Wiring frame for electrical contacting a stator

Abstract

Conductor frame (10) for electrically contacting stator windings (114) of a three-phase stator (110) comprising: an annular base body (12) with a top (12a) and a bottom (12b); three connection contacts (40) for electrically contacting a respective stator phase (P1, P2, P3) to an inverter (240) on the inverter side, wherein the connection contacts (40) are arranged on the top (12a); several axially insulated conductor planes (20) arranged in the annular base body (12), wherein the conductor planes (20) extend several times in the circumferential direction.(6) have spaced-apart conductor sections (22); several electrically conductive contact elements (30) extending axially through the annular base body (12), which are arranged radially spaced from the conductor sections (22), wherein the contact elements (30) are arranged distributed in the circumferential direction (6); wherein the conductor planes (20) further have conductor tongues (24) projecting radially from the conductor sections (22), which electrically connect the conductor sections (22) to the contact elements (30), wherein the conductor tongues (24) are arranged such that the conductor planes (20) and the contact elements (30) provide an electrical connection of the stator phases (P1, P2, P3) between the contact elements.(30) and the connection contacts (40), wherein at least some of the several contact elements (30) are designed for electrical contact with the stator windings (114), wherein the conductor frame (10) further comprises a connection device (50) which is electrically connected to the connection contacts (40) for electrical contacting a respective stator phase (P1, P2, P3) to the inverter (240), wherein the connection device (50) comprises a housing, three main lead pins and three cables for electrical connection between the main lead pins and the connection contacts (40), wherein the main lead pins are fixed in the housing and project from the housing in an axial direction (2), and wherein the connection device (50) is floatingly attached to the annular base body (12).

Description

Technical area

[0001] The present disclosure relates to a lead frame for electrically contacting stator windings. In particular, the present disclosure relates to a stator assembly for an electrical machine having such a lead frame, as well as to an electrical machine having such a stator assembly. Furthermore, the present disclosure relates to a method for producing a stator assembly for an electrical machine. background

[0002] Electrical machines have always been used in many technical fields for the conversion of electrical energy into kinetic energy and / or for the conversion of kinetic energy into electrical energy. An electrical machine is an electrical device that can convert electrical energy into mechanical energy (also called an electric motor or e-motor). The mechanical energy can in turn be used to generate kinetic energy, which can be used to drive other devices. If mechanical or kinetic energy is converted into electrical energy, the electrical machine can also be called a generator. Electrical machines can often be operated in both a motor and a generator function. An electric motor generally comprises a stator and a rotor spaced apart from it, which are housed in a motor housing. The stator is fixed in its position.The rotor moves relative to the stator and is typically mounted on a drive shaft that rotates with the rotor. The shaft can be used to transfer the rotational energy to other devices.

[0003] Most electric motors generate energy using a magnetic field and a winding current. For this purpose, known stators comprise several circumferentially distributed stator teeth that extend towards the rotor and form a ring-shaped stator. Each stator tooth is wound with a metallic, highly conductive material, such as a winding wire. Thus, each wound stator tooth forms a stator winding. The rotor usually consists of a rotor body connected to the drive shaft, on which circumferentially distributed permanent magnets are arranged, adjacent to and spaced from the stator teeth. When current is applied to the stator windings, a magnetic field is generated that acts on the permanent magnets of the rotor with a torque that can drive the rotor.

[0004] In particular, it is known to use a multi-phase, for example a three-phase, power supply, wherein the phases of the power supply are at least partially offset in time, for example offset sinusoidal signals. Accordingly, a stator can be referred to as a multi-phase or three-phase stator. Depending on the desired circuit, for example, each stator winding is assigned one of the phases and is accordingly supplied with current from the assigned phase. It is also known to arrange stator windings of a respective phase individually or in phase groups of several stator windings (for example, two, three or four stator windings in a phase group) next to one another. For example, a stator winding of the first phase, a stator winding of the second phase and then a stator winding of the third phase can be arranged one after the other in the circumferential direction (depending on the number of stator windings, then further in the circumferential direction following this pattern).If stator phases are arranged in phase groups, for example, two stator windings of the first phase, then two stator windings of the second phase and then two stator windings of the third phase can be arranged one after the other in the circumferential direction. If a stator comprises, for example, eighteen stator teeth or eighteen stator windings, the arrangement scheme just described can be followed twice more in the circumferential direction. Such a stator would then contain three phase groups of a respective stator phase, with each phase group containing two stator windings of a respective phase. Furthermore, it is known to wind each stator tooth with a separate winding wire or to use a single wire for several stator teeth of the same phase, in particular for stator teeth or stator windings of a phase group. If several stator teeth of the same phase, in particular stator teeth or stator windings of a phase group, are wound with a single orwound with a common wire can also be referred to as a winding group.

[0005] The wire ends of the stator windings must be electrically connected or contacted with the power supply of their respective phase and wired accordingly. For this electrical connection of the stator phases or electrical contacting of the stator windings, the stator windings are usually electrically contacted with a so-called lead frame. The technical term for this is often "lead frame". A lead frame usually comprises copper strips for connecting the phases, which are arranged in a plastic housing so that they are electrically insulated from one another. The wire ends of the stator windings are usually connected to the lead frame by welding, hot crimping or soldering. The stator phases are connected to a control unit (e.g. inverter) via the lead frame.

[0006] The object of the present invention is to provide a device for electrical contacting and interconnection of the stator windings which is improved in terms of efficiency, manufacturing effort and installation space. Summary of the invention

[0007] The present disclosure relates to a lead frame for electrically contacting stator windings according to claim 1. In particular, the present disclosure relates to a stator arrangement for an electrical machine according to claim 11, as well as to an electrical machine with a corresponding stator arrangement according to claim 14. Furthermore, the present disclosure relates to a method for producing a stator arrangement for an electrical machine according to claim 15.

[0008] According to a first aspect of the invention, a lead frame for electrically contacting stator windings of a three-phase stator is disclosed. The lead frame comprises an annular base body, three connection contacts, a plurality of lead levels, and a plurality of electrically conductive contact elements. The annular base body has a top side and a bottom side. The three connection contacts are designed for electrically contacting a respective stator phase to an inverter on the inverter side. The plurality of lead levels are arranged in an axially insulated manner in the annular base body. The lead levels have a plurality of lead sections spaced apart in the circumferential direction. The plurality of electrically conductive contact elements extend axially through the annular base body. Furthermore, the contact elements are arranged distributed in the circumferential direction. In addition, the contact elements are arranged radially spaced from the lead sections.The line levels further have line tabs projecting radially from the line sections, which electrically connect the line sections to the contact elements. The line tabs are arranged such that the line levels and the contact elements provide electrical interconnection of the stator phases between the contact elements and the connection contacts. Furthermore, at least some of the plurality of contact elements are designed for electrical contact with the stator windings. Line sections of different line levels can be electrically connected to one another using line tabs and contact elements. Thus, the contact elements can serve as a type of level contactor or through-contactor between different line levels that have a line tab in the region of the same contact element.In addition, by means of the at least some contact elements which are designed for electrical contact with the stator windings, on the one hand a stator winding can be connected to the contact element and on the other hand one or more line sections electrically connected to it can be electrically connected to the stator winding via this contact element.

[0009] In embodiments of the lead frame, at least some of the plurality of contact elements can have an opening on the underside for electrical contact with the stator windings. In particular, the openings can be designed such that the lead frame can be placed onto electrical ends of the stator. In other words, the opening forms at least one recess in the contact element, into which recess electrical ends of the stator (for example wire ends or electrical connectors connected thereto) can be inserted when the lead frame is assembled with the stator. The lead frame can, for example, be placed or plugged onto the electrical ends. Because the contact element is made of an electrically conductive material, mounting of the lead frame on and electrical contact with the stator can be achieved in a simple manner.Particularly in stator designs in which a plurality of stator teeth are wound by a single winding wire, only at least some of the plurality of contact elements can be formed with an opening. For example, adjacent stator teeth in winding groups of two or three (or more) stator teeth can be wound with a single winding wire. In such an example, the winding group with the two, three (or more) wound stator teeth would only be contactable with the lead frame via two wire ends. Consequently, only every fourth (with two stator windings in a winding group with a common winding wire) or every sixth (with three stator windings in a winding group with a common winding wire) contact element could be formed with an opening on the underside. In some designs, in particular, all contact elements can also be formed identically.For example, all contact elements can have openings on the underside. The electrical ends of the stator can be understood as those wire ends that are electrically contacted with the lead frame. For example, these can be wire ends of the winding wire or electrical connectors. The electrical connectors can be electrically connected to the wire ends. In the assembled state, the electrical connectors can be arranged between the wire ends and the lead frame. In particular, in the case of electrical connectors, the lead frame can be pressed onto the electrical ends.

[0010] In embodiments of the lead frame, at least some of the plurality of contact elements can have a passage that extends from the opening to the top side. The passage can provide space for the electrical ends, in particular for electrical connectors, which can be inserted, in particular pressed, into the contact elements or their passages. By providing a press-in option for the electrical ends, contacting and assembly of the lead arrangement and stator is made considerably easier, for example compared to contacting by welding. In advantageous embodiments, the passage can be designed to taper towards the top side. In embodiments, the taper can be conical or curved, for example. The taper can improve the holding of the electrical ends and / or the fit of the lead frame on the electrical ends.In addition, the taper can improve the positioning of the lead frame on the stator during the assembly process.

[0011] In embodiments of the lead frame, at least some of the plurality of contact elements can be designed for press-fitting electrical connectors of the stator windings of the stator. In particular, at least some of the plurality of contact elements can be configured such that the lead frame can be pressed onto the electrical connectors.

[0012] In embodiments of the lead frame, at least some of the plurality of contact elements can be provided in a number of wire ends present in the stator to be contacted. In some embodiments, the number of the plurality of contact elements can correspond to the number of wire ends present in the stator to be contacted.

[0013] In embodiments of the lead frame, at least some of the plurality of contact elements may be provided in a number of 6 to 72. In particular, at least some of the plurality of contact elements may be provided in a number of 12 to 36.

[0014] In embodiments of the lead frame, the plurality of contact elements can be provided in a number of 6 to 72. In particular, the plurality of contact elements can be provided in a number of 12 to 36.

[0015] In embodiments of the lead frame, the contact elements can be arranged at positions distributed in the circumferential direction. The positions are assigned to regions of the stator windings of a respective stator phase. In embodiments, the lead tabs can be arranged only at those positions in a respective lead level that are required for the electrical connection of the stator phases of the lead section connected to the lead tab.

[0016] In embodiments of the lead frame, the contact elements can be arranged radially inside and / or radially outside the lead sections.

[0017] In embodiments of the lead frame, the contact elements can be arranged at a distance from an inner circumference of the annular base body and / or from an outer circumference of the annular base body.

[0018] In embodiments of the lead frame, a radial width of the annular base body between an inner diameter of the annular base body and an outer diameter of the annular base body can be 20 mm or more. Preferably, the radial width of the annular base body can be 30 mm or more. Particularly preferably, the radial width of the annular base body can be 40 mm or more. In embodiments, the radial width of the annular base body can be between 20 mm and 80 mm, preferably between 30 mm and 60 mm, and particularly preferably between 25 mm and 45 mm. In embodiments, the radial width of the annular base body can substantially correspond to a radial width of the stator between its inner circumference and outer circumference. For example, this can include radial widths of 75% to 125% of the radial width of the stator.In embodiments, an inner diameter on the inner circumference of the annular base body can be, for example, 50 mm to 500 mm, preferably 100 mm to 250 mm and particularly preferably 125 mm to 200 mm.

[0019] In embodiments of the lead frame, the lead sections can extend, at least in sections, in the radial direction over at least 40% of a radial width of the annular base body between an inner diameter of the annular base body and an outer diameter of the annular base body. Preferably, the lead sections can extend over at least 50% of a radial width of the annular base body. Particularly preferably, the lead sections can extend over at least 60% of a radial width of the annular base body. By designing a radial width of a lead section in this way, an available total width (i.e., the radial width of the annular base body) can be utilized to a greater extent compared, for example, to conventionally used copper strips.In other words, in order to achieve a sufficient cable cross-section necessary for the current flow, this planar design of the cable sections can significantly reduce the axial thickness of the cable sections compared to a conventional cable frame.

[0020] In embodiments of the lead frame, an axial thickness of the lead levels can be at least 50 times smaller than a radial width of the lead levels. Preferably, the axial thickness of the lead levels can be at least 100 times smaller than the radial width of the lead levels. Particularly preferably, the axial thickness of the lead levels can be at least 200 times smaller than the radial width of the lead levels. By designing such an axial thickness of a lead level, an overall axial thickness of the annular base body between the top and bottom sides can be reduced. Overall, the required installation space in the axial direction can thus be reduced.

[0021] In embodiments of the lead frame, an axial thickness of the line levels can be 200 µm or less, preferably 150 µm or less, and particularly preferably 125 µm or less. In embodiments, the axial thickness can be at least 50 µm or at least 75 µm. In embodiments, the axial thickness can be 50 µm to 150 µm, preferably 70 µm to 130 µm, and particularly preferably 80 µm to 120 µm. Such an axial thickness of a line level can significantly reduce the axial installation space compared to copper strips conventionally used in lead frames.

[0022] In embodiments of the lead frame, the axial thickness of the annular base body can be 1 mm to 3 mm, preferably 1.2 mm to 2 mm, and particularly preferably 1.4 mm to 1.8 mm. Such an axial thickness of the annular base body between the top and bottom sides can reduce the required installation space in the axial direction.

[0023] In embodiments of the lead frame, the annular base body can have a multi-layer printed circuit board structure.

[0024] In embodiments of the lead frame, the line levels can be embedded in the substrate. In embodiments, the line levels can be electrically insulated from one another by the substrate, in particular electrically insulated from one another. In particular, the line sections of a line level can be electrically insulated from one another in the circumferential direction by the substrate. The line tabs can, in particular, be electrically conductively connected to the line sections. A line tab can, in particular, be assigned to only a single line section.

[0025] In embodiments of the lead frame, at least three lead levels, in particular at least six lead levels, can be arranged in the annular base body.

[0026] In embodiments of the lead frame, one of the plurality of lead levels can have at least two, preferably at least three, and particularly preferably at least four spaced-apart lead sections. In particular, the lead sections of a lead level can be spaced from one another in the circumferential direction. In particular, each lead level can have at least two, preferably at least three, and particularly preferably at least four spaced-apart lead sections in the circumferential direction.

[0027] In embodiments of the lead frame, the lead sections can extend in the circumferential direction. In particular, the lead sections can extend in the circumferential direction in a band-like manner.

[0028] In embodiments of the lead frame, each lead section can be connected to at least one lead tongue.

[0029] In embodiments of the lead frame, the lead tongues can surround the contact elements in the radial direction and / or in the circumferential direction. In particular, the lead tongues can completely surround the contact elements in the radial direction and in the circumferential direction.

[0030] In embodiments of the lead frame, the lead levels can be configured such that a star connection or a delta connection of the stator phases is provided.

[0031] In embodiments of the lead frame, the connection contacts can be electrically connected to at least one line level directly and / or via at least one conductor pin arrangement. In particular, the connection contacts can be electrically connected to a line section and / or a line tongue in at least one line level. The conductor pin arrangement can be electrically conductive. The conductor pin arrangement can extend in the axial direction. In embodiments, the conductor pin arrangement can comprise at least one or more conductor pins.

[0032] In embodiments of the lead frame, the annular base body can comprise a radial bulge on which the connection contacts are arranged. In particular, the bulge can protrude radially outward beyond the outer circumference.

[0033] In embodiments of the lead frame, the lead frame may further comprise a connection device. The connection device is electrically connected to the connection contacts for electrically contacting a respective stator phase with the inverter.

[0034] In some embodiments, the connecting device can be arranged on the top side of the annular base body. In some embodiments, the connecting device can be arranged axially above the connection contacts. In some embodiments of the lead frame, the connecting device can be attached to the annular base body in a floating manner. This allows tolerances to be compensated for during assembly of the lead frame in a stator housing. In some embodiments, the connecting device can be attached to the annular base body via a clip connection. For example, one or more clip arms can grip the underside of the annular base body.

[0035] In embodiments of the lead frame, the connection device can comprise a housing, three main line pins, and three cables for the electrical connection between the main line pins and the connection contacts. The main line pins can be fastened in the housing. In embodiments, the main line pins can be at least partially surrounded by a two-component (2K) overmolding. The 2K overmolding can form a section of the housing or the entire housing of the connection device. The 2K overmolding can eliminate the need for additional sealing elements. In particular, the main line pins can protrude from the housing in the axial direction (preferably in the direction away from the annular base body). In some embodiments, the cables can be ultrasonically welded to the connection contacts.

[0036] According to a second aspect of the invention, a stator arrangement for an electrical machine is disclosed. The stator arrangement comprises a stator and a lead frame according to the first aspect. The stator comprises a plurality of stator teeth wound with winding wire to form a stator winding on a stator tooth. The lead frame is arranged at an axial end of the stator and is electrically connected to electrical ends of the stator for interconnecting the stator phases. In particular, the lead frame can be electrically connected to wire ends of the winding wire for interconnecting the stator phases. In embodiments, the lead frame can be electrically connected directly to the wire ends or via electrical connectors.In other words, the term "electrically connected" with wire ends can encompass both a direct contact connection and an electrical connection implemented via an electrical connector. The stator assembly with the lead frame can simplify assembly and manufacturing. Furthermore, particularly when using a plug-in connection, the risk of contamination during manufacturing, such as with alternative welding processes, can be eliminated or at least reduced. Furthermore, the axial thickness (relative to a stator axis) of the stator assembly can be reduced by the lead-level structure.

[0037] In embodiments of the stator arrangement, the stator teeth can be wound with a winding wire individually or in winding groups of the same stator phase.

[0038] In embodiments of the stator arrangement, the stator arrangement can further comprise a plurality of electrical connectors. A respective wire end of the winding wire can be electrically connected to the lead frame via one of the plurality of electrical connectors. In embodiments, the lead frame can be plugged, in particular pressed, onto the electrical connectors for electrically contacting the stator windings. In particular, the lead frame can be plugged, in particular pressed, onto the electrical connectors via the contact elements. In embodiments, the electrical connectors can have a press-in section that is connected to the contact elements. In particular, in embodiments in which at least some contact elements have openings on the underside, a respective press-in section can be pressed into the opening of a contact element.In some embodiments, the electrical connectors can be designed as insulation displacement connectors with an insulation displacement section, wherein a respective insulation displacement section is plugged onto a respective wire end. In some embodiments, the press-in section and the insulation displacement section can be formed at axially opposite end regions of the electrical connector. By plugging the insulation displacement section onto the winding wire or its ends, contact or electrical connection between the electrical connector and the respective wire end can be achieved by a cold welding process. This, in turn, allows electrical contact or interconnection of the stator windings or stator phases to be achieved by simply connecting the lead frame to the electrical connectors.

[0039] In embodiments of the stator arrangement, the stator can further comprise a plurality of receiving sections. The receiving sections are configured to receive the wire ends and to receive electrical connectors. In particular, the receiving sections can be configured such that, by receiving the electrical connectors, the wire ends received in the receiving section are electrically connected to the electrical connector. Subsequently, electrical interconnection of the stator phases can be achieved by simply contacting the electrical connectors with the lead frame. In embodiments, the receiving sections can comprise a respective wire end receiving region configured to receive a respective wire end. In particular, the wire ends can be arranged at least partially in a respective wire end receiving region.In embodiments, the receiving sections can comprise a respective connector receiving region configured to receive a respective electrical connector. In particular, the electrical connectors can be arranged at least partially in a respective connector receiving region. In embodiments that comprise a wire end receiving region and a connector receiving region, the wire end receiving region and the connector receiving region can be arranged crossing one another, so that when an electrical connector is inserted into a connector receiving region, a wire end arranged in the wire end receiving region is cut by the electrical connector in an electrically contacting manner.

[0040] In embodiments of the stator assembly that comprise a plurality of electrical connectors and a plurality of receiving sections, the electrical connectors can each be arranged in a receiving section such that a press-in section of an electrical connector protrudes from the receiving section and is connected to the lead assembly. In embodiments, the press-in section of a connector can be connected to a contact element of the lead frame, in particular, pressed into a respective contact element.

[0041] In some embodiments of the stator assembly comprising a plurality of receiving sections, the receiving sections may comprise a respective lead frame receiving area configured to support the lead frame.

[0042] In some embodiments of the stator assembly comprising a plurality of receiving sections, the receiving sections may be integrated into a stator end cap of the stator.

[0043] In embodiments of the stator arrangement, the stator arrangement can further comprise a potting body and a stator housing. The stator housing can define an annular receiving area with a peripheral portion and an annular end wall. The stator can be arranged with the lead frame in the receiving area such that the lead frame is arranged adjacent to the annular end wall. In embodiments, the stator can be potted with the lead frame in the receiving area. Due to the potting body arranged between the stator housing and the stator with the lead frame, the stator with the lead frame can be at least partially embedded in the potting body. In embodiments, the stator housing can further comprise a passage in the annular end wall. A connection device (50) of the lead frame can protrude at least partially through the passage to the outside of the stator housing.

[0044] According to a third aspect of the invention, an electric machine is disclosed. In particular, the electric machine can be an electric motor. The electric machine comprises a machine housing, a shaft, at least one rotor, an inverter, and a stator arrangement according to the second aspect. The shaft is rotatably mounted in the machine housing. The rotor is arranged in a rotationally fixed manner on the shaft in the machine housing. The stator is arranged adjacent to the rotor in the machine housing. The inverter is designed to control the stator. Furthermore, the inverter is electrically connected to the lead frame.

[0045] In embodiments of the electrical machine, the inverter can be electrically connected to the lead frame via a connection device.

[0046] In embodiments of the electric machine, the stator can be arranged radially adjacent to the rotor in the machine housing. In embodiments, the rotor can comprise a plurality of rotor poles arranged circumferentially distributed on a rotor body of the rotor. In particular, the rotor poles can be designed as permanent magnets. In embodiments, the rotor can be configured externally and at least partially surround the stator radially outward.

[0047] In embodiments of the electric machine, the machine housing can comprise a rotor housing and a stator housing. The rotor housing and the stator housing can be connected to one another in a force-locking manner.

[0048] According to a fourth aspect of the invention, a method for producing a stator arrangement for an electrical machine is disclosed. The method comprises providing a stator having a plurality of stator teeth. The stator teeth are wound with stator windings having electrical ends. Furthermore, the method comprises providing a lead frame according to the first aspect. Furthermore, the method comprises contacting the stator windings by contacting electrical ends of the stator windings with the contact elements of the lead frame.

[0049] In embodiments of the method, an electrical connector can be clamped onto a respective wire end of the stator windings to form electrical ends of the stator. In embodiments, the wire ends of the stator windings can be pressed into an insulation displacement portion of a respective electrical connector.

[0050] In embodiments of the method, the electrical ends can be provided by inserting wire ends into a wire end receiving area of ​​the stator and inserting an electrical connector into a connector receiving area of ​​the stator, wherein an insulation displacement portion of the electrical connector makes electrical contact with the respective wire end.

[0051] In embodiments of the method, contacting electrical ends can comprise placing the lead frame on the stator. In embodiments, contacting electrical ends can comprise placing the lead frame on the electrical ends that protrude substantially in the axial direction from the stator. Preferably, contacting electrical ends can comprise pressing the lead frame onto the electrical ends that protrude substantially in the axial direction from the stator. In particular, contacting electrical ends can comprise placing and / or pressing the lead frame onto electrical connectors that protrude axially from the stator, in particular their press-in sections. In embodiments, the lead frame can be placed or pressed onto the electrical ends in the axial direction.

[0052] In embodiments of the method, contacting electrical ends may comprise pressing electrical connectors connected to the wire ends of the stator windings into the contact elements of the lead frame. In particular, contacting may comprise pressing press-in sections into the contact elements or into their opening on the underside.

[0053] In embodiments of the method, the method can further comprise providing a stator housing. The stator housing defines an annular receiving area with a circumferential section and an annular end wall. Furthermore, the method can comprise introducing the contacted stator with the lead frame arranged axially thereon into the receiving area of ​​the stator housing. In addition, the method can pot the stator with the lead frame in the stator housing by filling potting compound into the receiving area, whereby after the potting compound has hardened, a potting body is formed between the stator contacted with the lead frame and the stator housing. As a result of the potting, the stator contacted with the lead frame can be fixed in the potting body and thus in the stator housing after the potting compound has hardened.In some embodiments, the contacted stator with the lead frame can first be inserted into the stator housing in the axial direction, such that the lead frame is arranged adjacent to the annular end wall. In particular, the contacted stator with the lead frame can then be inserted into the stator housing in such a way that the upper side of the lead frame is arranged adjacent to the annular end wall. In some embodiments, a connection device of the lead frame can be guided at least partially through a passage in the annular end wall to the outside of the stator housing during insertion. This allows an inverter outside the stator housing to be electrically connected to the lead frame via the connection device.

[0054] In embodiments of the method, a resin material, in particular a synthetic resin material, can be used as the potting compound. In embodiments, the potting compound can be provided with thermally conductive fillers. Short description of the characters

[0055] Further features will be apparent from the accompanying drawings, which form a part of this disclosure. The drawings are intended to further explain the present disclosure and to enable those skilled in the art to practice the present disclosure. However, the drawings are to be understood as non-limiting examples. Common reference numerals in different figures indicate the same or similar features. Fig. 1 shows a schematic sectional view of the electric machine of the third aspect with the stator assembly including the lead frame; Fig. Figure 2a shows a plan view of the lead frame of the first aspect; Fig. 2b shows a plan view of the lead frame of the first aspect, wherein only a part of the contact elements are formed as contact sleeves; Fig. 3a-3f show six different line levels of the line frame in an exemplary configuration; Fig. 4a shows a perspective partial section of the lead frame in a sectional view; Fig. 4b shows a perspective partial section of the stator arrangement of the second aspect with a lead frame pressed onto the stator in the view according to Fig. 4a; Fig. 5a shows a perspective view of an exemplary wound stator tooth with electrical connectors; Fig. Figure 5b shows a perspective view of a stator with several wound stator teeth with electrical connectors made of Fig. 5a; Fig. 6 shows a stator arrangement with the stator from Fig. 5b and lead frame mounted thereon; Fig. 7 shows the stator arrangement Fig. 6 with an exemplary connection device of the lead frame; Fig. 8 shows the stator arrangement Fig. 7 in an orientation when inserted into a stator housing of the stator arrangement; Fig. 9 schematically shows a flow diagram of a method for producing a stator arrangement for an electrical machine according to the fourth aspect; Fig. 10 shows a plan view of the lead frame in a variation; Fig. 11a-11b Each shows a section of the lead frame from Fig. 10 with an exemplary connection device. Detailed description

[0056] Embodiments of the lead frame, the stator assembly, the electric machine and the method according to the present disclosure are explained below with reference to the drawings.

[0057] In the context of this application, the terms "axial" or "axial direction 2" refer to a central axis of the lead frame 10 or its annular base body 12. Furthermore, the terms "axial" or "axial direction 2" can refer to a rotation axis of the electric machine 200 or to a central axis of the stator assembly 100 or stator 110, respectively, which are arranged concentrically to the rotation axis. Since the respective axes of the lead frame 10, the stator 110, the stator assembly 100, and the electric machine 200 are essentially identical, they are represented by the same reference numeral. Depending on which element or entity is referred to, the (central) axis or the axis of rotation can be associated with the lead frame 10, the stator 110, the stator assembly 100, and / or the radial flux motor 200 and / or other elements or entities such as the rotor 220, the shaft 230.In the figures, the axial direction 2 is represented by the reference number 2. The term radial or radial direction is to be understood in relation to the axis / axial direction 2 and is represented by the reference number 4. Likewise, a circumference, circumferential or a circumferential direction refers to the axial direction 2 and is identified by the reference number 6. It should be understood that, although only one exemplary direction is shown in the respective figures, the respective opposite direction also falls under the respective term. For example, in . Fig. In Figure 2a, the circumferential direction 6 is represented by a clockwise arrow. However, a counterclockwise direction around the axis 2 can also be referred to as the circumferential direction 6. This also applies analogously to the axial direction 2 and the radial direction(s) 4.

[0058] In Fig. 1 shows an exemplary electric machine 200 according to the third aspect of the invention. Fig. 1 shows the electric machine 200 in a schematically highly simplified sectional view through a sectional plane defined by the axial direction 2 and the radial direction 4. The electric machine 200 comprises a machine housing 210, a rotor 220, a shaft 230, and an inverter 240 (also referred to as inverter 240). In addition, the electric machine 200 comprises a stator arrangement 100 according to the second aspect, which is described in detail below. The shaft 230 is rotatably mounted in the machine housing 210. For reasons of clarity, bearings of the electric machine for rotatably supporting the shaft are not shown in the figures. The rotor 220 is arranged in a rotationally fixed manner on the shaft 230 in the machine housing 210. Thus, the rotor 220 can rotate together with the shaft 230 about the rotor axis (dash-dotted line at reference numeral 2).

[0059] The stator 110 is arranged adjacent to the rotor 220 in the machine housing 210. In the example of Fig. 1, the electric machine 200 is configured as a radial flux motor. The stator 110 is arranged radially adjacent to the rotor 220 in the machine housing 210. In other words, the stator 110 and the rotor 220 are spaced apart from each other by a gap in the radial direction 4. The exemplary embodiments of the electric machine 200 shown in the figures relate to a radial flux motor with an external rotor 220. The rotor 220 is arranged radially outside the stator 110 or surrounds the stator 110 (at least partially) radially outside. Stator teeth 112 of the stator 110 protrude outward in the radial direction 4 toward the rotor 220. As will be explained in detail below, the stator 110 comprises a plurality of stator teeth 112 wound with winding wire to form a stator winding 114 on a stator tooth 112.

[0060] As in Fig. 1, the rotor 220 comprises a plurality of rotor poles 222, which are arranged distributed in the circumferential direction 6 on a rotor body 224 of the rotor 220. Alternatively, the rotor 220 comprises a rotor body 224 and a plurality of rotor poles 222. The rotor poles 222 can be designed, in particular, as permanent magnets. The rotor poles 222 are arranged distributed in the circumferential direction 6 on the rotor body 224 of the rotor 220. In the exemplary illustration of Fig. 1, the rotor body 224 of the rotor 220 is pot-shaped. The rotor poles 222 can be arranged on an inner circumference of the rotor body 224. In particular, the rotor poles 222 are magnetized in the radial direction 4. By applying current to the stator 110 or its stator windings 114, a magnetic flux can be generated in the radial direction 4 during operation, which induces a force in the rotor poles 222 (e.g., permanent magnets 222), which drives the rotor 220 (and thus the shaft 230).

[0061] In alternative embodiments, however, the present disclosure also extends to radial flux machines with an internal rotor. As an alternative to a radial flux machine, the electric machine can also be designed as an axial flux machine, in which a disc-shaped or annular rotor is arranged spaced apart from a disc-shaped or annular stator by a gap in the axial direction 2. In an axial flux machine, the stator teeth of the stator protrude in the axial direction toward the rotor, and the rotor poles of the rotor are magnetized in the axial direction, so that in an axial flux machine, magnetic flux can be generated in the axial direction.

[0062] Further in relation to Fig. 1, the machine housing 210 may comprise a rotor housing 212 and a stator housing 120. The rotor housing 212 and the stator housing 120 may, in particular, be connected to one another in a force-locking manner. Fig. 1, respective flanges on the rotor housing 212 and the stator housing 120 can be seen, via which a force-locking connection (e.g. via one or more screw connections not shown) of the two housings 212, 120 can be established.

[0063] The inverter 240 is designed to control the stator 110. Furthermore, the inverter 240 is electrically connected to a lead frame 10 of the stator assembly 100, which is described in detail below. In this regard, Fig. 1 further shows a connection device 50 of the lead frame 10, via which the inverter 240 can be electrically connected to the lead frame 10.

[0064] In the following, in particular with regard to the Fig. 2a, 2b, 3a-3f, 4a, 4b, 7, 10 of the lead frame 10 for electrically contacting stator windings 114 of a three-phase stator 110 according to the first aspect of the invention is described.

[0065] As particularly in Fig. 2a, 2b and 3a-3f, 10, the lead frame 10 comprises an annular base body 12, three connection contacts 40 (40u, 40v, 40w), several line levels 20 and several electrically conductive contact elements 30. The annular base body 12 has an upper side 12a and a lower side 12b (see, for example, also Fig. 4a). It should be understood that "annular" can also include shapes that deviate from a perfect circle, such as oval or polygonal. Shapes that include one or more sections protruding (e.g., radially protruding) from the annular base body 12 (e.g., its inner circumference 12c and / or its outer circumference 12d) can also be included. The three connection contacts 40 are designed for the inverter-side electrical contacting of a respective stator phase (P1, P2, P3) to an inverter 240. The plurality of line levels 20 are arranged in an axially insulated manner in the annular base body 12. The line levels 20 have a plurality of line sections 22 spaced apart in the circumferential direction 6 (see Fig. 3a-3f). The plurality of electrically conductive contact elements 30 extend axially through the annular base body 12 (see also Fig. 4a). Furthermore, contact elements 30 are arranged distributed in the circumferential direction 6. In addition, the contact elements 30 are arranged radially spaced from the line sections 22. The line levels 20 further have line tongues 24 projecting radially from the line sections 22, which electrically connect the line sections 22 to the contact elements 30 (see, for example, Fig. 3a-3f). The conductor tongues 24 are arranged such that the conductor levels 20 and the contact elements 30 provide an electrical connection of the stator phases (P1, P2, P3) between the contact elements 30 and the connection contacts 40. Furthermore, at least some of the plurality of contact elements 30 are designed for electrical contact with the stator windings 114. Conductor tongues 24 and contact elements 30 can electrically connect conductor sections 22 of different conductor levels 20 to one another. Thus, the contact elements 30 can serve as a type of level contactor or through-contactor between different conductor levels 20 that have a conductor tongue 24 in the region of the same contact element 30.In addition, by means of the at least some contact elements 30 which are designed for electrical contact with the stator windings 114, on the one hand a stator winding 114 can be connected to the contact element 30 and on the other hand one or more line sections 22 electrically connected to it can be electrically connected to the stator winding 114 via this contact element 30.

[0066] In the exemplary design of the management framework 10 from Fig. 2a and Fig. 2b (also Fig. 3a-3f and 10), the lead frame 10 has a number of 36 contact elements 30. For reasons of clarity, Fig. 2a, Fig. 2b and Fig. 10 only 6 contact elements 30 are provided with a reference symbol. It is also important to understand that the Fig. 3a-3f, 6 and 7, in the radially inner region of the annular base body 12, identify contact elements 30. In alternative embodiments, a lead frame 10 may also have more or fewer than 36 contact elements 30. For example, the lead frame 10 may comprise a number of 6 to 72 contact elements 30. In particular, the lead frame 10 may comprise a number of 12 to 36 contact elements 30. As the Fig. 2a, Fig. 2b and Fig. 10, the contact elements 30 are arranged at positions S distributed in the circumferential direction 6 i arranged. "i" stands for the ascending number of the position. In this example with 36 contact elements 30, there are 36 positions S1 to S 36 which are numbered clockwise. The positions S i are assigned to areas of stator windings 112 of a respective stator phase (P1, P2, P3) (see also Fig. 5b). In the example of Fig. 2a, 2b, 3a-3f, 5b and 10 are each two positions S i assigned to a stator winding 114. The “circumferentially distributed 6 positions S i " may also be referred to as circumferential positions. A circumferential position may include any position located on a radial vector that passes through the circumferential position. "Regions of stator windings 114" may be understood, in particular, as circumferential regions or circumferential sectors in which the stator winding 114 or the stator tooth 112, in particular wire ends 115 of the stator windings 114, are arranged.

[0067] In the illustrated embodiments, the contact elements 30 are arranged radially inside the line sections 22. In other words, the contact elements 30 are arranged in a radially inner region of the annular base body 12. This region is in the Fig. 2a and Fig. 2b, for example, by the dashed circle around the axial direction 2. In alternative embodiments, the contact elements 30 can also be arranged radially outside the line sections 22 or in a radially outer region of the annular base body 12. It would also be conceivable for some contact elements 30 to be arranged radially inside and some contact elements 30 radially outside the line sections 22. In addition, the contact elements are arranged at a distance from an inner circumference 12c of the annular base body 12 and from an outer circumference 12d of the annular base body 12. Although this can achieve a greater holding force of the contact elements 30 in the annular base body 12, some contact elements 30 can also be arranged on the inner circumference 12c and some contact elements 30 on the outer circumference 12d. All contact elements 30 could also be arranged on the inner circumference 12c or on the outer circumference 12d.

[0068] A line level 20 can be understood as an electrically conductive area with line sections 22 and line tongues 24 within an axial plane or a position in the axial direction 2. In this regard, the Fig. 3a-3f six line levels 20 of an exemplary embodiment of the lead frame 10 in an axial direction 2 from the top side 12a towards the bottom side 12b. The Fig. 3a-3f show exemplary sections through the lead frame 10 in different axial planes in which the lead planes 20 are arranged. Fig. 3a shows a first line level 20. The Fig. 3b shows a second line level 20. The Fig. 3c shows a third line level 20. The Fig. 3d shows a fourth line level 20. The Fig. 3e shows a fifth management level 20. The Fig. 3f shows a sixth line level 20. The first line level 20 is arranged closest to the top side 12a. The sixth line level 20 is arranged closest to the bottom side 12b. The remaining four line levels 20 are located between them, according to their numbering.

[0069] In some embodiments, the lead frame 10 or its annular base body 12 can have a multi-layer printed circuit board structure. The lead levels 20 are located in a respective layer or level of the multi-layer printed circuit board structure. In English, the printed circuit board structure can also be referred to as a “circuit board structure.” In such embodiments, the lead frame 10 can also be referred to as a printed circuit board lead frame. For example, the lead levels 20 (i.e., the electrically conductive regions) can be produced using known printing techniques. In particular, in such cases, one can also speak of a printed circuit board structure. In English, the term “printed circuit board structure” or “PCB structure” (printed circuit board; PCB) can be used for this. If the lead frame 10 has a PCB structure, the lead frame 10 can also be referred to as a PCB lead frame 10.As an alternative to printing the circuit levels 20, other manufacturing processes for the circuit levels 20 or the circuit frame 10 are also conceivable.

[0070] In particular, the conductive planes 20 are embedded in the substrate. The substrate can be made, for example, from conventional printed circuit board substrate material, such as glass fiber, Teflon (RTM), ceramic, polymers, or glass fiber epoxy laminate. By embedding them in the substrate, the conductive planes 20 can be electrically insulated from each other. This is the case, for example, in Fig. 4a, wherein the conductive planes 20 are axially insulated from each other by the substrate. As can be seen in particular from the Fig. 3a-3f, the line sections 22 extend in a band-like manner in the circumferential direction 6. The line sections 22 of a line level 20 are electrically insulated from one another in the circumferential direction 6 by the substrate.

[0071] The conductor tongues 24 are electrically conductively connected to the conductor sections 22 in order to establish an electrical connection between a conductor section 22 and a contact element 30. A conductor tongue 24 is in particular assigned to only a single conductor section 22 or is electrically connected thereto. In particular, each conductor section 22 is connected to at least one conductor tongue 24. Conductor sections that are not connected directly or via a conductor pin arrangement to a connection contact 40 comprise in particular at least two conductor tongues 24. As can be seen from the Fig. 3a-3f, the line tongues 24 are directly physically connected to the line sections 22.

[0072] In particular, the cable tongues 24 are only at those positions S iarranged in a respective line level 20, which are required for the electrical connection of the stator phases P1, P2, P3 of the line section 22 connected to the line tongue 24. In general, the three stator phases P1, P2, P3 can be referred to as phases U, V, W, where, for example, P1=U, P2=V and P3=W. However, the stator phases P1, P2, P3 could also be arranged in a different connection. In the embodiments described in detail here, the stator phases P1, P2, P3 are each arranged in two phase groups of six contact elements 30 or three stator teeth 112 (see also Fig. 5b). The phase groups are shown in the figures separated from each other by dashed lines in the radial direction 4 and are marked with the respective stator phase P1, P2, P3 (see e.g. Fig. 2a, 2b, 3a-3f, 5, 6, 7, 10).

[0073] In the Fig. 2a, Fig. 2b and Fig. 10 an exemplary line section 22 with a line tongue 24 in the first line level 20 is indicated by the dashed border. The exemplary line section 22 extends, as can be seen in the figures, approximately from the circumferential position at S4 to the circumferential position S7. The line section 22 is electrically connected to the connection contact 40, 40u and radially spaced from the contact elements 30 at the positions S4, S5, S6 and S7. Via the line tongue 24 projecting radially inward from the line section 22, the line section 22 is electrically connected to the contact element 30 at the position S7. Thus, for example, an electrically conductive connection can be established from a connection contact 40 via a line section 22 and a line tongue 24 to a contact element 30. Since the line levels 20 of the Fig. 3a-3f are arranged in the same rotational position, the further electrical flow (during operation) or the electrically conductive connection can be traced. In this regard, the position at reference symbol S i the first position S1. The same applies to the lead frame 10 of the Fig. 10, in which the reference symbol S i represents the first position S1. Following this in a clockwise direction are the contact elements 30 at the other positions S i shown in ascending order. In Fig. 3a is in the exemplary line section 22 of the Fig. 2a and Fig. 2b, the exemplary line section 22 with line tongue 24 can also be seen (in the lower area at approximately six o'clock). The electrical flow can now be conducted, for example, from the contact element 30 at position S7 into a wire end 115 at position S7 and through a stator winding 114. At the other wire end 115 of this stator winding 114 at position S8, the electrical flow can be conducted via the contact element 30 into the line tongues 24 of the fifth line level 20 arranged at position S8 (see Fig. 3e) and the sixth management level 20 (see Fig. 3f) and into the associated line sections 22. The embodiments described here and illustrated in the figures should be understood merely as exemplary configurations of the line frame 10, in particular its line levels 20, for the purpose of explaining the basic principle. Various configurations of the line levels 20, line sections 22, and line tabs 24 are encompassed by the scope of the present disclosure.

[0074] In particular, the design of the line levels 20 can be adapted to a design of the stator 110 used with the lead frame 10. In some embodiments, a configuration of the line levels 20 can be adapted to a desired connection, for example, to a star connection or a delta connection of the stator phases P1, P2, P3. For example, a different number of line levels 20 can be used or arranged in the annular base body 12. In some embodiments, the line levels 20 can also have different numbers of line sections 22, for example, at least two, preferably at least three, and particularly preferably at least four line sections 22 spaced apart from one another, in particular spaced apart in the circumferential direction 6.

[0075] Further in relation to the Fig. 3a-3f, the conductor tongues 24 can completely surround the contact elements 30 in the radial direction 2 and in the circumferential direction 6. This allows reliable electrical contact to be achieved between the conductor tongues 24 and the contact elements 30. In some embodiments, however, the conductor tongues 24 can also only at least partially surround the contact elements 30 in the radial direction 4 and / or at least partially in the circumferential direction 6.

[0076] In embodiments of the lead frame 10, a radial width of the annular base body 12 can be between an inner diameter of the annular base body 12 and an outer diameter of the annular base body 12, in particular 40 mm. It is understood that the inner diameter rests on the inner circumference 12c of the annular base body 12. Furthermore, the outer diameter rests on the outer circumference 12d of the annular base body 12. In alternative embodiments, the radial width of the annular base body 12 can be 20 mm or more. Preferably, the radial width of the annular base body 12 can be 30 mm or more. Particularly preferably, the radial width of the annular base body 12 can be 40 mm or more. In embodiments, the radial width of the annular base body 12 can be between 20 mm and 80 mm, preferably between 30 mm and 60 mm, and particularly preferably between 25 mm and 45 mm.In embodiments, the radial width of the annular base body can substantially correspond to a radial width of the stator 110 between its inner circumference and outer circumference. For example, this can include radial widths of 75% to 125% of the radial width of the stator 110. In some embodiments, the inner diameter of the annular base body 12 can be, for example, 160 mm. In alternative embodiments, the inner diameter of the annular base body 12 can also be smaller or larger. For example, the inner diameter at the inner circumference 12c of the annular base body 12 can be, for example, 50 mm to 500 mm, preferably 100 mm to 250 mm, and particularly preferably 125 mm to 200 mm.

[0077] The axial thickness of the annular base body 12 between the top side 12a and the bottom side 12b can be 1 mm to 5 mm, preferably 1.2 mm to 2 mm, and particularly preferably 1.4 mm to 1.8 mm. Such an axial thickness of the annular base body 12 allows the installation space required in the axial direction 2 to be reduced, for example, compared to a conventional lead frame.

[0078] The line sections 22 extend, at least in sections, in the radial direction 4 over at least 40% of the radial width of the annular base body 12. Preferably, the line sections 22 can extend over at least 50% of the radial width of the annular base body 12. Particularly preferably, the line sections 22 can extend over at least 60% of the radial width of the annular base body 12. Such a configured radial width of a line section 22 allows a greater utilization of the available total width (i.e., the radial width of the annular base body 12) compared to, for example, conventionally used copper strips.In other words, in order to achieve a sufficient line cross-section necessary for the current flow, this flat design of the line sections 22 allows an axial thickness of the line sections 22 to be significantly reduced compared to a conventional line frame. The radial width of a line section 22 can be understood in particular as a maximum radial width of the line section 22. In other words, individual line sections 22, in particular individual line sections 22 in circumferential regions of the connection contacts 40, can have smaller radial widths at least in sections (see, for example, the line section 22 at the connection contacts 40 in . Fig. 3b).

[0079] In the schematic representation of the Fig. 4a shows a sectional view through the lead frame 10, so that the axially spaced lead levels 10 and a sectioned contact element 30 can be seen. In order to make the lead levels 20 more clearly visible, they are not drawn to scale, at least in the axial direction 2, but are shown thicker. In embodiments of the lead frame 10, an axial thickness of a lead level 20 can be 200 µm or less, preferably 150 µm or less, and particularly preferably 125 µm or less. For example, the axial thickness of a lead level 20 can be 50 µm to 150 µm, preferably 70 µm to 130 µm, and particularly preferably 80 µm to 120 µm. In embodiments, the axial thickness of a lead level 20 can be at least 50 µm or at least 75 µm.By means of such a designed axial thickness of a conductor level 20 (and thus also such a designed axial thickness of the conductor sections 22 and the conductor tongues 24), an axial installation space can be greatly reduced compared to copper strips conventionally used in conductor frames.

[0080] In embodiments, the axial thickness of a line level 20 can be at least a factor of 20 smaller than a radial width of the line level 20. In particular, the axial thickness of a line level 20 can be at least a factor of 50 smaller than a radial width of the line level 20. Preferably, the axial thickness of a line level 20 can be at least a factor of 100 smaller than the radial width of the line level 20. Particularly preferably, the axial thickness of a line level 20 can be at least a factor of 200 smaller than the radial width of the line level 20. In particular, an axial thickness of a line section 22 can be at least a factor of 20, preferably at least a factor of 50, and particularly preferably at least a factor of 100 or 200 smaller than a radial width of the line section 22. By means of such a configured axial thickness of a line level 20 (orBy reducing the thickness of the conductor sections 22 and the conductor tongues 24, the overall axial thickness of the annular base body 12 between the top side 12a and the bottom side 12b can be reduced. Thus, the overall required installation space in the axial direction 2 can be reduced.

[0081] As particularly in the Fig. 4a, the contact elements 30 comprise an opening 32 on the underside 12b for electrical contact with the stator windings 114. In addition, the contact elements 30 have a passage 34 that extends from the opening 32 to the top side 12b. The passage has the opening 32 on the underside 12b and an opening on the top side 12a. This means that the contact elements 30 can be designed in the manner of a sleeve. Contact elements 30 with a passage 34 can also be referred to as contact sleeves. The passage 34 can (as in Fig. 4b) extend substantially in the axial direction 2. In some embodiments, the contact elements can be designed as VIA sleeves (VIA; vertical interconnect access).

[0082] In alternative embodiments of the lead frame 10, only at least some of the plurality of contact elements 30 may have an opening 32 on the underside 12b and / or a passage 34 for electrical contact with the stator windings 114. While the Fig. 2a shows a lead frame 10 in which all contact elements 10 are designed as contact sleeves, the Fig. 2b shows an exemplary variation in which only some of the plurality of contact elements 30 have an opening 32 and a passage 34. In the illustrated embodiment, these are the twelve contact elements 30 at positions S1, S6, S7, S 12 , S 13 , S 18 , S 19 , S 24 , S 25 , S 30 , S 31 and S36 Such a configuration can be particularly advantageous when the lead frame 10 is used with such configurations of stators 110 in which several stator teeth 112 are wound by a single winding wire 114, i.e., in winding groups. For example, adjacent stator teeth 112 in the circumferential area of ​​positions S1 to S6, S7 to S 12 , S 13 to S 18 , S 19 to S 24 , S 25 to S 30 and S 31 to S 36each wound in a winding group. For example, the winding group with three wound stator teeth 112 of positions S1 to S6 would only be contacted with the lead frame 10 via two wire ends 115, for example one wire end 115 at position S1 and one wire end at position S6. Expressed in more general terms, within a circumferential region of a phase group wound as a winding group, only two contact elements 30 can be formed with an opening 32 on the underside 12b and / or a passage 34. In alternative embodiments in which phase groups and / or winding groups are used, in particular all contact elements 30 can be formed identically, in particular with an opening 32 on the underside 12b and / or a passage 34.

[0083] In particular, the contact elements 30 for contacting the stator windings 114 can be provided in a number of wire ends 115 that are present in the stator 110 to be contacted. In some embodiments, the number of contact elements 30 can correspond to the number of wire ends 115 that are present in the stator to be contacted. In a few alternative embodiments, the number of at least some of the plurality of contact elements 30 can correspond to n times the number of wire ends 115, where n corresponds to a fraction less than 1 and greater than 0 or to a positive natural number. Alternatively, more contact elements 30 can be designed for contacting than are required. Conversely, multiple wire ends 115, for example two, three or more, can be contacted via a (single) contact element 30.

[0084] The openings 32 can, in particular, be designed such that the lead frame 10 can be placed onto electrical ends of the stator 110. In other words, the opening 32 forms at least one recess in the contact element 30, into which recess electrical ends of the stator 110 (for example, wire ends or electrical connectors connected thereto) can be inserted during assembly of the lead frame 10 with the stator 110. The lead frame 10 can, for example, be placed or plugged onto the electrical ends. Because the contact element 30 is made of an electrically conductive material, mounting of the lead frame 10 and electrical contact with the stator 110 can be achieved in a simple manner.

[0085] The electrical ends of the stator 110 can be understood as those wire ends that are electrically contacted with the lead frame 10. For example, these can be wire ends 115 of the winding wire 114 or electrical connectors 130. The electrical connectors 130 can be electrically connected to the wire ends 115. In the assembled state, the electrical connectors 130 can be arranged between the wire ends 115 and the lead frame 10. In particular, in the case of electrical connectors 130, the lead frame 10 can be pressed onto the electrical ends.

[0086] Through the passage 34, space can be provided for the electrical ends, in particular for electrical connectors 130, which can be inserted, in particular pressed, into the contact elements 30 or their passages 34. By providing a press-in option for the electrical ends, a considerably simpler contacting and assembly of the cable arrangement 10 and stator 110 is possible, for example, compared to contacting by welding. In the Fig. In the embodiment shown in Figure 4a, the passage 34 is cylindrical. In alternative embodiments, the passage 34 can be tapered toward the top side 12. In some embodiments, the taper can be conical or curved, for example. The taper can improve the retention of the electrical ends and / or the fit of the lead frame 10 on the electrical ends. Furthermore, the taper can improve the positioning of the lead frame 10 on the stator 110 during the assembly process.

[0087] In advantageous embodiments of the lead frame 10, the contact elements 30 can be designed for press-fitting electrical connectors 130 of the stator windings 114 of the stator 110. In particular, at least some of the plurality of contact elements 30 can be configured such that the lead frame 10 can be pressed onto the electrical connectors 130. This can be achieved, for example, by a tapered design of the passages 34 and / or by a dimensional and / or geometric adaptation of the contact elements 30 (in particular their openings 32 and / or their passages 34).

[0088] In embodiments of the lead frame 10, the connection contacts 40 can be electrically connected directly to at least one line level 20. In particular, the connection contacts 40 are electrically connected to a line section 22 and / or a line tongue 24 in at least one line level 20. This has already been explained above with reference to the exemplary line section 22 from the Fig. 2a, Fig. 2b and Fig. 10. For this purpose, the connection contacts 40 can, for example, extend at least partially in the axial direction 2 into the annular base body 12. See, for example, the line sections 22 in the first line level 20 of Fig. 3a and the sixth management level 20 of the Fig. 3f, which are electrically connected to the connection contact 40 in the circumferential area of ​​position S1 (see analogously also the connection contact 40 in the circumferential area between positions S2 and S3 and the corresponding line section in the fourth line level 20 of the Fig. 3d). Alternatively or additionally, a connection contact 40 can also be formed via a conductor pin arrangement (see, for example, lead frame 10 from the Fig. 10) can be electrically connected to at least one conductor level 20. The conductor pin arrangement can be electrically conductive. The conductor pin arrangement can extend in the axial direction 2. In embodiments, the conductor pin arrangement can comprise at least one or more conductor pins. The conductor pin arrangement can be arranged radially and / or circumferentially spaced from the conductor sections and connected to the conductor sections via connecting tabs.

[0089] As already mentioned in relation to Fig. 1, the lead frame 10 may further comprise a connection device 50. The connection device 50 is electrically connected to the connection contacts 40 for electrically contacting a respective stator phase P1, P2, P3 to the inverter 240. As particularly shown in Fig. 2a, Fig. 2b and Fig. 10 and Fig. 6, which show the lead frame 10 without the connecting device 50, the connecting contacts 40 are arranged on the upper side 12a of the annular base body 12 (alternatively, the connecting contacts 40 can be arranged, for example, on another outer surface of the annular base body 12). Accordingly, the connecting device 50 can be arranged as in Fig. 7, Fig. 11a and Fig. 11b, be arranged on the upper side 12a of the annular base body 12. In embodiments, the connection device 50 can be arranged axially above the connection contacts 40. For this purpose, the connection device 50 can comprise, for example, spacer elements. In embodiments of the lead frame, the connection device 50 can be attached to the annular base body 12 in a floating manner. This allows tolerances to be compensated for during assembly of the lead frame 10 in a stator housing 120. "Floating" can be understood as relatively movable (in particular radially and / or circumferentially and / or axially movable) within certain limits such that manufacturing and / or assembly tolerances can be compensated. This can be achieved, for example, by an elastic connecting element (e.g., a spring element or a rubber-like material) between the connection device 50 and the annular base body 12.

[0090] In designs such as the Fig. 11a and Fig. 11b, the connecting device 50 can be fastened to the annular base body 12 via a clip connection. For example, one or more clip arms can engage the underside 12b of the annular base body 12. The clip connection or its clip arm(s) can be designed to be elastic and / or circumferentially movable in order to provide a floating attachment. For example, in the region of a clip arm, a recess can be formed in the annular base body 12, which has a greater width in the circumferential direction 6 than the clip arm, so that the clip arm can move within the recess in the circumferential direction. In this regard, the lead frame 10 of the Fig. 10 corresponding recesses. In the illustrated embodiment, one recess is arranged on the inner circumference 12c and two recesses on the outer circumference 12d. This can provide an increased holding force. In other embodiments, however, more or fewer than three recesses can be provided in the lead frame 10. For example, at least one recess can be arranged on the inner circumference 12c and at least one recess on the outer circumference 12d. The number of clip arms on the connecting device can, in particular, correspond to the number of recesses in the annular base body 12. The connecting device 50 comprises a housing, three main line pins and three cables for electrical connection between the main line pins and the connection contacts 40 (see Fig. 7; Cable only partially inserted into the Fig. 11a and Fig. 11b). The main line pins can be fastened in the housing. In embodiments, the main line pins can be at least partially surrounded by a two-component (2K) overmolding. The 2K overmolding can form a section of the housing or the entire housing of the connection device 50. The 2K overmolding can eliminate the need for additional sealing elements. In particular, the main line pins can protrude from the housing in the axial direction 2 (preferably in the direction away from the annular base body 12 as in Fig. 7, Fig. 11a and Fig. 11b). In some embodiments, the cables may be ultrasonically welded to the terminals 40.

[0091] In embodiments of the lead frame 10, the annular base body 12 may include a radial bulge on which the connection contacts 40 are arranged (not shown in the figures). In particular, the bulge may protrude radially outward beyond the outer circumference 12d.

[0092] In particular with regard to the Fig. 1, Fig. 4b, Fig. 5a, Fig. 5b, Fig. 6, Fig. 7 and Fig. 8, the stator assembly 100 for the electric machine 200 according to the second aspect of the invention is described. The stator assembly 100 comprises a stator 110 and a lead frame 10 according to the first aspect. The stator 110 comprises a plurality of stator teeth 112 wound with winding wire to form a stator winding 114 on a stator tooth 112. The lead frame 10 is arranged at an axial end of the stator 110 and is electrically connected to electrical ends of the stator 110 for connecting the stator phases P1, P2, P3. In particular, the lead frame 10 can be electrically connected to wire ends 115 of the winding wire for connecting the stator phases P1, P2, P3. In embodiments, the lead frame 10 can be electrically connected directly to the wire ends 115 or via electrical connectors 130 to the wire ends 115.In other words, the term "electrically connected" to wire ends can encompass both a direct contacting connection and an electrical connection implemented via an electrical connector 130. The stator assembly 100 with the lead frame 10 can simplify assembly and manufacturing. Furthermore, particularly when using a plug-in connection, the risk of contamination during manufacturing, such as with alternative welding processes, can be eliminated or at least reduced. Furthermore, an axial thickness (relative to an axis of the stator 110) of the stator assembly 100 can be reduced by the lead-level structure of the lead frame 10.

[0093] The Fig. 5a shows an exemplary stator tooth 112 of the stator 110. As already mentioned, the stator tooth 112 is wound with a winding wire to form a stator winding 114. The Fig. Figure 5b shows the stator 110 comprising a plurality of stator teeth 112, wherein the stator teeth 112 are arranged distributed in the circumferential direction 6. In the example shown, the stator 110 is modularly designed with individual (separate) stator teeth 112 that are assembled together. Alternatively, the stator 110 can also be constructed in one piece with a plurality of stator teeth 112. For example, an annular stator yoke with stator teeth projecting radially therefrom can be provided for this purpose. The modular stator teeth 112 or the one-piece stator 110 can be manufactured from conventional laminated cores.

[0094] As can be seen from the Fig. 5a and Fig. As can be seen in Figure 5b, the stator teeth 112 are individually wound with a winding wire. Thus, each stator tooth 112 or each stator winding 114 has two wire ends 115. As already explained above, the stator phases P1, P2, P3 are arranged in two phase groups of six contact elements 30 or three stator teeth 112 each (see Fig. 5b). The stator teeth 112 or the stator windings 114 and their wire ends 115 at positions S7, S8, S9, S 10 , S 11 , S 12For example, they form a phase group of the stator phase P2 (or V). As also already mentioned above, in alternative embodiments, the stator teeth 112 of a phase group can also be wound in winding groups with a common winding wire. In such an example, the winding group with the three wound stator teeth 112 would only be contacted with the lead frame 10 via two wire ends 115. The phase groups and / or winding groups can also comprise a different number of adjacent stator teeth 112, for example two or four (or more) stator teeth 112. In further alternative embodiments, the stator teeth can also not be arranged in phase groups, but one stator tooth 112 or one stator winding 114 of the first stator phase P1, the second stator phase P2, and then the third stator phase P3 could follow one another in the circumferential direction 6 (not shown in the figures).

[0095] In particularly advantageous embodiments, the stator arrangement 100 further comprises a plurality of electrical connectors 130 (see Fig. 4b, Fig. 5a, Fig. 5b and Fig. 6). A respective wire end 115 of the winding wire can be electrically connected to the lead frame 10 via one of the plurality of electrical connectors 130.

[0096] The stator 110 further comprises several receiving sections 117 (see Fig. 4b, Fig. 5a and Fig. 5b). The receiving sections 117 are configured to receive the wire ends 115 and to receive electrical connectors 130. In particular, the receiving sections 117 can be configured such that, by receiving the electrical connectors 130, the wire ends 115 received in the receiving section 117 are electrically connected to the electrical connector 130. Subsequently, an electrical connection of the stator phases P1, P2, P3 can be achieved by simply contacting the electrical connectors 130 with the lead frame 10.

[0097] A respective receiving section 117 may include a wire end receiving area 117a, a connector receiving area 117b and a lead frame receiving area 117c (see Fig. 4b). The wire end receiving area 117a is configured to receive a wire end 115. In particular, a respective wire end 115 can be arranged at least partially in a respective wire end receiving area 117a. The connector receiving area 117b is configured to receive an electrical connector 130. In particular, the electrical connectors 130 can be arranged at least partially in a respective connector receiving area. In particular, the wire end receiving area 117a and the connector receiving area 117b can be arranged crossing one another, so that when an electrical connector 130 is inserted into a connector receiving area 117b, a wire end arranged in the wire end receiving area 117a is cut by the electrical connector 130 in an electrically contacting manner (see Fig. 4b, Fig. 5a and Fig. 5b).

[0098] In some embodiments, a respective receiving section 117 may include a lead frame receiving area 117c configured to support the lead frame 10 (see Fig. 4b).

[0099] In some embodiments, the stator may include a stator end cap 116. The receiving sections 117 may be integrated into the stator end cap 116 of the stator 110. For example, the stator may be overmolded with the stator end cap 116. The stator end cap 116 may, for example, be made of a plastic material. In embodiments, the stator end cap 116 may be one-piece or, as in Fig. 5a, the winding wire can be formed in several parts with several stator end cap sections 116, each on a stator tooth 112. The stator end cap 116 is arranged at least at the axial end of a stator tooth 112 or the stator teeth 112. The winding wire can be wound at least partially around the stator end cap 116 (see Fig. 5a).

[0100] A respective electrical connector 130 can in particular comprise a press-in section 132 and an insulation displacement section 134. The press-in section 132 is configured for electrical contact with the lead frame 10. The insulation displacement section 134 is configured for electrical contact with a wire end 115. The press-in section 132 and the insulation displacement section 134 can in particular be formed at axially opposite end regions of the electrical connector 130. The electrical connectors 130 can each be arranged in the receiving section 117 such that a press-in section 132 of an electrical connector 130 protrudes from the receiving section 117 (see Fig. 5b). The press-in sections 132 are connected, in particular electrically connected, to the line arrangement 10 or its contact elements 30. In particular, in FIG. 1, the press-in sections 132 are pressed through the openings 32 in the passages 34 of the contact elements 30. As shown in the Fig. 4b and Fig. 6, the lead frame 10 can be placed or pressed onto the press-in sections 132. In more general terms, the press-in section 132 of an electrical connector 130 can be connected to a contact element 30 of the lead frame 10, in particular pressed into a respective contact element 30. A respective insulation displacement section 134 is plugged onto a respective wire end 115. By plugging the insulation displacement section 134 onto the winding wire or its wire ends 115, contact or electrical connection between the electrical connector 130 and the respective wire end 115 can be achieved by a cold welding process. This, in turn, makes it possible to electrically contact or interconnect the stator windings 114 or stator phases P1, P2, P3 by simply connecting (in particular plugging) the lead frame 10 to the electrical connectors 130.Alternatively, the lead frame 10 can be plugged, in particular pressed, onto the electrical connectors 130 for electrically contacting the stator windings 114. In particular, the lead frame 10 can be plugged, in particular pressed, onto the electrical connectors 130 via the contact elements 30.

[0101] As in Fig. 1, the stator assembly 100 may further comprise a potting body 140 and a stator housing 120. The stator housing 120 may define an annular receiving area with a peripheral portion 122 and an annular end wall 124 (see also Fig. 8). The stator 110 can be arranged with the lead frame 10 in the receiving area, so that the lead frame 10 is arranged adjacent to the annular end wall 124. In particular, the stator 110 can be arranged on the peripheral section 122. In embodiments, the stator 110 can be potted with the lead frame 10 in the receiving area. Due to the potting body 140 arranged between the stator housing 120 and the stator 110 with the lead frame 10, the stator 110 with the lead frame 10 can be at least partially embedded in the potting body 140 (see Fig. 1). In embodiments, the stator housing 120 may further include a passage 126 in the annular end wall 124 (see Fig. 8). The connection device 50 of the lead frame 10 can protrude at least partially through the passage 126 to the outside of the stator housing 110 or its axial end wall 124 (see Fig. 1).

[0102] In some embodiments, the potting body 140 may comprise a resin material. In particular, the potting body 140 may comprise a synthetic resin material. In some embodiments, the potting body 140 may comprise heat-conducting particles. In particular, the heat-conducting particles may be made of a non-metallic material. This may prevent or at least reduce impairment of the electrical and / or magnetic insulation effect of the potting body 140. For example, the potting body 140 may comprise glass fibers.

[0103] The Fig.9 shows a schematic flow diagram of a method 300 for producing a stator arrangement 100 for an electric machine 200 according to the fourth aspect. The method 300 comprises providing 310 a stator 110 having a plurality of stator teeth 212. The stator teeth 112 are wound with stator windings 114 having electrical ends. Furthermore, the method 300 comprises providing 320 a lead frame 10 according to the first aspect. Furthermore, the method 300 comprises contacting 330 the stator windings 114 by contacting electrical ends of the stator windings 114 with the contact elements 30 of the lead frame 10.

[0104] In embodiments of method 300, an electrical connector 130 may be clamped onto a respective wire end 115 of the stator windings 114 to form electrical ends of the stator 110. The wire ends 115 of the stator windings 114 may be pressed into an insulation displacement portion 134 of a respective electrical connector 130.

[0105] In embodiments of method 300, the electrical ends can be provided by inserting wire ends 115 into a wire end receiving area 117a of stator 110 and inserting an electrical connector 130 into a connector receiving area 117b of stator 110. An insulation displacement portion 134 of electrical connector 130 can establish electrical contact with the respective wire end 115.

[0106] In embodiments of the method 300, the contacting 330 of electrical ends can comprise placing the lead frame 10 onto the stator 110. In particular, the contacting 330 of electrical ends can comprise placing the lead frame 10 onto the electrical ends that protrude substantially in the axial direction from the stator 110. Preferably, the contacting 330 of electrical ends can comprise pressing the lead frame 10 onto the electrical ends that protrude substantially in the axial direction from the stator 110. In particular, the contacting 330 of electrical ends can comprise placing and / or pressing the lead frame 10 onto electrical connectors 130 that protrude axially from the stator, in particular their press-in sections 132. In embodiments, the lead frame 10 can be placed or pressed onto the electrical ends in the axial direction 2.

[0107] In embodiments of the method 300, the contacting 330 of electrical ends may comprise pressing electrical connectors 130 connected to the wire ends 115 of the stator windings 114 into the contact elements 30 of the lead frame 10. In particular, the contacting 330 may comprise pressing press-in sections 132 into the contact elements 30 or into their opening 32 on the underside 12b.

[0108] In embodiments of the method 300, the method 300 may further comprise providing 340 a stator housing 120. The stator housing 120 defines an annular receiving area with a peripheral portion 122 and an annular end wall 124.

[0109] Furthermore, the method 300 can comprise introducing 350 the contacted stator 110 with the lead frame 10 arranged axially thereon into the receiving area of ​​the stator housing 120. In embodiments, the contacted stator 110 with the lead frame 10 can first be introduced into the stator housing 120 in the axial direction 2, so that the lead frame 10 is arranged adjacent to the annular end wall 124. In particular, the contacted stator 110 with the lead frame 10 can then be introduced into the stator housing 120 such that the upper side 12a of the lead frame 10 is arranged adjacent to the annular end wall 124. In embodiments, a connection device 50 of the lead frame 10 can be guided at least partially through a passage 126 in the annular end wall 124 to the outside of the stator housing 120 during introduction.As a result, an inverter 240 can be electrically connected to the lead frame 10 outside the stator housing 120 via the connection device 50.

[0110] In addition, the method 300 can include potting 360 the stator 110 with the lead frame 10 in the stator housing 120 by filling potting compound into the receiving area, whereby after the potting compound has hardened, a potting body 140 is formed between the stator 110 contacted with the lead frame 10 and the stator housing 120. By potting, the stator 110 contacted with the lead frame 10 can be fixed in the potting body 140 and thus in the stator housing 120 after the potting compound has hardened.

[0111] In embodiments of method 300, a resin material, in particular a synthetic resin material, can be used as the potting compound. In embodiments, the potting compound can be provided with heat-conducting fillers.

[0112] Although the present invention has been described above and defined in the appended claims, it should be understood that the invention may alternatively be defined according to the following embodiments: 1. Lead frame (10) for electrically contacting stator windings (114) of a three-phase stator (110), comprising: an annular base body (12) with an upper side (12a) and a lower side (12b); three connection contacts (40) for the inverter-side electrical contacting of a respective stator phase (P1, P2, P3) to an inverter (240); a plurality of axially insulated line levels (20) arranged in the annular base body (12), wherein the line levels (20) have a plurality of line sections (22) spaced apart in the circumferential direction (6); a plurality of electrically conductive contact elements (30) extending axially through the annular base body (12) and arranged radially spaced from the line sections (22), wherein the contact elements (30) are arranged distributed in the circumferential direction (6); wherein the line levels (20) further comprise line tongues (24) projecting radially from the line sections (22) and electrically connecting the line sections (22) to the contact elements (30), wherein the line tongues (24) are arranged such that the line levels (20) and the contact elements (30) provide an electrical connection of the stator phases (P1, P2, P3) between the contact elements (30) and the connection contacts (40), wherein at least some of the plurality of contact elements (30) are designed for electrical contact with the stator windings (114). 2. Lead frame (10) according to embodiment 1, wherein at least some of the plurality of contact elements (30) have an opening (32) on the underside (12b) for electrical contact with the stator windings (114), in particular so that the lead frame (10) can be placed on electrical ends of the stator (110). 3. Lead frame (10) according to embodiment 2, wherein at least some of the plurality of contact elements (30) have a passage (34) extending from the opening (32) to the top side (12a). 4. Lead frame (10) according to embodiment 3, wherein the passage (34) is tapered towards the top side (12). 5. Lead frame (10) according to any one of embodiments 1 to 4, wherein at least some of the plurality of contact elements (30) are designed for press-fitting electrical connectors (130) of the stator windings (114) of the stator (110), in particular such that the lead frame (10) can be pressed onto the electrical connectors (130). 6. Lead frame (10) according to any one of the preceding embodiments, wherein the at least some of the plurality of contact elements (30) are provided in a number of wire ends (115) present in the stator (110) to be contacted. 7. Lead frame (10) according to any one of the preceding embodiments, wherein at least some of the plurality of contact elements (30) are provided in a number of 6 to 72, in particular 12 to 36. 8. Lead frame (10) according to any one of the preceding embodiments, wherein the plurality of contact elements (30) are provided in a number of 6 to 72, in particular 12 to 36. 9. Lead frame (10) according to any one of the preceding embodiments, wherein the contact elements (30) are arranged at positions (S i ) are arranged, which are assigned to regions of stator windings (112) of a respective stator phase (P1, P2, P3). 10. Lead frame (10) according to embodiment 9, wherein the lead tongues (24) are only at those positions (S i ) are arranged in a respective line level (20) which is required for the electrical connection of the stator phases (P1, P2, P3) of the line section (22) connected to the line tongue (24). 11. Lead frame (10) according to any one of the preceding embodiments, wherein the contact elements (30) are arranged radially inside and / or radially outside the lead sections (22). 12. Lead frame (10) according to any one of the preceding embodiments, wherein the contact elements (30) are arranged at a distance from an inner circumference (12c) of the annular base body (12) and / or from an outer circumference (12d) of the annular base body (12). 13. Lead frame (10) according to any one of the preceding embodiments, wherein a radial width of the annular base body (12) between an inner diameter of the annular base body (12) and an outer diameter of the annular base body (12) is 20 mm or more, preferably 30 mm or more, and particularly preferably 40 mm or more. 14. Lead frame (10) according to any one of the preceding embodiments, wherein the lead sections (22) extend at least in sections in the radial direction (4) at least over 40%, preferably at least over 50% and particularly preferably at least over 60% of a radial width of the annular base body (12) between an inner diameter of the annular base body (12) and an outer diameter of the annular base body (12). 15. Lead frame (10) according to any one of the preceding embodiments, wherein an axial thickness of the lead planes (20) is at least 50 times smaller, preferably at least 100 times smaller, and particularly preferably at least 200 times smaller than a radial width of the lead planes (20). 16. Lead frame (10) according to any one of the preceding embodiments, wherein an axial thickness of the lead planes (20) is 200µm or less, preferably 150µm or less, and particularly preferably 125µm or less. 17. Lead frame (10) according to any one of the preceding embodiments, wherein an axial thickness of the annular base body (12) is 1 mm to 3 mm, preferably 1.2 mm to 2 mm, and particularly preferably 1.4 mm to 1.8 mm. 18. Lead frame (10) according to any one of the preceding embodiments, wherein the annular base body (12) has a multi-layer printed circuit board structure. 19. Lead frame (10) according to any one of the preceding embodiments, wherein the lead levels are embedded in the substrate, in particular wherein the lead levels are electrically insulated from one another by the substrate. 20. Lead frame (10) according to any one of the preceding embodiments, wherein at least three lead levels (20), in particular at least six lead levels (20) are arranged in the annular base body (12). 21. Lead frame (10) according to any one of the preceding embodiments, wherein each lead level (20) has at least two, preferably at least three, and particularly preferably at least four lead sections (22) spaced apart from one another in the circumferential direction (6). 22. Lead frame (10) according to any one of the preceding embodiments, wherein the lead sections (22) extend in the circumferential direction (6). 23. Lead frame (10) according to any one of the preceding embodiments, wherein each lead section (22) is connected to at least one lead tongue (24). 24. Lead frame (10) according to any one of the preceding embodiments, wherein the lead tongues (24) surround the contact elements (30) in the radial direction (2) and in the circumferential direction (6), in particular completely in the radial direction (2) and in the circumferential direction (6). 25. Lead frame (10) according to any one of the preceding embodiments, wherein the lead planes (20) are configured to provide a star connection or a delta connection of the stator phases (P1, P2, P3). 26. Lead frame (10) according to any one of the preceding embodiments, wherein the connection contacts (40) are electrically connected directly and / or via at least one conductor pin arrangement to a line section (22) in at least one line level (20). 27. Lead frame (10) according to any one of the preceding embodiments, wherein the annular base body (12) comprises a radial bulge on which the connection contacts (40) are arranged. 28. Lead frame (10) according to any one of the preceding embodiments, further comprising a connection device (50) which is electrically connected to the connection contacts (40) for electrically contacting a respective stator phase (P1, P2, P3) to the inverter (240). 29. Lead frame (10) according to embodiment 28, wherein the connecting device (50) is arranged on the upper side (12a) of the annular base body (12). 30. Lead frame (10) according to any one of embodiments 28 or 29, wherein the connecting device (50) is floatingly attached to the annular base body (12). 31. Lead frame (10) according to any one of embodiments 28 to 30, wherein the connection device (50) comprises a housing, three main line pins and three cables for electrical connection between the main line pins and the connection contacts (40), wherein the main line pins are fixed in the housing and protrude from the housing in the axial direction (2). 32. Stator assembly (100) for an electrical machine (200), the stator assembly (100) comprising: a stator (110) having a plurality of stator teeth (112) wound with winding wire to form a stator winding (114) on a stator tooth (112), a lead frame (10) according to any one of the preceding embodiments, wherein the lead frame (10) is arranged at an axial end of the stator (110) and is electrically connected to electrical ends of the stator (110) for interconnecting the stator phases (P1, P2, P3). 33. Stator arrangement (100) according to embodiment 32, wherein the stator teeth (112) are wound with a winding wire individually or in winding groups of the same stator phase (P1, P2, P3). 34. The stator assembly (100) of any one of embodiments 32 or 33, further comprising a plurality of electrical connectors (130), wherein a respective wire end (115) of the winding wire is electrically connected to the lead frame (10) via one of the plurality of electrical connectors (130). 35. Stator arrangement (100) according to embodiment 34, wherein the lead frame (10) is plugged, in particular pressed, onto the electrical connectors (130) for electrically contacting the stator windings (114). 36. Stator assembly (100) according to any one of embodiments 34 or 35, wherein the electrical connectors (130) have a press-in portion (132) that communicates with the contact elements (30). 37. Stator arrangement (100) according to any one of embodiments 34 to 36, wherein the electrical connectors (130) are designed as insulation displacement connectors with an insulation displacement portion (134), wherein a respective insulation displacement portion (134) is plugged onto a respective wire end (115). 38. The stator assembly (100) of any of embodiments 32 to 37, wherein the stator (110) further comprises a plurality of receiving portions (117) configured to receive the wire ends (115) and to receive electrical connectors (130). 39. Stator assembly (100) according to embodiment 38, wherein the receiving sections (117) comprise a respective wire end receiving area (117a) configured to receive a respective wire end (115). 40. The stator assembly (100) of any of embodiments 38 or 39, wherein the receiving portions (117) comprise a respective connector receiving area (117b) configured to receive a respective electrical connector (130). 41. Stator arrangement (100) according to embodiments 39 and 40, wherein the wire end receiving region (117a) and the connector receiving region (117b) are arranged to cross one another, so that when an electrical connector (130) is inserted into a connector receiving region (117b), a wire end arranged in the wire end receiving region (117a) is cut by the electrical connector (130) in an electrically contacting manner. 42. Stator assembly (100) according to any one of embodiments 38 to 41, when at least dependent on embodiment 34, wherein the electrical connectors (130) are each arranged in a receiving portion (117) such that a press-in portion (132) of an electrical connector (130) protrudes from the receiving portion (117) and is connected to the line assembly (10). 43. The stator assembly (100) of any of embodiments 38 to 42, wherein the receiving portions (117) comprise a respective lead frame receiving area (117c) configured to support the lead frame (10). 44. Stator assembly (100) according to any one of embodiments 38 to 43, wherein the receiving portions (117) are integrated into a stator end cap (116) of the stator (110). 45. Stator assembly (100) according to any one of embodiments 32 to 44, further comprising a potting body (140) and a stator housing (120) defining an annular receiving area with a peripheral portion (122) and an annular end wall (124), wherein the stator (110) is arranged with the lead frame (10) in the receiving area, so that the lead frame (10) is arranged adjacent to the annular end wall (124). 46. ​​Stator arrangement (100) according to embodiment 45, wherein the stator (110) is cast with the lead frame (10) in the receiving area and is at least partially embedded in the cast body (140) by the cast body (140) arranged between the stator housing (120) and the stator (110) with the lead frame (10). 47. The stator assembly (100) of any of embodiments 45 to 46, wherein the stator housing (120) further comprises a passage (126) in the annular end wall (124), wherein a lead frame terminal device (50) extends at least partially through the passage (126) to the exterior of the stator housing (110). 48. Electrical machine (200), in particular electric motor (200), comprising: a machine housing (210), a shaft (230) which is rotatably mounted in the machine housing (210), at least one rotor (220) which is arranged in a rotationally fixed manner on the shaft (230) in the machine housing (210), a stator assembly (100) according to any one of embodiments 32 to 47, wherein the stator (110) is arranged adjacent to the rotor (220) in the machine housing (210), and an inverter (240) for controlling the stator (110), wherein the inverter (240) is electrically connected to the lead frame (10). 49. Electrical machine (200) according to embodiment 48, wherein the inverter (240) is electrically connected to the lead frame (10) via a connection device (50). 50. The electric machine (200) of any of embodiments 48 or 49, wherein the stator (110) is disposed radially adjacent to the rotor (220) in the machine housing (210). 51. Electrical machine (200) according to embodiment 50, wherein the rotor (220) is formed externally and comprises a plurality of rotor poles (222) which are arranged distributed in the circumferential direction (6) on a rotor body (224) of the rotor (220). 52. The electric machine (200) according to any one of embodiments 48 to 51, wherein the machine housing (210) comprises a rotor housing (212) and a stator housing (120), wherein the rotor housing (212) and the stator housing (120) are non-positively connected to one another. 53. A method (300) for producing a stator arrangement (100) for an electrical machine (200), comprising the steps: Providing (310) a stator (110) having a plurality of stator teeth (212) wound with stator windings (114) having electrical ends, Providing (320) a lead frame (10) according to any one of embodiments 1 to 31, Contacting (330) the stator windings (114) by contacting electrical ends of the stator windings (114) with the contact elements (30) of the lead frame (10). 54. The method (300) of embodiment 53, wherein an electrical connector (130) is clamped onto a respective wire end (115) of the stator windings (114) to form electrical ends of the stator (110). 55. The method (300) according to embodiment 54, wherein the wire ends (115) of the stator windings (114) are pressed into an insulation displacement portion (134) of a respective electrical connector (130). 56. The method (300) according to any one of embodiments 53 to 55, wherein the electrical ends are provided by inserting wire ends (115) into a wire end receiving area (117a) of the stator (110) and inserting an electrical connector (130) into a connector receiving area (117b) of the stator (110), wherein an insulation displacement portion (134) of the electrical connector (130) makes electrical contact with the respective wire end (115). 57. Method (300) according to any one of embodiments 53 to 56, wherein the contacting (330) of electrical ends comprises placing, in particular pressing, the lead frame (10) onto the electrical ends projecting substantially in the axial direction (2) from the stator (110). 58. The method (300) according to any one of embodiments 53 to 57, wherein contacting electrical ends comprises pressing electrical connectors (130) connected to the wire ends (115) of the stator windings (114) into the contact elements (30) of the lead frame (10). 59. The method (300) of any of embodiments 53 to 58, further comprising: Providing (340) a stator housing (120) defining an annular receiving area with a peripheral portion (122) and an annular end wall (124), Inserting (350) the contacted stator (110) with the lead frame (10) arranged axially thereon into the receiving area of ​​the stator housing (120), Casting (360) of the stator (110) with the lead frame (10) in the stator housing (120) by filling casting compound into the receiving area, whereby after the casting compound has hardened, a casting body (140) is formed between the stator (110) contacted with the lead frame (10) and the stator housing (120). 60. Method (300) according to embodiment 59, wherein the contacted stator (110) with the lead frame (10) is first introduced into the stator housing (120) in the axial direction (2), so that the lead frame (10) is arranged adjacent to the annular end wall (124). 61. Method (300) according to embodiment 60, wherein a connecting device (50) of the lead frame (10) is guided at least partially through a passage (126) in the annular end wall (124) to the outside of the stator housing (120) during insertion. 62. Method according to any one of embodiments 59 to 61, wherein a resin material, in particular a synthetic resin material, is used as the potting compound, which is optionally provided with heat-conducting fillers. List of reference symbols 2 Axial direction 4 Radial direction 6 Circumferential direction 10 lead frames 12 basic bodies 12a top 12b bottom 12c inner circumference 12d outer circumference 20 management level 22 line sections 24 cable tongue 30 contact element 32 Opening 34 passage 40 connection contact 50 connection device 100 Stator arrangement 110 Stator 112 stator tooth 114 Stator winding 115 winding end 116 Stator end cap 117 Recording section 117a Wire end receiving area 117b Connector receiving area 117c Lead frame receiving area 120 stator housing 122 circumferential section 124 Annular end wall 126 Inverter passage 130 connectors; insulation displacement connectors 132 press-fit section 134 insulation displacement section 140 casting bodies 200 Electric Machine 210 machine housing 212 rotor housing 220 rotor 222 rotor magnet 224 rotor body 230 Wave 240 inverters

Claims

[1] Lead frame (10) for electrically contacting stator windings (114) of a three-phase stator (110), comprising: an annular base body (12) with an upper side (12a) and a lower side (12b); three connection contacts (40) for the inverter-side electrical contacting of a respective stator phase (P1, P2, P3) to an inverter (240); a plurality of axially insulated line levels (20) arranged in the annular base body (12), wherein the line levels (20) have a plurality of line sections (22) spaced apart in the circumferential direction (6); a plurality of electrically conductive contact elements (30) extending axially through the annular base body (12) and arranged radially spaced from the line sections (22), wherein the contact elements (30) are arranged distributed in the circumferential direction (6); wherein the line levels (20) further comprise line tongues (24) projecting radially from the line sections (22) and electrically connecting the line sections (22) to the contact elements (30), wherein the line tongues (24) are arranged such that an electrical connection of the stator phases (P1, P2, P3) between the contact elements (30) and the connection contacts (40) is provided by the line levels (20) and the contact elements (30), wherein at least some of the plurality of contact elements (30) are designed for electrical contact with the stator windings (114). [2] Lead frame (10) according to claim 1, wherein at least some of the plurality of contact elements (30) have an opening (32) on the underside (12b) for electrical contact with the stator windings (114), in particular so that the lead frame (10) can be placed on electrical ends of the stator (110), and optionally, wherein at least some of the plurality of contact elements (30) have a passage (34) extending from the opening (32) to the top side (12a). [3] Lead frame (10) according to any one of claims 1 or 2, wherein at least some of the plurality of contact elements (30) are designed for press-fitting electrical connectors (130) of the stator windings (114) of the stator (110), in particular so that the lead frame (10) can be pressed onto the electrical connectors (130). [4] Lead frame (10) according to any one of the preceding claims, wherein the at least some of the plurality of contact elements (30) are provided in a number of wire ends (115) present in the stator (110) to be contacted. [5] Lead frame (10) according to any one of the preceding claims, wherein the contact elements (30) are arranged radially inside and / or radially outside the lead sections (22). [6] Lead frame (10) according to any one of the preceding claims, wherein the lead sections (22) extend at least in sections in the radial direction (4) at least over 40%, preferably at least over 50% and particularly preferably at least over 60% of a radial width of the annular base body (12) between an inner diameter of the annular base body (12) and an outer diameter of the annular base body (12). [7] Lead frame (10) according to any one of the preceding claims, wherein an axial thickness of the lead planes (20) is at least 50 times smaller, preferably at least 100 times smaller, and particularly preferably at least 200 times smaller than a radial width of the lead planes (20). [8] Lead frame (10) according to any one of the preceding claims, wherein an axial thickness of the lead planes (20) is 200µm or less, preferably 150µm or less, and particularly preferably 125µm or less. [9] Lead frame (10) according to any one of the preceding claims, wherein each lead level (20) has at least two, preferably at least three, and particularly preferably at least four lead sections (22) spaced apart from one another in the circumferential direction (6). [10] Lead frame (10) according to any one of the preceding claims, further comprising a connection device (50) which is electrically connected to the connection contacts (40) for electrically contacting a respective stator phase (P1, P2, P3) to the inverter (240), and optionally, wherein the connection device (50) is floatingly attached to the annular base body (12). [11] Stator assembly (100) for an electrical machine (200), the stator assembly (100) comprising: a stator (110) having a plurality of stator teeth (112) wound with winding wire to form a stator winding (114) on a stator tooth (112), a lead frame (10) according to any one of the preceding claims, wherein the lead frame (10) is arranged at an axial end of the stator (110) and is electrically connected to electrical ends of the stator (110) for interconnecting the stator phases (P1, P2, P3). [12] Stator arrangement (100) according to claim 11, further comprising a plurality of electrical connectors (130), wherein a respective wire end (115) of the winding wire is electrically connected to the lead frame (10) via one of the plurality of electrical connectors (130), and optionally, wherein the lead frame (10) is plugged, in particular pressed, onto the electrical connectors (130) for electrically contacting the stator windings (114). [13] The stator assembly (100) of any one of claims 11 or 12, wherein the stator (110) further comprises a plurality of receiving portions (117) configured to receive the wire ends (115) and to receive electrical connectors (130). [14] Electric machine (200), in particular electric motor (200), comprising: a machine housing (210), a shaft (230) which is rotatably mounted in the machine housing (210), at least one rotor (220) which is arranged in a rotationally fixed manner on the shaft (230) in the machine housing (210), a stator assembly (100) according to any one of claims 11 to 13, wherein the stator (110) is arranged adjacent to the rotor (220) in the machine housing (210), and an inverter (240) for controlling the stator (110), wherein the inverter (240) is electrically connected to the lead frame (10). [15] Method (300) for producing a stator arrangement (100) for an electrical machine (200) comprising the steps: Providing (310) a stator (110) having a plurality of stator teeth (212) wound with stator windings (114) having electrical ends, Providing (320) a lead frame (10) according to any one of claims 1 to 10, Contacting (330) the stator windings (114) by contacting electrical ends of the stator windings (114) with the contact elements (30) of the lead frame (10).

Images