Material-saving plug connection for stamped grids

Abstract

Arrangement (1) comprising a stamped grid (2) made of metal and a carrier (3) made of plastic, wherein the stamped grid (2) is connected with the carrier (3) by at least one plug connection (4), wherein the at least one plug connection (4) is constituted via a respective fixing element (5) of the stamped grid (2), which engages into a respective receptacle (6) of the carrier (3) and which is at least partially formed within a respective cutout (7) of the stamped grid (2) at a side (8) of the stamped grid (2) facing the carrier (3).

Description

Technical Field

[0001] This invention relates to an arrangement structure including a stamped grid and a carrier, and a method for manufacturing the arrangement structure. The invention also relates to an assembly for manufacturing an electric motor, the assembly including the arrangement structure. Background Technology

[0002] In the prior art, there is a known arrangement in which a carrier is connected to multiple stamping grids, and these stamping grids are fixed to the carrier. For this purpose, the carrier is positioned below the stamping grids. The stamping grids are made of stamping strip. Stamping waste is typically generated during the stamping process.

[0003] In addition, in the manufacture of motors, such arrangement structures are known to be used as transport protectors for stamped grids or as assembly aids for mounting stamped grids onto motor stators, as well as as fasteners for stamped grids during subsequent plastic overmolding.

[0004] In existing technical solutions, there is a need to reduce the amount of stamping waste. Therefore, the objective of this invention is to reduce stamping waste. Summary of the Invention

[0005] This task is solved by the features of the independent claim. Other advantageous embodiments of the invention are given in the dependent claims. The features listed in the dependent claims can be combined with each other in a technically meaningful manner and can define other embodiments of the invention. Furthermore, the features given in the claims are further specifically defined and explained in the description, which illustrates other preferred embodiments of the invention.

[0006] According to the present invention, an arrangement structure is proposed, comprising a stamped grid made of metal and a carrier made of plastic. The stamped grid is connected to the carrier via at least one plug-in connection, wherein the at least one plug-in connection is formed via corresponding fixing elements of the stamped grid, the corresponding fixing elements engaging in corresponding receiving portions of the carrier, and the corresponding fixing elements being at least partially formed within corresponding cutouts in the stamped grid, located on the side of the stamped grid facing the carrier.

[0007] This arrangement is preferably configured for use in motors. However, the advantages described herein can generally also be achieved in all applications where stamped grids are connected to a carrier.

[0008] The arrangement includes a stamped grid made of metal and a carrier made of plastic. The stamped grid can be formed by stamping from stamped strip. The stamped strip preferably has thickness, length, and width. The stamped strip is preferably sheet metal.

[0009] The stamped grid is preferably a sheet metal formed by stamping from stamping strip. The thickness of the sheet metal is preferably a several times smaller than the length and / or width of the sheet metal. The stamped grid may have two opposing surfaces and multiple surfaces extending along its edges. The side of the stamped grid facing the carrier may be adjacent to one of the surfaces of the stamped grid facing the carrier.

[0010] The stamped grid preferably comprises a conductive material. Particularly preferably, the stamped grid comprises copper.

[0011] The stamped grid is connected to the carrier via at least one plug-in connection. The stamped grid can be connected to the carrier via one plug-in connection or multiple plug-in connections. Preferably, the stamped grid is connected to the carrier via three plug-in connections. The at least one plug-in connection connects the carrier and the stamped grid. The advantage of this at least one plug-in connection is that it makes connecting the stamped grid to the carrier particularly easy during assembly.

[0012] Preferably, multiple plug-in connections are distributed along the stamping grid.

[0013] The at least one plug-in connection is formed via a corresponding fixing element of the stamped grid, the corresponding fixing element being engaged in a corresponding receiving portion of the carrier.

[0014] Each receiving portion is preferably designed to hold the fixing element within it. Each receiving portion can be adapted to the shape of the fixing element. Each receiving portion is preferably configured to hold the fixing element at at least two opposing points.

[0015] The corresponding fixing element can be configured as a retaining pin.

[0016] The plug-in connection is preferably configured such that the resistance to inserting the fixing element into the receiving portion is less than the resistance to pulling the fixing element out of the receiving portion.

[0017] The advantage of the at least one plug-in connection is that the stamped grid is reliably held on the carrier.

[0018] The fixing element is at least partially formed within a corresponding cutout in the stamped grid, located on the side of the stamped grid facing the carrier.

[0019] The stamped grid can have multiple sides. When the stamped grid is connected to the carrier, at least one side faces the carrier.

[0020] The corresponding cut can be a planar recess in a stamped grid. In this case, it is preferable to remove material from the area of ​​the stamped grid located between two opposing surfaces, thereby retaining a fixing element in the cut.

[0021] Each of the cuts may have an opening facing the side of the stamping grid toward the carrier, wherein the corresponding fixing element faces the opening of the corresponding cut.

[0022] Preferably, the stamped grid is arranged on a surface of the carrier in a bent and / or folded manner, wherein the stamped grid has corresponding folded portions along its extension direction. Preferably, these folded portions have a bending angle of 10° to 90°.

[0023] This arrangement connects the stamping grid to the carrier and reduces the structural height of the arrangement. The fixing element is at least partially formed within a corresponding cutout in the stamping grid and located on the side of the stamping grid facing the carrier. This has a particular advantage: compared to a stamping grid where the fixing element protrudes from the side of the stamping grid facing the carrier, the width of the stamping grid can be reduced, thereby also reducing the width of the stamping strip, thus advantageously reducing potential stamping waste. Furthermore, according to the invention, this arrangement also has the advantage of saving CO2 emissions during the manufacturing process due to the reduction in stamping waste.

[0024] In a preferred embodiment of this arrangement, the arrangement includes a second metal stamped grid, wherein the second stamped grid is connected to a carrier via at least one plug-in connection, wherein the at least one plug-in connection is formed via a corresponding fixing element of the second stamped grid, the corresponding fixing element engaging in a corresponding receiving portion of the carrier, and the corresponding fixing element being at least partially formed within a corresponding cutout of the second stamped grid, located on the side of the second stamped grid facing the carrier. Preferably, the second stamped grid is arranged at a distance from the first stamped grid.

[0025] Particularly preferably, the arrangement includes a third stamped metal grid, which is connected to the carrier via at least one plug-in connection. The at least one plug-in connection is formed via a corresponding fixing element of the third stamped grid, which engages in a corresponding receiving portion of the carrier. The corresponding fixing element is at least partially formed within a corresponding cutout of the third stamped grid, located on the side of the third stamped grid facing the carrier. Preferably, the third stamped grid is arranged at intervals from the second stamped grid and the stamped grid itself.

[0026] In another preferred embodiment of this arrangement, the corresponding fixing element of the at least one plug-in connection is completely formed within the corresponding cutout of the stamped grid.

[0027] Even if only a portion of the fixing element is formed in the cutout, the advantages of the claimed invention can be achieved. However, if the fixing element is fully arranged in the corresponding cutout of the stamping grid, the fixing element will not extend beyond the underside of the stamping grid. Therefore, this embodiment has a particular advantage in minimizing stamping waste.

[0028] In another preferred embodiment of this arrangement, the stamped grid extends between two side edges, wherein, in at least one of the plug-in connections, a corresponding cutout of the stamped grid is located at one of the two side edges of the stamped grid, and / or, in at least one of the plug-in connections, the corresponding cutout of the stamped grid is spaced apart from the two side edges of the stamped grid between the two side edges. The case of "and" is preferred.

[0029] The advantage of this implementation is that the force from the carrier acting on the stamping grid is distributed through multiple plug-in connections.

[0030] Preferably, a plug-in connection with a corresponding cut is arranged at each of the two side edges of the stamped grid, and in at least one other plug-in connection, the corresponding cut of the stamped grid is arranged between the two side edges at a distance from the two side edges of the stamped grid.

[0031] In another preferred embodiment of this arrangement, the surface of the corresponding fixing element of the at least one plug-in connection is at least partially a ribbed surface.

[0032] Ribbed surfaces describe the structure of the surface. The surface is preferably provided with parallel grooves, slots, ribs, and / or burrs.

[0033] Preferably, the corresponding fixing element has an extending direction, wherein the surface of the corresponding fixing element is partially ribbed perpendicular to the extending direction of the fixing element.

[0034] Particularly preferably, the fixing element has a cedar-shaped profile. For this purpose, the base of the fixing element is preferably wider than the end of the fixing element, and the surface has serrations or barbs.

[0035] By using the surface of the fixing element, the fixing element can be locked in the receiving part, so that the force required to insert the fixing element into the receiving part is less than the force required to remove the fixing element from the receiving part.

[0036] The advantage of this embodiment is that the fixing element can be held in the receiving part particularly reliably, and the connection between the carrier and the stamping grid during assembly is particularly simple.

[0037] In another preferred embodiment of this arrangement, the at least one plug-in connection is a friction connection.

[0038] Each receiving portion for the corresponding fixing element may have clamping claws to clamp the fixing element upon insertion.

[0039] The advantage of this embodiment is that the fixing element can be held in the receiving part particularly reliably, but can also be released, and connecting the carrier to the stamping grid during assembly is particularly simple.

[0040] In another preferred embodiment of this arrangement, the carrier has a groove into which the stamped grid is inserted, and the corresponding receiving portion of the at least one plug-in connection is formed in the groove.

[0041] This embodiment of the arrangement structure has the following advantages: by arranging the receiving portion of the corresponding fixing element in the groove and extending the stamping grid into the carrier, the structural height of the arrangement structure can be reduced.

[0042] The carrier preferably has a surface facing the stamped grid. The groove can be a slot in the carrier surface facing the stamped grid. The groove can be a channel in the carrier surface facing the stamped grid. Alternatively, the groove can be a channel or a guide on the carrier surface facing the stamped grid. The stamped grid can extend partially into the carrier.

[0043] The groove preferably has two ends, wherein the first end is the starting end of the groove and the second end marks the ending end of the groove. The at least one insertable receiving portion may have a material protrusion spaced apart from the first end and / or spaced apart from the second end within the groove. The distance between the material protrusion and the first end and / or the second end is configured such that the retaining element can be clamped within the receiving portion between the material protrusion and the first end and / or between the material protrusion and the second end. This material protrusion may be referred to as a clamping claw.

[0044] The at least one receiving portion of the plug connection may have spaced-apart material protrusions in the groove, spaced apart from the first end and / or spaced apart from the second end. The spacing between the two material protrusions is configured such that the fixing element can be clamped between the two material protrusions. The material protrusions may be referred to as clamping claws.

[0045] Another advantage of this implementation is that the stamped grid is guided in the groove and can at least reduce or prevent movement laterally to the groove.

[0046] As another aspect of the present invention, a method for manufacturing an arrangement structure is provided. This method includes the following steps: a) Stamping grids are stamped from stamping strip. b) Forming the stamped grid. c) The carrier and the stamping grid are connected by at least one plug-in connection, wherein a corresponding fixing element of the stamping grid is inserted into a corresponding receiving portion of the carrier.

[0047] The described advantages and features of the arrangement are applicable to and can be transferred to this method, and vice versa.

[0048] The method is preferably performed in the order described. In step a), the strip is preferably stamped using a stamping tool of a punch press. This stamping tool can be a cutting tool, thereby giving the stamped grid the desired profile.

[0049] In step b), the stamped grid is deformed. Forming the stamped grid may include bending and folding individual sections of the stamped grid.

[0050] In step c), the carrier is connected to the stamping grid via the at least one plug-in connection. For this purpose, a corresponding fixing element of the stamping grid is inserted into a corresponding receiving portion of the carrier. Preferably, the stamping grid is guided into a groove in the carrier.

[0051] As another aspect of the present invention, an assembly for manufacturing an electric motor is proposed.

[0052] The advantages and features of the described arrangement and method are applicable to and can be transferred to the component, and vice versa. Preferably, the arrangement used in the component is configured to be identical to the described arrangement.

[0053] The assembly includes a stator, a rotor, and an arrangement structure comprising a plurality of stamped grids made of metal and a carrier made of plastic. Each stamped grid is connected to the carrier via at least one plug-in connection, wherein the at least one plug-in connection is formed via a corresponding fixing element of the corresponding stamped grid, the corresponding fixing element engaging in a corresponding receiving portion of the carrier, and the corresponding fixing element being at least partially formed within a corresponding cutout of the corresponding stamped grid, located on the side of the corresponding stamped grid facing the carrier. The rotor is rotatable about a rotation axis, wherein the stator is arranged around the rotation axis and around the rotor.

[0054] This component is used in the manufacture of motors, wherein the arrangement can be used in particular as a transport protector for stamped grids, or to hold the stamped grids in place when they are subsequently covered with plastic. This component has the particular advantage of generating less stamping waste during the stamping of the grids, and the low structural height of the arrangement results in a low structural height for the component itself.

[0055] Preferably, this arrangement is located on the end side of the stator. The surface of the stamped grid arranged on the carrier of this arrangement faces away from the stator.

[0056] Preferably, the motor is an electric motor, especially a delta-connected brushless DC-Motor.

[0057] In a preferred embodiment of the component, each of the stamped grids forms an interconnecting ring.

[0058] The interconnecting rings preferably each have a connection contact for applying a phase and multiple connection elements for electrically connecting the respective interconnecting rings to the stator region.

[0059] In another preferred embodiment of the component, the carrier constitutes a transport protective element and / or an assembly aid.

[0060] The interconnecting rings can be guided in their respective grooves, and the carrier can connect to the interconnecting rings via their respective plug-in connections, thereby allowing the interconnecting rings to maintain their position on the carrier during transportation. This simplifies the process of installing the interconnecting rings onto the stator's connection points.

[0061] Alternatively or additionally, the interconnecting ring can be covered with plastic and, through its connection with the carrier, can be reliably held in the arrangement during the covering process. Attached Figure Description

[0062] The following reference Figure 1 Further explanation of the existing technology.

[0063] The following reference Figures 2 to 6 The present invention will be further described below. Figures 2 to 6 A particularly preferred embodiment is shown, but the invention is not limited thereto. Figures 2 to 6 The dimensions shown are for illustrative purposes only. The accompanying drawings illustrate: Figure 1 A schematic diagram of the connection between a stamped grid and a carrier as known in the prior art, and Figure 2 A schematic diagram of the arrangement structure according to the present invention, and Figure 3 : Figure 2 A schematic side view of the stamped grid according to the present invention, and Figure 4 A schematic diagram of the components according to the present invention, and Figure 5 : Figure 4 A cross-sectional view of the arrangement structure of the components according to the present invention, and Figure 6 : Figure 5 A perspective view of the arrangement structure of the components according to the present invention. Detailed Implementation

[0064] Figure 1 A schematic diagram is shown of a stamped grid 2 and a carrier 3, as known in the prior art, connected by three fixing elements 5. This connection has a structural height h1.

[0065] Figure 2 A schematic diagram of the arrangement structure 1 according to the present invention is shown. The arrangement structure 1 includes a stamped grid 2 made of metal and a carrier 3 made of plastic, wherein the stamped grid 2 is connected to the carrier 3 by three plug-in connections 4, wherein the plug-in connections 4 are formed via corresponding fixing elements 5 of the stamped grid 2, the corresponding fixing elements 5 being engaged in corresponding receiving portions 6 of the carrier 3 and being completely formed within corresponding cutouts 7 of the stamped grid 2, located on the side 8 of the stamped grid 2 facing the carrier 3.

[0066] The stamped grid 2 extends between two side edges 9.1 and 9.2. In a plug-in connection 4, a corresponding cutout 7 of the stamped grid 2 is provided at the side edge 9.1 of the stamped grid 2. In a plug-in connection 4, a corresponding cutout 7 of the stamped grid 2 is provided at the side edge 9.2 of the stamped grid 2.

[0067] In a plug-in connection 4, the corresponding cutout 7 of the stamped grid 2 is disposed between the two side edges 9.1 and 9.2 at a distance from the two side edges 9.1 and 9.2 of the stamped grid 2.

[0068] The surface 10 portion of the corresponding fixing element 5 of the plug-in connection 4 is ribbed. Each plug-in connection 4 is a friction connection.

[0069] The carrier 3 has a groove 11 into which the stamped grid 2 is inserted. A corresponding receiving portion 6 for the plug-in connection 4 is formed in the groove 11.

[0070] Arrangement structure 1 has a structural height h2, wherein the structural height h2 is lower than Figure 1 The structural height h1 in the text.

[0071] To manufacture arrangement structure 1, one method includes the following steps: a) Stamping grid 2 is stamped from stamping strip 12. b) Form the stamped grid 2. c) The carrier 3 and the stamping grid 2 are connected by three plug-in connections 4, wherein the corresponding fixing element 5 of the stamping grid 2 is inserted into the corresponding receiving part 7 of the carrier 3.

[0072] Figure 3 It shows Figure 2The diagram shows a schematic side view of the stamped grid according to the present invention. The stamped grid 2 is formed by stamping from stamped strip 12. The stamped strip 12 is a sheet metal.

[0073] Figure 4 A schematic diagram of an assembly 13 for manufacturing an electric motor according to the present invention is shown. Assembly 13 includes a stator 18, a rotor 17, and an arrangement structure 1. The stator 18 and rotor 17 are arranged about a rotation axis 19. The arrangement structure 1 is arranged on the end side of the stator 18.

[0074] Figure 5 A cross-sectional view of an arrangement structure 1 for manufacturing an electric motor according to the present invention is shown. The arrangement structure 1 includes a plurality of stamped grids 2.1, 2.2, 2.3 made of metal and a carrier 3 made of plastic, wherein each of the stamped grids 2.1-2.3 is connected to the carrier 3 by three plug-in connections 4, wherein the plug-in connections 4 are formed via corresponding fixing elements 5 of the respective stamped grids 2.1-2.3, the corresponding fixing elements 5 engaging in the corresponding receiving portion 6 of the carrier 3 and being at least partially formed in the corresponding cutouts 7 of the respective stamped grids 2.1-2.3, located on the side 8 of the respective stamped grids 2.1-2.3 facing the carrier 3.

[0075] The corresponding fixing element 5 of the plug-in connection 4 is completely formed within the corresponding cutout 7 of the corresponding stamped grid 2.1-2.3.

[0076] The surface 10 of the corresponding fixing element 5 of the plug-in connection 4 is ribbed.

[0077] Each of the plug-in connections 4 is a friction connection. The carrier 3 has a plurality of grooves 11 into which corresponding stamped grids 2.1-2.3 are inserted, and the receiving portion 6 of the corresponding plug-in connection 4 is formed in each corresponding groove 11.

[0078] Each of the stamped grids 2.1-2.3 forms an interconnecting ring 14.1-14.3. Each interconnecting ring 14.1-14.3 has a connection contact 15 for applying a phase and a plurality of connection elements 16 for connecting the respective interconnecting ring 14.1-14.3 to the stator 18.

[0079] The arrangement structure 1 serves as a transport protection component and an assembly aid in the manufacturing of the motor.

[0080] Figure 5 It shows Figure 4 A perspective view of the components according to the present invention. Stamped grids 2.1-2.3 each extend between two side edges 9.1, 9.2. In a plug-in connection 4, corresponding cutouts 7 of each respective stamped grid 2.1-2.3 are provided at the side edge 9.1 of each respective stamped grid 2.1-2.3.

[0081] In a plug-in connection 4, the corresponding cutouts 7 of each corresponding stamped grid 2.1-2.3 are provided at the side edge 9.2 of each corresponding stamped grid 2.1-2.3.

[0082] In a plug-in connection 4, the corresponding cutout 7 of the stamped grid 2 is disposed between the two side edges 9.1 and 9.2 at a distance from the two side edges 9.1 and 9.2 of the stamped grid 2.

[0083] Explanation of reference numerals in the attached figures 1. Layout Structure 2.2.1-2.3 Stamped grid 3. Carrier 4. Plug-in connection 5. Fixing components 6. Reception Section 7. Incision 8. Side of the stamped grid 9.1, 9.2 Edges of the stamped grid 10. Surface of the fixing element 11 Grooves 12 Stamped strip 13 components 14.1, 14.2, 14.3 Interconnection Rings 15 Connecting contact points 16 Connecting elements 17 Rotors 18 stators 19. Axis of rotation

Claims

1. An arrangement structure (1) comprising a stamped grid (2) made of metal and a carrier (3) made of plastic, wherein, The stamped grid (2) is connected to the carrier (3) via at least one plug-in connection (4), wherein the at least one plug-in connection (4) is formed via a corresponding fixing element (5) of the stamped grid (2), the corresponding fixing element (5) is engaged in a corresponding receiving portion (6) of the carrier (3), and the corresponding fixing element (5) is at least partially formed in a corresponding cutout (7) of the stamped grid (2), located on the side (8) of the stamped grid (2) facing the carrier (3).

2. The arrangement structure (1) according to claim 1, wherein, The corresponding fixing element (5) of the at least one plug-in connection (4) is completely formed within the corresponding cut (7) of the stamping grid (2).

3. The arrangement structure (1) according to any one of the preceding claims, wherein, The stamped grid (2) extends between two side edges (9.1, 9.2), and in at least one of the plug-in connections (4), a corresponding cutout (7) of the stamped grid (2) is provided at one of the two side edges (9.1, 9.2) of the stamped grid (2), and / or, in at least one of the plug-in connections (4), the corresponding cutout (7) of the stamped grid (2) is spaced apart from the two side edges (9.1, 9.2) of the stamped grid (2) between the two side edges (9.1, 9.2).

4. The arrangement structure (1) according to any one of the preceding claims, wherein, The surface (10) of the corresponding fixing element (5) of the at least one plug-in connection (4) is at least partially a ribbed surface.

5. The arrangement structure (1) according to any one of the preceding claims, wherein, The at least one plug-in connection (4) is a friction connection.

6. The arrangement structure (1) according to any one of the preceding claims, wherein, The carrier (3) has a groove (11) into which the stamped grid (2) is inserted. Furthermore, the corresponding receiving portion (6) of the at least one plug-in connection (4) is formed in the groove (11).

7. A method for manufacturing an arrangement structure (1) according to any one of the preceding claims, comprising the following steps: a) The stamped grid (2) is stamped from the stamped strip (12), b) The stamped grid (2) is formed. c) The carrier (3) and the stamping grid (2) are connected by at least one plug-in connection (4), wherein the corresponding fixing element (5) of the stamping grid (2) is inserted into the corresponding receiving part (6) of the carrier (3).

8. A component (13) for manufacturing an electric motor, wherein, The component (13) includes a stator (18), a rotor (17), and an arrangement structure (1), wherein the arrangement structure (1) includes a plurality of stamped grids (2.1, 2.2, 2.3) made of metal and a carrier (3) made of plastic, wherein each of the stamped grids (2.1-2.3) is connected to the carrier (3) via at least one plug-in connection (4), wherein the at least one plug-in connection (4) is formed via a corresponding fixing element (5) of the corresponding stamped grid (2.1-2.3), the corresponding fixing element (5) engaging in a corresponding receiving portion (6) of the carrier (3), and the corresponding fixing element (5) is at least partially formed in a corresponding cutout (7) of the corresponding stamped grid (2.1-2.3) located on the side (8) of the corresponding stamped grid (2.1-2.3) facing the carrier (3).

9. The component according to claim 8, wherein, Each of the stamped grids (2.1-2.3) forms an interconnecting ring (14.1, 14.2, 14.3).

10. The component according to claim 8 or 9, wherein, The carrier (3) constitutes a transport protective component and / or an assembly auxiliary component.

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