DE102006017081A1 - Stator for an electric motor and method of manufacture - Google Patents

Abstract

The invention relates to a stator (5) for an electric motor, having several stator pole teeth (1) and a bearing seat (6) which is divided into several segments (4), at least one of these segments (4) having a relevant stator pole tooth (1) connected is. The invention also relates to a method for producing such a stator.

Description

The The invention relates to a stator for an electric motor and a Process for producing such a stator.

such Stators are particularly suitable for use in motor vehicles. In the automotive sector electric motors play as small engines are formed, due to the limited space a significant Role. Small motors are electric motors with small dimensions and usually have a power up to 1 kW.

electric motors can as an inner rotor or external rotor motors be educated. Internal rotor motors have an outer stator and an inner rotor. The rotor is inserted coaxially in the stator. at an external rotor motor surrounds the outer rotor the inner stator coaxial. The rotor or the rotor shaft is rotatably mounted in all variants. The bearing of the rotor shaft is realized, for example, with one or more end shields. The rotor shaft can either directly in a bearing plate or in a friction-reducing bearing, which is arranged in a bearing plate is, be stored. The use of end shields is expensive, since they are extra Represent components.

As an alternative to a bearing plate, the stator may have an integrated bearing seat. So is out of the DE 103 12 614 A1 an electric machine with a rotor bearing integrated in the stator known. The rotor shaft is rotatably mounted in rolling bearings, which are received by bearing rings, which are arranged in the stator of the electric machine. The use of bearing rings is expensive.

in the The prior art also stators are known, which are composed of Statorpolzähnen. The stator pole teeth are preferably coupled together. For this purpose will be the stator pole teeth either outside with thin ones Bars provided or hinged. Such a built-up Stator can be opened. The Statorpolzähne remain preferably coupled. In the unfolded state, the stator can be handled easily become. Also can applied with little effort and high density electrical windings become. After winding, the stator pole teeth become closed collapsed of the stator.

It is also known stators for electrical insulation with plastic to overmold. This adds extra insulator or foils not required.

Of the Invention is based on the object, a stator for a Electric motor and a method for producing such indicate thus a simple construction of an electric motor with a small space allows becomes.

According to the invention Task solved by a stator having the features specified in claim 1, and by a method having the features specified in claim 7.

advantageous Embodiments of the invention are the subject of the dependent claims.

It becomes a stator with multiple stator pole teeth and one into several segments subdivided bearing seat proposed, with at least one of these Segments is connected to a respective Statorpolzahn. By Assembling the connected to the segments Statorpolzähne for Stator can thus produced in the same step, the bearing seat become. Due to the integration of the segments with the Statorpolzähnen requires the stator also has a small installation space. The bearing seat can either directly pick up a rotor shaft or a bearing for a rotor shaft.

Appropriately, the connected segment is made of plastic. This one can be low Processed effort and in different, beneficial ways be connected to the Statorpolzahn.

In a particularly preferred embodiment The segment is injected around one or a part of the Statorpolzahns and so connected to the stator pole tooth. This allows with little effort a stable, positive fit Connection. Alternatively, the arranged part of the Statorpolzahns also be a component connected to the stator pole tooth.

Preferably the overmolded part of the stator pole tooth is integral with the stator pole tooth educated. this makes possible a particularly stable connection.

advantageously, is the molded part as a reinforcing anchor for the bearing seat educated. A reinforcing anchor, in particular in one-piece design, provides an efficient means of reinforcement of the bearing seat.

A connection of adjacent Statorpolzähne succeeds in an advantageous manner by means of a arranged in a Statorpolzahn recess for a portion of a film hinge. The depression can in particular special designed as a groove. Such a film hinge, which is partially disposed in the recess of the respective Statorpolzahns and partially in the recess of the adjacent Statorpolzahns, provides a flexible connection between the two Statorpolzähnen. The flexible connection allows in particular with little effort, the unfolding of the stator for winding and the subsequent Collapse, repeated if necessary. Such a film hinge can also be used independently of a segmented bearing seat.

Preferably the film hinge is made of plastic. This way you can it in one operation with the encapsulation of electrical insulation and / or the segment of the bearing seat. Thereby will not be an additional injection mold needed. The foil hinge can be injected directly into the recess become. Alternatively, it can be in the same or in a separate injection process prefabricated and subsequently be inserted into the recess.

It become embodiments preferred in which the recess is in the manner of an undercut expands. This prevents movement of the film hinge the depression under tension.

In a preferred embodiment of the method according to the invention When encapsulating insulation on at least one side the Statorpolzahns and / or a film hinge for flexible coupling two adjacent Statorpolzähne generated. This eliminates additional Steps for creating an insulation and / or a hinge. A film hinge can outer webs or with the stator pole teeth Flexible replacement of hinges made. It is expediently sprayed into two corresponding recesses of adjacent stator pole teeth, so that these adjacent stator pole teeth are coupled together become.

Appropriately, is the connection to a single Statorpolzahn or in a unfolded state of multiple Statorpolzähne performed. Thereby the stator pole tooth is easily accessible. The Segment can be manufactured with high precision. Alternatively, the connection may be in a folded state multiple stator pole teeth respectively.

The particular advantages of the invention are that produced with little effort, an electric motor with low space requirements can be.

claimed is accordingly also a Electric motor with a stator according to the invention.

One embodiment The invention will be explained in more detail with reference to drawings. Show:

1A . 1B schematically two coupled, unfolded Statorpolzähne in front view and perspective view,

2A to 2C schematically individual Statorpolzähne in unimpacted state in a loose arrangement for a stator in cross section and in perspective view,

3A to 3C schematically a collapsed stator in front view and perspective view, and

4 to 5 schematically the connection of several or two Statorpolzähne by means of a film hinge in detail.

each other corresponding parts are in all figures with the same reference numerals Mistake.

In 1A are two substantially T-shaped Statorpolzähne 1 represented by means of a film hinge 2 in the unfolded state are coupled flexibly hinged together. Other, adjacent Statorpolzähne are not shown for clarity. Each stator pole tooth 1 is made of painted with baked enamel or linked single sheets.

1B shows the same Statorpolzähne 1 perspective. Each stator pole tooth 1 consists of a respective package of sheets not individually illustrated, wherein the frontal sheet as part of the Statorpolzahns 1 a reinforcing anchor 3 which is angled at about 90 ° to the end-side sheet in a cold bending process and formed integrally therewith. Other angles are possible.

Each laminated core is including the respective reinforcing anchor 3 encapsulated with plastic for electrical insulation. In the area of reinforcing anchors 3 the plastic is form-fitting with the reinforcing anchor 3 connected and to a segment 4 shaped a bearing seat. The plastic can be reinforced in glass fiber reinforced or modified with mineral additives.

Both the film hinges 2 as well as the insulation and the segments 4 including reinforcing anchors 3 , are preferably in a single operation in the unfolded state of the Statorpolzähne 1 produced by spraying. In an al ternativen, not shown approach, the syringes in the folded state of the Statorpolzähne 1 respectively. In an alternative, not shown approach, the Statorpolzähne 1 be sprayed separately in the uncoupled state.

In the unfolded or separate state of the Statorpolzähne 1 These are provided in high density with windings, such as copper wire. Subsequently, the Statorpolzähne 1 collapsed, where they are previously coupled if necessary.

The 2A . 2 B and 2C show stator pole teeth 1 in the non-overmolded state. In 2A are schematically the original contours of the end plates of folded Statorpolzähnen 1 with reinforcing anchors 3 recognizable, wherein the reinforcing anchors 3 are formed integrally with the front plates. In 2 B is the theoretical bending line for bending a reinforcing anchor 3 displayed. After bending the reinforcing anchors 3 in an exemplary cold bending process, the stator pole teeth are located 1 in the in 2C shown form, which represents in perspective in the folded state. The reinforcement anchors 3 act after the overmolding as a reinforcement for the surrounding plastic and thus as a reinforcement for the bearing seat 6 , reinforcing anchor 3 may in non-formed embodiments at both ends of a Statorpolzahns 1 be arranged on the respective end plates, if both sides segmented bearing seats 6 are provided.

After folding over the over-molded stator pole teeth 1 lies in the 3A . 3B and 3C in front view or in perspective or as a longitudinal section imaged stator 5 in front. He has a total of twelve Statorpolzähne, for example 1 on, according to the to the 1A . 1B are coupled manner described. The individual segments 4 each of which is associated with a respective stator pole tooth 1 is connected, form a bearing seat in the folded state 6 , In this either a rotor shaft can be mounted directly rotatable or a bearing for a rotor shaft can be arranged. For a low friction is preferably a bearing, such as a rolling bearing, in the bearing seat 6 pressed. 3C shows the over-molded stator pole teeth 1 with one in the camp seat 6 arranged ball bearings 7 and a rotor shaft 8th in longitudinal section.

For reinforcement, the bearing seat 6 be enclosed in all cases from inside and / or outside.

4 shows several through film hinges 2 coupled stator pole teeth 1 in a superimposed representation of folded and unfolded position. For collapsed position, the common center M of the rotational symmetry of the stator 5 shown.

In 5 is the connection of two stator pole teeth 1 by means of a film hinge 2 shown in detail. With solid lines is the collapsed position of the Statorpolzähne 1 and shown in dashed lines the unfolded position. Both stator pole teeth 1 have a respective recess 9 on where the film hinge 2 partially arranged. The wells 9 expand to a predetermined depth, so that the positive action of an undercut against an outward movement of the film hinge 2 is achieved. An unwanted separation of the Statorpolzähne 1 is thereby prevented.

The foil hinge 2 is expediently in the folded position of Statorpolzähne 1 into the wells 9 pushed in or injected. In this position, the openings of the wells 9 optimally accessible. The insertion of the film hinge 2 in the folded position is preferably in one operation with an insulating encapsulation of the Statorpolzähne 1 produced.

1

stator pole

2

film hinge

3

reinforcing anchor

4

segment

5

stator

6

bearing seat

7

ball-bearing

8th

rotor shaft

9

deepening

B

bending axis

M

Focus

Claims (13)

Stator ( 5 ) for an electric motor, comprising a plurality of stator pole teeth ( 1 ) and a bearing seat ( 6 ), which is divided into several segments ( 4 ), wherein at least one of these segments ( 4 ) with a respective Statorpolzahn ( 1 ) connected is. Stator ( 5 ) according to claim 1, characterized in that the connected segment ( 4 ) consists of plastic. Stator ( 5 ) according to claim 2, characterized in that the segment ( 4 ) around a part of the stator pole tooth ( 1 ) is sprayed. Stator ( 5 ) according to claim 2 or 3, characterized ge indicates that the overmolded part of the stator pole tooth ( 1 ) integral with the Statorpolzahn ( 1 ) is trained. Stator ( 5 ) according to claim 3 or 4, characterized in that the overmolded part as a reinforcing anchor ( 3 ) for the bearing seat ( 6 ) is trained. Stator ( 5 ) according to one of the preceding claims, characterized by a depression ( 9 ) for a part of a film hinge ( 2 ) for coupling with an adjacent stator pole tooth ( 1 ). Stator ( 5 ) according to claim 6, characterized in that the film hinge ( 2 ) consists of plastic. Stator ( 5 ) according to claim 6 or 7, characterized in that the depression ( 9 ) widens in the form of an undercut. Electric motor with a stator ( 5 ) according to any one of the preceding claims. Method for producing a stator ( 5 ) for an electric motor, in particular according to one of claims 1 to 9, wherein a stator pole tooth ( 1 ) with a segment ( 4 ) of a bearing seat ( 6 ) is connected. Method according to claim 10, characterized in that the segment ( 4 ) is formed from plastic by at least a part of the Statorpolzahns ( 1 ) is coated with the plastic. A method according to claim 10 or 11, characterized in that during encapsulation insulation on at least one side of the Statorpolzahns ( 1 ) and / or a film hinge ( 2 ) for flexible coupling of two adjacent Statorpolzähne ( 1 ) be generated. Method according to one of claims 10 to 13, characterized in that the connection to a single Statorpolzahn ( 1 ) or in an unfolded state of several Statorpolzähne ( 1 ) is carried out.