Component with an integrated conductor track connector, and assembly

Abstract

The invention relates to a component (101) with an integrated conductor track connector (1), having a plurality of electrical conductors (2), in particular as a stamped grid; a first overmoulding (3) which at least partially encases the electrical conductors (2) and defines an arrangement of the electrical conductors (2) for forming the conductor track connector (1); and at least a second overmoulding (4) which at least partially encases the first overmoulding (3) and forms a component section of the component (101), wherein at least the first overmoulding (3) has at least one resilient and / or fixing structure (7) which is designed to cushion the component (101) with respect to an adjacent second component (102) and / or fix the component on said second component. The invention also relates to an assembly (100) having the component (101) with an integrated conductor track connector (1).

Description

[0001] Component with an integrated conductor track connector and assembly

[0002] Description

[0003] The invention relates to a component with an integrated conductor track connector and an assembly comprising the component with the integrated conductor track connector.

[0004] Conventional stamped grid connectors comprise a plurality of electrical conductors that are stamped from a metal plate and overmolded with a solid plastic, the stamped grid connector. This plastic ensures the relative positioning of the electrical conductors to one another and forms the stamped grid connector. This is joined to a higher-level component in a subsequent process. This higher-level component is then assembled into an overall assembly. In order to compensate for individual part and joining tolerances in the higher-level assembly of the interconnected components, a separate component, such as a rubber-like component, is conventionally arranged between the stamped grid connector and the adjacent component. This results in additional costs. The weight of the assembly also increases as a result. Furthermore, the assembly process for such an assembly is very complex.Such lead frame connectors do not perform any further function in the higher-level assembly.

[0005] The object of the invention is to provide a component with an integrated conductor track connector that is cost-effective and enables time- and cost-efficient assembly of the same in an assembly. It is also an object of the invention to provide an assembly with these advantages.

[0006] These objects are achieved by the features of the subordinate claims. The subclaims contain advantageous embodiments of the invention.

[0007] The objects are achieved in particular by a component according to the invention with an integrated conductor track connector. The component has a plurality of electrical conductors, a first overmolding, and at least one second overmolding. The first overmolding at least partially encloses the electrical conductors and defines an arrangement of the electrical conductors to form the conductor track connector. The second overmolding at least partially encloses the first overmolding and forms a component section of the component. At least the first overmolding has at least one resilient and / or fixing structure that cushions the component relative to an adjacent second component and / or fixes it to it.

[0008] As a result, the first overmolding enables an integral cushioning and / or fixing function of the conductor track connector integrated in the component, which in particular eliminates the need to provide additional cushioning and / or fixing structures. The integral cushioning and / or fixing structure is preferably in contact with the adjacent second component in an assembled state of the component.

[0009] Advantageously, the first overmolding, together with the electrical conductors, forms the conductor track connector. The second overmolding advantageously forms the (remaining) component, wherein the second overmolding at least partially encases the first overmolding and the electrical conductors, so that the conductor track connector is integrated into the component. The at least one second overmolding forms the component sections of the component, wherein the component comprises the component sections and the conductor track connector.

[0010] The component can advantageously have a plurality of first overmoldings. Such a plurality of overmoldings are preferably formed in a multi-component injection molding process or formed in several individual injection molding processes successively.

[0011] Particularly preferably, the component has exactly one second overmolding. Particularly preferably, the component has exactly one first overmolding.

[0012] It is particularly advantageous if the plurality of electrical conductors is formed as a lead frame. Alternatively or additionally, at least one electrical conductor can be formed by etching a metal layer and, together with the first overmolding, form a printed circuit board. In other words, in an alternative embodiment, the conductor track connector is a printed circuit board integrated into the component.

[0013] Advantageously, the first overmolding and the at least one second overmolding have different material properties. The first overmolding and the at least one second overmolding differ, in particular, in their elasticity. Particularly preferably, the first overmolding is easier to elastically deform than the second overmolding and thus, in particular, has a lower modulus of elasticity than the second overmolding. For example, the first overmolding is formed from an elastic plastic. Preferably, the at least one second overmolding is formed from a solid and / or hard plastic.

[0014] Preferably, the resilient structure of the first overmolding is a projection, wherein the projection in particular has a higher elasticity than the second overmolding. Preferably, the projection protrudes from a surface of the first overmolding, in particular in the direction of the adjacent component. In an assembled state, the projection is advantageously in contact with the adjacent component. Particularly preferably, the projection extends along a projection extension direction perpendicular to an extension direction or length direction of the electrical conductors. In an advantageous embodiment, the at least one resilient structure of the first overmolding is spiral-shaped, leaf-spring-shaped, or wave-shaped. In this case, several resilient structures can preferably be present, which have different shapes.

[0015] Preferably, the at least one fixing structure is a clamp and / or a hook configured to engage the adjacent second component and fix the component thereto. Preferably, the configuration of at least one structure as a fixing clamp or as a fixing hook is combined with the configuration of the same structure as a resilient one (fixing and resilient structure). For example, such a resilient and fixing structure is configured as a spring-loaded clamp or as a leaf-spring-shaped hook.

[0016] Preferably, the at least one fixing structure is a screw tube configured to accommodate a screw for fixing the component to the adjacent second component. The structure formed as a screw tube is preferably fixing and resilient. The fixing and resilient screw tube advantageously exhibits greater elasticity than the second overmolding.

[0017] In an advantageous embodiment, the first overmolding is formed from an elastic material. The first overmolding is advantageously formed from an elastic plastic, in particular from a thermoplastic and / or elastomer. Advantageously, the elasticity of the first overmolding is higher than that of the second overmolding at the same temperature. Elasticity preferably refers to an intrinsic material property of the first overmolding and the second overmolding, which is independent of the geometric configuration of the corresponding overmolding.

[0018] Advantageously, the second overmolding is made of a solid plastic.

[0019] Preferably, the first overmolding and the at least one resilient and / or fixing structure are formed together as an injection-molded component.

[0020] Preferably, the first overmolding and at least one second overmolding are formed together as a multi-component injection-molded component. It is particularly preferred if the first overmolding and all second overmoldings, in particular a single second overmolding, are formed together as an injection-molded component, in particular a multi-component injection-molded component. Preferably, the first overmolding and the at least one second overmolding are formed together as a two-component injection-molded component, wherein the first overmolding comprises a first component and the second overmolding comprises the second component. Advantageously, to produce the component with an integrated conductor track connector according to the invention, the electrical conductors, preferably as a lead frame, are first introduced into a first tool, in particular a first injection-molded tool, and are overmolded with the first overmolding.This results in the conductor connector as a semi-finished product (of the component). The conductor connector formed in this way has at least one resilient and / or fixing structure (integral). The conductor connector is then inserted into a second tool, which is different from the first tool, and overmolded with the second overmolding. This results in the component with the integrated conductor connector. The second overmolding or the second tool essentially defines the geometry of the component.

[0021] In an advantageous embodiment, the injection-molded material of the first overmolding has greater elasticity than that of the second overmolding. This advantageously creates a substantially gas-tight connection between the first overmolding (the conductor track connector) and the second overmolding during the formation of the second overmolding, thereby preventing or reducing corrosion of the electrical conductors.

[0022] The invention also relates to an assembly. The assembly comprises the component with an integrated conductor track connector according to one of the preceding embodiments. The component with an integrated conductor track connector is preferably a stator cover (with an integrated conductor track connector). The assembly also comprises a second component adjacent to the component with an integrated conductor track connector. The adjacent second component is, in particular, a stator of an electrical machine. The assembly also comprises a third component, which is connected to the component with an integrated conductor track connector. The third component is, in particular, a stator holder. The second component is clamped between the first overmolding of the component with an integrated conductor track connector and the third component.

[0023] The first overmolding of the component with integrated conductor track connector is configured, in particular, to at least partially compensate for individual part tolerances and / or assembly tolerances between the components by means of at least one resilient structure and / or to fix the first component to the second component by means of at least one fixing structure. In advantageous embodiments of the structure as resilient and fixing, the first overmolding is configured to at least partially compensate for individual part and / or assembly tolerances between the components and simultaneously fix the first component to the second component.

[0024] Particularly preferably, the second component is a housing of the stator of the electrical machine. The conductor track connector is preferably configured to be connected to the stator of the electrical machine in a current-carrying and / or signal-carrying manner. The stator cover preferably covers the stator in an assembled state.

[0025] It is particularly preferred if the stator cover (second overmolding) is formed by overmolding the conductor track connector (first overmolding) and the integral connection formed as a common component in this way, consisting of the conductor track connector and the stator cover, is assembled with the stator / stator housing (second component) in order to cover the stator / stator housing and to enable an electrical connection.

[0026] The component with the integrated conductor connector is connected to the third component. These components are preferably welded and / or screwed and / or glued and / or clipped together.

[0027] Further details, advantages, and features of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawings. It shows:

[0028] Fig. 1 is a schematic detailed view of a conductor track connector of a component according to a first embodiment of the present invention;

[0029] Fig. 2 is a schematic sectional view of an assembly comprising the component according to the first embodiment of the present invention;

[0030] Fig. 3 is a schematic detailed view of a conductor track connector of a component according to a second embodiment of the present invention; and

[0031] Fig. 4 is a schematic sectional view of an assembly comprising the component according to the second embodiment of the present invention.

[0032] Fig. 1 shows a schematic detailed view of a conductor track connector 1 of a component 101 according to a first embodiment of the present invention. The first component 101 is illustrated in Fig. 2, which shows a schematic sectional view of an assembly 100 comprising the first component 101 according to the first embodiment.

[0033] The conductor track connector 1 has a plurality of electrical conductors 2. The electrical conductors 2 are designed as a lead frame. The conductor track connector 1 also has a first overmolding 3, which partially encases the electrical conductors 2. In the present example, as shown in Fig. 1, the electrical conductors 2 protrude from the first overmolding 3. This enables an electrical connection of the electrical conductors 2 to further components and / or connections (not shown). The first overmolding 3 is formed in particular by overmolding, in particular by injection molding, the electrical conductors 2, in particular in a lead frame state. The first overmolding 3 and the electrical conductors 2 are also referred to collectively below as conductor track connector 1.

[0034] The first overmolding 3 has a plurality of resilient structures 7, in this example three. In the present example, the resilient structures 7 are formed as cylindrical projections extending along a projection extension direction 104 (hereinafter also referred to as "assembly direction"). The projection extension direction 104 is perpendicular to an extension direction 6 of the electrical conductors 2. The extension direction 6 of the electrical conductors 2 refers to a primary longitudinal extension of the electrical conductors 2.

[0035] The resilient structures 7 are formed integrally, in particular by injection molding, with the first overmolding 3. The first overmolding 3 is formed from an elastic material, in particular from an elastic plastic, so that the projections 7 have a resilient function / effect.

[0036] The conductor track connector 1 is integrated in the first component 101, as will be explained below with reference to the assembly 100 of Fig. 2.

[0037] The first component 101 has a second overmolding 4, which partially encloses the first overmolding 3 together with the electrical conductors 2. In the present example, the projections 7 protrude from the second overmolding 4. As mentioned above, the first overmolding 3 is formed from an elastic plastic. The second overmolding 4 is preferably formed from a solid plastic, which has a lower elasticity than the material of the first overmolding 3. This can ensure the strength and / or rigidity of the component 101. Furthermore, when the first overmolding 3 is overmolding with the second overmolding 4, a substantially gas-tight connection is created between them, so that, for example, corrosion of the electrical conductors 2 can be prevented or reduced.The first component 101 thus has the integrated conductor track connector 1 as well as component sections, wherein the component sections are sections of the component 101 in addition to the conductor track connector 1.

[0038] The assembly 100 comprises the above-described (first) component 101, a second component 102, and a further, third component 103. The first component 101 is, for example, a stator cover. The second component 102 is, for example, a stator or stator housing and is also referred to as the adjacent second component 102. The third component 103 is, for example, a holder or fixation of the stator.

[0039] The first component 101, the second component 102, and the third component 103 are assembled along the assembly direction 104 (hereinafter "projection extension direction"). The first component 101 and the third component 103 are connected to one another, preferably welded together. As a result, the second component 102 is clamped between the first component 101 and the third component 103. The conductor track connector 1, as an integral part of the first component 101, is located between the second overmolding 4 of the first component 101 and the second component 102.

[0040] The resilient structures 7, here the projections 7, of the first overmolding 3 are configured to cushion the first component 101 against an adjacent component, in this example against the second component 102. As a result, individual part and / or assembly tolerances, for example, manufacturing tolerances and / or temperature-dependent tolerances, are compensated for by the projections 7.

[0041] In the present embodiment, the resilient structures 7 are each formed as, in particular, cylindrical, projections that protrude from a lower surface 5 of the first overmolding 3. The projections 7 extend in particular in the assembly direction 104.

[0042] The projections 7 have the particular effect that further resilient components such as rubber rings are not necessarily necessary, since the cushioning function is already integrated in the first component 101.

[0043] Although not shown, at least the first component 101 has openings through which the electrical conductors 2 can be contacted and / or led to the outside.

[0044] Fig. 3 shows a schematic detailed view of a conductor track connector 1 of a component 101 according to a second embodiment of the present invention. Fig. 4 shows a schematic side view of an assembly 100 comprising the first component 101 according to the second embodiment of the present invention.

[0045] In the first embodiment explained above, the resilient structures 7 have a resilient function due to their material properties, in particular their elasticity. In the second embodiment explained below, the resilient function of the structures 7 is advantageously achieved at least partially by a shape of the structures 7.

[0046] As a comparison of Fig. 3 with Fig. 4 shows, the conductor track connector 1 has two wave-shaped, resilient structures 7. The first overmolding 3, together with the resilient structures 7, preferably comprises elastic material. Alternatively, the first overmolding 3, together with the resilient structures 7, can be formed from a solid plastic. For example, the first overmolding 3 and the second overmolding 4 can be formed from the same material. The wave shape of the structures 7 shown in Fig. 4 results in a shaping-related elasticity of the structures 7, so that they cushion the first component 101 against the second component 102.

[0047] The elastic shape of the structures 7 is preferably not limited to the illustrated waveform. Alternatively or in addition to the illustrated waveform, the structures 7 can be spiral-shaped or leaf-spring-shaped.

[0048] The structures 7 can fulfill a fixing function alternatively or in addition to the illustrated resilient function. For example, at least one structure 7 is designed as a hook that engages the second component 102. For this purpose, the second component 102 has, for example, an eyelet and / or a recess and / or an undercut. The fixing function is preferably combined with the resilient function. For example, such a structure 7 designed as a hook is made of an elastic material.

[0049] Furthermore, for example, by providing an internal thread in at least one of the structures 7 shown in Figs. 1 and 2, the structures 7 can be designed as a screw tube, which is configured to receive a screw for fixing the first component 101 and the second component 102. By elastically configuring such a structure 7 as a screw tube, a simultaneously resilient and fixing integral structure of the component 101 can be provided.

[0050] In addition to the above written description of the invention, reference is hereby explicitly made to the graphic representation of the invention in Figs. 1 to 4 for its supplementary disclosure.

[0051] List of reference symbols

[0052] 1 conductor track connector

[0053] 2 electrical conductors

[0054] 3 first overmolding 4 second overmolding

[0055] 5 lower surface

[0056] 6 Direction of extension of the electrical conductors

[0057] 7 Structure

[0058] 100 assembly 101 first component

[0059] 102 second component

[0060] 103 third component

[0061] 104 Mounting direction (projection extension direction)

Claims

AMENDED CLAIMS received by the International Bureau on 26 June 2024 (26.06.2024) 1. An assembly (100), comprising: a first component (101) with an integrated conductor track connector (1) as a stator cover, the first component (101) comprising: a plurality of electrical conductors (2), in particular as a stamped grid; a first overmolding (3) which at least partially encloses the electrical conductors (2) and defines an arrangement of the electrical conductors (2) to form the conductor track connector (1); and at least one second overmolding (4) which at least partially encloses the first overmolding (3) and forms a component section of the first component (101), wherein at least the first overmolding (3) has at least one resilient and / or fixing structure (7); the adjacent second component (102) as a stator of an electrical machine, which is connected to the first component (101) with an integrated conductor track connector (1);and a third component (103) as a stator holder, which is connected to the first component (101) with an integrated conductor track connector (1), wherein the second component (102) is clamped between the first overmolding (3) of the first component (101) with an integrated conductor track connector (1) and the third component (103); and wherein the resilient and / or fixing structure (7) is designed to cushion the first component (101) relative to the adjacent second component (102) and / or to fix it thereto.

2. The assembly (100) according to claim 1, wherein the first overmolding (3) and the at least one second overmolding (4) have different material properties, in particular different elasticities, from one another. 12 AMENDED SHEET (ARTICLE 19) 3. Assembly (100) according to one of the preceding claims, wherein the resilient structure (7) of the first overmolding (3) is a projection, wherein the projection in particular has a higher elasticity than the second overmolding (4).

4. Assembly (100) according to one of the preceding claims, wherein the at least one resilient structure (7) is spiral-shaped, leaf-spring-shaped, or wave-shaped.

5. The assembly (100) according to any one of the preceding claims, wherein the fixing structure (7) is a clamp and / or a hook configured to engage the adjacent second component (102) and to fix the first component (101) thereto.

6. The assembly (100) according to any one of the preceding claims, wherein the fixing structure (7) is a screw tube configured to receive a screw for fixing the first component (101) to the adjacent second component (102) and, in particular, as a fixing and resilient structure (7), has a higher elasticity than the second overmolding (4).

7. Assembly (100) according to one of the preceding claims, wherein the first overmolding (3) is formed from an elastic material, in particular from an elastic plastic.

8. Assembly (100) according to one of the preceding claims, wherein the first overmolding (3) and the at least one resilient and / or fixing structure (7) are formed together as an injection-molded component. 13 AMENDED SHEET (ARTICLE 19)

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