Stator tool unit for segmented stator

Abstract

The present disclosure relates to a stator tooth unit (10) for a stator (110). The stator has an axis (111) and a plurality of stator tooth units (10) arranged circumferentially about the axis (111). The stator tooth unit (10) includes stator teeth (20), insulators (30), and coils (40). The stator teeth (20) define a radially outer side (20a) and a radially inner side (20b). The radially inner side (20b) is opposite to the radially outer side (20a). The stator teeth (20) further define a first circumferential side (20c) and a second circumferential side (20d). The second circumferential side (20d) is opposite the first circumferential side (20c). The insulator (30) at least partially covers the stator teeth (20). A coil (40) is wound around the partially covered stator teeth (20). The insulator (30) comprises an insulating wall (32) which extends away from the stator teeth (20) on the first and second circumferential sides (20c, 20d). The insulating wall (32) comprises a sealing structure (54, 56) on at least one circumferential side (20c, 20d). The sealing structure (54, 56) is configured to form a seal (50) with an insulating wall (32) of an adjacent stator tooth unit (10).

Description

Technical Field

[0001] The present disclosure relates to a stator teeth unit for a stator, and to a stator including a plurality of stator teeth units. Furthermore, the present disclosure relates to a stator assembly including the stator, and to an electric motor including the stator assembly. The present disclosure further describes a method for manufacturing a stator assembly including a plurality of stator teeth units. Background Art

[0002] For decades, electric motors have been used in various fields of technology to generate kinetic energy. An electric motor is an electrical device configured to convert electrical energy into mechanical energy (also called an electric motor or electric motor), or an electrical device configured to convert mechanical energy into electrical energy (also called a generator). The mechanical energy can then be used to generate kinetic energy that can be used to drive other devices. An electric motor can typically include a stator and a rotor housed in a motor housing. The stator can be fixed in place, and the rotor can move relative to the stator. Typically, the rotor is rotatably fixed to a shaft that rotates with the rotor. The shaft can be used to transfer the rotational energy to other devices. Most electric motors use a magnetic field and winding currents to generate energy.

[0003] Depending on the configuration, the electric motor can be configured as, for example, a radial flux machine or an axial flux machine. In a radial flux machine, the rotor typically comprises a cylindrical body that carries magnets around its circumference. The stator is typically hollow cylindrical and surrounds the rotor at a certain radial distance. This type of radial flux machine is also referred to as a radial flux machine with an internal rotor (or a radial flux machine with an external stator). Alternatively, a radial flux machine can also be designed with an external rotor. This means that the stator is located inside and surrounded by the hollow cylindrical rotor. The stator has several circumferentially distributed winding elements on the radial inside (with an inner rotor) or radial outside (with an outer rotor) of the stator. Each winding element includes stator teeth extending radially from the stator yoke toward the rotor. Wires of a metallic, well-conducting material (such as copper) are wound around the stator teeth to form the windings. When current is applied to the windings, the rotor, which is attached to the motor's shaft, is subjected to a torque generated by the magnetic field. The magnetic flux generated by the magnetic field is the radial flux in a radial flux machine. A set of rotors fixed to the shaft can be referred to as a rotor assembly. Typically, the rotor assembly is rotatably supported by bearings in the motor housing.

[0004] The continued development of electric motors and the trend towards using electric current as an energy carrier and energy source are leading to a continuous expansion of their application range. Electric motors are not only used in small electronic devices such as laptops or household appliances, which typically operate in the low-voltage range. Increasingly, larger electric motors are also being used in the high-voltage range, operating at voltages of up to 800 or 850 volts and higher.

[0005] Electric motors, particularly in high-voltage applications, such as traction motors used in vehicles like automobiles, often generate excessive heat during operation. During operation, heat can be generated, for example, in the stator windings. Another challenge can be electrically insulating the windings from their surroundings. Known solutions for insulating the windings and conducting heat to the stator housing include potting the stator in the stator housing. However, production using stator potting is labor-intensive and requires various manufacturing tools and steps.

[0006] An object of the present disclosure is to provide an insulating stator that can be produced more efficiently. Summary of the Invention

[0007] The present disclosure relates to a stator teeth unit for a stator as defined in claim 1. The present disclosure further relates to a stator having a plurality of such stator teeth units as defined in claim 8 and a stator assembly comprising such a stator as defined in claim 10. According to claim 13, the present disclosure relates to an electric machine comprising such a stator assembly. According to claim 14, the present disclosure describes a method for manufacturing such a stator assembly. The dependent claims describe advantageous embodiments of the present disclosure.

[0008] According to a first aspect, the present invention relates to a stator tooth unit for a stator. The stator has an axis and a plurality of stator tooth units arranged circumferentially about the axis. The stator tooth unit includes stator teeth, an insulator, and a coil. The stator teeth define a radially outer side and a radially inner side, the radially inner side being opposite the radially outer side. The stator teeth further define a first circumferential side and a second circumferential side, the second circumferential side being opposite the first circumferential side. The insulator at least partially covers the stator teeth. The coil is wound around the partially covered stator teeth. The insulator includes an insulating wall extending away from the stator teeth on the first and second circumferential sides. The insulating wall includes a sealing structure on at least one circumferential side. The sealing structure is configured to form a seal with the insulating wall of an adjacent stator tooth unit. Providing insulating walls on the stator teeth eliminates the need for complex and large molding tools used to pot the stator in a stator housing. This is possible due to the circumferential extension of the insulating wall and its function of forming a seal with adjacent stator tooth units. In other words, the insulating wall of the stator tooth unit provides a portion of the boundary for filling the stator with resin during potting of the stator in the stator housing. Consequently, less potting tooling is required. In particular, there is no need to prepare and clean the molding tool, nor is there any need for demolding. In summary, the provided stator tooth unit enables more efficient production of stator devices and electric motors.

[0009] In an embodiment, the insulating wall may be positioned adjacent to one of the radially outer side or the radially inner side. In other words, the stator tooth unit may be configured for a radially inner stator (ie, the insulating wall is positioned adjacent to the radially outer side) or a radially outer stator (ie, the insulating wall is positioned adjacent to the radially inner side).

[0010] In an embodiment, the insulating wall may extend axially along the stator tooth, at least along the axial thickness of the stator tooth. The axial thickness of the stator tooth may be defined between a first axial surface (also referred to as an upper axial surface) and a second axial surface (also referred to as a lower axial surface) of the stator tooth. By extending at least along the axial thickness of the stator tooth, a sealing and potting boundary may be provided for at least the axial height of the stator tooth.

[0011] In an embodiment, the insulating wall may extend axially above the stator tooth. In an embodiment, the insulating wall may extend axially below the stator tooth. Specifically, the insulating wall may extend axially above and below the stator tooth. For example, the insulating wall may extend away from the stator tooth on a first axial side (i.e., extending axially above the stator tooth) and / or away from the stator tooth on a second axial side (i.e., extending axially below the stator tooth). More specifically, the insulating wall may extend away from the first axial surface (i.e., extending axially above the stator tooth) and / or away from the second axial surface (i.e., extending axially below the stator tooth). For example, the insulating wall may extend at least above and / or below the stator tooth surface to extend axially over the coil turns of the coil arranged on the first and second axial sides. By extending axially above the stator tooth, the insulating wall may define a first edge arranged on the first axial side. By extending axially below the stator tooth, the insulating wall may define a second edge arranged on the second axial side. These edges may define respective ends of the insulating wall in the axial direction and may therefore be referred to as axial edges. In an embodiment, the first axial edge and / or the second axial edge may extend substantially in the circumferential direction.

[0012] In an embodiment, the sealing structure may extend at least along the axial thickness of the insulating wall. In particular, the sealing structure may extend from a first axial edge to a second axial edge of the insulating wall. By extending at least along the axial thickness of the insulating wall, a sealing and potting boundary may be provided for at least the axial height of the stator tooth, more specifically, at least the axial thickness of the insulating wall.

[0013] In an embodiment, the sealing structure may include a first sealing structure arranged on a first circumferential side of the insulating wall and a second sealing structure arranged on a second circumferential side of the insulating wall. More specifically, the insulating wall may include two side edges. The first side edge is arranged on the first circumferential side. The second side edge is arranged on the second circumferential side. These side edges may define the respective ends of the insulating wall in the circumferential direction and may therefore also be referred to as circumferential edges. In an embodiment, the side edges may extend substantially in the axial direction. In some embodiments, the circumferential edges may be inclined, for example, up to 30°, relative to the axial direction. Specifically, the circumferential edges of the insulating wall may be parallel to each other. The sealing structure may be formed in the circumferential edges, or may represent the circumferential edges.

[0014] In an embodiment, the first sealing structure may be configured to form a seal with a second sealing structure of an adjacent stator tooth unit.

[0015] In some embodiments, the first sealing structure can be configured to hold a separate sealing element together with a second sealing structure of an adjacent stator tooth unit, such that the first sealing structure of the stator tooth unit, the separate sealing element, and the second sealing structure of the adjacent stator tooth unit collectively form a seal. In an embodiment, at least one of the first sealing structure and the second sealing structure can include a sealing groove for receiving the separate sealing element.

[0016] In some embodiments, the first sealing structure may include a flexible sealing lip configured to press against a second sealing structure of an adjacent stator tooth. In some embodiments, the second sealing structure may, for example, provide a support surface against which the flexible sealing lip can press. In alternative embodiments, the flexible sealing lip may be provided at the second sealing structure, and the first sealing structure may provide the support structure. In some embodiments, both sealing structures may include a flexible sealing lip configured to press against a sealing lip of an adjacent stator tooth unit.

[0017] In some embodiments, the first sealing structure may include a sealing groove, and the second sealing structure may include a sealing protrusion.The sealing groove and the sealing protrusion may be configured to sealingly engage with the sealing protrusion and the sealing groove of an adjacent stator tooth unit, respectively.

[0018] In an embodiment, the stator tooth unit may further include a first engaging structure formed on a first circumferential side and a second engaging structure formed on a second circumferential side. The engaging structure may be configured to engage corresponding adjacent stator tooth units. For example, the first engaging structure may be configured to engage the second engaging structure of an adjacent stator tooth unit. The second engaging structure may be configured to engage the first engaging structure of an adjacent stator tooth unit. In an embodiment in which the insulating wall is positioned adjacent to one of the radially outer side or the radially inner side, the engaging structure may be positioned adjacent to the other of the radially outer side or the radially inner side. In other words, the stator tooth unit may be configured for a radially inner stator (i.e., the engaging structure is positioned adjacent to the radially inner side) or a radially outer stator (i.e., the engaging structure is positioned adjacent to the radially outer side).

[0019] In an embodiment, an engagement structure may be provided in a stator tooth and may be configured to engage a stator tooth of an adjacent stator tooth unit.

[0020] In an embodiment, the first engagement structure and the second engagement structure can be formed complementarily and configured to engage the stator teeth of adjacent stator tooth units in a form-fitting manner. Specifically, the engagement structure can be configured to circumferentially fix the adjacent stator tooth units (i.e., to resist relative circumferential movement). At least when several stator tooth units are joined so as to form a ring (i.e., a stator or a segmented stator), the engagement structure can also fix the stator tooth units to resist radial movement. More specifically, the first engagement structure can engage the second engagement structure of a stator tooth that is adjacent in a first circumferential direction. The second engagement structure can engage the first engagement structure of another stator tooth that is adjacent in a second circumferential direction opposite to the first circumferential direction. The form-fitting engagement makes it easy to assemble several stator tooth units to form a stator. In addition, the form-fitting engagement can provide a retaining force against radial forces during operation of the stator.

[0021] In an embodiment, the first engagement structure may protrude from the stator tooth on a side surface of the stator tooth on a first circumferential side.In an embodiment, the first engagement structure may extend axially along the stator tooth, in particular along an axial thickness of the stator tooth.

[0022] In an embodiment, the second engagement structure may be recessed into the stator tooth on a side surface of the stator tooth on the second circumferential side.In an embodiment, the second engagement structure may extend axially along the stator tooth, in particular along an axial thickness of the stator tooth.

[0023] In an embodiment, the stator tooth may comprise a stack of metal laminations defining an axial thickness between a first axial surface and an opposing second axial surface of the stator tooth.

[0024] In an embodiment, the stator teeth may be double-T shaped, with a central tooth web located between a radially outer portion and a radially inner portion.

[0025] In some embodiments, the insulator may be an overmolded plastic component. In some examples, the insulator material may include polyamide or fiber-reinforced polyamide, such as glass fiber reinforced polymer. In some examples, the insulator material may include PA66. In some embodiments, the material may include 20% to 40%, for example, 30%, of glass fiber. The percentage may refer to the weight percentage of the insulator material.

[0026] In an embodiment, the insulator may further include a coil insulation portion disposed between the coil and the stator teeth. Specifically, the coil insulation portion may be disposed at least on the central tooth web. In an embodiment, the coil insulation portion may include radially inner coil stops and / or radially outer coil stops configured to retain the coil in the central tooth web region. In an embodiment, the coil stops may be angled toward the central tooth web region. The coil insulation portion may be configured to electrically insulate the coil from the stator teeth.

[0027] In an embodiment, the insulator may further include a support portion. The support portion may be configured to support at least one of a wire end of the coil, a lead frame for the stator, and / or an electrical connector for connecting the wire end of the coil to the lead frame. In an embodiment, the support portion may include a wire end support portion, a connector support portion, and / or a lead frame support portion.

[0028] In a second aspect, the present invention further relates to a stator for an electric motor. The stator may include a plurality of stator tooth units according to the first aspect. The stator tooth units may be arranged circumferentially around the axis of the stator. The insulating walls of adjacent stator tooth units may form respective seals, and the plurality of stator tooth units may collectively form a closed circumference. Because the stator includes a plurality of stator tooth units, the stator may also be referred to as a "segmented stator."

[0029] In an embodiment of the stator, the insulating walls of adjacent stator tooth units may collectively form a radially outer circumferential boundary. The insulating walls of the respective stator tooth units may be positioned adjacent to the radially outer side. In other words, a radially inner stator may be provided for a radially outer rotor. In an embodiment of the stator, the engaging structures of adjacent stator tooth units may be engaged such that the stator teeth of the adjacent stator tooth units collectively form a radially inner circumferential boundary. The engaging structures of the respective stator tooth units may be positioned adjacent to the radially inner side. In other words, a radially inner stator may be provided for a radially outer rotor.

[0030] In other embodiments involving a radially outer stator, the insulating wall may be arranged at a radially inner portion of the stator teeth, thereby forming a radially inner circumferential boundary, and the stator teeth may form a radially outer circumferential boundary via the engagement structure with which they engage.

[0031] In embodiments of the stator, the stator may further include a lead frame. The lead frame may be arranged at a lower axial side of the stator tooth unit. The lead frame may be electrically connected to the coil. In embodiments, the insulating wall may extend axially at least below the lead frame. In other words, a second axial edge of the insulating wall may extend axially beyond the lead frame. This provides insulation between the coil and the lead frame relative to the stator housing and protects the lead frame.

[0032] In an embodiment of the stator, the lead frame may be electrically connected to the wire ends of the coil via a connector. In other words, the stator may include a plurality of connectors that connect the respective wire ends of the coil to the lead frame.

[0033] In a third aspect, the present invention further relates to a stator arrangement for an electric motor. The stator arrangement may include a stator according to the second aspect, a resin body and a stator housing. The stator housing may define an annular receiving portion having a first circumferential wall, an annular end wall and a second circumferential wall. The second circumferential wall may be radially opposite to the first circumferential wall. The stator may be at least partially arranged in the annular receiving portion. In an embodiment, the resin body may include an epoxy resin. In an embodiment, the resin body may be configured to firmly hold the stator in the stator housing. The resin body may be arranged between the insulating wall and the first circumferential wall. In addition, the resin body may be arranged at least at the bottom of the annular receiving portion, that is, between the stator and the annular end wall. In an embodiment of the stator arrangement, the stator teeth may be supported on the first circumferential wall.

[0034] In an embodiment of the stator arrangement, the insulating wall may be arranged adjacent to the second circumferential wall. The insulating wall may extend axially over at least an overlapping portion of the second circumferential wall. The overlapping portion may describe a portion of the second circumferential wall over which the insulating wall may extend axially, and may also be referred to as an axial overlapping portion. The overlapping portion is particularly advantageous for potting the stator in the stator housing because the overlapping portion may reduce leakage of liquid resin and may simplify the pre-potting step.

[0035] In embodiments comprising an overlap, the overlap may be 0.5 mm to 10 mm, specifically 1 mm to 5 mm. In some embodiments, the overlap may be at least 1 mm.

[0036] In embodiments comprising an overlapping portion, the resin body may radially fill the space between the insulating wall and the second circumferential wall at least over an axial sub-portion of the overlapping portion.

[0037] In embodiments including an overlapping portion, the second circumferential wall may be formed such that, at least at the axial position of the overlapping portion, the radial distance between the insulating wall and the second circumferential wall is at most 2 mm, specifically at most 1 mm, and more specifically at most 0.5 mm. In some examples, the radial distance may be at most about 0 mm to about 2 mm, specifically at most about 0.2 mm to about 1 mm.

[0038] In a fourth aspect, the present invention further relates to an electric machine. In particular, the electric machine may be an electric motor. The electric machine may include a machine housing, a shaft, a rotor, and a stator assembly according to the third aspect. The shaft may be rotatably supported in the machine housing. The rotor may be fixedly disposed on the shaft in the machine housing. The stator of the stator assembly may be disposed adjacent to the rotor in the machine housing.

[0039] In an embodiment of the electric machine, the stator may be arranged radially adjacent to the rotor.

[0040] In an embodiment of the electric machine, the rotor may be configured as a radially outer rotor. The rotor may include a plurality of circumferentially distributed rotor poles arranged on a rotor body of the rotor. Specifically, the rotor poles may be arranged radially outward of the stator.

[0041] In an embodiment of the electric machine, the machine housing may include a rotor housing and a stator housing. The rotor housing and the stator housing may be connected by a press fit. In an example, the rotor housing and the stator housing may be connected by threaded connections at corresponding flanges of the stator housing and the rotor housing.

[0042] In a fifth aspect, the present invention further relates to a method for manufacturing a stator device. The method may include providing a plurality of stator tooth units, each stator tooth unit having a stator tooth, an insulator having an insulating wall, and a coil wound around the stator tooth. The method may further include arranging the stator tooth units circumferentially so that the insulating walls together form a closed circumference, thereby forming a stator. The method may further include providing a stator housing, the stator housing defining an annular receiving portion having a first circumferential wall, an annular end wall, and a second circumferential wall radially opposite to the first circumferential wall. The method may further include inserting the stator into the annular receiving portion so that the axial portion of the insulating wall is arranged between the first circumferential wall and the second circumferential wall. The method may further include potting the stator in the stator housing by filling liquid resin between the insulating wall and the first circumferential wall, so that after the liquid resin hardens, a resin body is formed between the insulating wall and the first circumferential wall.

[0043] In an embodiment of the method, a stator teeth unit according to the first aspect may be provided. In particular, the method may relate to manufacturing a stator arrangement according to the third aspect.

[0044] In an embodiment of the method, prior to potting, a removable seal may be arranged to seal the gap between the insulating wall and the second circumferential wall.

[0045] As an alternative to removable seals, potting can include pre-potting a first amount of liquid resin to at least partially fill the overlapping portion between the insulating wall and the second circumferential wall. The first amount of liquid resin can be at least partially hardened to form a first resin body portion, thereby sealing the insulating wall and the second circumferential wall. After pre-potting, a second amount of liquid resin can be filled between the insulating wall and the first circumferential wall to form a second resin body portion. The first resin body portion and the second resin body portion can together form a resin body. This two-step potting method eliminates the need for a separate potting tool for sealing between the insulating wall and the second circumferential wall. This prevents liquid resin from leaking through the gap between the second circumferential wall and the insulating wall. Such leakage could potentially impair the function of the motor in which the stator assembly is used. For example, excess resin could be pushed through the gap into the machine housing. During operation, the rotor could come into contact with the excess resin and ultimately be damaged. Furthermore, open potting, i.e., without the need for a closed potting tool, is possible. This can improve the efficiency of the manufacturing process. In an embodiment, the first amount may be filled by a gap between the insulating wall and the first circumferential wall and / or between the insulating wall and the first circumferential wall.

[0046] In an embodiment of the method including pre-potting, the pre-potting may include preheating the stator assembly prior to filling with the second amount of liquid resin to at least partially harden the first amount of liquid resin. The preheating may be performed, for example, in an oven. The preheating may be controlled so that a sealing function is established. Pre-hardening only the first amount of liquid resin may improve the interface between the first resin body portion and the second resin body portion (e.g., may improve bonding). However, in other embodiments, the first amount of liquid resin may also be completely hardened.

[0047] In an embodiment of the method, potting may be performed with the upper axial surfaces of the stator teeth pointing in a direction opposite to gravity. In some embodiments, potting may be performed under vacuum as open potting.

[0048] In an embodiment of the method, the method may further comprise connecting the lead frame to the stator via a connector at a lower axial side of the stator. In particular, the connection may be performed before the stator is inserted. Specifically, the lead frame is pressed onto a connector inserted into the stator, in particular into a connector support. In an embodiment, the lead frame may be attached to the stator in the direction of gravity, while the stator is positioned such that the lower axial surface points in a direction opposite to gravity. In a specific embodiment, the stator may be inserted into the stator housing first with its lower axial side (i.e., the side of the lead frame). BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Other features will be readily apparent from the accompanying drawings, which form a part of this disclosure. The accompanying drawings are intended to further explain this disclosure and enable those skilled in the art to practice this disclosure. However, the accompanying drawings are intended to serve as non-limiting examples. Common reference numerals on different drawings indicate the same or similar features.

[0050] Figure 1a shows a side cross-sectional view of a motor according to a fourth aspect of the present disclosure, the motor including the stator device of the third aspect having a resin body;

[0051] Figure 1b Shown Figure 1a Detailed section A;

[0052] Figure 2a Shown without resin body Figure 1a A side sectional view of

[0053] Figure 2b Shown Figure 2a Detailed section A;

[0054] Figure 3 shows an exemplary stator tooth of the stator teeth unit of the first aspect;

[0055] Figure 4 shows a stator tooth partially covered with an insulator of a stator tooth unit according to the first aspect;

[0056] Figure 5 It is shown that the stator teeth unit according to the first aspect forms a seal with an adjacent stator teeth unit.

[0057] Figure 6 shows a perspective view of a portion of a stator according to the second aspect, the stator having a plurality of circumferentially arranged stator tooth units of the first aspect;

[0058] Figure 7 shows a bottom view of a portion of a stator according to the second aspect, the stator having a plurality of circumferentially arranged stator tooth units of the first aspect;

[0059] Figures 8a to 8c Three exemplary embodiments of sealing structures of adjacent stator tooth units are shown;

[0060] Figure 9 shows a perspective view of a stator according to the second aspect, the stator having a plurality of circumferentially arranged stator tooth units of the first aspect;

[0061] Figure 10 shows a perspective view of a stator according to a second aspect, the stator having a lead frame and a connector assembly;

[0062] Figure 11 A flow chart of a method for manufacturing a stator arrangement according to the fifth aspect is schematically shown. DETAILED DESCRIPTION

[0063] Embodiments of a stator teeth unit, a stator, a stator device, a motor, and a method according to the present disclosure will be described below with reference to the accompanying drawings.

[0064] In the context of the present application, the expression "axial", "axially" or "axial direction" refers to the rotation axis of the motor 200 (and / or the rotating shaft 230 and / or the rotor 220) and / or the axis 111 of the stator 110 including the plurality of stator tooth units 10. Therefore, the terms "axial", "axially" or "axial direction" are similarly applied to the stator tooth units 10. Figure 7 as well as Figures 9 and 10 ), the axial direction is indicated by reference numeral 2. The expressions "radial", "radially" or "radial direction" should be understood relative to the axis / axial direction 2 of the motor 200 or the stator 110 and are indicated by reference numeral 4. The expressions "circumferential", "circumferentially" or "circumferential direction" should be understood relative to the axis / axial direction 2 of the motor 200 or the stator 110 and are indicated by reference numeral 6. It should be understood that although one corresponding exemplary direction is shown in the corresponding figures, the corresponding opposite direction also falls within the corresponding expressions. For example, Figure 7 The circumferential direction 6 is shown by an arrow oriented counterclockwise. However, a clockwise direction around the axis 2 can also be indicated as the circumferential direction 6.

[0065] Figure 1a and Figure 2aAn exemplary electric machine 200 according to the fourth aspect of the present disclosure is shown in a side cross-sectional view. Electric machine 200 includes a stator arrangement 100 according to the third aspect of the present disclosure, a machine housing 210, a rotor 220, and a shaft 230. Specifically, the depicted electric machine 200 may be configured as an electric motor. In alternative embodiments, electric machine 200 may be a generator. In other words, electric machine 200 may be an electric motor and / or a generator. Shaft 230 may be rotatably supported in machine housing 210. Rotor 220 may be fixedly disposed on shaft 230 in machine housing 210. As explained further below, stator arrangement 100 may include a stator according to the second aspect of the present disclosure. Stator 110 of stator arrangement 100 may be disposed adjacent to rotor 220 in machine housing 210. Stator 110 is radially disposed adjacent to rotor 220. More specifically, rotor 220 is separated from stator 110 by a radial gap. In other words, electric machine 200 may be a radial gap machine or a radial flux machine. In the depicted example, the rotor 220 radially surrounds the stator 110. In other words, the rotor 220 can be configured as a radially outer rotor 220. The rotor 220 can include a plurality of circumferentially distributed rotor poles 222 (e.g., magnets 222) disposed on a rotor body 224 of the rotor 220. Specifically, the rotor poles 222 can be disposed on a radially inner surface of the rotor 220 and pointed toward the stator 110. The machine housing 210 can include a rotor housing 212 and a stator housing 120. For example, the rotor housing 212 and the stator housing 120 can be connected by a press fit. In the depicted example, the rotor housing 212 and the stator housing 120 can be connected by threaded connections at respective flanges of the stator housing 120 and the rotor housing 212.

[0066] Figure 1b and Figure 2b Shown Figure 1a and Figure 1b The corresponding detailed section A. Figure 1a 、 Figure 1b and Figure 2a 、 Figure 2b The difference between Figure 2a 、 Figure 2b , for illustrative purposes, the resin body 140 of the stator device 100 is not depicted. This should not be understood as the stator device 100 not including the resin body 140.

[0067] exist Figure 1a 、 Figure 1b 、 Figure 2a and Figure 2b Further visible in the figure are the stator tooth units 10 of the stator 110, which each include a stator tooth 20, an insulator 30 and a coil 40. The stator 110 includes a plurality of stator tooth units 10, such as for example Figure 9 As described in .

[0068] The following will be about Figure 5 、 Figure 6 and Figure 7 The stator teeth unit 10 according to the first aspect of the present disclosure is further described in detail. As mentioned above, the stator teeth unit 10 includes a stator tooth 20, an insulator 30, and a coil 40. The insulator 30 at least partially covers the stator tooth 20 and includes an insulating wall 32 (see FIG. Figure 6 ).like Figure 7 As shown, coils 40 are wrapped around the partially covered stator teeth 20 .

[0069] Figure 3 , an exemplary stator tooth 20 is shown. The stator tooth 20 defines a radially outer side 20a and a radially inner side 20b. The radially inner side 20b is opposite the radially outer side 20a. The stator tooth 20 further defines a first circumferential side 20c and a second circumferential side 20d. The second circumferential side 20d is opposite the first circumferential side 20c. The radial sides 20a and 20b should not be strictly understood as surfaces, ends, or portions of the stator tooth 20, but may refer to respective radial regions relative to the stator tooth 20. For example, the radially outer side 20a may refer to a radial region closer to the radially outer end than to the radially inner end, and / or a radial region disposed radially outward of the radially outer end of the stator tooth 20. The radially inner side 20b may refer to a radial region closer to the radially inner end than to the radially outer end, and / or a radial region disposed radially inward of the radially inner end of the stator tooth 20. Similarly, the circumferential sides 20c, 20d should not be strictly understood as surfaces or ends, but rather may indicate respective circumferential areas relative to a circumferential end and an opposite second circumferential end of the stator tooth 20. The stator tooth 20 may further define a first axial surface 23a and an opposite second axial surface 23b. The first axial surface 23a and the second axial surface 23b may define respective axial ends of the stator tooth 20 and respective axial sides 22a, 22b relative to the stator tooth 20. Between the first axial surface 23a (e.g., the upper axial surface 23a) and the second axial surface 23b (e.g., the lower axial surface 23b), an axial thickness 22 of the stator tooth 20 may be defined. In some embodiments, as Figure 3 As shown, the stator teeth 20 may include or may be formed from a stack of metal laminations. The stack of metal laminations may define an axial thickness 22 between a first axial surface 23a and a second axial surface 23b. Figure 3As further shown, the stator tooth 20 can be double-T shaped. The stator tooth 20 can have a central web 28 located between a radially outer portion 27 and a radially inner portion 29. The radially inner portion 27 can define a radially inner surface 21 b. The radially inner surface 21 b can point radially inward (i.e., toward the radially inner side 20 b). The radially inner surface 21 b can define the radially inner end of the stator tooth 20. The radially outer portion 29 can define a radially outer surface 21 b. The radially outer surface 21 a can point radially outward (i.e., toward the radially outer side 20 a). The radially outer surface 21 a can define the radially outer end of the stator tooth 20.

[0070] More about Figure 3 The stator tooth 20 may include a first engagement structure 24 and a second engagement structure 26. The first engagement structure 24 is formed on the first circumferential side 20c. The second engagement structure 26 is formed on the second circumferential side 20d. Figure 7 As shown, the engagement structures 24, 26 are configured to engage corresponding adjacent stator tooth units 10. For example, the first engagement structure 24 can be configured to engage the second engagement structure 26 of the adjacent stator tooth unit 10. Vice versa, the second engagement structure 26 can be configured to engage the first engagement structure 24 of the adjacent stator tooth unit 10. In other words, the first engagement structure 24 and the second engagement structure 26 can be formed complementarily and configured to engage the stator teeth 20 of the adjacent stator tooth units 10 in a form-fitting manner. In an example, the engagement structures 24, 26 can be configured as protrusions and recesses having a consistent profile (see, for example, Figure 3 and Figure 7 For example, the first engagement structure 24 may protrude from the stator tooth 20 on the side surface 21 c of the stator tooth 20 on the first circumferential side 20 c. Figure 3As shown, the first engagement structure 26 can extend axially along the stator tooth 20, particularly along the axial thickness 22 of the stator tooth 20. The second engagement structure 26 can be recessed into the stator tooth 20 on the side surface 21d of the stator tooth 20 on the second circumferential side 20d. Similar to the first engagement structure 24, the second engagement structure 26 can extend axially along the stator tooth 20, particularly along the axial thickness 22 of the stator tooth 20. As mentioned above, the exemplary figures of the present disclosure relate to a radially outer rotor 220 (and a radially inner stator 110, i.e., the stator tooth unit 10 depicted is configured for a radially inner stator). Therefore, the engagement structures 24, 26 are positioned adjacent to the radially inner side 20b (and the insulating wall 32, described later, is positioned adjacent to the radially outer side 20a). More specifically, the engagement structures 24, 26 can be provided in the radially inner portion 27 of the stator tooth 20. However, it should be understood that the present disclosure also covers stator tooth units 10 for radially outer stators, wherein the insulating wall 32 will be positioned adjacent the radially inner side 20b and the engagement structures 24, 26 will be positioned adjacent the radially outer side 20a (e.g., in the radially outer portion 29 of the stator tooth 20).

[0071] Although the depicted engagement structures 24, 26 are provided in the stator teeth 20 and may be configured to engage the stator teeth 20 of an adjacent stator tooth unit 10, in other embodiments, the engagement structures 24, 26 may not be provided in the stator teeth 20, but may be provided in other components of the stator tooth unit 10, such as the insulator 30. For example, the insulator 30 may be configured to define the engagement structures 24, 26 as described above.

[0072] In summary, the engagement structures 24, 26 are configured to circumferentially secure adjacent stator tooth units 10 (i.e., resist relative circumferential movement). At least when several stator tooth units 10 are engaged so as to form a ring (i.e., a stator 110 (e.g., a segmented stator 110)) (see, e.g., Figure 6 、 Figure 7 、 Figure 9 ), the engagement structures 24, 26 can also fix the stator tooth unit 10 to resist radial forces. More specifically, the first engagement structure 24 can be engaged in a first circumferential direction (e.g., Figure 7 The second engagement structure 26 can be engaged in a second circumferential direction opposite to the first circumferential direction (ie, in the circumferential direction indicated by the arrow 6 in FIG). Figure 7The first engagement structure 24 of another stator tooth unit 10 adjacent to the stator tooth unit 10 (in the circumferential direction opposite to the arrow 6 in FIG). The form-fitting engagement facilitates the assembly of several stator tooth units 10 to form a stator. In particular, when the engagement structures 24, 26 are formed in the stator teeth 20, the engagement structures 24 and 26 can be easily manufactured, for example by cutting metal laminations accordingly. Furthermore, the form-fitting engagement can provide a retaining force against radial and / or circumferential forces during operation of the stator 110.

[0073] Figure 4 The stator teeth 20 are shown partially covered with an insulator 30. As mentioned above, the insulator 30 includes an insulating wall 32. As for example Figure 1b 、 Figure 2b and Figure 4 As shown, the insulator 30 may further include a coil insulation portion 38. The coil insulation portion may be disposed between the coil 40 and the stator tooth 20. Specifically, the coil insulation portion 38 may be disposed at least on the central tooth web 28. In some embodiments, the coil insulation portion 38 may include a radially inner coil stopper and / or a radially outer coil stopper 38a (e.g., see Figure 4 and Figure 6 ). The coil stop 38a is configured to hold the coil 40 in the central web region 28. The radially inner coil stop and / or the radially outer coil stop 38a may be provided on the first axial side 22a and / or the second axial side 22b. Figure 6 As shown, the coil stop 38a can be inclined toward the central tooth web region 28. The coil insulation portion 38 can be configured to electrically insulate the coil 40 relative to the stator teeth 20. In some embodiments, the insulator 30 can further include a support portion 37 (e.g., see Figure 1b 、 Figure 2b 、 Figure 3 and Figure 4 ). The support portion 37 may be configured to support at least one of the wire ends 42 of the coil 40, the lead frame 150 for the stator 110, and / or the electrical connector 130 for connecting the wire ends 42 of the coil 40 to the lead frame 150. In this regard, Figure 1b 、 Figure 2b and Figure 3 The support portion 37 shown may include a wire end support portion 37a, a connector support portion 37b and / or a lead frame support portion 37c. Figure 1b 、 Figure 2b and Figure 4As can be seen in FIG, the wire end 42 can be inserted into the wire end support portion 37a. The connector 130 can be inserted into the connector support portion 37b, whereby the electrical connector 130 can establish an electrical connection to the wire end 42, for example, by a cold shut process. The lead frame 150 can be pressed onto the connector 130 and can be supported by the lead frame support portion 37c (see in particular FIG. Figure 1b and Figure 2b Insulator 30 may be an overmolded plastic component. In some examples, the insulator material may include a polymer or a fiber-reinforced polymer, such as a glass-reinforced polymer. For example, the insulator material may include polyamide or a fiber-reinforced polyamide, such as a glass-reinforced polyamide. In some examples, the insulator material may include PA66. In some embodiments, the material may include 20% to 40%, such as 30%, of glass fiber. The percentage may refer to the weight percentage of the material of insulator 30.

[0074] Reference again Figure 4 , the insulating wall 32 extends away from the stator tooth 20 on the first circumferential side 20c. The insulating wall 32 may also extend away from the stator tooth 20 on the second circumferential side 20d. In other words, the insulating wall 32 includes a portion arranged on the stator tooth 20 on the first circumferential side 20c and another portion arranged on the stator tooth 20 on the second circumferential side 20d. More specifically, the insulating wall 32 may define two side edges. The first side edge is arranged on the first circumferential side 20c. The second side edge is arranged on the second circumferential side 20d. These side edges may define respective ends of the insulating wall 32 in the circumferential direction 6 and may therefore also be referred to as circumferential edges. In an embodiment, as for example Figure 4 、 Figure 5 and Figure 6 As shown in , the side edges may extend substantially along the axial direction 2. In other embodiments, the circumferential edges may be inclined, for example up to 30°, relative to the axial direction 2. In particular, the circumferential edges of the insulating wall 32 may be parallel to each other.

[0075] In addition to the circumferential extension of the insulating wall 32 , the insulating wall 32 also extends axially above and axially below the stator tooth 20 (see, for example, Figure 4 and Figure 5). As shown, the insulating wall 32 can extend away from the stator tooth 20 on the first axial side 22a (i.e., extend axially above the stator tooth 20) and / or extend away from the stator tooth on the second axial side 22b (i.e., extend axially below the stator tooth 20). More specifically, the insulating wall 32 can extend away from the first axial surface 23a (i.e., extend axially above the stator tooth 20) and / or extend away from the second axial surface 23b (i.e., extend axially below the stator tooth 20). It should be noted that the terms "axially above" and "axially below" refer to positions / directions during potting or assembly of the stator device 100. In this regard, Figure 9 The stator 110 is depicted in an orientation in which it is assembled / potted in a stator housing 120. Figure 9 In the case of , the direction of gravity will be oriented from the top of the sheet to the bottom of the sheet. Figure 1a and Figure 2a The direction of gravity during assembly / potting will be from the left side of the sheet to the right side of the sheet. Figure 5 , the direction of gravity is similarly in the direction of the arrow in the axial direction 2. Therefore, the first axial side 22a / first axial surface 23a may also be referred to as the upper axial side 22a / upper axial surface 23a. Similarly, the second axial side 22b / second axial surface 23b may also be referred to as the lower axial side 22b / lower axial surface 23b. In some embodiments, the insulating wall 32 may extend at least above and below the axial surfaces 23a, 23b to extend axially over the coil turns of the coil 40 (for example, see Figure 1b 、 Figure 2b and Figure 5 ). By extending axially above the stator tooth 20, the insulating wall 32 can define a first edge arranged on the first axial side 22a. By extending axially below the stator tooth 20, the insulating wall 32 can define a second edge arranged on the second axial side 22b. These edges can define respective ends of the insulating wall 32 in the axial direction 2 and can therefore be referred to as axial edges. In an embodiment, the first axial edge and / or the second axial edge can extend substantially in the circumferential direction 6 (see Figures 4 to 6 ). In other embodiments, the axial edge may deviate from the circumferential shape and may be formed tangentially, for example.

[0076] However, in other embodiments, the insulating wall 32 may extend axially only above or below the stator tooth 20. In further embodiments, the insulating wall 32 may extend axially along the stator tooth 20, at least along the axial thickness 22 of the stator tooth 20. By extending at least along the axial thickness 22 of the stator tooth 20, a sealing and potting boundary for at least the axial height of the stator tooth 20 may be provided.

[0077] As previously mentioned, the exemplary figures of the present disclosure relate to a radially outer rotor 220 (and a radially inner stator 110, i.e., the depicted stator teeth unit 10 is configured for a radially inner stator). Figure 4 As shown, the insulating wall 32 is positioned adjacent to the radially outer side 20 a, in particular, near the radially outer end of the stator tooth 20 (and the aforementioned engagement structures 24 , 26 are positioned adjacent to the radially inner side 20 b). Specifically, the radially outer surface 21 a of the stator tooth 20 is not covered by the insulating wall 32. In embodiments, the insulating wall may be radially recessed relative to the radially outer surface 21 a, in particular, recessed radially inward. In other embodiments, the insulating wall 32 may be flush with the radially outer surface 21 a of the stator tooth 20. It should be understood that the present disclosure also encompasses stator tooth units 10 for radially outer stators, in which the insulating wall 32 would be positioned adjacent to the radially inner side 20 b and the engagement structures 24 , 26 would be positioned adjacent to the radially outer side 20 a.

[0078] refer to Figure 4 、 Figure 5 、 Figure 6 、 Figure 7 、 Figure 8a 、 Figure 8b and Figure 8c , the insulating wall 32 further includes a sealing structure 54, 56 located on at least one circumferential side 20c, 20d. More specifically, the sealing structure 54, 56 can be arranged on the first side edge and / or the second side edge of the insulating wall 32. The sealing structure 54, 56 is configured to form a seal 50 with the insulating wall 32 of the adjacent stator tooth unit 10 (see, for example, Figure 5 ). In some examples, the sealing structures 54, 56 may include a first sealing structure 54 arranged on the first circumferential side 20c of the insulating wall 32 and a second sealing structure 56 arranged on the second circumferential side 20d of the insulating wall 32. The sealing structures 54, 56 may be formed in a circumferential edge or may represent a circumferential edge. The first sealing structure 54 may be configured to form a seal 50 with the second sealing structure 56 of the adjacent stator tooth unit 10. By providing the insulating wall 32 on the stator tooth 10, a complex and large molding tool for potting the stator 110 in the stator housing 120 may be omitted. This is possible due to the circumferential extension of the insulating wall 32 and the function of the insulating wall to form the seal 50 with the adjacent stator tooth unit 10. In other words, the insulating wall 32 of the stator tooth unit 10 provides a portion of the boundary (e.g., the outer circumference 114) for filling the stator 110 with liquid resin during potting of the stator 110 in the stator housing 120. Therefore, less tooling is required for potting. In particular, there is no need to prepare a molding tool and clean it, nor is there any need for demolding. In summary, the provided stator teeth unit 10 enables more efficient production of the stator arrangement 100 and the electric machine 200.

[0079] like Figure 4 and Figure 5 As shown, the sealing structures 54, 56 can extend at least along the axial thickness 33 of the insulating wall 32. In particular, the sealing structures 54, 56 can extend from a first axial edge to a second axial edge of the insulating wall 32. By extending at least along the axial thickness 33 of the insulating wall 32, a sealing and potting boundary can be provided for at least the axial height 22 of the stator tooth 20, more specifically at least the axial thickness 33 of the insulating wall 32.

[0080] Figures 8a to 8c Three exemplary (and non-limiting) embodiments of how the sealing structures 54 , 56 may be configured are shown.

[0081] according to Figure 8a (See also Figures 5 to 7 ), the first sealing structure 54 can be configured to hold the separate sealing element 52 together with the second sealing structure 56 of the adjacent stator tooth unit 10, so that the first sealing structure 54 of the stator tooth unit 10, the separate sealing element 52 and the second sealing structure 56 of the adjacent stator tooth unit 10 together form the seal 50. In an embodiment, at least one of the first sealing structure 54 and the second sealing structure 56 may include a sealing groove for receiving the separate sealing element 52.

[0082] according to Figure 8b The first sealing structure 54 may include a flexible sealing lip 54a configured to press against a second sealing structure 56 of an adjacent stator tooth unit 10. In some embodiments, the second sealing structure 56 may, for example, provide a support surface against which the flexible sealing lip 54a may press. In alternative embodiments, the flexible sealing lip 54a may be provided at the second sealing structure 56, and the first sealing structure 54 may provide the support structure. In some embodiments, both sealing structures 54, 56 may include a flexible sealing lip 54a that may press against a sealing lip 54a of an adjacent stator tooth unit 10.

[0083] according to Figure 8c The first sealing structure 54 may include a sealing groove 54b, and the second sealing structure 56 may include a sealing protrusion 56b. The sealing groove 54b and the sealing protrusion 56b may be configured to sealingly engage with the sealing protrusion 56b and the sealing groove 54b of the adjacent stator tooth unit 10, respectively.

[0084] For example, in Figure 6 、 Figure 7 、 Figure 9 and Figure 10, a stator 110 for an electric motor 200 according to a second aspect of the present disclosure is depicted. The stator 110 includes a plurality of stator tooth units 10 according to the first aspect. The stator tooth units 10 are arranged circumferentially around an axis 111 of the stator 110. The insulating walls 32 of adjacent stator tooth units 10 form respective seals 50. Thus, the plurality of stator tooth units 10 together form a closed circumference. Since the stator 110 includes a plurality of stator tooth units 10, the stator 110 can also be referred to as a segmented stator 110. The insulating walls 32 of adjacent stator tooth units 10 can together form a radially outer circumferential boundary 114. The joining structures 24, 26 of adjacent stator tooth units 10 can be joined so that the stator teeth 20 of adjacent stator tooth units 10 together form a radially inner circumferential boundary 112. In other embodiments involving radially outer stators, insulating walls 32 may be disposed at radially inner portions of stator teeth 20 , thereby forming radially inner circumferential boundaries 112 , and stator teeth 20 may form radially outer circumferential boundaries 114 via the engagement structures 24 , 26 with which they engage.

[0085] In particular, Figure 1a 、 Figure 2a and Figure 10 As shown, the stator 110 may further include the lead frame 150 mentioned above. The lead frame 150 may be arranged at the lower axial side 22b of the stator tooth unit 10. The lead frame 150 may be electrically connected to the coil 40. For example, the lead frame 150 may be electrically connected to the wire ends 42 of the coil 40 via the connectors 130 mentioned above. In other words, the stator may include multiple connectors 130 that connect the respective wire ends 42 of the coil 40 to the lead frame 150. In an embodiment, the insulating wall 32 may extend axially at least below the lead frame 150. In other words, the second axial edge of the insulating wall 32 may extend axially beyond the lead frame 150. In this way, the coil 40 and the lead frame 150 can be insulated from the stator housing 120, and the lead frame 150 can be protected.

[0086] Figure 1a 、 Figure 1b 、 Figure 2a 、 Figure 2b , a stator arrangement 100 according to a third aspect of the present disclosure is shown. The stator arrangement 100 comprises a stator 110 according to the second aspect, a resin body 140 and a stator housing 120. The stator housing 120 may define an annular receiving portion having a first circumferential wall 122, an annular end wall 124 and a second circumferential wall 126. The second circumferential wall 126 is radially opposite to the first circumferential wall 122. The stator 110 is at least partially arranged in the annular receiving portion. In an embodiment, the resin body 140 may include an epoxy resin. In an embodiment, the resin body 140 may be configured to firmly hold the stator 110 in the stator housing 120. As Figure 1a and Figure 1b As shown, the resin body 140 is arranged between the insulating wall 32 and the first circumferential wall 122. In addition, the resin body 140 is arranged at least at the bottom of the annular receiving portion, that is, between the stator 110 and the annular end wall 124. Figure 1a 、 Figure 1b 、 Figure 2a 、 Figure 2b As shown, the stator tooth 20 may be supported on the first circumferential wall 122. More specifically, the stator tooth 20 may abut the first circumferential wall 122 with its radial inner surface 21b. In addition, the stator tooth 20 may be axially supported on a step of the first circumferential wall 122.

[0087] Specifically, if Figure 1b 、 Figure 2b As shown, the insulating wall 32 can be arranged adjacent to the second circumferential wall 126. The insulating wall 32 can extend axially over at least an overlapping portion 126a of the second circumferential wall 126. The overlapping portion 126a can describe a portion of the second circumferential wall 126 over which the insulating wall 32 can extend axially, and can also be referred to as an axial overlapping portion. The overlapping portion 126a is particularly advantageous for potting the stator 110 in the stator housing 120 because the overlapping portion can reduce leakage of liquid resin and simplify the pre-potting step. In some embodiments, the overlapping portion 126a can be 0.5 mm to 10 mm. Specifically, the overlapping portion 126a can be 1 mm to 5 mm. In some embodiments, the overlapping portion 126a can be at least 1 mm.

[0088] like Figure 1b As shown, resin body 140 radially fills the space between insulating wall 32 and second circumferential wall 126 at overlapping portion 126 a. In other embodiments, resin body 140 may only fill at least an axial sub-portion of overlapping portion 126 a. In other words, the surface of resin body 140 in the region between insulating wall 32 and second circumferential wall 126 may be arranged axially further toward annular end wall 124.

[0089] In a specific embodiment, the second circumferential wall 126 can be formed such that at least at the axial position of the overlapping portion 126a, the radial distance 126b between the insulating wall 32 and the second circumferential wall 126 is at most 2 mm, specifically at most 1 mm, and more specifically at most 0.5 mm. In some examples, the radial distance 126b can be at most about 0 mm to about 2 mm, specifically at most about 0.2 mm to about 1 mm. In other words, at least in one axial plane defined by the radial direction 4 and the circumferential direction 6, the radial distance 126b is at most 2 mm, specifically at most 1 mm, and more specifically at most 0.5 mm. This reduced radial distance 126b at the axial position or axial plane can reduce leakage of liquid resin or partially hardened resin and thus act as a seal or at least a barrier to prevent leakage. As Figure 1b and Figure 2b As shown, second circumferential wall 126 may, for example, include a radial step toward insulating wall 32 to reduce radial distance 126b. In other embodiments, second circumferential wall 126 may radially taper toward or away from annular end wall 124. This means that radial distance 126b may decrease toward or away from annular end wall 126b to provide a reduced radial distance 126b at at least one axial location. In still other embodiments, second circumferential wall 126 may contact and / or conform to the contour of insulating wall 32.

[0090] refer to Figure 11 , a method 300 for manufacturing a stator arrangement 100 according to a fifth aspect of the present disclosure is explained. The method 300 may include providing 310 a plurality of stator tooth units 10, each having a stator tooth 20, an insulator 30 having an insulating wall 32, and a coil 40 wound around the stator tooth 20. The method 300 may further include circumferentially arranging 320 the stator tooth units 10 such that the insulating walls 32 collectively form a closed circumference 112, 114, thereby forming the stator 110. The method 300 may further include providing 340 a stator housing 120 defining an annular receiving portion having a first circumferential wall 122, an annular end wall 124, and a second circumferential wall 126 diametrically opposite the first circumferential wall 122. The method 300 may further include inserting 350 the stator 110 into the annular receiving portion such that an axial portion of the insulating wall 32 is disposed between the first circumferential wall 122 and the second circumferential wall 126. The method 300 may further include potting 360 the stator 110 in the stator housing 120 by filling liquid resin between the insulating wall 32 and the first circumferential wall 122 , such that a resin body 140 is formed between the insulating wall 32 and the first circumferential wall 122 after the liquid resin hardens.

[0091] In particular, the stator teeth unit 10 according to the first aspect may be provided according to the method 300. In particular, the method 300 may relate to manufacturing a stator arrangement 100 according to the third aspect.

[0092] In some embodiments of the method 300 , prior to potting 360 , a removable seal may be arranged to seal the gap between the insulating wall 32 and the second circumferential wall 126 .

[0093] As an alternative to a removable seal, potting 360 can include pre-potting a first amount of liquid resin to at least partially fill the overlapping portion 126a between the insulating wall 32 and the second circumferential wall 126. The first amount of liquid resin can be at least partially hardened to form a first resin body portion to seal between the insulating wall 32 and the second circumferential wall 126. After pre-potting, a second amount of liquid resin can be filled between the insulating wall 32 and the first circumferential wall 122 to form a second resin body portion. The first and second resin body portions can together form the resin body 140. This two-step potting method eliminates the need for a separate potting tool for sealing between the insulating wall 32 and the second circumferential wall 126. This prevents liquid resin from leaking through the gap between the second circumferential wall 126 and the insulating wall 32. Such leakage could potentially impair the function of the motor 200 in which the stator assembly 100 is used. For example, excess resin could be pushed through the gap into the machine housing 210. For example, during operation, the rotor 220 could come into contact with the excess resin and ultimately be damaged. Furthermore, open potting, i.e., without the need for a closed potting tool, is possible. This can improve the efficiency of the manufacturing process. In an embodiment, the first volume can be filled by the gap between the insulating wall 32 and the first circumferential wall 122 and / or between the insulating wall 32 and the first circumferential wall 122.

[0094] In an embodiment, pre-potting may include preheating the stator assembly 100 prior to filling with the second amount of liquid resin to at least partially harden the first amount of liquid resin. Preheating may be performed, for example, in an oven. Preheating may be controlled to establish a sealing function. Pre-hardening only the first amount of liquid resin may improve the interface between the first and second resin body portions (e.g., may improve bonding). However, in other embodiments, the first amount of liquid resin may also be fully hardened.

[0095] In an embodiment of the method, potting 360 may be performed with the upper axial surfaces 23a of the stator teeth 20 pointing in a direction opposite to gravity. In some embodiments, potting 360 may be performed as an open potting under vacuum.

[0096] In an embodiment, method 300 can further include connecting 330 the lead frame 150 to the stator 110 via the connector 130 at the lower axial side 22b of the stator 110. In particular, connecting 330 can be performed before inserting 350 the stator 110. Specifically, the lead frame 150 can be pressed against the connector 130 inserted into the stator, specifically into the connector support portion 37b. In an embodiment, the lead frame 150 can be attached to the stator 110 in the direction of gravity, while the stator 110 is positioned such that the lower axial surface 23b points in a direction opposite to gravity. In a specific embodiment, the stator 110 can be inserted into the stator housing 120 first with the lower axial side 22b (i.e., side 150 of the lead frame).

[0097] Although the present invention has been described above and defined in the appended claims, it will be appreciated that the invention may alternatively be defined in accordance with the following embodiments:

[0098] 1. A stator teeth unit (10) for a stator (110), the stator having an axis (111) and a plurality of stator teeth units (10) arranged circumferentially around the axis (111), the stator teeth unit (10) comprising:

[0099] a stator tooth (20) defining a radially outer side (20a) and a radially inner side (20b) opposite the radially outer side (20a), and defining a first circumferential side (20c) and a second circumferential side (20d) opposite the first circumferential side (20c),

[0100] - an insulator (30) at least partially covering the stator tooth (20), and

[0101] - a coil (40) wound around the partially covered stator teeth (20),

[0102] wherein the insulator (30) comprises an insulating wall (32) extending away from the stator tooth (20) on the first circumferential side and the second circumferential side (20c, 20d), and

[0103] The insulating wall (32) includes a sealing structure (54, 56) on at least one circumferential side (20c, 20d), the sealing structure (54, 56) being configured to form a seal (50) with the insulating wall (32) of an adjacent stator tooth unit (10).

[0104] 2. The stator tooth unit (10) according to embodiment 1, wherein the insulating wall (32) is positioned adjacent to one of the radially outer side (20a) or the radially inner side (20b).

[0105] 3. The stator tooth unit (10) according to any one of the preceding embodiments, wherein the insulating wall (32) extends axially along the stator tooth (20), at least along the axial thickness (22) of the stator tooth (20).

[0106] 4. The stator tooth unit (10) according to any one of the preceding embodiments, wherein the insulating wall (32) extends axially above and / or axially below the stator tooth (20).

[0107] 5. The stator tooth unit (10) according to any one of the preceding embodiments, wherein the sealing structure (54, 56) extends along the axial thickness (33) of the insulating wall (32).

[0108] 6. A stator tooth unit (10) as described in any of the aforementioned embodiments, wherein the sealing structure (54, 56) includes a first sealing structure (54) arranged on a first circumferential side (20c) of the insulating wall (32) and a second sealing structure (56) arranged on a second circumferential side (20d) of the insulating wall (32).

[0109] 7. The stator tooth unit (10) of embodiment 6, wherein the first sealing structure (54) is configured to form the seal (50) with the second sealing structure (56) of the adjacent stator tooth unit (10).

[0110] 8. A stator tooth unit (10) as described in any one of Examples 6 or 7, wherein the first sealing structure (54) is configured to maintain a separate sealing element (52) together with a second sealing structure (56) of an adjacent stator tooth unit (10), so that the first sealing structure (54) of the stator tooth unit (10), the separate sealing element (52) and the second sealing structure (56) of the adjacent stator tooth unit (10) together form the seal (50).

[0111] 9. A stator tooth unit (10) as described in any one of embodiments 6 or 7, wherein the first sealing structure (54) includes a flexible sealing lip (54a) configured to press against the second sealing structure (56) of an adjacent stator tooth (10).

[0112] 10. The stator tooth unit (10) of any one of embodiments 6 or 7, wherein the first sealing structure (54) includes a sealing groove (54b), and wherein the second sealing structure (56) includes a sealing protrusion (56b).

[0113] 11. The stator tooth unit (10) as described in any of the aforementioned embodiments further includes a first engaging structure (24) formed on the first circumferential side (20c) and a second engaging structure (26) formed on the second circumferential side (20d), wherein these engaging structures (24, 26) are configured to engage corresponding adjacent stator tooth units (10).

[0114] 12. The stator teeth unit (10) of embodiment 11 (if dependent upon at least embodiment 2), wherein the engagement structures (24, 26) are located adjacent the other of the radially outer side (20a) or the radially inner side (20b).

[0115] 13. The stator tooth unit (10) of any one of embodiments 11 or 12, wherein the engagement structures (24, 26) are provided in the stator tooth (20) and are configured to engage the stator teeth (20) of an adjacent stator tooth unit (10).

[0116] 14. A stator tooth unit (10) as described in any one of embodiments 11 to 13, wherein the first engaging structure (24) and the second engaging structure (26) are formed complementarily and are configured to engage the stator teeth (20) of adjacent stator tooth units (10) in a shape-fitting manner.

[0117] 15. A stator tooth unit (10) as described in any one of embodiments 11 to 14, wherein the first engagement structure (24) protrudes from the stator tooth (20) on the side surface (21c) of the stator tooth (20) on the first circumferential side (20c).

[0118] 16. A stator tooth unit (10) as described in any one of embodiments 11 to 15, wherein the second engagement structure (26) is recessed into the stator tooth (20) on the side surface (21d) of the stator tooth (20) on the second circumferential side (20d).

[0119] 17. A stator tooth unit (10) as described in any of the preceding embodiments, wherein the stator tooth (20) comprises a stack of metal laminations that define an axial thickness (22) between a first axial surface (23a) and an opposite second axial surface (23b) of the stator tooth (20).

[0120] 18. The stator tooth unit (10) of any one of the preceding embodiments, wherein the stator tooth (20) is double-T-shaped with a central tooth web (28) located between a radially outer portion (27) and a radially inner portion (29).

[0121] 19. The stator tooth unit (10) according to any one of the preceding embodiments, wherein the insulator (30) is an overmolded plastic component.

[0122] 20. A stator tooth unit (10) as described in any of the preceding embodiments, wherein the insulator (30) further includes a coil insulation portion (38), which is arranged between the coil (40) and the stator tooth (20), specifically, the coil insulation portion (38) is arranged on the central tooth web (28).

[0123] 21. A stator tooth unit (10) as described in any of the preceding embodiments, wherein the insulator (30) further includes a support portion (37) configured to support at least one of the wire end (42) of the coil (40), a lead frame (150) for the stator (110), and / or an electrical connector for connecting the wire end (42) of the coil (40) to the lead frame (150).

[0124] 22. A stator (110) for an electric motor (200), the stator comprising:

[0125] A plurality of stator tooth units (10) according to any one of the preceding embodiments,

[0126] wherein the stator tooth units (10) are arranged circumferentially around the axis (111) of the stator (110), and

[0127] The insulating walls (32) of adjacent stator tooth units (10) jointly form a closed circumference by forming corresponding sealing members (50).

[0128] 23. The stator (110) of embodiment 22, wherein the insulating walls (32) of adjacent stator tooth units (10) together form a radially outer circumferential boundary (114).

[0129] 24. A stator (110) as described in any of embodiments 22 or 23 (if at least dependent on embodiment 11), wherein the joining structures (24, 26) of adjacent stator tooth units (10) are joined so that the stator teeth (20) of adjacent stator tooth units (10) jointly form a radial inner circumferential boundary (112).

[0130] 25. The stator (110) of any one of embodiments 22 to 24, further comprising a lead frame (150) arranged at a lower axial side (22b) of the stator tooth units (10) and electrically connected to the coils (40).

[0131] 26. The stator (110) of embodiment 25, wherein the lead frame (150) is electrically connected to the wire ends (42) of the coils (40) via connectors (130).

[0132] 27. A stator device (100) for an electric motor (200), wherein the stator device (100) comprises:

[0133] The stator (110) according to any one of embodiments 22 to 26,

[0134] a resin body (140), and

[0135] a stator housing (120) defining an annular receiving portion having a first circumferential wall (122), an annular end wall (124), and a second circumferential wall (126) radially opposite the first circumferential wall (122),

[0136] The stator (110) is at least partially arranged in the annular receiving portion.

[0137] 28. The stator arrangement (100) of embodiment 27, wherein the stator teeth (20) are supported on the first circumferential wall (122).

[0138] 29. A stator device (100) as described in any of embodiments 27 or 28, wherein the insulating walls (32) are arranged adjacent to the second circumferential wall (126), and wherein the insulating walls (32) extend axially at least over the overlapping portion (126a) of the second circumferential wall (126).

[0139] 30. The stator device (100) according to embodiment 29, wherein the overlapping portion (126a) is 0.5 mm to 10 mm, specifically 1 mm to 5 mm.

[0140] 31. A stator device (100) as described in any of embodiments 29 or 30, wherein the resin body (140) radially fills the space between the insulating walls (32) and the second circumferential wall (126) at least in an axial sub-portion of the overlapping portion (126a).

[0141] 32. A stator device (100) as described in any of embodiments 29 or 31, wherein the second circumferential wall (126) is formed so that at least at the axial position of the overlapping portion (126a), the radial distance (126b) between the insulating walls (32) and the second circumferential wall (126) is at most 2 mm, specifically at most 1 mm, and more specifically at most 0.5 mm.

[0142] 33. An electric machine (200), in particular an electric motor (200), comprising:

[0143] Machine housing (210),

[0144] a shaft (230) rotatably supported in the machine housing (210),

[0145] a rotor (220) fixedly arranged on the shaft (230) in the machine housing (210),

[0146] The stator arrangement (100) of any one of Embodiments 27 to 32, wherein the stator (110) is arranged adjacent to the rotor (220) in the machine housing (210).

[0147] 34. The electric machine (200) of embodiment 33, wherein the stator (110) is radially arranged adjacent to the rotor (220).

[0148] 35. An electric machine (200) as described in any of embodiments 33 or 34, wherein the rotor (220) is configured as a radially outer rotor and includes a plurality of circumferentially distributed rotor poles (222) arranged on a rotor body (224).

[0149] 36. The electric machine (200) of any one of embodiments 33 to 35, wherein the machine housing (210) comprises a rotor housing (212) and the stator housing (120), wherein the rotor housing (212) and the stator housing (120) are connected in a press-fit manner.

[0150] 37. A method (300) for manufacturing a stator arrangement (100), the method comprising:

[0151] Providing (310) a plurality of stator tooth units (10), each stator tooth unit having a stator tooth (20), an insulator (30) having an insulating wall (32), and a coil (40) wound around the stator tooth (20),

[0152] The stator tooth units (10) are arranged circumferentially (320) such that the insulating walls (32) together form a closed circle (112, 114), thereby forming a stator (110),

[0153] providing (340) a stator housing (120) defining an annular receiving portion having a first circumferential wall (122), an annular end wall (124), and a second circumferential wall (126) radially opposite the first circumferential wall (122),

[0154] inserting (350) the stator (110) in the annular receiving portion such that axial portions of the insulating walls (32) are disposed between the first and second circumferential walls (122, 126), and

[0155] The stator (110) is potted (360) in the stator housing (120) by filling liquid resin between the insulating walls (32) and the first circumferential wall (122), so that after the liquid resin is hardened, a resin body (140) is formed between the insulating walls (32) and the first circumferential wall (122).

[0156] 38. The method of embodiment 37, wherein a stator teeth unit (10) according to any one of embodiments 1 to 21 is provided.

[0157] 39. The method of any one of embodiments 37 or 38, wherein, prior to potting (360), a removable seal is arranged to seal the gap between the insulating walls (32) and the second circumferential wall (126).

[0158] 40. The method of any one of embodiments 37 or 38, wherein potting (360) comprises:

[0159] pre-potting a first amount of liquid resin to at least partially fill the overlapping portion (126a) between the insulating walls (32) and the second circumferential wall (126), wherein the first amount of liquid resin at least partially hardens to form a first resin body portion to seal between the insulating walls (32) and the second circumferential wall (126), and after pre-potting,

[0160] A second amount of liquid resin is filled between the insulating walls (32) and the first circumferential wall (122) to form a second resin body portion, wherein the first resin body portion and the second resin body portion together form the resin body (140).

[0161] 41. The method of embodiment 40, wherein pre-potting includes preheating the stator assembly to at least partially harden the first amount of liquid resin before filling the second amount of liquid resin.

[0162] 42. The method of any one of embodiments 37 to 41, wherein the potting (360) is performed with the upper axial surfaces (23b) of the stator teeth (20) pointing in a direction opposite to gravity.

[0163] 43. The method of any one of embodiments 37 to 42, further comprising connecting (330) a lead frame (150) to the stator (110) via a connector (130) at a lower axial side (22b) of the stator (110).

[0164] List of Reference Numerals

[0165] 2 Axial direction

[0166] 4 Radial direction

[0167] 6 Circumferential direction

[0168] 10 stator tooth units

[0169] 20 stator teeth

[0170] 20a, 21a radially outer side / surface

[0171] 20b, 21b radially inner side / surface

[0172] 20c, 21c First circumferential side / surface

[0173] 20d, 21d Second circumferential side / surface

[0174] 22 Axial thickness of stator teeth

[0175] 22a, 23a Upper axial side / surface

[0176] 22b, 23b Lower axial side / surface

[0177] 24 first bonding structure

[0178] 26 Second bonding structure

[0179] 27 radial inner portion

[0180] 28 Central tooth web

[0181] 29 radially outer portion

[0182] 30 Insulator

[0183] 32 Insulation Wall

[0184] 33 Axial thickness of the insulation wall

[0185] 37 Support part

[0186] 37a Wire end support part

[0187] 37b Connector support part

[0188] 37c Lead frame support part

[0189] 38 Coil insulation part

[0190] 38a Coil stop

[0191] 40 Coils

[0192] 42 line end

[0193] 50 seals

[0194] 52 Sealing element

[0195] 54 First sealing structure

[0196] 54a Flexible sealing lip

[0197] 54b Seal recess

[0198] 56 Second sealing structure

[0199] 56b Sealing protrusion

[0200] 100 stator assembly

[0201] 110 stator

[0202] 111 stator axis

[0203] 112 Internal circumferential boundary

[0204] 114 External circumferential boundary

[0205] 120 stator housing

[0206] 122 First circumferential wall

[0207] 124 annular end wall

[0208] 126 Second circumferential wall

[0209] 126a Overlap

[0210] 126b Radial distance

[0211] 130 connector

[0212] 140 resin body

[0213] 150 lead frame

[0214] 160 Connector device

[0215] 200 motor

[0216] 210 machine housing

[0217] 212 rotor housing

[0218] 220 rotor

[0219] 222 rotor magnet

[0220] 224 rotor body

[0221] 230 axis

Claims

1. A stator teeth unit (10) for a stator (110), the stator having an axis (111) and a plurality of stator teeth units (10) arranged circumferentially around the axis (111), the stator teeth unit (10) comprising: a stator tooth (20) defining a radially outer side (20a) and a radially inner side (20b) opposite the radially outer side (20a), and defining a first circumferential side (20c) and a second circumferential side (20d) opposite the first circumferential side (20c), - an insulator (30) at least partially covering the stator teeth (20), and - a coil (40) wound around the partially covered stator teeth (20), Characterized in that the insulator (30) comprises an insulating wall (32) which extends away from the stator tooth (20) on the first circumferential side (20c) and the second circumferential side (20d), and The insulating wall (32) includes a sealing structure (54, 56) on at least one circumferential side (20c, 20d), the sealing structure (54, 56) being configured to form a seal (50) with the insulating wall (32) of an adjacent stator tooth unit (10).

2. The stator teeth unit (10) according to claim 1, wherein: The insulating wall (32) extends axially along the stator tooth (20), at least along an axial thickness (22) of the stator tooth (20).

3. The stator teeth unit (10) according to claim 1, wherein: The insulating wall (32) extends at least one of axially above and axially below the stator tooth (20).

4. The stator teeth unit (10) according to claim 1, wherein: The sealing structure (54, 56) includes a first sealing structure (54) arranged on a first circumferential side (20c) of the insulating wall (32) and a second sealing structure (56) arranged on a second circumferential side (20d) of the insulating wall (32), wherein the first sealing structure (54) is configured to form the seal (50) with the second sealing structure (56) of an adjacent stator tooth unit (10).

5. The stator teeth unit (10) according to claim 1, further comprising: A first engagement structure (24) is formed on the first circumferential side (20c) and a second engagement structure (26) is formed on the second circumferential side (20d), wherein the engagement structures (24, 26) are configured to engage respective adjacent stator tooth units (10).

6. The stator teeth unit (10) according to claim 5, wherein: The insulating wall (32) is positioned adjacent one of the radially outer side (20a) or the radially inner side (20b), and wherein the engagement structure (24, 26) is positioned adjacent the other of the radially outer side (20a) or the radially inner side (20b).

7. The stator teeth unit (10) according to claim 1, wherein: The insulator (30) is an overmolded plastic component.

8. The stator teeth unit (10) according to claim 1, wherein: The insulator (30) further includes a support portion (37) configured to support at least one of a wire end (42) of the coil (40), a lead frame (150) for the stator (110), and an electrical connector for connecting the wire end (42) of the coil (40) to the lead frame (150).

9. A stator (110) for an electric motor (200), the stator comprising: A plurality of stator tooth units (10) according to claim 1, wherein the stator teeth units (10) are arranged circumferentially around the axis (111) of the stator (110), and The insulating walls (32) of adjacent stator tooth units (10) jointly form a closed circumference by forming corresponding sealing members (50).

10. The stator (110) according to claim 9, wherein: The insulating walls (32) of adjacent stator tooth units (10) together form a radially outer circumferential boundary (114).

11. A stator device (100) for an electric motor (200), wherein: The stator device (100) comprises: The stator (110) according to claim 9, a resin body (140), and a stator housing (120) defining an annular receiving portion having a first circumferential wall (122), an annular end wall (124), and a second circumferential wall (126) radially opposite the first circumferential wall (122), Wherein, the stator (110) is at least partially arranged in the annular receiving portion.

12. The stator device (100) according to claim 11, wherein: The insulating wall (32) is arranged adjacent to the second circumferential wall (126), and wherein the insulating wall (32) extends axially at least over an overlapping portion (126a) of the second circumferential wall (126).

13. The stator arrangement (100) according to claim 12, wherein: The resin body (140) radially fills the space between the insulating wall (32) and the second circumferential wall (126) at least in an axial sub-portion of the overlapping portion (126a).

14. The stator device (100) according to claim 12, wherein: The second circumferential wall (126) is formed so that at least at the axial position of the overlapping portion (126a), a radial distance (126b) between the insulating wall (32) and the second circumferential wall (126) is at most 2 mm.

15. An electric machine (200), in particular an electric motor (200), comprising: Machine housing (210), a shaft (230) rotatably supported in the machine housing (210), a rotor (220) fixedly arranged on the shaft (230) in the machine housing (210), The stator arrangement (100) of claim 11, wherein the stator (110) is arranged adjacent to the rotor (220) in the machine housing (210).

16. A method (300) for manufacturing a stator arrangement (100), the method comprising: Providing (310) a plurality of stator tooth units (10), each stator tooth unit having a stator tooth (20), an insulator (30) having an insulating wall (32), and a coil (40) wound around the stator tooth (20), The stator tooth units (10) are arranged (320) circumferentially so that the insulating walls (32) together form a closed circle (112, 114), thereby forming a stator (110), providing (340) a stator housing (120) defining an annular receiving portion having a first circumferential wall (122), an annular end wall (124), and a second circumferential wall (126) radially opposite the first circumferential wall (122), inserting (350) the stator (110) into the annular receiving portion such that an axial portion of the insulating wall (32) is disposed between the first circumferential wall (122) and the second circumferential wall (126), and The stator (110) is potted (360) in the stator housing (120) by filling liquid resin between the insulating wall (32) and the first circumferential wall (122), so that after the liquid resin is hardened, a resin body (140) is formed between the insulating wall (32) and the first circumferential wall (122).

17. The method of claim 16, wherein: Potting (360) includes: pre-potting a first amount of liquid resin to at least partially fill the overlapping portion (126a) between the insulating wall (32) and the second circumferential wall (126), wherein the first amount of liquid resin at least partially hardens to form a first resin body portion for sealing between the insulating wall (32) and the second circumferential wall (126), and after pre-potting, A second amount of liquid resin is filled between the insulating wall (32) and the first circumferential wall (122) to form a second resin body portion, wherein the first resin body portion and the second resin body portion together form the resin body (140).

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