Method for producing stator assembly for electric machine

Abstract

The invention relates to a method for manufacturing a stator assembly (1) for an electric machine (100), comprising a stator (2) and a bus bar (4) for electrically connecting a coil (6) of the stator (2) to a controller (101) of the electric machine (100). Simplified and cost-effective production with reduced cycle time is achieved by covering the bus bar (4) with an electrically insulating bus bar material and then electrically connecting it to the coil (4), the joining sections (8) of the coil (6) electrically connected to the bus bar (4) also being electrically insulated individually after said electrical connection. The invention also relates to a stator assembly (1) produced in this way and to an electric machine (100) having such a stator assembly (1).

Description

Technical Field

[0001] The invention relates to a method for producing a stator component for an electric machine, and also to a stator component produced in this way and an electric machine having such a stator component. Background Art

[0002] The motor has a stator including a coil. The coil is used for electromagnetic interaction between the stator and the rotor of the motor. The coil of the stator is usually powered and / or controlled by a controller of the motor. The electrical connection between the coil and the controller is usually achieved through a bus bar. Usually, the bus bar is arranged at the axial upper side of the stator and is electrically connected to the coil. In addition, the bus bar usually has a plug section to establish an electrical connection between the bus bar and the controller.

[0003] In particular, in moist and wet environments, it is desirable to electrically insulate the conductive components of the busbars and the connection points between the busbars and the coils.

[0004] From US 2010 / 0148615 A1 it is known to produce an assembly having a stator and busbars. To produce the assembly, which is also referred to as stator assembly below, the busbars are arranged on the upper side of the stator. The busbars and the stator are then overmolded with an electrically insulating material.

[0005] US 2011 / 0215662 A1 proposes fixing the busbars to the upper side of the stator with clips and then overmolding them with an electrically insulating material.

[0006] From US 2015 / 0188376 A1 it is known to arrange busbars on the upper side of a stator and to cover the busbars with a casting mold, wherein an electrically insulating material is injected into the casting mold in such a way that it envelops the busbars. Summary of the invention

[0007] The present invention is concerned with the problem of providing improved or at least alternative embodiments for a method for producing a stator component of the type mentioned above, as well as for such a stator component and an electric machine having such a stator component.

[0008] According to the invention, this problem is solved by the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.

[0009] The invention is therefore based on the following basic idea: in order to manufacture an assembly comprising a stator and a busbar of an electric machine, the busbar is first overmolded with an electrically insulating material, the unit thus manufactured is arranged on the stator and electrically connected to the stator, and then the connection point between the stator and the busbar is overmolded with an electrically insulating material. Compared to the variants known from the prior art in which the busbar is overmolded after being mounted on the stator, the solution according to the invention achieves a simplified process during manufacturing and thus also a reduction in manufacturing time, i.e. a reduction in the cycle time during manufacturing. In addition, the idea according to the invention enables a more precise shielding of the busbar with an electrically insulating material. This improves the electrical insulation of the busbar. The subsequent overmolding of the connection point between the busbar and the stator also achieves a precise electrical insulation, so that this can also be simplified and achieved with a reduced manufacturing time. In addition, the consumption of electrically insulating material is thus reduced. Therefore, the solution according to the invention achieves an improvement in the electrical insulation of the assembly and a reduction in the cycle time in the manufacture of the assembly, and also a reduction in manufacturing costs.

[0010] An assembly produced in this way is also referred to below as a stator assembly.

[0011] According to the idea of ​​the present invention, a stator and a busbar are provided for manufacturing a stator assembly. The stator has an upper side in the axial direction. In addition, the stator has at least three coils. The corresponding coil is guided by a segment on the upper side, and the segment is also referred to as a coil segment hereinafter. The corresponding coil segment is arranged in an associated segment on the upper side, and the corresponding such segment on the upper side is also referred to as a joining segment hereinafter. That is to say, the corresponding coil is arranged in an associated joining segment on the upper side with a coil segment. The busbar has an associated conductor for the corresponding coil, i.e., at least three conductors. Therefore, the corresponding conductor is also associated with the coil segment. The corresponding conductor has an associated segment for the associated coil segment, and an electrical connection is formed between the conductor and the coil segment via the associated segment. The corresponding such segment of the conductor is also referred to as a conductor segment hereinafter. In addition, the corresponding conductor has another segment spaced apart from the conductor segment, and an electrical connection to the controller of the associated motor is formed via the other segment. The corresponding such segment of the conductor is also referred to as a plug segment hereinafter. In order to manufacture the stator assembly, the above-mentioned unit is first manufactured with a busbar and an electrically insulating material. Therefore, the unit corresponds to a subassembly of the stator assembly and is also referred to as a busbar subassembly hereinafter. The manufacture of the busbar subassembly includes casting an electrically insulating material on the busbar, which is also referred to as a busbar material hereinafter. Therefore, the busbar subassembly is manufactured by overmolding the busbar with an electrically insulating busbar material. This is done so that the electrically insulating sheath of the busbar material covers the busbar, while the corresponding conductor segment is exposed and therefore accessible. The busbar subassembly is arranged on the upper side of the stator so that the corresponding conductor segment is located in the joint segment of the associated coil segment. Subsequently, the corresponding coil segment is electrically connected to the associated conductor segment in the associated joint segment, and the electrically insulating material is cast on the corresponding joint segment. This is done so that at least one cap of the electrically insulating material electrically insulates the joint segment, and therefore also electrically insulates the coil segment, and then electrically insulates the conductor segment. The electrically insulating material made of at least one cap is also referred to as a cap material hereinafter. That is, the respective joining section is overmolded with the electrically insulating cap material, so that at least one cap made of the cap material electrically insulates the respective joining section.

[0012] The electrical connection of the respective coil segments to the associated conductor segments can be achieved in any desired manner.

[0013] Advantageously, the respective coil segment is electrically connected to the associated conductor segment by means of resistance welding. This results in a mechanically stable and permanent electrical connection between the respective conductor and the associated coil.

[0014] The stator assembly is used in an electric machine. In such electric machines for use in moist and / or humid environments, particularly advantageous synergies arise. Precise, simple, low-cost electrical insulation of the stator assembly is particularly advantageous in such applications.

[0015] The electric machine may be, for example, an electric compressor used in air conditioning systems, wherein the compressor, in particular the stator assembly, may be in contact with a coolant and / or a refrigerant.

[0016] An electric machine, in particular an electric compressor, comprises, in addition to a stator assembly, a rotor which rotates about an axial rotation axis during operation.

[0017] Thus, the axial direction is preferably a direction coaxial or parallel to the axis of rotation. Furthermore, a specified direction refers to the axial direction. Thus, "axial" means parallel or coaxial to the axial direction. A circumferential direction surrounds / encircles the axial direction. Furthermore, "radial" extends transversely to the axial direction.

[0018] The electric machine advantageously further comprises a controller. The controller is used to power the coils of the stator and / or control the coils of the stator. The busbars electrically connect the coils to the controller. Advantageously, the controller is arranged on a side of the busbar subassembly axially facing away from the upper side. The electrical connection to the controller is established by electrically connecting the corresponding plug section to the controller. Preferably, this is a plug connection, preferably an axial plug connection.

[0019] Preferably, the motor for the controller has an associated housing, which is also referred to as the controller housing in the following text. The controller is therefore arranged in the controller housing. Preferably, the busbars, in particular the corresponding plug sections, enter the control housing and are electrically connected to the controller in the control housing.

[0020] Preferably, the bus bar subassembly seals the control housing.

[0021] In principle, it is conceivable to overmold all joining sections or at least two joining sections together, so that the associated cap insulates all joining sections or at least two joining sections.

[0022] In a preferred embodiment, at least two joining segments, preferably corresponding joining segments, are partially overmolded with a cap material such that they are respectively insulated with an associated cap. In other words, at least two joining segments, preferably corresponding joining segments, are partially overmolded with a cap material such that the associated cap insulates the corresponding joining segment and the caps are spaced apart from each other. As a result, the amount of cap material required is significantly reduced. As a result, the manufacture of the stator assembly is both less expensive and faster, i.e. with a reduced cycle time.

[0023] The corresponding electrically insulating material, ie the busbar material and the cap material, may be any electrically insulating material.

[0024] For example, the bus bar material is plastic.

[0025] Preferably, the corresponding joining section is overmolded with a hot melt adhesive as the cap material, so that at least one cap is produced by means of hot melting. This results in a mechanically strong production of the cap.

[0026] Preferably, the at least one cap is mechanically stiffer than a sheath of the busbar subassembly. Advantageously, the sheath is deformable, preferably elastically deformable, and the respective cap is rigid compared to the sheath.

[0027] The hot melt adhesive is advantageously a polymer adhesive. This results in a simple and precise production of the corresponding cap. At the same time, the corresponding cap thus exhibits a higher mechanical stability / hardness and higher electrical insulation properties.

[0028] If at least two joining sections are manufactured, each of which has an associated cap, the caps can be manufactured one after the other. For example, one cap can be manufactured first and then the next cap.

[0029] In a preferred embodiment, at least two caps, preferably all caps, are manufactured together. This further simplifies the manufacture of the stator assembly. To this end, before manufacturing the corresponding caps, a unit having a stator and a busbar subassembly is preferably manufactured, wherein the coil segments and the conductor segments are electrically connected. The unit is also referred to as a stator unit hereinafter. That is, the stator unit is manufactured before manufacturing the corresponding caps. In order to manufacture the stator unit, the busbar subassembly is arranged on the upper side of the stator so that the corresponding conductor segments are arranged in the joining segments of the associated coil segments. In addition, the corresponding coil segments are electrically connected to the associated conductor segments in the associated joining segments. Then, at least one cap is manufactured on the stator unit.

[0030] Preferably, the respective at least one cap is manufactured using an open casting mold. This results in a simplified and precise manufacture of the respective cap. That is, a casting mold is provided for manufacturing at least one cap. The casting mold has an associated recess for the respective joining section. Such a respective recess is also referred to as a cap recess hereinafter. Furthermore, the casting mold has an open side opposite to the cap recess. The casting mold is arranged on the stator unit with the open side so that the respective cap recess surrounds the associated joining section. The cap material is then injected into the cap recess to manufacture the cap.

[0031] The busbar assembly is advantageously manufactured so that it has a load-bearing section and a plug interface. The load-bearing section has a conductor section and extends radially and in a circumferential direction in an annular manner. The plug interface has a plug section and adjoins the load-bearing section, preferably protruding axially. Therefore, the load-bearing section also includes at least part of the sheath.

[0032] In a preferred embodiment, at least one groove is formed in the sheath in the load-bearing section, which groove is open in the axial direction and extends transversely to the axial direction. The at least one groove is spaced apart from the corresponding conductor, so that no electrical connection of the conductor to the environment is established. Preferably, the load-bearing section is arranged on the upper side and mechanically connected to the stator, while the plug interface is loose relative to the stator and is axially spaced apart relative to the stator, so that the plug interface can be moved axially relative to the stator. As a result, the installation of the stator assembly in the electric machine is significantly simplified and tolerance compensation is significantly improved. As a result, the electric machine can be manufactured at lower costs and with reduced cycle times.

[0033] In a preferred embodiment, the plug interface is received in an electrically insulating base body, from which the plug section protrudes axially. This results in a simplified handling of the plug interface and thus a simplified electrical connection of the stator assembly to the controller and thus a simplified assembly of the motor.

[0034] Advantageously, the base body and the plug interface form a plug, in particular a male connector. This simplifies the installation of the electric machine, in particular simplifies the connection of the busbar to the controller.

[0035] The substrate may be part of a bus bar subassembly.

[0036] Preferably, the base body can be manufactured by encapsulating the plug segment with a cap material. That is, the plug interface can be overmolded with the cap material so that a base body made of the cap material is manufactured, wherein the base body receives the plug segment and the plug segment protrudes from the base body. This results in a further simplified and cost-effective manufacture of the stator assembly.

[0037] An advantageous embodiment is one in which the base body is also produced using a casting mold. This means that a casting mold is provided which has an associated recess for the base body, which recess is also referred to below as the base body recess. The casting mold is arranged on the stator unit with the open side so that the base body recess surrounds the plug segment. The cap material is injected into the base body recess, whereby the base body is produced. Thus, there is a combined production of both the at least one cap and the base body.

[0038] It should be understood that in addition to the method for manufacturing a stator assembly, the stator assembly so manufactured is also within the scope of the present invention.

[0039] It should also be understood that an electric machine having a stator assembly is also within the scope of the present invention.

[0040] Further important features and advantages of the invention are apparent from the dependent claims, the drawings and the accompanying description based on the drawings.

[0041] It is to be understood that the features mentioned above and those yet to be explained below can be used not only in the combination indicated in each case but also in other combinations or alone, without departing from the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Preferred embodiments of the invention are shown in the drawings and will be explained in more detail in the following description, wherein the same reference numerals indicate the same or similar or functionally identical components.

[0043] The accompanying drawings schematically show:

[0044] Figure 1 is a simplified cross-sectional view of an electric machine having a stator assembly,

[0045] Figure 2 is an axonometric view of the stator of the stator assembly,

[0046] Figure 3 is an axonometric view of the busbar subassembly of the stator assembly,

[0047] Figure 4 is another isometric view of the busbar subassembly.

[0048] Figure 5 is an axonometric view of the state of the stator assembly during manufacture,

[0049] Figure 6 yes Figure 5 Axonometric view in the area of ​​the joining section in the illustrated state,

[0050] Figure 7 is an axonometric view of the stator assembly.

[0051] Figure 8 is a 3D view of the casting mold used to manufacture the stator assembly.

[0052] Fig. 9 is a spatial view of a stator assembly in another exemplary embodiment,

[0053] Fig.10 is a highly simplified schematic diagram of an air conditioning system with an electric machine in a motor vehicle. DETAILED DESCRIPTION

[0054] like Figure 1 , Figure 7 and Fig. 9 The stator assembly 1 shown in the example is used for Figure 1 and Fig.10 In the motor 100 shown in the example of FIG. 1 , the stator assembly 1 includes Figure 2 The stator 2 is shown separately in FIG. The stator assembly also includes Figure 3 and Figure 4The subassembly 3 is shown separately in FIG. The subassembly 3 includes busbars 4 and will also be referred to as busbar subassembly 3 hereinafter. In operation, the stator 2 interacts with the rotor of the motor 100 (the rotor is not shown for simplicity) so that the rotor surrounds only Figure 1 The rotation axis R shown in FIG. 1 rotates. In operation, an electromagnetic interaction occurs between the stator 2 and the rotor. To this end, the stator 2 is controlled and / or powered by means of a controller 101 of the motor 100. Figure 1 As can be seen in FIG. 1 , the controller 101 may be arranged in an associated housing 103 of the electric machine 100 , said housing 103 separating the controller 101 from the stator 2 . The housing 103 is also referred to as a control housing 103 hereinafter.

[0055] Especially from Figure 2 As can be seen in the figure, the stator 2 has an upper side 5 in direction A, which is also referred to as axial direction A below. The stator 2 also has at least three coils 6 for electromagnetic interaction with the rotor. Purely as an example, the stator 2 can have three such coils 6. The respective coils 6 are arranged on the upper side 5 in sections 7, which are also referred to as coil sections 7 below. The respective coil sections 7 are arranged in associated sections 8 of the upper side 5, which are also referred to as joining sections 8 below. The respective coil sections 7 are therefore arranged in associated joining sections 8 on the upper side 5. The coil sections 7 of different coils 6 are spaced apart from each other, so that the joining sections 8 are also spaced apart from each other. In the exemplary embodiment shown, the coil sections 7 and therefore the joining sections 8 are spaced apart from each other in the circumferential direction C.

[0056] The busbar 4 of the busbar subassembly 3 electrically connects the coil 6 of the stator 2 and the controller 101. Figure 3 and Figure 4 As can be seen in FIG. 1 , the bus bar 4 (see in particular Figure 3 ) has an associated conductor 9 for the respective coil 6. Thus, the respective conductor 9 is assigned to the coil section 7 of the associated coil 6. Figure 3As can be seen, the respective conductor 9 can be multi-part. In the exemplary embodiment shown, purely by way of example, the respective conductor 3 comprises a bar 10 extending essentially in the circumferential direction C and a pin 11 electrically and mechanically connected to the bar 10 and protruding axially. The pin 11 is shown in different variants in the figures. For the associated coil segment 7, the respective conductor 9 has an associated segment 12 for electrical connection to the coil segment 7, said segment 12 also being referred to as conductor segment 12 hereinafter. In the exemplary embodiment shown, the respective conductor segment 12 is part of the bar 10 of the associated conductor 9. Purely by way of example, in the exemplary embodiment shown, the respective conductor segment 12 protrudes radially. The respective conductor 9 also comprises a segment 13 spaced apart from the conductor segment 12 for electrical connection to the controller 101, said segment 13 also being referred to as plug segment 13 hereinafter. In the exemplary embodiment shown, the respective pin 11 forms the plug segment 13 of the associated conductor 9. Thus, as Figure 1 As shown, the busbar 4 is connected to the controller 101 in the axial direction A by means of a plug-in connection. For this purpose, in the exemplary embodiment shown, the corresponding plug segment 13 is arranged and accommodated in the plug interface 20 of the busbar subassembly 3. The plug interface 20 protrudes axially. In the stator assembly 1, the plug interface 20 is part of a plug 21, which also has an electrically insulating base body 22 that receives the plug segment 13. The base body 22 thus accommodates the plug segment 13, in the exemplary embodiment shown, the pin 11, wherein the plug segment 13 protrudes axially from the base body 22. Figure 1 It can be seen that the busbar subassembly 3 enters the controller housing 103 together with the plug 21 to establish an electrical connection between the coil 6 and the controller 101 , while also sealing the controller housing 103 .

[0057] To manufacture the stator assembly 1, firstly the stator 2 and the busbar 4 are provided. Next, the busbar subassembly 3 is first manufactured and then attached and connected to the stator 2. Then, the corresponding joining sections 8 are insulated.

[0058] Reference below Figure 3 and Figure 4 The production of the busbar subassembly 3 is explained. In addition to the busbar 4, the busbar subassembly 3 also includes an electrically insulating sheath 14 made of an electrically insulating material, which is also referred to as busbar material in the following text. The busbar material is, for example, a plastic with a certain mechanical flexibility. The sheath 14 thus encloses the corresponding conductor 9 and thus insulates it, leaving the corresponding conductor section 12 exposed. In addition, the plug section 13, i.e. the pin 11 in the exemplary embodiment shown, protrudes axially radially from the sheath 14. For a better understanding, the sheath 14 is Figure 3 are shown as transparent or only in outline.

[0059] The busbar subassembly 3 is thus manufactured by overmolding the busbar 4 with the busbar material, so that the electrically insulating sheath 14 made of the busbar material covers / casts the busbar 4 and exposes the corresponding conductor sections 12. This can be achieved, for example, by injection molding the busbar 4 with the busbar material.

[0060] like Figure 5 and Figure 6 As shown, the busbar subassembly 3 is arranged on the upper side 5 of the stator 2 such that the respective conductor segment 12 is arranged in the joining segment 8 of the associated coil segment 7. Furthermore, the respective coil segment 7 is electrically connected to the associated conductor segment 12 in the associated joining segment 8. Figure 5 and Figure 6 The state is shown after the respective conductor segment 12 has been electrically connected to the associated coil segment 7 . Figure 6 An enlarged cross section of one of the joining sections 8 is shown. Figure 6 It can be seen that in the exemplary embodiment shown, the respective coil section 7 is formed by the wire 15 of the associated coil 6. The electrical connection of the respective conductor section 12 to the associated coil section 7 can be achieved by resistance welding. Figure 5 and Figure 6 It can further be seen that in the exemplary embodiment shown, the stator 2 has, purely by way of example, an axially protruding adapter 16 on the upper side 5, which engages in an associated receptacle 17 of the busbar subassembly 3 in order to position the busbar subassembly 3 relative to the stator 2. In the exemplary embodiment shown, the receptacle 17 is a purely exemplary component of the jacket 14.

[0061] As in Figure 7 As can be seen, for example, after the corresponding coil segment 7 is electrically connected to the associated conductor segment 12, the associated joining segment 8 is insulated by means of at least one electrically insulating cap 18 made of an electrically insulating material, which is also referred to as cap material hereinafter. To this end, the corresponding joining segment 8 is overmolded with an electrically insulating cap material so that at least one cap 18 made of the cap material electrically insulates the joining segment 8 and therefore also electrically insulates the conductor segment 12 and the coil segment 7 arranged in the joining segment 8. In the exemplary embodiment shown, the associated cap 18 insulates the corresponding joining segment 8. That is, the corresponding joining segment 8 is partially overmolded with the cap material so that the associated cap 18 electrically insulates the corresponding joining segment 8. Therefore, according to the spaced arrangement of the joining segments 8, the caps 18 are spaced apart from each other in the circumferential direction C.

[0062] In the exemplary embodiment shown, the respective coil segment 7 is first electrically connected to the associated conductor segment 12 and then at least one cap 18 is produced. Figure 5 and Figure 6 A unit 19 comprising the stator 2 and the busbar subassembly 3 is shown, wherein respective coil segments 7 are electrically connected to associated conductor segments 12. Said unit 19 will also be referred to as stator unit 19 in the following.

[0063] In the exemplary embodiment shown, the axial direction A is coaxial with the rotation axis R of the rotor. The directions shown here refer to the axial direction A. Therefore, "axial" extends coaxially or parallel to the axial direction A. The rotation axis R therefore extends axially. Furthermore, "radial" extends radially transversely to the axial direction A. The circumferential direction C extends around the axial direction A.

[0064] In the exemplary embodiment shown, the corresponding cap 18 is produced by means of hot melt bonding. That is to say, the corresponding joining section 8 is overmolded with a hot melt adhesive as cap material. The hot melt adhesive is, for example, a polymer adhesive.

[0065] In the exemplary embodiment shown, the use Figure 8 The casting mold 50 shown as an example in the figure is used to manufacture the corresponding cap 18. The casting mold 50 has an associated recess 51 for the corresponding joining section 8 for manufacturing the associated cap 18, which recess is also referred to as the cap recess 51 below. Therefore, the cap recess 51 is spaced apart according to the spaced-apart arrangement of the joining section 8. The casting mold 50 has an open side opposite to the cap recess 51, that is, it is an open casting mold 50. In order to manufacture the cap 18, the casting mold 50 is arranged on the stator unit 19 with the open side so that the corresponding cap recess 51 surrounds the associated joining section 8 (not shown). The cap material is then injected into the cap recess to manufacture the corresponding cap 18.

[0066] exist Figures 1 to 7 In the exemplary embodiment shown, the plug 21 is part of the busbar subassembly 3 .

[0067] like Fig. 9 As shown, the base body 22 of the plug 21 can alternatively be produced by casting a cap material around the plug connection 20, so that the base body 22 is made of the cap material. For this purpose, the casting mold 50 for the base body 22 has an associated recess 52, which is also referred to as the base body recess 52 below. When the casting mold 50 is arranged on the stator unit 19 with the open side, the base body recess 52 surrounds the plug connection 20. When the cap material is subsequently injected into the base body recess 52, the base body 22 is produced.

[0068] As in Fig. 9 As can be further seen in FIG, the stator assembly 1 can also have more than three joining segments 8 and therefore more than three caps 18. Fig. 9In the exemplary embodiment shown, the stator component 1 has, purely by way of example, eight such joining segments 8 and therefore eight such caps 18 .

[0069] For example, from Figure 3 and Figure 4 It can be seen that the busbar subassembly 3 in the exemplary embodiment shown is manufactured such that it has a bearing section 23 extending radially and in the circumferential direction C in an annular manner. The bearing section 23 comprises a conductor section 12, which in the exemplary embodiment shown is shown together with the bar 10. The plug interface 20 adjoins the bearing section 23 and protrudes axially. The busbar subassembly 3 is mechanically connected to the stator 2 via the bearing section 23, for example via the adapter 16 and the receptacle 17. That is, in the exemplary embodiment shown, the receptacle 17 is part of the bearing section 23. In contrast, the plug interface 20, in particular the plug 21, is loose relative to the stator 2 and is axially spaced relative to the stator 2, so that the plug interface 20, in particular the plug 21, can be axially moved relative to the stator 2. For this purpose, a first circumferentially extending section 24 of the bearing section 23 is attached to the stator 2. That is, in the exemplary embodiment shown, the section 24 has a receptacle 17. The section 24 will also be referred to as the connecting section 24 hereinafter. The connecting section 24 is adjoined by a section 25 of the support section 23, which is axially spaced apart from the stator 2 and is arranged loosely relative to the stator 2 (see in detail Figure 5 The section 25 is also referred to below as the loose section 25 . The plug interface 20 , in particular the plug 21 , is connected to the loose section 25 and is radially and circumferentially spaced apart from the connecting section 24 .

[0070] For example, from Figure 4 As can be seen in the figure, at least one groove 26 is formed in the load-bearing section 23 of the sheath 14. In the exemplary embodiment shown, at least one groove 26 is formed in the loose section 25 of the sheath 14. The respective groove 26 is open in the axial direction A and extends transversely relative to the axial direction A. In the exemplary embodiment shown, purely by way of example, eight such grooves 26 are formed in the loose section 25, wherein every two such grooves 26 are axially opposite. This results in a simplified axial deformation and movement of the loose section 25. This results in a simplified axial mobility of the plug interface 20, in particular the plug 21.

[0071] The motor 100 can reliably operate even in a wet / humid environment. Therefore, the motor 100 is advantageously used in a wet / humid environment. For example, the motor 100 may be an electric compressor 102 for compressing a coolant or a refrigerant.

[0072] like Fig.10As shown in simplified form in FIG. 1 , the motor 100 may be used as a compressor 102 in an air conditioning system 200 to compress a coolant or refrigerant circulating in the air conditioning system 200. Therefore, the air conditioning system 200 includes a circuit 201 through which a coolant or refrigerant circulates during operation, and the compressor 102 is included in the circuit 201 and compresses the coolant or refrigerant during operation. The air conditioning system 200 may also include a condenser 202 incorporated in the circuit 201 for condensing the coolant or refrigerant, an expander 203 incorporated in the circuit 201 for expanding the coolant or refrigerant, and an evaporator 204 incorporated in the circuit 201 for evaporating the coolant or refrigerant. Fig.10 Air flow 205 indicated by arrows in may be directed through evaporator 204 to cool interior space 301. Interior space 301 and air conditioning system 200 may be part of a motor vehicle 300.

Claims

1. A method for manufacturing a stator assembly (1) for an electric machine (100), comprising: - providing a stator (2), said stator (2) comprising: an upper side (5) in the axial direction (A), at least three coils (6), each coil (6) being arranged with a coil section (7) in an associated joining section (8) on the upper side (5), - providing a bus bar (4) having associated conductors (9) for the respective coils (6), wherein the respective conductor (9) for the associated coil section (7) comprises a conductor section (12) and a plug section (13) spaced apart from the conductor section (12), the plug section (13) being used for connection to a controller (101) of the motor (100), - manufacturing a busbar subassembly (3) by overmolding a busbar (4) with an electrically insulating busbar material such that an electrically insulating sheath (14) of the busbar material envelops the busbar (4) and exposes the respective conductor segments (12), - arranging the busbar subassembly (3) on the upper side (5) of the stator (2) such that the respective conductor segment (12) is arranged in the joining segment (8) of the associated coil segment (7), - electrically connecting the corresponding coil segment (7) in the associated joining segment (8) to the associated conductor segment (12), and overmolding the corresponding joining segment (12) with an electrically insulating cap material so that at least one cap (18) of the cap material electrically insulates the corresponding joining segment (8).

2. The method according to claim 1, characterized in that At least two joining sections (8) are partially overmolded with a cap material so that the associated cap (18) insulates the respective joining section (8) and the caps (18) are spaced apart from each other.

3. The method according to claim 1 or 2, characterized in that: The respective joining section (8) is overmolded with a hot-melt adhesive as cap material, so that at least one cap (18) is produced by means of hot-melting.

4. The method according to claim 3, characterized in that At least one joining section (8) is overmolded with a polymer adhesive as a hot melt adhesive.

5. The method according to any one of claims 1 to 4, characterized in that - before manufacturing the corresponding cap (18), manufacturing a stator unit (19) with a stator (2) and a busbar subassembly (3) such that: The busbar subassembly (3) is arranged on the upper side (5) of the stator (2) such that the respective conductor segment (12) is arranged in the joining segment (8) of the associated coil segment (7), The corresponding coil segment (7) in the associated joining segment (8) is electrically connected to the associated conductor segment (12), - At least one cap (18) is manufactured on the stator unit (19).

6. The method according to claim 5, characterized in that - providing a casting mold (50) for producing at least one cap (18), said casting mold having an associated cap recess (51) for the respective engagement section (8) and an open side opposite the at least one cap recess (51), the casting mold (50) is arranged with the open side on the stator unit (19) so that the corresponding cap recess (51) surrounds the associated joining section (8), - Injecting cap material into at least one cap recess (51), thereby producing at least one cap (18).

7. The method according to any one of claims 1 to 6, characterized in that - the busbar subassembly (3) is manufactured such that the busbar subassembly (3) has a carrier section (23) with a conductor section (12), the carrier section (23) extending radially and annularly in a circumferential direction (C), and the busbar subassembly (3) has a plug section (13) and adjoining the carrier section (23), preferably a plug interface (20) protruding axially, - at least one groove (26) is formed in the jacket (14) in the load-bearing section (23), the groove (26) being open in the axial direction (A) and extending transversely to the axial direction (A), The support section (23) is arranged on the upper side (5) and connected to the stator (2), while the plug interface (20) is loose relative to the stator (2) and is axially spaced relative to the stator (2), so that the plug interface (20) can be moved axially relative to the stator (2).

8. The method according to claim 7, characterized in that The plug interface (20) is overmolded with the cap material such that an electrically insulating base (22) of the cap material receives the plug section (20) and the plug section (20) protrudes from the base (22).

9. The method according to claim 8 and any one of claims 6 or 7, characterized in that - providing a casting mold (50) having an associated base body recess (52) for the base body (22), the casting mold (50) is arranged with the open side on the stator unit (19) so that the base body recess (52) surrounds the plug connection (20), - Injecting the cap material into the base body recess (52) and thereby producing the base body (22).

10. A stator assembly (1) for an electric machine (100), in particular for an electric compressor (102), wherein: The stator assembly (1) is manufactured according to the method according to any one of claims 1-9.

11. An electric motor (100), in particular an electric compressor (102), - having a stator component (1) according to claim 10, - having a rotor which rotates during operation about an axial rotation axis (R), - a controller (101) for powering and / or controlling the coils (6) of the stator (2), -in, The busbars (4) electrically connect the corresponding coils (6) to the controller (101).

12. The electric machine (100) according to claim 11, characterized in that The electric motor (100) comprises a controller housing (103), in which a controller (101) is arranged, wherein a corresponding plug section (13) enters into the controller housing (103) and is connected to the controller (101) in the controller housing (103).

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