Patent ID: 12249309

In the drawings, reference numbers may be reused to identify similar and/or identical elements.

DETAILED DESCRIPTION

An inverter can be used to apply power to an electric motor from a power source. For example, the inverter may be connected between a direct current (DC) bus and an electric motor. The inverter includes switches that can be switched to convert DC power into alternating current (AC) power for application to the electric motor.

The present application involves damping enhancement of a bubble sheet (a damping panel). The damping panel may be disposed within a vehicle. More specifically, the damping panel may be adhered or attached to any component in the vehicle that generates noise, vibration, or harshness (NVH). For example, the damping panel may be disposed on an inverter cover (a cover of an inverter) of the vehicle. In another example, the damping panel may be disposed on an engine cover of the vehicle. In yet another example, the damping panel may be disposed on a vehicle panel or floor pan of the vehicle. In yet another example, the damping panel may be disposed on a battery tray panel of the vehicle. Additionally, the damping panel may equally be applied to non-vehicles for a component that generates NVH.

With reference toFIGS.1-2, a damping panel20is provided. The damping panel20may include a first metal portion24, a second metal portion26, and a cavity28disposed between the first metal portion24and the second metal portion26. The first and second metal portions24,26may be made of a metal, such as aluminum, magnesium, or another suitable metal.

The first metal portion24may include a first end (side)30, a second end (side)32opposing the first end30, and lateral ends (sides)34,36connecting the first and second ends30,32. The lateral sides34,36are opposite each other.

Similarly, the second metal portion26may include a first end (side)38, a second end (side)40opposing the first end38, and lateral ends (sides)42,44connecting the first and second ends38,40. The lateral sides38,40are opposite each other. While the first and second metal portions24,26are shown in a rectangular shape, the first and second metal portions24,26may be each formed in any shape. For example, the first and second metal portions24,26may be formed in a circular shape. In another example, the first metal portion24may be formed in a circular shape and the second metal portion26may be formed in a square shape.

The first metal portion24also includes a first surface46(i.e., an exterior surface) and a second surface48(i.e., an interior surface) opposite the first surface46. The second metal portion26includes a first surface50(i.e., an exterior surface) and a second surface52(i.e., an interior surface) opposing the first surface50. The first and second metal portions24,26may be sheets of the metal prior to the creation of the cavity28.

The first and second metal portions24,26are secured together at some locations to define a fixed region54. The fixed region54includes where the first and second metal portions24,26are joined together. Other locations where the first and second metal portions24,26are not joined together provide a non-fixed region56.

The first, second, and lateral ends30,32,34,36of the first metal portion24may be positioned adjacent to the first, second, and lateral ends38,40,42,44of the second metal portion26, respectively. The second surface48of the first metal portion24may face the second surface52of the second metal portion26and contact the second surface52of the second metal portion26at the fixed region54. The second surface48of the first metal portion24and the second surface52of the second metal portion26may be secured together at the fixed region54and not secured at the non-fixed region56.

The fixed region54may be one continuous fixed region or include multiple fixed regions. The fixed region54may have a suitable shape and size for the application. In the example shown, the fixed region54is formed into a plurality of fixed regions. The fixed region54includes a first (fixed) region58that extends around a perimeter of the second metal portion26in a substantially rectangular shape and includes a plurality of second regions60that extend substantially linearly. While an example number of fixed regions is illustrated, the present application is also applicable to other numbers and configurations of fixed regions. Fixed regions may extend in other directions and be evenly or unevenly spaced apart from each other. For example, the plurality of second regions60in the shown embodiment are positioned inboard of the first region58. The plurality of second regions60extend in a direction between the first and second ends38,40of the second metal portion26, are substantially evenly spaced apart, and extend substantially parallel to each other.

The non-fixed region56may form the cavity28between the second surface48of the first metal portion24and the second surface52of the second metal portion26. The cavity28may extend toward the first metal portion24, the second metal portion26, or a combination of the first and second metal portions24,26. For example, the cavity28illustrated inFIG.2extends towards the second metal portion26. Additionally, the non-fixed region56may be one continuous non-fixed region or include multiple non-fixed regions, depending on the positioning and configuration of the fixed region54.

The non-fixed region56may have a suitable shape and size for the application. In the example of multiple non-fixed regions, the non-fixed regions may be positioned in a suitable configuration. While an example number of non-fixed regions is shown, the present application is also applicable to other numbers of non-fixed regions and different arrangements and configurations of non-fixed regions, such as extending in other directions and be evenly or unevenly spaced apart from each other.

In the example shown, the non-fixed region56includes a first portion62joined with a plurality of second portions64to form one continuous region. The first portion62is formed in a substantially rectangular shape and positioned adjacent to the first region58of the fixed region54. The second portions64are formed in a substantially linear shape and positioned adjacent to the second regions60of the fixed region54. More specifically, the plurality of second portions64has seven portions including a first, second, third, fourth, fifth, sixth, and seventh longitudinal portions66,68,70,72,74,76,78. However, the quantity of second portions64may vary, including greater than and less than seven.

A damping material may be disposed on the first metal portion24, the second metal portion26, or a combination of the first and second metal portions24,26. More specifically, the damping material may contact the first surface46of the first metal portion24, the second surface48of the first metal portion24, the first surface50of the second metal portion26, the second surface52of the second metal portion26, or a combination thereof. In some examples, the damping material may contact a location of the damping panel20where a high vibration energy is identified. The damping material may be, for example, an acrylic, propylene oxide, ethylene oxide, polyolefin elastomers, a silicone, a combination of two or more of the above, or another suitable damping material.

With reference toFIGS.3-4, a damping panel120may include a damping material122disposed within (filling) a cavity128of the damping panel120. The damping panel120may be the same as the damping panel20with added damping material122. Accordingly, the damping panel120includes a first metal portion124fixed to a second metal portion126, and a non-fixed region156including a first portion162and a plurality of second portions164.

As shown inFIG.3, the damping material122may be disposed within (and fill) the entire cavity128. As shown inFIG.4, the damping material122may be disposed within less than all of the cavity128. For example, the damping material122may be disposed within all or less than all of the first portion162of the non-fixed region156, all or less than all of the second portions164of the non-fixed region156, or a combination thereof.

In the example ofFIG.4, the damping material122is disposed within all of the first portion162and within all of a second, fourth, and sixth longitudinal portions168,172,176of the non-fixed region156. Air (or another gas) is disposed within a first, third, fifth, and seventh longitudinal portions166,170,174,178of the non-fixed region156. The damping material122may be applied to the second portions164of the non-fixed region156in an alternating configuration or in another configuration.

Referring toFIGS.5-8, a damping panel220may include a damping material222disposed on a first surface250(i.e., exterior surface) of a second metal portion226. The damping panel220may be the same as the damping panel20with the damping material222added. Accordingly, the damping panel220includes a first metal portion224fixed to the second metal portion226at a fixed region, and a non-fixed region256including a first portion262and a plurality of second portions264. With reference toFIGS.5-6, the damping material222may be disposed on the first surface250of the second metal portion226on the entirety of the non-fixed region256.

With reference toFIGS.7-8, the damping material222may be disposed on the first surface250of the second metal portion226for less than all of the non-fixed region256. For example, the damping material222may be disposed on all or less than all of the first portion262of the non-fixed region256, all or less than all of the second portions264of the non-fixed region256, or a combination thereof. In the example ofFIGS.7-8, the damping material222is disposed on all of the first portion262and on all of a second, fourth, and sixth longitudinal portion268,272,276of the non-fixed region256. The damping material222is not disposed on the longitudinal portions of the non-fixed region256between the second, fourth, and sixth longitudinal portions268,272,276of the non-fixed region256. The damping material222may be applied to the second portions264of the non-fixed region256in an alternating configuration or in another suitable configuration. In some examples, the damping material222is applied to a portion of the non-fixed region256where high vibration energies are identified.

Referring toFIGS.9-10, a damping panel320may include a damping material322disposed on a second surface352(i.e., interior surface) of a second metal portion326. The damping panel320may be the same as the damping panel20with the damping material322added. According, the damping panel320includes a first metal portion324fixed to the second metal326at a fixed region, and a non-fixed region356including a first portion362and a plurality of second portions364.

With reference toFIG.9, the damping material322may be disposed on the second surface352of the second metal326for entire the non-fixed region356. With reference toFIG.10, the damping material322may be disposed on the second surface352of the second metal326for less than all of the non-fixed region356. For example, the damping material322may be disposed on all or less than all of the first portion362of the non-fixed region356, all or less than all of the second portions364of the non-fixed region356, or a combination thereof. In the shown embodiment, the damping material322is disposed on all of the first portion362and on all of a first, third, fifth, and seventh longitudinal portions366,370,374,378of the non-fixed region356. The damping material322is not disposed on the longitudinal portions of the non-fixed region356between the first, third, fifth, and seventh longitudinal portion366,370,374,378of the non-fixed region356. The damping material322may be applied the second portions364of the non-fixed region356in an alternating configuration or in another suitable configuration.

FIG.11illustrates a first damping curve500, a second damping curve502, and a third damping curve504for the damping panels20,120,320, respectively. More specifically, first damping curve500represents the damping performance for the damping panel20(FIGS.1-2), where there no damping material have been applied. The second damping curve502represents the damping performance for the damping panel120with the damping material122applied to all of the cavity128(FIG.3). The third damping curve504represents the damping performance for the damping panel320with the damping material322applied to the second surface352of the second metal326for all of the non-fixed region356(e.g.,FIG.9). Each of the damping curves500,502,504track acceleration as a function of frequency. In other words, each of the damping curves500,502,504represents a Frequency Response Function (FRF). A lower acceleration in response to frequency yields a more favorable damping performance. As shown, the third damping curve504of damping panel320represents a lower acceleration in response to frequency than both the first and second damping curves500,502. Additionally, the third damping curve504does not introduce any new vibration energy transfer functions not found in the first and second damping curves500,502. Thus, the damping panel320with damping material322applied to only the second surface352of the second metal326, may provide enhanced damping performance relative to the damping panel20while utilizing less damping material than damping panel120with damping material122applied to all of the cavity128.

FIG.12illustrates a first damping curve506, a second damping curve508, and a third damping curve510for the damping panel20as shown inFIGS.1-2, the damping panel220as shown inFIGS.5-6, and the damping panel220as shown inFIGS.7-8, respectively. More specifically, the first damping curve506represents the damping performance for the damping panel20, where no damping material has been applied. The second damping curve508represents the damping performance for the damping panel220when damping material222has been applied to the first surface250of the second metal226for all of the non-fixed region256. The damping curve508represents the damping performance of the damping panel220when damping material222have been applied on the first surface250of the second metal226for less than all of the non-fixed region256. Each of the damping curves506,508,510tracks acceleration as a function of frequency. In other words, each of the damping curves506,508,510represents a Frequency Response Function (FRF). A lower acceleration in response to frequency yields a more favorable damping performance. As shown, the second damping curve508and the third damping curve510are comparable and represent a lower acceleration in response to frequency than the first damping curve506. Thus, the damping panel220provides enhanced damping as compared to damping panel20. Furthermore, the damping panel220when damping material222has been applied to less than all of the non-fixed region256provides a similar damping performance as compared to when damping material222has been applied to all of the non-fixed region256.

FIG.13illustrates a first damping curve512, a second damping curve514, and a third damping curve516for the damping panel20as shown inFIGS.1-2, the damping panel320as shown inFIG.9, and the damping panel320as shown inFIG.10, respectively. More specifically, the first damping curve512represents the damping performance of the damping panel20, where no damping material has been applied. The second damping curve514represents the damping performance of the damping panel320when damping material322has been applied to the second surface352of the second metal326for all of the non-fixed region356. The third damping curve516represents the damping performance for the damping panel320when damping material322has been applied to the second surface352of the second metal326for less than all of the non-fixed region356. Each of the damping curves512,514,516track acceleration as a function of frequency. In other words, each of the damping curves512,514,516represents a Frequency Response Function (FRF). A lower acceleration in response to frequency yields a more favorable damping performance. As shown, the second damping curve514and the third damping curve516are comparable. The second and third damping curves514,516demonstrate a lower acceleration in response to frequency than the first damping curve512without introducing new vibration energy transfer functions. Thus, the damping panel320provides enhanced damping as compared to damping panel20. Furthermore, the damping panel320with damping material322applied to less than all of the non-fixed region356provides a similar damping performance to when damping material322is applied to all of the non-fixed region356.

Therefore, the damping panels220,320with damping material222,322allow for an enhanced damping performance when compared to the damping panel20without damping material. Additionally, damping panels220,320when using damping material222,322in less than all of the non-fixed regions256,356provide comparable results to when using damping material222,322for all of the non-fixed region256,356. Accordingly, damping panels220,320applying damping material222,322to less than all of the non-fixed regions256,356may be used without the extra cost and weight of additional damping material, while still achieving a comparable damping performance.

Additionally, applying damping material to a damping panel may result in an enhanced stiffness performance. For example, the damping panels220,320using damping materials222,322may provide an enhanced stiffness performance as compared to damping panel20.

With reference toFIG.14, a method1000of manufacturing a damping panel is provided. At1100, the method may optionally include applying the damping material to a surface of a first metal portion and/or a surface of a second metal. The surfaces of the first and second metal portions face each other and will later define the inner surfaces of the cavity.

At1200, the method may include positioning a first metal portion and the second metal portion adjacent to each other (e.g., one on top of the other). At1300, the method may include fixing the first metal portion and the second metal portion to one another at selective locations to provide the fixed portion. The first and second metal portions are not fixed together at locations where the damping material is applied. At1400, the method may include injecting air (or another gas) between the first and second metal portions to create the cavity. The injection of the air (or other gas) creates the cavity by bubbling at least one of the first and second metal portions outwardly. At1500, the method may include injecting damping material between the first and second metals. In various implementations, the damping material may be injected while the air (or other gas) is injected.

The method1000of manufacturing a damping panel will now be described in greater detail. The method is described in relation to damping panels20,120,220,320ofFIGS.1-10. However, the method equally applies to other damping panels.

At1100, the method1000may optionally include applying damping material to a second metal portion. For example, the damping material222may be applied to the first surface250of the second metal portion226(FIGS.5-8), the second surface352of the second metal portion226(FIGS.9-10), or a combination thereof. Additionally, the damping material may be applied to all of the first or second surface, less than all of the first or second surface, or a combination thereof. For example, the damping material222may be applied to all of the first surface250of the second metal portion226(FIGS.5-6), less than all of the first surface250of the second metal portion226(FIGS.7-8), all of the second surface of the second metal portion226(FIG.9), or less than all of the second surface of the second metal portion226(FIG.10).

At1200, the method1000may include positioning a first metal portion with respect to the second metal portion. Positioning may include placing a surface of the first metal portion in direct contact with a surface of the second metal portion. Positioning may also include locating the first and/or second metal portions with respect to the other of the first and/or second metal portion according to a predetermined assembly specification. For example and with reference toFIGS.1-2, the second surface48of the first metal portion24may be positioned to contact the second surface52of the second metal portion26. Additionally, the first end30of the first metal portion24may be located a set distance from the first end38of the second metal portion26. Positioning may be performed in a fixture or jig, and may include clamping the first metal portion to the second metal portion.

Returning toFIG.14, the method at1300may further include fixing the first metal portion and the second metal portion to one another at selective locations. The fixing may be performed by adhering or welding the first metal portion to the second metal portion to create an air-tight seal between the first and second metal portions. In some embodiments, the fixing may be performed by welding. A weld may be in the form of a plurality of welds or a single continuous weld. The quantity and positioning of welds may be dependent upon the damping panel's size, shape, and complexity. For example, the weld may be substantially evenly spaced apart from one another and symmetrically positioned, or alternatively, unequally spaced and asymmetrically positioned. The weld(s) may be formed in another shape. Some examples of shapes include circular, linear, rectangular, and the like. For example and with reference toFIGS.1-2, a plurality of welds are provided to fix the first and second metal portions24,26. A continuous weld (not shown) is provided around the perimeter of the second metal portion26. The continuous weld is formed in a substantially linear pattern at the lateral ends42,44of the second metal portion26, formed in curved pattern at the second end40of the second metal portion26, and formed in a wave-like pattern at the first end38of the second metal portion26to create the first region58. Additionally, a plurality of linear welds are formed in a direction between the first and second ends30,32, are substantially evenly spaced apart, and symmetrically positioned to create the plurality of second regions60.

Returning toFIG.14, the method1000at1400may include injecting air (or another gas) between the first and second metal portions. Injecting air (or another gas) between the first and second metal portions (e.g., via one or more non-fixed portions extending to the outer edge) allows the first metal portion, the second metal portion, or a combination of the first and second metal portions to deform away from each other at the non-fixed portions. Deformation of the first and/or second metal portion creates a cavity between the first and second metal portions. The cavity may be one continuous cavity or alternatively, a plurality of cavities, depending on the locations of the fixed portion(s). The cavity may be formed in any shape or size.

For example and with reference toFIGS.1-2, air (or other gas) is injected within the non-fixed region56of the damping panel20to create the cavity28in the non-fixed region56. The cavity28is one continuous cavity such that the non-fixed region56has the first portion62joined with the plurality of second portions64. The first portion62of the cavity28is formed in a substantially rectangular shape and each of the second portions64is formed in a substantially linear shape.

Returning toFIG.14, the method1000at1500may optionally include injecting damping material between the first and second metals. The damping material may be injected within the cavity. More specifically, the damping material may be injected within all of the cavity or less than all of the cavity. For example and with reference toFIG.3, the damping material122is injected within all of the cavity128. In another example and with reference toFIG.4, the damping material122is injected within less than all of the cavity128. More specifically, the damping material122may be injected within all or less than all of the first portion162and all or less than all of the plurality of second portions164. In various implementations, the damping material122may be injected concurrently with the injection of air (or other gas) to create the cavity.

FIG.15is a functional block diagram and side view of an example damping system. An inverter (or inverter module)1504includes switches that connect and disconnect an electric motor1508to and from a power source1512, such as a direct current (DC) bus or another suitable power source. The inverter1504is disposed within a housing1516. A damping panel (e.g., as inFIGS.3-10)1520is disposed on the housing1516, such as an exterior surface of the housing1516. The damping panel1520damps noise and vibration generated by the inverter1504, such as switching of the switches.

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”