclosure. The cover94may enclose a chamber (e.g., chamber118shown inFIGS.6-7) of the pump90. In various aspects, the pump90is an electric water pump (eWP). However, the pump may alternatively be any other type of pump having a noncircular joint (e.g., an electric oil pump (eOP)). Alternatively, a cover may engage a noncircular lip to at least partially enclose a chamber on other assemblies, such as a cooling fan.

Referring toFIG.6, the housing92is shown with the lip96in an undeformed state (i.e., prior to roll-forming). The lip96may extend upward from a body110of the housing92. The lip96may at least partially define a cavity112. The housing92may include a first surface114that at least partially forms a base of the cavity112. The first surface114may include a groove116. The groove116may extend around an entire perimeter of the cavity112. The cover94may be placed into the cavity112to enclose a chamber118into which the electronics assembly may be disposed.

The lip96may extend around an entire outer perimeter of the cavity112. The lip96may be adapted to deform inward120, toward a center of the cavity112upon the application of a force applied in a downward direction122(i.e., parallel to a longitudinal axis123of the cavity112). The lip96may include a second or outer surface124, a third or inner surface126, and a fourth or top surface128. The top surface128may extend between the outer surface124and the inner surface126. The top surface128may be adapted to engage the rollers of a roll-forming tool (e.g., rollers20,22of the roll-forming tool10ofFIGS.1-4). When the rollers engage the top surface128, a longitudinal axis of the roll-forming tool (e.g., longitudinal axis14ofFIG.1) may be aligned with the longitudinal axis123of the cavity112. Thus, the top surface128may extend substantially perpendicular to both the longitudinal axis123of the cavity112and the longitudinal axis of the roll-forming tool.

The outer surface124of the lip96may form a first angle130with the top surface128of the lip96. The first angle130may be greater than 0° and less than or equal to about 90°. By way of example, the first angle130may be greater than or equal to about 60° and less than or equal to about 70°, and optionally greater than or equal to about 63° to less than or equal to about 65°. The inner surface126of the lip96may form a second angle132with the top surface128of the lip96. The second angle132may be greater than 0° and less than or equal to about 90°. By way of example, the second angle132may be greater than or equal to about 60° and less than or equal to about 70°, optionally greater than or equal to about 67° and less than or equal to about 69°. The first and second angles130,132may have different magnitudes. The first angle130may be less than the second angle132. The outer surface124may include a first length134substantially parallel to the longitudinal axis123of the cavity112. The inner surface126may include a second length136substantially parallel to the longitudinal axis123of the cavity112. The first length134may be greater than the second length136. By way of example, a ratio of the first length to the second length may be greater than 1, optionally greater than or equal to 1.5, optionally greater than or equal to 2, optionally greater than or equal to 2.5, optionally greater than or equal to 3, optionally greater than or equal to 3.5, optionally greater than or equal to 4, optionally greater than or equal to 4.5, and optionally greater than or equal to 5. A noncircular edge138may extend around an outer perimeter of the lip96. In various alternative aspects, the lip96may include different or additional features (e.g., undercuts, perforations) that facilitate deformation in a preferred direction (e.g., inward).

The pump90may further include a seal140that is disposed at least partially within the groove116. The seal140may be room-temperature-vulcanizing (RTV) silicone, an O-ring, a seal-in-place gasket, a noncircular-cross-section seal, or any other appropriate seal known to those skilled in the art. In another aspect, the cover94may be coated with rubber for sealing to act as a rubber-coated metal (RCM) gasket (not shown). The seal140may engage the cover94.

With reference toFIG.7, the housing92is shown with the lip96in a deformed configuration (i.e., after roll-forming). In the deformed configuration, the lip96is deformed inward to engage the cover94. Thus, the lip96and the cover94may form a joint150to retain the cover94. The joint150may be noncircular and may extend around an interface between the lip96and the cover94. The lip96may form a hook or inward projection152. The cover94may be disposed longitudinally between the lip96of the housing92and the seal140. The cover94may be disposed in the cavity112to enclose the chamber118. In various aspects, the chamber118is hermetically sealed.

Referring toFIG.8, another pump170according to certain aspects of the present disclosure is provided. The pump170includes a housing172and a cover174. The housing172includes a lip176. In a deformed configuration, as shown, the lip176cooperates with the cover174to at least partially enclose a cavity (not shown) of the housing172.

Profiles of the cover174and the lip176in a direction substantially parallel to a surface178of the cover174may be asymmetric about at least one axis. For example, the profiles of the cover174and the lip176may be substantially asymmetric about a first axis180, and substantially symmetric about a second axis182substantially perpendicular to the first axis180. More particularly, a first portion184may have a first radius of curvature, and a second portion186may have a second radius of curvature greater than the first radius of curvature. In various alternative aspects, a lip and cover define other non-circular profiles.

The present disclosure also provides a method of roll-forming a noncircular feature, such as a joint. The method is described in the context of the pump90ofFIGS.5-7and the roll-forming tool10ofFIGS.1-4. However, one skilled in the art will appreciate that the method may be used to roll-form any feature having a noncircular profile. An example method210is depicted inFIG.9. At212, the method may include disposing the seal140within the groove116. After disposing the seal140in the groove116, at214, the cover94may be disposed in the cavity112. After the cover94is placed in the cavity112, the roll-forming tool10may be used to form the joint150, as described in greater detail below.

At216, the roll-forming tool10may be rotated about the fixed longitudinal axis14. At218, as the roll-forming tool10rotates, the first and second rollers20,22may be engaged with the noncircular lip96. More particularly, the first and second rollers20,22of the roll-forming tool10may be operably engaged with the top surface128of the lip96of the housing92. At220, as the tool10rotates about the longitudinal axis14, the rollers20,22engage the top surface128to rotate about the lateral axis18of the axle16. A load may concurrently be applied to the lip96through the tool10in the downward direction122. As described above, the first and second rollers20,22can maintain continuous and concurrent contact with the lip96as the longitudinal axis14of the tool10remains fixed during rotation of the tool10. The operable engagement of the rollers20,22with the lip96causes the lip96to deform inward120to transition from the undeformed configuration (FIG.6) to the deformed configuration (FIG.7). In the deformed configuration, the joint150between the lip96of the housing92and the cover94is formed. At222, the rollers20,22may be disengaged with the lip96.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.