Method of casting components with inserts for noise reduction
View Patent ↗The invention provides a method for manufacturing a powertrain component enclosure member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the powertrain component enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.
1. A method for manufacturing an enclosure member, comprising the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.
2. The method of claim 1 , wherein said enclosure member comprises an electric motor drive housing.
3. The method of claim 1 wherein said enclosure member comprises a transmission housing.
4. The method of claim 1 , wherein said enclosure member comprises a rear end housing.
5. The method of claim 1 , wherein said enclosure member comprises an engine block.
6. The method of claim 1 , wherein said enclosure member comprises a differential case.
7. The method of claim 1 , wherein said enclosure member comprises an exhaust manifold.
8. The method of claim 1 , wherein said enclosure member comprises a cylinder head.
9. A method of reducing objectionable noise in a vehicle comprising:
casting at least one insert into a wall of a powertrain enclosure member which at least partially houses noise-generating rotating components of the powertrain; and
wherein said insert is at least partially pre-coated to prevent bonding of a major portion of the insert with the wall to provide a proper interfacial boundary between the insert and the wall for damping noise.
10. A method for manufacturing an enclosure member, comprising the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to substantially prevent bonding between the insert and the casting material; and (B) casting a wall of the enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping, wherein said at least one insert is provided with peripheral tabs to support the insert in a suspended position within the mold for said casting.