Patent Grant
11692467
The teachings herein are related to assemblies, and more specifically to container assemblies, such as oil pan assemblies, including a laminate bottom portion and a nut attached to the laminate bottom portion. The nut may provide a sealable opening to a cavity of the assembly. The laminate bottom portion preferably includes a polymeric layer sandwiched between two metallic layers. The nut preferably is a clinch nut.
Drain plugs are provided in a variety of assemblies for draining a fluid from a container and then closing the drain. This is often accomplished by welding a nut to a bottom portion of the container. When, the container is formed from a steel, typically a steel nut is spot welded to the container. When the container includes a monolithic aluminum container (e.g., formed from aluminum sheet), a nut typically is projection welded onto the container. As another example, the assembly may include an aluminum bottom portion where the aluminum bottom portion is machined from cast aluminum to provide a threaded opening for receiving a drain plug. When the assembly includes a steel laminate (including a thin polymeric layer between two steel layers), a nut can also be projection welded to the steel layers.
Cast aluminum typically has porosity, pores or inclusions which result in local areas of weakness. Such a material may result in failure in an oil pan assembly particularly if one of the weak areas is at or near a drain. Furthermore, cast aluminum with a machined threaded opening may be susceptible to stripping of threadings due to the relatively soft nature of aluminum (e.g., relative to steel).
Examples of assemblies including a closable drain include those described in U.S. Pat. No. 8,210,315 B2 (issued on Jul. 3, 2012 to Diehl et al.); U.S. Pat. No. 8,109,704 (issued on Feb. 7, 2012 to Lewis et al.); and US Patent Application Publication 2012/0318799 A1 (published on Dec. 20, 2012 by Spix et al.).
In U.S. Pat. No. 8,109,704 a two-piece cage nut assembly is employed for a drain. It appears that legs of the cage are welded (e.g., projection welded) to a bottom portion of an oil pan. U.S. Pat. No. 8,109,704 teaches that the need for drainage channels near the bottom of the cage nut assembly. The only sealing in U.S. Pat. No. 8,109,704 is by a seal in the area of the flange of the bolt. The nut extends considerably into the oil pan because the threading only begins after the channel. Such a nut can be described as having a high stove pipe. The draining of the oil pan will initially be fast due to flow through the main opening. However, this will change to a flow through only the channel when the level drops below the top of the nut. This prolonged slow flow may result in a service person incorrectly thinking that the draining is completed. Additionally, if the channel becomes blocked drainage below the top of the nut may be prevented. In these circumstances, there may be insufficient drainage of the oil. This is a complex design and requires that the seal between the bolt flange and a bottom surface of the oil pan be a primary seal.
However, these methods are not usually compatible with laminate materials having aluminum layers. For example, when a laminate includes a polymeric layer between two aluminum layers, it may be difficult to projection weld a nut, and a relatively thin aluminum layer may fail from applied torques (e.g., during removing or inserting a drain plug). For example, a projection weld on an aluminum laminate material typically results in engagement with only a single layer of aluminum, causing weakness due to the relatively thin layer of aluminum (relative to the total thickness of the aluminum laminate material). Furthermore, the aluminum layers may be too thin to allow for machining to provide a threaded opening.
There is a need for an oil pan assemblies having one or any combination of the following features: drain attachment that are simple in design and/or simple in assembly; an assembly that includes both a primary seal and a secondary seal, an assembly with a short stove pipe so that nearly complete drainage may be completed, a single drainage mechanism (e.g., so that discontinuity in the drainage rate is avoided), drain attachment having good push through resistance, drain attachment having good torque resistance, drain attachment having good twist resistance, low or improved NVH properties (i.e., low or reduced noise, low or reduced vibration, low or reduced harshness, or any combination thereof), and light weight.
One or more of the aforementioned needs may be met with a container assembly (e.g., an oil pan assembly) according to the teachings herein.
One aspect of the teachings herein is directed at a container assembly (e.g., an oil pan assembly) comprising: a container having a cavity for holding a fluid and including a bottom portion, wherein the bottom portion includes a laminate material including a first aluminum layer having a surface facing the cavity of the container, a second aluminum layer having a surface facing an outside of the container, and a polymeric layer interposed between the first and second metal layers; an opening in the bottom portion extending through the first and second aluminum layers for draining the fluid from the container; and a clinch nut attached to at least the first aluminum layer and position for receiving a drain plug that seals the opening and provides a primary seal to prevent flow of the fluid. The first aluminum layer may be an interior layer of the container. For example, an interior surface of the container may include the first aluminum layer. The second aluminum layer may be an exterior layer of the container. For example, an exterior surface of the container may include the second aluminum layer. The polymeric layer preferably contacts or is directly attached to the first aluminum layer, the second aluminum layer, or both. The bottom portion of the container preferably is formed of the laminate material. The entire container preferably is formed of the laminate material.
This aspect of the teachings may be further characterized by one or any combination of the following features: the attachment between the clinch nut and the first aluminum layer forms a seal around an entire circumference of the opening; the clinch nut is attached to both the first and second aluminum layers; a ratio of a thickness of the first aluminum layer to a thickness of the second aluminum later is about 0.33 or more (e.g., about 0.5 or more, about 0.7 or more, about 0.9 or more, or about 1.0 or more); a ratio of the thickness of the first aluminum later to the thickness of the second aluminum layer is about 3 or less (e.g., about 2 or less, about 1.4 or less, or about 1.1 or less); the polymeric layer has a thickness of about 0.2 mm or less, preferably about 0.1 mm or less, more preferably about 0.5 mm or less, and most preferably about 0.03 mm or less; the polymeric layer has a thickness of about 0.001 mm or more (for example, about 0.003 mm or more, about 0.01 mm or more, or about 0.02 mm or more); the polymeric layer has a thickness that is about 15% or less (preferably about 10% or less, even more preferably about 5% or less, and most preferably about 2% or less) of a total thickness of the laminate material; the first and second aluminum layers have a combined thickness of about 0.5 mm or more (e.g., about 0.7 mm or more, about 0.9 mm or more, or about 1.1 mm or more); the combined thickness of the first and second aluminum layers is about 4 mm or less (e.g., about 3 mm or less, about 2.5 mm or less, or about 2 mm or less); the clinch nut is an aluminum clinch nut; the clinch nut is a steel that is coated; the clinch nut includes a steel; the clinch nut has a passage with internal threading and includes 3 or more turns of the threading (preferably 4 or more turns; preferably the number of turns is about 7 or less, more preferably about 6 or less and most preferably about 5 or less); the clinch nut includes a first portion (i.e., a stove pipe portion) that extends into the cavity of the container; the clinch nut does not extend below the bottom surface of the container; the stove pipe portion preferably has a length of about 15 mm or less (more preferably about 12 mm or less, even more preferably about 10 mm or less, and most preferably about 9 mm or less); the first portion of the clinch nut has a height that is sufficiently short so that an amount of fluid remaining in the cavity after a draining of the cavity is reduced or minimized; the first portion has a height of about 15 mm or less (preferably about 10 mm or less, and more preferably about 5 mm or less) as measured in a vertical direction from a top surface of the laminate to a top edge of the first portion (i.e., the distance by which the clinch nut protrudes into the cavity of the container); the a container assembly (e.g., oil pan assembly) includes a drain plug for sealing the opening; the drain plug has a threaded shaft for affecting a primary seal; the drain plug forms a secondary seal entirely outside of the affected area of the clinch nut; the secondary seal is obtained by an elastomeric ring (i.e., an elastomeric washer) that contacts the aluminum outer surface of the container only at a flat area; the drain plug includes a threaded shaft for screwing into the clinch nut; the drain plug includes a head portion configured for receiving a tightening tool (for example for torqueing the drain plug to a pre-determined torque); the drain plug includes an elastomeric washer in contact with a flange portion of the drain plug and positioned so that the flange portion applies a force to the elastomeric washer for forming a seal between the flange portion and an outside surface of the bottom of the container; the flange portion has a diameter of about 10 mm or more (preferably about 15 mm or more, and more preferably about 20 mm or more); a ratio of a diameter of the elastomeric washer to a diameter of the shaft of the drain plug is about 2 or more (or about 2.5 or more); a ratio of a diameter of the flange of the drain plug to a diameter of the shaft of the drain plug is about 2 or more (or about 2.5 or more); the container assembly (e.g., the oil pan assembly) has a weight that is less than the weight of a similar sized oil pan assembly where the container is formed of steel; the container assembly (e.g., the oil pan assembly) has one or more improved noise, vibration, or harshness (i.e., NVH) properties compared to a similar sized container assembly where the container is formed of steel or cast aluminum; the container assembly (e.g., the oil pan assembly) has a durability (e.g., torque resistance, pull-out resistance, twist-off resistance, or any combination thereof) that is at least as good as the durability of a similar sized container assembly where the container is formed of cast aluminum; the clinch nut includes a coated steel (e.g., a zinc coated steel); the container assembly (e.g., the oil pan assembly) includes a coated steel drain plug (e.g., a zinc coated steel); or the shaft of the drain plug and/or the stove pipe of the clinch nut is formed of a mixed metal.
Another aspect according to the teachings herein is directed at a method of forming a container assembly (e.g., an oil pan assembling) comprising the steps of attaching a clinch nut to a container (e.g., an oil pan container) formed of a laminate material including a polymeric layer interposed between two aluminum layers, wherein the clinch nut directly attaches to both of the aluminum layers.
The oil pan assemblies according to the teachings herein preferably have improved NVH properties. The oil pan assemblies according to the teachings herein, preferably are durable (e.g., as characterized by push-out resistance, twist-out resistance, torque resistance, or any combination thereof).
The container assembly (e.g., the oil pan assembly) includes a container having a cavity for containing a liquid, such as oil, and a drain component attached to the container for removing liquid (e.g., oil) from the cavity. The container preferably includes a composite material having a polymeric layer for improving one or more NVH properties. The drain component preferably includes or consists essentially of a clinch nut. The drain component may be sealed by one or more seals, and preferably is sealed using both a primary seal and secondary seal. The drain of the oil preferably occurs through the opening of the clinch nut. The container assembly (e.g., the oil pan assembly) may also include a sealing component (e.g., a drain plug) for reversibly sealing the drain component.
Container
The container assembly (e.g., the oil pan assembly) includes a container (e.g., an oil pan) having a cavity for holding a volume of oil. The container may have one or more openings for circulating the oil to a mechanical component for controlling the temperature of the mechanical component. It may be necessary to periodically drain the oil from the container. As such the container typically has one or more openings for draining the oil.
The container may be any size and shape. The container has one or more walls having an interior surface suitable for contact with the fluid in the container (e.g., at elevated temperatures). The walls of the container have an exterior surface. The exterior surface may be an exposed surface (e.g., exposed to air). The opening for draining the oil is preferably at or near a bottom portion of the container. Some or all of the walls of the container includes or is formed of a composite material. Preferably the bottom portion of the container includes the composite material.
Composite Material/Laminate Material
The container (e.g., the oil pan) preferably includes or is formed of a composite material including a polymeric layer for improving one or more NVH properties. More preferably, the walls of the oil pan are formed of a composite material including a polymeric layer. The composite material includes, consists essentially of, or consists entirely of a laminate material including a polymeric layer interposed between two metallic layers. The metallic layer preferably includes a generally light weight metal or metal alloy. For example, the density of the material of the metallic layer may be less than the density of steel. Preferably the density of the metal or metal alloy of the metallic layer is about 6 g/cm3 or less, more preferably about 4.4 g/cm3 or less, even more preferably about 3.6 g/cm3 or less, and most preferably about 2.9 g/cm3 or less. Preferably, the metallic layer includes or consists essentially of aluminum or an aluminum alloy (e.g., including about 50 weight percent or more aluminum atoms, based on the total weight of the aluminum alloy).
The composite material 10 may be a laminate material including a first metallic layer 12, a second metallic layer 14, and a polymeric layer interposed between the first and second metallic layers, such as illustrated in
Preferably the laminate material is an aluminum composite material. As used herein, an aluminum composite material includes two metallic layers, wherein at least one metallic layer (and preferably both metallic layers) is an aluminum layer. The aluminum layer may consist essentially of aluminum or may be an aluminum alloy having about 50 weight percent or more (preferably about 80 weight percent or more) aluminum atoms, based on the total weight of the alloy. The aluminum may be selected for heat treatability, drawability, or both. Preferred aluminums include soft aluminum and have a high drawability. Examples of particularly useful aluminum grades are 5000 series and 6000 series, such as 5754 and 5182 grades of aluminum layers. In forming the composite material, a surface of the aluminum may be cleaned and/or passivated.
A wall of the container (e.g., the oil pan) may be formed from a sheet of the composite material (e.g., from the aluminum composite material). Preferably the sheet of the composite material has a uniform thickness (e.g., before forming). Preferably the average wall thickness of the oil pan is within about 20% (more preferably within about 10%) of the original thickness of the sheet before forming into the wall.
The total thickness of the composite material and/or the average wall thickness of the container (e.g., the oil pan) preferably is about 0.5 mm or more, more preferably about 0.7 mm or more, even more preferably about 0.9 mm or more, and most preferably about 1.1 mm or more. If the thickness is too small, the oil pan may be damaged during use, such as during plugging of the drain. The total thickness of the composite material and/or the average wall thickness of the container (e.g., the oil pan) preferably is about 4 mm or less, more preferably about 3 mm or less, even more preferably about 2.5 mm or less, and most preferably about 2 mm or less. If the thickness is too high, the cost and or weight of the container may be too high.
The first and second metallic layers may have a thickness that is the same or that is different. The ratio of the first metallic layer (e.g., aluminum or aluminum alloy layer) to the second metallic layer preferably is about 0.33 or more, about 0.5 or more, about 0.7 or more, about 0.9 or more, or about 1.0 or more. The ratio of the first metallic layer to the second metallic layer preferably is about 3 or less, about 2 or less, about 1.4 or less, or about 1.1 or less. Each of the metallic layers should be sufficiently thick so that the layer does not easily tear and/or so that the layer can provides significantly to the strength of the structure.
The thickness of the polymeric layer preferably is sufficiently low so that any reduction in the stiffness of the composite material (e.g., relative to the materials of the metallic layers) at a temperature of about 25° C. is about 40% or less (preferably about 30% or less, more preferably is about 20% or less, and most preferably is about 10% or less). The stiffness may be characterized by the flexural modulus (e.g., as measured according to ASTM D790). Preferably, the thickness of the polymeric layer is about 0.2 mm or less, more preferably about 0.1 mm or less, even more preferably about 0.5 mm or less, and most preferably about 0.03 mm or less. The polymeric layer may have a thickness of about 0.001 mm or more, about 0.003 mm or more, about 0.010 mm or more, or about 0.02 mm or more.
The ratio of the thickness of the polymeric layer to the total thickness of the composite material preferably is about 0.20 or less, more preferably about 0.15 or less, even more preferably about 0.10 or less, even more preferably about 0.05 or less, and most preferably about 0.02 or less.
The container may include one or more reinforcing features, such as a rib that increase the stiffness of the container. This may be particularly important when using an aluminum laminate material where the polymeric core layer softens at elevated operating temperatures of an oil pan.
Materials for the Polymeric Layer
The polymeric layer may include, consist essentially of, or consist entirely of one or more polymers. Preferably, the amount of the polymer in the polymeric layer is about 50, more preferably about 80 weight percent or more, and most preferably about 90 weight percent, based on the total weight of the polymeric layer. The polymeric layer preferably includes one or more polymers having a low hardness. As used herein, polymer having a low hardness may be characterized by a Shore A durometer (measured according to ASTM D2240) of about 90 Shore A or less, preferably about 75 Shore A or less, and more preferably about 65 Shore A or less). Preferably the polymeric layer includes a polymer having a hardness of about 10 Shore A or more (e.g., about 20 Shore A or more, or about 30 Shore A or more). The polymer may have a crystallinity (e.g., as measured by differential scanning calorimetry according to ASTM D3418) of about 60% or less, about 50% or less, about 40% or less, about 30% or less, about 20% or less, or about 10% or less. For example, the polymer may be a generally amorphous polymer having a crystallinity of about 5% or less or about 0%. The polymeric layer may include a filler at a concentration of 3 wt. % or more, or may be substantially free (i.e., a filler concentration of less than 3 weight percent, or about 1 weight percent or less) or may be entirely free of filler. The polymeric material preferably includes an elastomeric material. A particularly preferred elastomeric material is an acrylic elastomer. The polymeric material may be formed with a cross-linking agent, so that the polymeric material includes a cross-linked elastomer. The polymeric material may include a generally high molecular weight polymer (e.g., having a molecular weight of about 30,000 or more, about 80,000 or more, or about 200,000 or more). The polymeric material may be selected to provide adhesion to the aluminum and/or an adhesive or other bonding agent may be employed for improving the adhesion of the polymeric material to the aluminum.
Examples of composite materials that may be employed include structures including a viscoelastic material sandwiched between two sheets of aluminum, such as commercially available as QUIET ALUMINUM® brand composite material from MATERIAL SCIENCES CORPORATION.
Clinch Nut
The container assembly (e.g., the oil pan assembly) preferably includes a clinch nut attached to the composite material (e.g., the aluminum composite material) for providing a sealable drain for removing fluid from the container (e.g., the oil pan). The clinch nut may be attached to one or both of the metallic layers of the composite material. Preferably the clinch nut is attached to both of the metallic layers of the composite material.
The clinch nut should have an opening for draining fluid from the assembly. The opening of the clinch nut preferably forms a passage that extends a length of the clinch nut (e.g., from one end of the clinch nut to an opposing end of the clinch nut. The clinch nut may have a top rim at an entrance from the cavity into the passage. The clinch nut may have a bottom rim at an exit from the passage. The draining of the oil preferably occurs only through the passage of the clinch nut. For example, the clinch nut may be free of lateral openings, grooves, or other passages that extend through a wall of the clinch nut or between the clinch nut and the container. The opening of the clinch nut should be internally threaded for receiving a plug for closing the opening and stopping the flow of the fluid. The attachment between the clinch nut and the composite material preferably forms a seal around an entire circumference of the opening so that the fluid cannot leak from a space between the composite material and the clinch nut.
The clinch nut has a stove pipe portion that extends from an inner surface of the pan (e.g., the oil pan) into the cavity of the pan. The stove pipe portion should be sufficiently short so that substantially all of the fluid can be drained from the cavity of the pan.
The clinch nut should have a sufficient number of turns of the internal threading so that the drain plug can be securely attached. Preferably, the drain plug should be capable of being securely attached without damage to the internal threading of the opening (e.g., by stripping, or by over-torqueing). Preferably, the number of turns of threadings in the opening of the clinch nut is about 2 or more, more preferably about 3 or more, and most preferably about 4 or more.
The number of turns of the internal threading preferably is sufficiently small so that the length of the stove pipe of the clinch nut is generally small. Preferably the number of turns of threadings in the opening of the clinch nut is about 7 or less, more preferably about 6 or less, and even more preferably about 5 or less.
At least a portion of the turns of the internal threading preferably is located in the portion of the clinch nut that extends below the stove pipe portion (e.g., the portion between the external surface and the internal surface of the region of the pan adjacent to the clinch nut. Preferably, the number of turns of the internal threading located below the stove pipe portion is about 0.1 or more, more preferably about 0.3 or more, even more preferably about 0.4 or more, and most preferably about 0.5 or more.
When assembled, the clinch nut preferably does not extend below the outer surface of the oil pan (i.e., at the bottom of the oil pan). If a portion of the clinch nut extends below the outer surface of the oil pan, it preferably is sufficiently short so that it does not interfere with the sealing of the drain (e.g., using an elastomeric seal over a flange surface of the drain plug).
The clinch nut may have one or more of the features illustrated in
The connector portion of the clinch nut preferably forms a mechanical joint with the laminate or composite material. The mechanical joint preferably seals a circumference around the opening. This seal between the clinch nut and one or more face surfaces of the laminate or composite material preferably is a liquid-tight seal, and more preferably is a gas-tight seal. By forming a mechanical joint, it is possible to use different materials for a wall of the container (e.g., the laminate or composite material) and the clinch nut. The clinch nut may have an extension member 29. The extension member preferably extends in the direction of the bolt head. The extension member may be bent (e.g., in a radial direction) to apply a force on the laminate or composite material. When bent, the extension member may hold the laminate or composite material in place. The clinch nut may include anti-rotation features to prevent the clinch nut from rotating with respect to the laminate or composite material.
Container Assembly/Oil Pan Assembly
The container assembly (e.g., the oil pan assembly) may be formed by attaching the clinch nut to the laminate material. The region of the attachment may have one or more of the features illustrated in
The composite material preferably is stamped for forming the container (e.g., the container of the oil pan assembly). For example, a portion of the container may be formed by stamping one sheet of a composite material forming a stamped part. The stamped part may be sealingly connected to another portion of the container (preferably also formed by stamping the composite material). Preferably, the container is formed by sealingly connecting two or more stamped parts each formed of the composite material. The clinch nut is preferably attached to the stamped part after stamping and prior to sealingly connecting with another part.
A bottom view of an illustrative clinch nut is shown in
The use of a composite material including a polymeric layer has been found to provide benefits when connecting to a clinch nut, compared with the use of a monolithic metal material. For example, the container wall formed of the composite material may flow more easily for forming the joint (and forming a seal between the clinch nut and the composite material encircling the opening). As another example, the container wall formed of the composite material may have reduced residual stress in the region of the clinch nut, as compared to a monolithic material. Without being bound by theory, it is believed that the polymeric layer is capable of elastically and/or plastically deforming (and preferably also capable of relaxing), and this behavior improves the performance during and after joining with the clinch nut. For example, the polymeric layer may provide a bias that pushes the metallic layers in one or more directions (e.g., an outward direction) for enhancing the integrity of a seal.
Plug
The plug may be formed of any material that allows for repeated sealing of the drain hole and removal for draining of the oil. The material of the plug should be capable of sealing at operating temperatures and environment (e.g., heated oil) of the oil pan. The material of the drain plug may be selected so that the risk of damage from stripping of the threads of the plug and the clinch nut are reduced or eliminated.
The plug may be used to form a primary seal, and preferably forms both a primary and a secondary seal. The plug may have a threaded shaft for forming a seal (e.g., a primary seal) when inserted into the threaded opening of the clinch nut. The plug may have a flange portion for compressing an elastomeric seal (e.g., an elastomeric ring) against an outer wall of the container for forming a seal (e.g., a secondary seal).
The plug preferably includes a metallic material.
The plug may include one metal alloy. The plug may include a plurality of metal alloys. For example, the plug may have a layer structured. The layer structure may have a core layer of a first metal alloy and an outer layer of a different metal alloy.
The plug may include or be formed of a bi-metal including an outer layer and an inner layer. The outer layer preferably has a lower hardness than the inner layer. The difference in the hardness may be about 10 or more, about 20 or more, or about 30 or more HRB.
The outer layer may include a generally low hardness material (such as a zinc coating).
The plug may be engineered (e.g., designed and/or formed of selected materials) so that the plug is damaged prior to damaging the clinch nut and/or damaging the oil pan.
Flange
The plug component has a flange portion for creating a seal between the flange portion and an outer surface of the bottom of the oil pan. Preferably the seal is a secondary seal. The flange portion preferably is sufficiently large so that a seal is made outside a circumference of the clinch nut on the outer surface. For example, the flange portion should be sufficiently large to form a seal in the region of the container outside of the region affected by the clinch nut (e.g., outside of the attachment portion of the clinch nut). The plug component preferably includes a sealing ring formed of an elastomeric material. The sealing ring may be attached to the flange portion or may be removably located over the flange portion. The sealing ring may be characterized by an inner circumference and an outer circumference. Some or all of the inner circumference may contact oil which has escaped past the primary seal. Preferably, the outer circumference of the sealing ring contacts an atmosphere outside of the container assembly (e.g., oil pan assembly).
The drain plug may include one or more of the features illustrated in
The seal or gasket for the plug preferably provides a seal between an outside surface of the container and a surface of the plug (e.g., a flange surface of the plug). The seal may have an opening for fitting over the shaft of the plug. The opening may be characterized as an inside diameter of the seal, such as the seal 45 illustrated in
The teachings herein are not limited to oil pan assemblies, but may be applied to other containers. The container may be employed for a fluid that is a gas or a liquid. Preferably the fluid is a liquid. The container may be isolated from the atmosphere or may have an opening to the atmosphere. The fluid (e.g., the liquid) preferably is at ambient temperature or at elevated temperatures (e.g., elevated over ambient temperature by about 40° C. or more, about 70° C. or more, or about 100° C. or more), and more preferably is exposed to cycles between ambient temperature and elevated temperatures. The fluid may experience a decrease in its viscosity (e.g., in units of poise) during an operational cycle (preferably a decrease in its viscosity of about 10% or more, about 30% or more, about 50% or more, or about 70% or more). The container may be employed for holding a food ingredient, water, an industrial liquid, or a vehicle fluid. The container may be used for an automotive fluid. The container may be used for holding a fluid during transport. The container may be used for a transmission fluid. The container may be used for a refrigerant. The container may be used for storing a reservoir of a reactant for a vehicle exhaust system. The container may be formed from a single material. In some applications the container may be formed from two or more different materials. For example, a container may be formed by attaching a first material (e.g., a stamped aluminum composite material) to a second material (e.g., a monolithic metal, preferably a monolithic aluminum). A preferred second material may be a material used for an engine block, such as an aluminum engine block. Although the teachings generally teach the use of aluminum (e.g., for the laminate/composite material), it will be appreciated that other metals may be substitute throughout, in the teachings herein and in the claims. For example, a metal for the container may be chosen to be compatible with the fluid (e.g., liquid) being held in the container and/or the thermal cycling of the container or the fluid.
If the container is formed by joining two or more different materials, it is preferred that the different materials have similar coefficients of linear thermal expansion (i.e., CLTE) in a temperature range of use (e.g., from about 0° C. to about 80° C., from about 0° C. to about 100° C., from about 0° C. to about 150° C., or from about −30° C. to about 180° C.). Preferably the ratio of the higher coefficient of linear thermal expansion to the lower coefficient of linear thermal expansion (of two materials having different CLTE) is about 10 or less, more preferably about 5 or less, even more preferably about 3 or less, and most preferably about 2 or less. For example, one material may be made of a monolithic metal and the other material may be a laminate including one or more metal layers, wherein at least one (and preferably all) of the metal layers are of the same metal (e.g., same class of metal, or same grade of metal) as the monolithic metal. It is contemplated that one or more walls of the container may include a non-laminate material.
Hardness may be measured using Rockwell Hardness (e.g., A, B, C, D, or E scale). For example, RHC refers to Rockwell hardness C scale using a load of 150 kgf and an indenter that is a 120° diamond having a spheroconical shape. RHB refers to Rockwell hardness B scale, measured using a load of about 10 kgf and an indenter that is a 1/16 inch diameter steel sphere.
Hard steel is typically characterized by a hardness of 55-66 HRC or even higher.
Stainless steel 304 L typically has a hardness of 25-32 HRC (e.g., about 70 HRB)
Aluminum 6061-T6; 6061-T651 typically has a hardness of about 60 HRB.
Strong aluminum alloys typically have a hardness greater than about 65 HRB. For example, Aluminum 2024-T3 has a hardness of about 75 HRB. Aluminum alloys having a hardness of about 87 or more HRB (075 aluminum) may also be used.
Cast aluminum oil pans are typically made by a process that results pores and/or inclusions that result in localized weakness. Thus, there is a risk of failure if a weak area is near the drain area.
In contrast, the present invention preferably includes rolled aluminum sheets and thus avoids localized weaknesses due to pores and/or inclusions.
The clinch nut may be formed of a material that is the same material as the plug, or may be formed of a different material (e.g., a different type of metal or a different grade of metal).As used herein metals that are of different types may have different primary metal element (i.e. a metal element present at the highest concentration in atomic percent), wherein metals that are different grades may have primary metals that are the same.
In the various aspects of the teachings herein, the clinch nut or the plug (and more preferably both the clinch nut and the plug) use a steel, and more preferably a coated steel. The coated steel may be coated with a metal or metal alloy having a lower hardness than the steel substrate. The coating may be a zinc-containing coating, including, consisting essentially of, or consisting entirely of zinc. For example, the zinc-containing coating may be a zinc alloy (or mixture) include about 30 atomic percent or more zinc, about 60 atomic percent or more zinc, or about 80 atomic percent or more zinc. By way of example, the zinc-containing coating may include aluminum, magnesium, or both.
Preferably, the clinch nut brings both of the aluminum layers of the laminate material into the strength of the joint, so that the joint can match the joint strength of monolithic aluminum of equivalent total gage thickness (for example with respect to torque strength).
Preferably the clinch nut and/or the drain plug are formed of a relatively hard material with a covering of a relatively soft material. For example, by employing a hard material, it may be possible to reduce the height of the stove pipe (i.e., by reducing the number of turns of threading). By using a soft cover material, it may be possible to reduce or eliminate the chance of over-torqueing the seal and stripping the threads. By way of example, the clinch nut and/or the drain plug may include a steel material or other material harder than steel with a covering of a zinc-containing coating or other material that is as soft as, or softer than zinc. The clinch nut and the drain plug may be formed of different grades of steel (which each may be free of coating or may include a coating, such as a zinc-containing coating according to the teachings herein). Preferably, the different grades of steel are selected so that the drain plug will fail (e.g., break, have threadings strip, or otherwise fail) before stripping the threading of the clinch nut.
Preferably, the surface of the clinch nut (e.g., the interior threaded surface) has a hardness greater than the hardness of the surface of the drain plug (e.g., the exterior threaded surface), more preferably the difference in hardness is about 1 or more, even more preferably about 1.5 or more, and most preferably about 2.0 or more, on the Mohr hardness scale.
General Information Applicable to the Teachings
It is to be understood that the disclosed embodiments are merely exemplary of the teachings that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present teachings.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or variable is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as “parts by weight” herein also contemplates the same ranges expressed in terms of percent by weight, and vice versa. Thus, an expression in the Detailed Description of the Invention of a range in terms of at “‘x’ parts by weight of the resulting composition” also contemplates a teaching of ranges of same recited amount of “x” in percent by weight of the resulting composition. Relative proportions derivable by comparing relative parts or percentages are also within the teachings, even if not expressly recited.
Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints.
The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of, or even consisting of, the elements, ingredients, components or steps.
Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.
Relative positional relationships of elements depicted in the drawings are part of the teachings herein, even if not verbally described. Further, geometries shown in the drawings (though not intended to be limiting) are also within the scope of the teachings, even if not verbally described.
Noise, vibration, harshness (NVH) analysis is performed on oil pans made with different materials. In Example 1, the walls of the oil pan are formed from an aluminum composite material. The aluminum composite material includes two sheets of aluminum, each having a thickness of about 0.79 mm, and a polymeric core layer having a thickness of about 0.025 mm sandwiched between the two aluminum sheets. The thickness of the aluminum composite material is about 1.6 mm and the mass of the oil pan is about 0.509 kg. In Comparative Example 1, the walls of the oil pan are formed from a monolithic aluminum. The thickness of the aluminum composite material is about 1.6 mm and the mass of the oil pan is about 0.509 kg.
The structure of the oil pan employed in the NVH analysis is shown in
The acoustical analysis uses an acoustical model with an 11 mm target element size. The acoustic model excludes the mounting flange from the acoustic mesh.
The modeling employs a boundary element method (BEM). Here, the applied structural velocities are used as the boundary conditions for the acoustic mesh. Both sides of the front cover radiate noise. The modeling calculates the averaged normal velocity, the radiated sound power.
The results of the modeling when using the unit acceleration control (i.e., similar to a shaker table with velocity control) are shown in
Example 2 is prepared by attaching the aluminum composite material of Example 1 to a clinch nut, the test specimens have dimensions of about 76.2 mm×76.2 mm. The clinch nut has a base portion with a diameter of about 30 mm and an upper portion having a diameter of about 16 mm. The opening of the clinch nut is about 12.7 mm in diameter. The clinch nut has M12×1.75 threading. After attaching the clinch nut to the aluminum composite material, the specimens are tested for torque resistance, push-out resistance and twist-out resistance.
Torque Resistance Test
The torque resistance is the maximum torque that can be applied to the head of a drain plug in the clinch nut before failure of the test specimen. The torque resistance is measured on 50 specimens. The average torque resistance is 27 Nm and the standard deviation is 3 Nm.
Push-Out Test
The force required to push out the clinch nut from the oil pan bottom is measured on 15 specimens. The average push-out resistance is about 1.86 kN with a standard deviation of about 0.34 k N.
Twist-Out Test
The twist-out resistance is measured by torqueing the base portion of the clinch nut until failure of the attachment is observed. The test is repeated on 15 specimens. The average twist-out resistance is about 38.4 Nm and the standard deviation is about 3.4 Nm.
Example 2 meets the needs for torque resistance, push-out resistance, and twist-out resistance.
Comparative Example 3 is prepared similar to Example 2, except a steel nut is attached using projection welding. The steel nut does not form a joint with the aluminum composite material.
Comparative Example 4 is prepared similar to Comparative Example 3, except the aluminum composite material is replaced by a steel composite material including steel sheets instead of aluminum sheets. Comparative Example 4 fails the torque resistance test because the nut only welds to one of the steel layers of the steel composite material.
Comparative Example 5 is prepared similar to Example 2, except the aluminum composite material is replaced by a cast aluminum material. The standard deviation of the torque test is increased and some failures occur due to local weaknesses in the cast aluminum.
10 Composite material/laminate material
12 First metallic layer
14 Second metallic layer
16 Polymeric layer
17 Inner surface of laminate material
18 Outer surface of laminate material
20 Clinch nut
21 Passage through the clinch nut
22 Bottom rim of opening
24 Upper rim of opening
26 Stove pipe portion
27 Top region of stove pipe
28 Base region of stove pipe
29 Extension member
30 Connector portion
32 Internal threadings
34 Height at the top of the clinch nut relative to the inner surface of the oil pan
35 Region of laminate affected by clinch nut
36 Flat region of the laminate encircling the area affected by the clinch nut
38 Circumference around the opening
40 Drain plug/Bolt
42 Flange portion
43 Flange surface
44 Threadings
45 Seal (e.g., elastomeric seal)
46 Shaft
47 Recessed Surface
48 Head portion
52 First portion of clinch nut (e.g., for providing a strong connection with the container.
54 Second portion of clinch nut (e.g., for providing additional length for threadings for receiving a drain plug).
56 Seal (e.g., elastomeric seal)
58 Uneven surface (e.g., due to the clinch nut/composite material seal)
60 Container assembly including a clinch nut and a laminate
62 Seal between clinch nut and the composite material
64 Seal between the clinch nut and the drain plug
66 Seal between the drain plug and the composite material
70 Opening in elastomeric seal
71 First portion of the seal (e.g., for spacing the sealing region from the plug).
72 Second portion of the seal (preferably including a sealing ridge for sealing the components)
73 Sealing region/sealing surface of the second portion
74 Size of opening (e.g., inside diameter of the seal)
75 Outside dimension (e.g. outside diameter) of the seal
76 Length of the second portion (e.g., diameter of sealing bead)
77 Thickness of second portion.
78 Sealing distance (e.g., diameter formed by the sealing region).
80 Structure for oil pan/container
82 Drain hole
84 Flange
86 Holes
100 Oil Pan formed of Aluminum Composite Material (Example 1)
102 Oil Pan formed of Monolithic Aluminum (Comparative Example 1)
| Number | Date | Country | Kind |
|---|---|---|---|
| 201711328996.9 | Dec 2017 | CN | national |
The present application claim priority to U.S. Provisional Patent Applications US 62/531,070 filed on Jul. 11, 2017, 62/559,123 filed on Sep. 15, 2017, and 62/569,223 filed on Oct. 6, 2017, and to Chinese Patent Application 2017113289969 filed on Dec. 13, 2017; the contents of which are each incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2018/041390 | 7/10/2018 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2019/014179 | 1/17/2019 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4193435 | Frosch | Mar 1980 | A |
| 4223073 | Caldwell | Sep 1980 | A |
| 5251370 | Muller | Oct 1993 | A |
| 7357225 | Dorian | Apr 2008 | B2 |
| 7919174 | Ruokolainen | Apr 2011 | B2 |
| 8109704 | Lewis et al. | Feb 2012 | B2 |
| 8210315 | Diehl et al. | Jul 2012 | B2 |
| 8418812 | Rosen | Apr 2013 | B1 |
| 8517651 | Babej | Aug 2013 | B2 |
| 20040042871 | Wojciechowski | Mar 2004 | A1 |
| 20040086355 | Couillais | May 2004 | A1 |
| 20050188636 | Burns | Sep 2005 | A1 |
| 20060062977 | Sigler | Mar 2006 | A1 |
| 20080098979 | Vincer et al. | May 2008 | A1 |
| 20080260489 | Brown et al. | Oct 2008 | A1 |
| 20110194913 | Lewis | Aug 2011 | A1 |
| 20120171413 | Fisk et al. | Jul 2012 | A1 |
| 20120318799 | Spix | Dec 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| S60-92749 | Jun 1985 | JP |
| 2016178651 | Nov 2016 | WO |
| Entry |
|---|
| International Search Report and Written Opinion, Application No. PCT/2018/041390 dated Oct. 10, 2018. |
| International Preliminary Report on Patentability, Application No. PCT/2018/041390 dated Dec. 31, 2019. |
| Number | Date | Country | |
|---|---|---|---|
| 20200131958 A1 | Apr 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62569223 | Oct 2017 | US | |
| 62559123 | Sep 2017 | US | |
| 62531070 | Jul 2017 | US |
