Sealed housing of an e-bike drive device

Abstract

The invention relates to a housing (8) for receiving drive components of an e-bike drive device (1), comprising: a first housing part (7a), a second housing part (7b) and a seal unit (180) for sealingly connecting the first housing part (7a) to the second housing part (7b) in an assembled state. The seal unit (180) has both a sealing component (182) and a coupling component (190) which differs from the sealing component (182), wherein the sealing component (182) is designed to form the sealing connection by being compressed between the first housing part (7a) and the second housing part (7b) in the assembled state, and wherein the coupling component (190) is in contact with both the first housing part (7a) and the second housing part (7b) in the assembled state and is designed to ensure functional coupling between the first housing part (7a) and the second housing part (7b) in the assembled state.

Description

[0001] FAZ-105-PCT 1 30.09.2025

[0002] Sealed housing of an e-bike drive unit

[0003] The present invention relates to a housing for receiving drive components of an e-bike drive unit, as well as a corresponding e-bike drive unit for providing assistive torque to a rider of an e-bike, and a corresponding e-bike. Furthermore, the invention relates to a sealing unit for sealingly connecting a first and a second housing part of a housing for receiving drive components of an e-bike drive unit.

[0004] In the field of e-bike drive systems, it is common for housings for drive components such as electric motors and gearboxes to consist of several parts. These housing parts must not only be mechanically connected but also sealed to prevent the ingress of dirt and moisture and to ensure the lubrication of the internal components. Common systems typically include separate seals and mechanical connecting elements, as well as alignment and adjustment elements, to meet these requirements. The seals are often made of elastomers or other flexible materials that are compressed between the housing parts to create a sealing connection.

[0005] Another task, often accomplished with separate housing parts by providing additional components besides the seals, is the functional coupling of the two housing parts to be joined. By using separate housing parts, i.e., separating the housing, there is fundamentally a spatial and material separation between the two parts. This separation must be compensated for after joining the housing parts, possibly with additional elements, in order to re-establish a desired uniform, continuous material connection or to transfer a material-related property or function between the housing parts.

[0006] In addition to the seals, mechanical adjustment elements may be required to precisely align the housing parts longitudinally and transversely, as well as axially and radially. These alignment elements often include adjustment pins or separate sleeves that are placed in corresponding bores in the housing parts. These adjustment elements ensure that the housing parts are correctly positioned during assembly before they are permanently and securely joined together, if necessary, by screws or other fasteners. Such screws primarily serve to secure the two housing parts to be joined longitudinally or axially, thus preventing them from being lost, while the adjustment elements ensure the precise alignment of the parts to be joined (even during the assembly process).Furthermore, in addition to the seals, further functional coupling elements may be necessary to ensure a desired material property or functionality continuously from a first to a connected second housing part.

[0007] According to current technology, the assembly of such housings therefore regularly requires a large number of components and work steps to ensure sealing, mechanical connection and alignment, and functional coupling. This can make the assembly process complicated and time-consuming, increasing the likelihood of assembly errors that can lead to leaks, misalignment, or a lack of functionality. Consequently, there remains a need for improved solutions that enable simpler and more reliable assembly.

[0008] Therefore, the present invention aims to provide a housing for e-bike drive devices that at least partially overcomes the described disadvantages of known systems.

[0009] Furthermore, it is a task to provide a suitable e-bike drive device, a suitable e-bike, and a suitable sealing unit usable for this purpose.

[0010] The problem is solved with respect to a housing by a housing for receiving drive components of an e-bike drive device with the features of claim 1, with respect to an e-bike drive device by an e-bike drive device for providing a supporting torque for a rider of an e-bike with the features of claim 11, with respect to an e-bike by an e-bike with the features of claim 12, and with respect to a sealing unit by a sealing unit for sealing a connection between a first and a second housing part of a housing with the features of claim 13.

[0011] Central to the present invention is the realization that the effort associated with the assembly process and the manufacturing effort can be reduced, since, as proposed, several functions are performed by the sealing unit connecting the two housing parts. Thus, the sealing unit serves both as a seal, by means of its sealing component, and as a functional coupling of the housing parts, namely by means of its coupling component. This leads to a reduction in the number of components and assembly steps, as well as a minimization of the required installation space.

[0012] Specifically, a housing for accommodating drive components of an e-bike drive system is proposed, comprising at least a first housing part (in particular a lower housing section) and a second housing part (in particular an upper housing section). Furthermore, the proposed housing includes a sealing unit for sealing the connection between the first and second housing parts in an assembled state. In this context, the assembled state is understood to be the state in which the first and second housing parts are connected to each other as intended using the sealing unit. In particular, the shape and / or properties of the sealing unit in such an assembled state may differ from those in a disassembled state, when the sealing unit is isolated and separate.As proposed, the sealing unit comprises both a sealing component and a coupling component that differs from the sealing component. In particular, "different from the sealing component" can be understood to mean that the coupling component has a different material or is made of a different material, or at least has a different material composition and thus different properties. As proposed, the sealing component is designed to form the sealing connection by means of compression between the first housing part and the second housing part in the assembled state. As proposed, the coupling component is in contact with both the first and second housing parts in the assembled state and is designed to ensure a functional coupling between the first and second housing parts in the assembled state.

[0013] The use of the terms "first" and "second" housing parts here does not imply any hierarchy in terms of importance or significance. The description serves solely to distinguish between the at least two housing parts that need to be joined and sealed. In the application and corresponding embodiments, a third housing part may also be provided. The sealing unit, or a corresponding sealing unit (then regularly referred to as a "further sealing unit"), can serve as the sealing connection between such a third housing part and a second housing part. To avoid unnecessary repetition, the sealing unit described in connection with the first and second housing parts can also be applied to the (further) sealing unit that serves to connect the second and third housing parts (and vice versa).In principle, further embodiments based on the claims can be designed by replacing the combination of the first and second housing parts with the combination of the second and third housing parts, and / or by replacing the feature of the sealing unit with the feature of the further sealing unit.

[0014] Another advantage of the proposed sealing unit is that the coupling component essentially absorbs forces and the sealing component is only compressed to a desired degree, which can improve the longevity of the sealing unit or the stability of the seal.

[0015] The sealing component may be made of or consist of an elastic material to ensure a reliable seal. In particular, the sealing component may contain or be made of elastomer.

[0016] The sealing component is particularly well bonded to the coupling component. The sealing component is preferably vulcanized to the coupling component. FAZ-105-PCT 5 30.09.2025

[0017] The coupling component can be made of metal or consist of metal. It can also be made of fiber-reinforced plastic or consist of fiber-reinforced plastic. An example of such a usable fiber-reinforced plastic is carbon fiber-reinforced plastic. Essentially, the sealing component ensures a functional coupling between the housing parts, for which a specific material or associated properties may be desired.

[0018] In particular, the coupling component has a material different from, or consists of, the sealing component. Specifically, the coupling component has a higher hardness and / or lower elasticity and / or greater stiffness than the sealing component.

[0019] Preferably, the sealing component is arranged outside the coupling component when viewed in the radial direction.

[0020] Preferably, in the assembled state, the coupling component is in contact with the interior of the housing, while, in particular, the sealing component is essentially not in direct contact with the interior of the housing in the assembled state. According to one embodiment, "essentially not in direct contact with the interior" can be understood to mean that a minimal point contact between the interior and the sealing component may exist via a recess in the coupling component, which may be provided for a venting channel, but that essentially the majority or substantial portion of the sealing component is not in direct contact with the interior.

[0021] In this context, the radial direction is understood to be the direction from the interior of the housing outwards towards the external environment, usually along the sealing plane, i.e., along the sealing surfaces of the abutting and to be joined housing parts. The axial direction, on the other hand, is understood to be the direction perpendicular to that radial direction, and thus FAZ-105-PCT 6 30.09.2025

[0022] Direction in the sense of a normal to the sealing surfaces of the housing parts to be joined.

[0023] Preferably, the sealing unit is rotationally symmetrical. The rotationally symmetrical design of the sealing unit ensures an even distribution of forces and easy assembly.

[0024] Preferably, the coupling component is not compressed in the assembled state. This distinguishes the coupling component from the sealing component. While the sealing component is compressed to provide the sealing effect between the housing parts or their sealing surfaces, the coupling component advantageously retains its mechanical integrity and shape without being deformed by external forces, thus enabling precise alignment of the two components. This property of the coupling component offers several advantages. First, it allows for precise and stable alignment of the housing parts relative to each other without the need for additional adjustment elements such as dowel pins or sleeves. This reduces the complexity and number of components required and simplifies the assembly process.Secondly, the non-compressed coupling component contributes to the structural integrity of the housing by providing a stable connection between the housing parts without placing excessive stress on the sealing component. This extends the service life of the seal and improves the overall reliability of the housing. Finally, the non-compressed coupling component allows for easy disassembly and reuse of the housing parts, as it retains its shape and function, thus enabling repeated assembly without loss of sealing and coupling performance. These features make the housing particularly suitable for applications in e-bike drive systems, where a compact design, reliability, and ease of maintenance are of paramount importance.

[0025] In one embodiment, the coupling component is designed for precise alignment between the first and second housing parts. This precise alignment can include both a predetermined axial position and a predetermined radial position between the housing parts. Axial positioning refers to alignment along the longitudinal axis of the housing parts, while radial positioning refers to alignment along the radial direction, i.e., perpendicular to the longitudinal axis. A significant advantage of this design is that it eliminates the need for additional mechanical adjustment or alignment elements such as dowel pins or separate sleeves. Instead, the coupling component of the sealing unit performs these functions, reducing the number of components required and simplifying the assembly process.As a general rule, screws can also be inserted at the end of the assembly process to permanently fix or secure the housing parts, or to adjust the desired compression of the sealing component. This ensures axial retention without the screws being responsible for the fundamental adjustment. In particular, it can be provided that the axial and / or radial alignment of the first housing part with the second housing part is achieved without dowel pins and / or sleeves, especially solely by the coupling component of the sealing unit.

[0026] In one embodiment, the coupling component is designed to provide an electrically conductive connection between the first and second housing parts. This coupling component ensures that the two housing parts are electrically connected, which is particularly important for electromagnetic compatibility (EMC) and related EMC testing. This electrically conductive connection can be achieved, for example, by using metallic components or materials, or electrically conductive plastics, in the coupling component. The electrically conductive connection minimizes electromagnetic interference that could be generated by the e-bike's drive components and ensures that the housing can function as a type of Faraday cage.This can be particularly important to ensure the functionality and reliability of the electronics in the e-bike. Eliminating separate elements or components for electrical conductivity between housing parts offers advantages in both assembly and manufacturing due to the reduction in the number of components. Furthermore, the security of the housing connection and operational reliability can also be increased. This is especially beneficial in the event of vibrations and shocks that occur during riding, as no additional connections can be damaged or even come loose. Integrating the electrically conductive connection into the coupling component of the sealing unit reduces the need for additional parts and simplifies the assembly process, since the sealing unit combines both the sealing and the electrical connection in a single component.This leads to a reduction in the number of components and assembly steps required, which in turn minimizes production costs and the required installation space. The use of an electrically conductive coupling component in the sealing unit thus represents an efficient and cost-effective solution for meeting EMC requirements while simultaneously improving the mechanical stability and ease of assembly of the housing. In particular, a fixed and unchanging shape for the coupling component ensures constant contact between the housing parts, thereby minimizing electrical interference.

[0027] In one embodiment, the coupling component, viewed axially and in the assembled state, has a greater axial extent than the sealing component. Preferably, this can also apply in the disassembled state.

[0028] Alternatively, the coupling component may be designed to have a smaller axial extent than the sealing component when viewed in the disassembled state. Preferably, this applies only to the disassembled state and not to the assembled state. It is also preferable that the axial extent of the coupling component and the sealing component, viewed in the axial direction and assembled state, is the same in the area of ​​the facing sealing surfaces of the housing parts.

[0029] According to one embodiment, the coupling component has a first axial contact surface for axial contact with a first end face section of the first housing part during assembly, and / or a second axial contact surface for axial contact with a second end face section of the second housing part during assembly. The first axial contact surface and the second axial contact surface can be of equal size, particularly when viewed radially. This configuration enables precise axial alignment of the housing parts relative to each other without the need for additional adjustment elements such as dowel pins or separate sleeves (FAZ-105-PCT 9 30.09.2025). The coupling component thus performs the function of positioning the housing parts in both the longitudinal and transverse directions, simplifying assembly and reducing the number of components required.Integrating the sealing and coupling functions into a single sealing unit simplifies the assembly process and increases the reliability of the connection. The proposed sealing unit thus offers a multifunctional solution that ensures both the mechanical connection and alignment of the housing components as well as their sealing.

[0030] According to one embodiment, the coupling component has a first radial contact surface for radial contact with a first inner surface section of the first housing part during assembly, and / or a second radial contact surface for radial contact with a second inner surface section of the second housing part during assembly. The first radial contact surface and the second radial contact surface are preferably arranged on opposite sides of the sealing component, viewed in the axial direction. Alternatively or additionally, the first radial contact surface and the second radial contact surface can be of the same size, viewed in the axial direction, and / or arranged at the same height in the radial direction. This arrangement allows for precise alignment of the housing parts relative to each other, which can eliminate the need for additional adjustment elements such as dowel pins or separate sleeves.This multifunctional sealing unit reduces the number of components required, simplifying the assembly process and minimizing the required installation space. The proposed housing and sealing unit are therefore particularly suitable for e-bike drive systems where a compact and lightweight design is crucial. Integrating multiple functions into the sealing unit, and thus into the e-bike drive system housing, allows for efficient use of available space and contributes to weight reduction without compromising the functionality and reliability of the seal and mechanical connection.

[0031] In principle, the above-described statements can also apply to a housing with a second housing part and a third housing part and with regard to a sealing unit between that second and third housing part, either with the simultaneous provision of a first housing part and, if applicable, a sealing unit between the first and second housing part, or with the provision of only the second and third housing part with a sealing unit in between.

[0032] According to a further embodiment of the housing, the housing for receiving drive components of an e-bike drive device comprises, in addition to the first and second housing parts, a third housing part, in particular a housing cover, as well as a further sealing unit for sealing the connection between the second housing part and the third housing part in an assembled state. The further sealing unit has both a sealing component and a coupling component that differs from the sealing component.The sealing component is designed to form the sealing connection by means of compression between the second and third housing parts in the assembled state, while the coupling component is in contact with both the second and third housing parts in the assembled state and is designed to ensure a functional coupling between the second and third housing parts in the assembled state. The sealing component and / or the coupling component are preferably substantially similar to the sealing component or coupling component of the aforementioned sealing unit (between the first and second housing parts). This applies in particular to the functions and materials of the components. The shapes and / orThe geometries of the individual components of the different sealing units can, for example, differ from one another to accommodate the different designs of the housing parts to be joined. The coupling component of the other sealing unit can, in principle, again perform the function of aligning the housing parts it connects, thus eliminating the need for additional adjustment elements such as dowel pins or separate sleeves. This leads to a reduction in the number of components and assembly steps, as well as a minimization of the required installation space. Alternatively or additionally, the coupling component can also serve to provide electrical conductivity between the housing parts, which is particularly important for compliance with EMC requirements.Integrating these functions into the sealing unit simplifies the assembly process and increases the reliability of the connection, as the sealing component is made of an elastic material, FAZ-105-PCT 11 30.09.2025, which ensures a reliable seal, while the coupling component is made of a dimensionally stable and electrically conductive material, which ensures a stable and secure electrical connection.

[0033] In principle, it can be provided that, in the assembled state, the second housing part is positioned between the first and third housing parts, and the first housing part is connected to the second housing part via the sealing unit between them, and the second housing part is connected to the third housing part via another sealing unit between them. As a result, a housing can be essentially divided into three parts while maintaining a reliable seal.

[0034] In one embodiment of the housing, the first housing part can be the lower housing section and is preferably designed to accommodate a reduction gear of the e-bike drive unit. Alternatively or additionally, the second housing part can be the upper housing section and is preferably designed to accommodate an electric motor of the e-bike drive unit. Alternatively or additionally, the third housing part can be the housing cover. The housing cover can preferably have a recess for routing electrical connections, for example, from the e-bike battery to the electric motor of the e-bike drive unit.

[0035] In one embodiment, the sealing unit, particularly the sealing component, has at least two, preferably four, through-openings to allow the passage of fasteners along the axial direction. These fasteners serve to connect the second housing part to the first housing part and the third housing part to the second housing part. The through-openings are preferably located at the outer corners of the sealing component when viewed radially. This arrangement enables efficient connection of the housing parts by ensuring precise alignment and a reliable seal. While the use of screws to connect the housing parts remains possible, these screws are not responsible for axial and radial positioning during assembly but merely serve to secure the connection in the axial direction.In the present design, however, such screws can be used directly and precisely for the intended compression of the sealing component. The arrangement of the through-holes in the outer corners of the sealing component also ensures an even distribution of forces and a stable connection between the housing parts.

[0036] Preferably, the sealing unit can be designed such that, in its disassembled state, it has an open venting channel. This open channel is closed when the sealing component is compressed during assembly, allowing a defined opening pressure to be set. This contributes to pressure relief and prevents overpressure in the housing. In particular, the coupling component can have a ventilation recess and the sealing component a ventilation channel, wherein the ventilation recess and the ventilation channel are arranged substantially identically to each other in the disassembled state. However, it is possible for the ventilation recess and the ventilation channel to have different diameters or opening widths, in particular the ventilation recess having a larger opening width than the ventilation channel.The resulting venting function prevents overpressure in the housing and ensures an even pressure distribution, which increases the service life of the seal and the housing parts.

[0037] According to an independent, subordinate aspect of the invention, an e-bike drive device is further proposed in detail, which is designed to provide an assisting torque for a rider of an e-bike and comprises the following:

[0038] - an electric motor which has a motor output shaft;

[0039] - an e-bike component driven to propel the e-bike, in particular a bottom bracket axle, a chainring or a pulley of the e-bike, wherein the driven e-bike component is configured to be driven in an assisted state of the e-bike drive device both by the rider's muscle power and by the assisting torque of the e-bike drive device; and

[0040] - a reduction gear, wherein the reduction gear connects the motor output shaft of the electric motor to the driven e-bike component. FAZ-105-PCT 13 09 / 30 / 2025

[0041] As proposed, the e-bike drive device has a housing as described above or below.

[0042] According to an independent, subordinate aspect of the invention, an e-bike is further proposed in detail, which has a proposed e-bike drive device as described above or below.

[0043] Finally, according to an independent, subordinate aspect of the invention, a sealing unit is further proposed in detail, which sealing unit is designed for the sealing connection of a first and a second housing part of a housing, wherein it is preferably a proposed housing as described above or below, which housing is designed for receiving drive components of an e-bike drive device (preferably as described above or below).The proposed sealing unit comprises both a sealing component and a coupling component that differs from the sealing component, wherein the sealing component is configured to form the sealing connection by means of compression between the first housing part and the second housing part in an assembly state, and wherein the coupling component is in contact with both the first housing part and the second housing part in the assembly state and is configured to ensure a functional coupling between the first housing part and the second housing part in the assembly state.

[0044] In principle, to avoid repetition, features described here only in relation to one proposed item (housing, sealing unit, e-bike drive unit or e-bike) can also be transferred to the other proposed items in a technically meaningful way and form independent further embodiments of these proposed items. The described advantages and technical effects should also be transferred to the other items. Therefore, the following section focuses first on further embodiments of the proposed e-bike drive unit, which e-bike drive units can particularly benefit from the proposed housings and sealing units, as their use can save installation space. FAZ-105-PCT 14 30.09.2025

[0045] Preferably, the reduction gear of the e-bike drive unit has at least one gear in contact with oil for lubrication and heat dissipation. Appropriate oil lubrication ensures heat dissipation and further reduces the installation space.

[0046] According to one embodiment, the e-bike drive device comprises a reduction gear with at least two gear stages, preferably in the form of an input gear stage and an output gear stage. The reduction gear has a total oil chamber comprising an approximately cylindrical input oil chamber section, an approximately cylindrical output oil chamber section, and an oil chamber connecting section. The oil chamber connecting section connects the input oil chamber section and the output oil chamber section, with the axis of the input oil chamber section being approximately perpendicular to the axis of the output oil chamber section. The total oil chamber enables a uniform distribution of the oil within the reduction gear, resulting in improved lubrication and cooling of the gear components.The cylindrical oil chamber sections offer an optimal geometry for lubricant distribution, while the oil chamber connection section ensures a continuous connection between the two main sections. This arrangement helps reduce friction and wear, extending the service life of the transmission components. Furthermore, the vertical arrangement of the axles allows for a compact design of the e-bike drive unit, which is particularly advantageous for installation in confined spaces, as is often the case with e-bikes. Integrating these features into the e-bike drive unit results in improved performance and reliability of the drive system, ultimately contributing to a better riding experience.

[0047] According to one embodiment, the e-bike drive device comprises an input side of the reduction gear, which is connected to the motor output shaft of the electric motor, and an output side of the reduction gear, which is connected or connectable to the driven e-bike component. The reduction gear is configured from the input side to the output side to reduce the speed of the motor output shaft, with the input-side gear stage being configured for a first reduction of the speed of the motor output shaft and the output-side gear stage for a further reduction of the speed. Preferably, the output-side gear stage connects to the input-side gear stage, and an output shaft of the input-side gear stage is an input shaft of the output-side gear stage.The input gear stage, typically a planetary gear set, handles the initial speed reduction, while the output gear stage, often a right-angle or bevel gear set, provides a further reduction. This configuration enables a compact and efficient transmission of torque from the electric motor to the driven e-bike component, resulting in improved performance and reliability of the e-bike drive system. The mechanical coupling of the gear stages also reduces wear and increases the system's lifespan. Another advantage of this arrangement is the ability to house the gear stages within a single unit, minimizing installation space and simplifying assembly. The use of oil as a lubricant and for heat dissipation further enhances the efficiency and longevity of the gearbox by reducing friction and improving heat dissipation.Integrating the gear stages into a single housing also allows for improved sealing and protection of the internal components from environmental influences. The specific arrangement of the gear stages and their mechanical coupling thus offer an efficient and reliable solution for transmitting and reducing speed in an e-bike drive system.

[0048] According to one embodiment, the e-bike drive device comprises an input-side gear stage designed as a planetary gear set and / or an output-side gear stage designed as a right-angle gear set, in particular a bevel gear set. The planetary gear set consists of several gears, including a ring gear, several planet gears, and a sun gear, as well as a planet carrier on which the planet gears are mounted by means of planet gear pins. The input shaft of the planetary gear set is rotationally fixed to the motor output shaft or formed integrally with it, which enables efficient transmission of torque from the electric motor to the gearbox. The right-angle gear set has a bevel pinion and a ring gear, the ring gear preferably being rotationally fixed to the output shaft of the reduction gear set in one direction of rotation. A particularly preferred embodiment is FAZ-105-PCT 16 30.09.The 2025 standard stipulates that the input shaft of the bevel gear unit must be rotationally fixed to the planetary gear unit's carrier. This configuration enables a compact and efficient transmission of torque from the electric motor to the driven e-bike component, such as a bottom bracket axle or chainring. The use of a planetary gear unit and a right-angle gearbox achieves a high gear ratio and thus efficient use of the electric motor, resulting in improved performance and range for the e-bike. Furthermore, the rotationally fixed connection of the bevel gear unit's input shaft to the planetary gear unit's carrier ensures a stable and reliable coupling of the two gear stages, increasing the lifespan and ease of maintenance of the e-bike drive system.

[0049] According to one embodiment, the e-bike drive device comprises an output shaft of the bevel gear transmission, which can be connected to or is connected to the driven e-bike component in a rotationally fixed manner, at least in one direction. Alternatively or additionally, the bottom bracket shaft can be connected to or is connected to the driven e-bike component in a rotationally fixed manner, at least in one direction.

[0050] According to one embodiment of the e-bike drive device, an input shaft of the planetary gear is connected to the motor output shaft in a rotationally fixed manner or is formed in one piece with the motor output shaft.

[0051] In one embodiment, the e-bike drive unit comprises both the input and output sides of the reduction gear, with both sides containing oil as a lubricant and for heat dissipation. This means that both the input and output gear stages of the reduction gear are lubricated and cooled with oil. Preferably, the input side of the reduction gear also contains grease as a lubricant, enabling combined lubrication using oil and grease. This combined lubrication can be implemented particularly on the input side, and preferably also on the output side of the reduction gear. The use of oil and grease in combination offers several advantages: The grease ensures particularly reliable lubrication of the gear components, while the oil enables effective heat dissipation.This is particularly important to control the operating temperature of the e-bike drive unit (FAZ-105-PCT 17 30.09.2025) and prevent overheating, thus increasing the drive unit's lifespan and performance. Ensuring chemical compatibility between the oil and grease is crucial to prevent any mutual interference with their lubricating and cooling properties. This lubrication strategy maximizes drive unit efficiency and improves heat dissipation, resulting in overall better performance of the e-bike drive unit. Furthermore, the option to use both oil and grease offers flexibility in lubricant selection, depending on the specific requirements and operating conditions of the e-bike drive unit.

[0052] According to one embodiment, the e-bike drive device comprises an input side of the reduction gear containing an input lubricant, in particular grease, and an output side containing oil for lubrication and heat dissipation. The input and output sides of the reduction gear are separated and sealed from each other in such a way that the input lubricant and the oil in the output side of the reduction gear do not mix. This separation is achieved by a special seal that ensures the different lubricants remain in their respective areas and can perform their specific functions. The grease on the input side ensures reliable lubrication of the gear components, while the oil on the output side not only serves as a lubricant but also aids in heat dissipation to prevent overheating of the gear components.Separating the lubricants also prevents chemical reactions between the different lubricants that could impair lubrication. This is particularly important to ensure the mechanical integrity and thermal stability of the gearbox. Sealing can be achieved using special seals or sealing units, especially externally with the proposed sealing units, which are designed to meet the requirements of the different lubricants and ensure permanent separation. These seals must be resistant to both grease and oil and must not fail under operating conditions. Furthermore, using grease on the input side can reduce noise, resulting in quieter operation of the e-bike drive system.Oil lubrication on the output side enables effective heat dissipation, which is particularly advantageous under high loads (FAZ-105-PCT 18 30.09.2025) and long operating times. Overall, this configuration contributes to improved performance, reliability, and service life of the e-bike drive unit by optimally utilizing the advantages of the different lubricants and preventing their mixing.

[0053] According to one embodiment of the e-bike drive device, the gear in contact with oil as a lubricant and for heat dissipation is at least one of the following gears: a ring gear, in particular of an output gear stage; a bevel pinion, in particular of an output gear stage; a planet gear, in particular of an input gear stage; a ring gear, in particular of an input gear stage; and / or a sun gear, in particular of an input gear stage. Preferably, the planet gear and / or the ring gear are made of or consist of plastic.

[0054] According to one embodiment of the e-bike, the e-bike has a bicycle frame with a down tube, wherein the electric motor and / or the input-side gear stage are arranged in the down tube or within a contour of the down tube.

[0055] According to one embodiment of the sealing unit, the coupling component is designed for precise alignment between the first and second housing parts. This is preferably achieved by providing a predetermined axial position between the first and second housing parts; or more preferably, by providing a predetermined radial position between the first and second housing parts. Preferably, the alignment of the first and second housing parts is achieved without dowel pins and / or sleeves.

[0056] According to one embodiment of the sealing unit, the coupling component is designed to provide an electrically conductive connection between the first housing part and the second housing part.

[0057] In principle, the aforementioned design of the sealing unit can also apply to a sealing unit for the sealing connection of a second and a third housing part of a housing. Therefore, FAZ-105-PCT 19 30.09.2025

[0058] Features “first and second housing part” are replaced by “second and third housing part”.

[0059] Preferably, the proposed housing may use an oil, or the gear may be in contact with an oil, which has a kinematic viscosity of at least ISO VG 10 (ISO 3448), in particular at least ISO VG 15 (ISO 3448), preferably at least ISO VG 22 (ISO 3448), more preferably at least ISO VG 68 (ISO 3448), and more preferably at least ISO VG 100 (ISO 3448). It is particularly preferred if the kinematic viscosity of the oil used is in the range of ISO VG 10 to ISO VG 680, in particular ISO VG 15 to ISO VG 460, more preferably ISO VG 22 to ISO VG 320, more preferably ISO VG 32 to ISO VG 320, and more preferably ISO VG 68 to ISO VG 150, according to ISO 3448.

[0060] The advantages of the present invention are particularly evident when a thinner oil is used, since the cooling and lubrication of the entire drive system, and especially the distribution of a thin oil within the drive system, possibly originating from an oil bath, presents a particular challenge. This is all the more true when, as described in the present disclosure, low circumferential speeds prevail for the oil-contacting gear in the e-bike. Sealing is of particular importance, especially with a correspondingly thinner oil.

[0061] The viscosity of the oil used can be understood, within the scope of this disclosure, as the kinematic viscosity at 40 °C according to ISO 3448. This kinematic viscosity can be measured according to ISO 3104.

[0062] In particular, the gear in contact with oil is configured such that it rotates at a maximum speed of 400 rpm, more specifically 300 rpm, preferably 250 rpm, and more preferably 150 rpm. Preferably, the gear in contact with oil is configured such that it rotates at a maximum speed equal to that of the driven e-bike component, in particular the bottom bracket axle, chainring, or pulley of the e-bike. In particular, the gear in contact with oil is non-rotatably connected to the driven e-bike component, in particular the bottom bracket axle, chainring, or pulley of the e-bike. This connection may be indirect.

[0063] The gear in contact with oil is in particular a gear of the output gear stage of a gearbox of the drive unit.

[0064] Preferably, the gear in contact with oil is immersed in an oil bath, particularly exclusively in the oil bath, but no other gear is immersed. Furthermore, preferably only the gear in contact with oil and no other transmission component is immersed in the oil bath.

[0065] In particular, the oil bath is only formed along one axis or axis segment of the gear in contact with the oil, so that the oil bath does not extend over several spaced-apart gear or drive components arranged on different axes, which would potentially immerse several gear or drive components in the single oil bath. Consequently, gear components distributed across multiple shafts or shaft segments are not in immersive contact with the oil bath.

[0066] In particular, the electric motor itself is separated from an oil bath. Preferably, no electric motor components, and further preferably, no transmission components of a first transmission stage following the output side of the electric motor, are in immersion in an oil bath.

[0067] In particular, the maximum diameter of the gear in contact with oil is 100 mm, more particularly 80 mm, preferably 70 mm, more preferably 60 mm, more preferably 55 mm.

[0068] For appropriate diameters and rotational speeds of the oil-contacting gear, the present invention and the achieved good sealing of the housing are of particular importance, since lubrication in the entire drive, especially the transport of the oil, is particularly critical, at least with regard to thinner oils used, as no special centrifugal or even atomizing effects are observed with respect to the oil contacting the gear (FAZ-105-PCT 21 30.09.2025), and thus special measures are regularly taken to ensure good oil distribution. This applies all the more if, as is preferably provided here, the rotational speed of the oil-contacting gear is selected or set such that the centrifugal acceleration acting on the gear's surface due to rotation is less than the acceleration due to gravity.

[0069] The present invention is explained in detail below with reference to an exemplary embodiment and the accompanying figures. These show:

[0070] Fig. 1 shows a perspective view of an embodiment of an e-bike drive device according to the invention,

[0071] Fig. 2 shows the e-bike drive device from Fig. 1 in a sectional view as a vertical section and in installation position,

[0072] Fig. 3 shows the e-bike drive device from Fig. 1 in a sectional view as a horizontal section,

[0073] Fig. 4 shows a sectional view of a section of a proposed housing,

[0074] Fig. 5 shows a proposed sealing unit, as used in the embodiment according to Fig. 4, in two views: according to view a) in a sectional view, and according to view b) in an enlarged detail view.

[0075] Fig. 6 shows individual components of the proposed housing in isolation and in different views: in view a) the second housing part or upper housing section in perspective view looking at the sealing surface, in view b) the first housing part or lower housing section in perspective view looking at the sealing surface, and in view c) a sealing unit shown separately in perspective view, FAZ-105-PCT 22 30.09.2025

[0076] Fig. 7 shows individual components of the proposed housing in isolation and in different views: in view a) the third housing part or housing cover in perspective view looking at the inside or sealing surface, in view b) the second housing part or upper housing section in perspective view looking at the sealing surface, in view c) a sealing unit shown separately in perspective view, and in view d) a sectional view of the sealing unit from view c) in a partial view.

[0077] Fig. 8 shows an embodiment of an e-bike according to the invention in a schematic view, and

[0078] Fig. 9 shows a more detailed perspective view of a section from Fig. 8 focusing on the bottom bracket area.

[0079] In the figures, unless otherwise stated, the same reference symbols denote the same components with the same function.

[0080] Fig. 1 shows a perspective view of an e-bike drive unit 1, which includes a sealing unit 180. This sealing unit 180 seals the first housing part 7a to the second housing part 7b. Additionally, a further sealing unit 181 is provided, which connects the second housing part 7b to the third housing part 7c in the form of the housing cover. The sealing units 180 and 181 each consist of a sealing component 182 and a coupling component 190. While these two components are not visible in Fig. 1, they are partially visible in Fig. 2, and even more clearly in Figs. 4, 5, 6, and 7. Therefore, reference can be made to all figures in the present and subsequent description.

[0081] The sealing component 182 of the sealing units 180 and 181 consists of an elastic material, specifically an elastomer, which is vulcanized onto the coupling component 190. This elastomer is compressed between the housing parts 7a and 7b or 7b and 7c during assembly, thereby creating the sealing effect between the respective housing parts. The coupling component 190 consists of a dimensionally stable material, such as metal or fiber-reinforced FAZ-105-PCT 23 30.09.2025

[0082] plastic, and is bonded to the sealing component, preferably by vulcanization as mentioned.

[0083] The coupling component 190 of the sealing unit 180 ensures the precise axial and radial alignment of the two housing parts, 7a and 7b. This is achieved without the use of dowel pins or sleeves, simplifying assembly and reducing the number of components required. The coupling component 190 of the additional sealing unit 181 also provides an electrically conductive connection between the two housing parts, 7b and 7c, which is important for electromagnetic compatibility (EMC).

[0084] The housing parts 7a, 7b, and 7c are generally connected to each other by screws 170, which pass through through-holes 183 in the sealing components 182 (see Fig. 6, view c), and Fig. 7, view c)). These screws 170 serve to secure the housing parts 7a, 7b, and 7c in the axial direction, respectively, while the sealing units 180 and 181, with the aid of their coupling components 190, take over the alignment and adjustment, particularly during the assembly process.

[0085] Additionally, a venting function can be integrated into the sealing units, as is the case here with regard to sealing unit 180 and as shown in Fig. 5, see left sealing component 182 in view b) and view c). This is achieved by an outlet in the sealing carrier, i.e., the coupling component 190, which has a ventilation recess 185 for this purpose, and by a channel in the elastomeric sealing lip, i.e., by the ventilation channel 195 in the sealing component 182. In the disassembled, uninstalled state, the resulting channel is open and is closed when the sealing component 182 is compressed in the installed state. By means of the defined compression of the resulting channel, an opening pressure can be set to prevent overpressure in the housing 8.

[0086] The e-bike drive device 1, which is shown in a vertical section in Fig. 2 and in a horizontal section in Fig. 3, further comprises an electric motor 2, which has a motor output shaft 31, and a driven E- FAZ-105-PCT 24 30.09.2025

[0087] Bike component 78, specifically a chainring 3, which can be driven both by the rider's muscle power and by the supporting torque of the electric motor 2. A reduction gear 5 transmits the torque from the motor output shaft 31 to the driven e-bike component 78. The reduction gear 5 comprises an input-side gear stage 13 and an output-side gear stage 14, both of which are housed in the casing 8, specifically in the first casing part 7a, while the electric motor 2 is located in the second casing part 7b.

[0088] The housing 8 also contains oil 9, which serves as a lubricant and for heat dissipation. The sealing units 180 and 181 contribute to the operational reliability of the e-bike drive unit 1 through the precise alignment achieved with the coupling component 190, the electrical conductivity they provide, and their venting and basic sealing functions. All of this is combined in a single component type, specifically through the two components: sealing unit 180 and sealing unit 181. This significantly contributes to the compactness and thus the efficiency of the e-bike drive unit 1.

[0089] Fig. 2 shows the e-bike drive unit 1 in its basic installed position with regard to its orientation. The first housing part 7a can therefore also be referred to as the lower housing section and the second housing part 7b as the upper housing section.

[0090] As can be seen in the sectional views (Fig. 2 and Fig. 3), the motor output shaft 31 is connected to an input-side gear stage 13, which is designed as a planetary gear set 15. The planetary gear set 15 comprises a sun gear 25, several planet gears 23, a planet carrier 28, and a ring gear 26.

[0091] The output gear stage 14 is designed as a bevel gear 30 and comprises a bevel pinion 27 and a ring gear 98. The bevel pinion 27 is rotationally fixed to the planet carrier 28 of the planetary gear 15. The ring gear 98 is connected to a driven e-bike component 78, here in the form of a chainring 3. The axis of rotation A of the motor output shaft 31 is perpendicular to the axis of rotation B of the driven e-bike component 78. FAZ-105-PCT 25 30.09.2025

[0092] The housing 8 of the e-bike drive unit 1 consists of three housing parts: lower housing section 7a, upper housing section 7b, and housing cover 7c. The housing parts 7a and 7b are connected to each other by means of the sealing unit 180. The sealing unit 180 comprises the sealing component 182 made of elastomer and the coupling component 190 made of metal or fiber-reinforced plastic. The sealing component 182 is vulcanized onto the coupling component 190.

[0093] The coupling component 190 of the sealing unit 180 ensures precise alignment of the housing parts 7a and 7b in axial and radial directions, thus eliminating the need for additional adjustment elements such as dowel pins or sleeves.

[0094] Housing parts 7b and 7c are connected to each other by means of the additional sealing unit 181. The additional sealing unit 181 comprises the sealing component 182 made of elastomer and the coupling component 190 made of metal or fiber-reinforced plastic. The sealing component 182 is vulcanized onto the coupling component 190. The coupling component 190 of the additional sealing unit 181 also ensures an electrically conductive connection between housing parts 7b and 7c to guarantee electromagnetic compatibility (EMC).

[0095] The housing 8 is designed to form a total oil chamber 120, which surrounds the gear stages 13 and 14 of the reduction gear 5 and is filled with oil 9 for lubrication and heat dissipation. The ring gear 98 is partially immersed in an oil bath 24 to ensure effective lubrication and cooling. The total oil chamber 120 of the reduction gear 5 comprises an approximately cylindrical inlet-side oil chamber section 122, an approximately cylindrical outlet-side oil chamber section 124, and an oil chamber connecting section 126 that connects the two oil chamber sections. The axis D of the inlet-side oil chamber section 122 is perpendicular to the axis E of the outlet-side oil chamber section 124. The oil 9 serves both as a lubricant and for heat dissipation.

[0096] The input-side gear stage 13 is designed as a planetary gear set 15 and includes a sun gear 25, which is non-rotatably connected to the motor output shaft 31. The planet gears 23 are mounted on a planet carrier 28, which in turn is connected to an input shaft 100 of the bevel gear set 96. The output-side gear stage 14 is designed as a bevel gear set 30 and includes a pinion 27 and a ring gear 98. The output shaft 94 of the bevel gear set 96 is non-rotatably connected to the driven e-bike component 78.

[0097] The e-bike drive unit 1 is designed to be housed in a confined space, such as the down tube 17 of a bicycle frame 16 of an e-bike 4 (see Figs. 8 and 9). The compact design and efficient heat dissipation contribute to improved handling and higher performance of the e-bike.

[0098] Fig. 4 shows a sectional view of the housing 8 of the e-bike drive unit, schematically simplifying the representation of the first housing part 7a and the second housing part 7b. These housing parts 7a and 7b are connected to each other by means of the sealing unit 180. The sealing unit 180 comprises the sealing component 182 and the coupling component 190. The sealing component 182 is arranged between the sealing surfaces 155 of the housing parts 7a and 7b and is compressed in the axial direction z, thus providing a seal. The coupling component 190 is in contact with both the first housing part 7a and the second housing part 7b and ensures functional coupling and, in this case, precise alignment of the housing parts 7a and 7b in the radial direction r and the axial direction z. The coupling component 190 is not compressed.

[0099] The coupling component 190 abuts with its first axial contact surface 191 the first end face section 151 of the first housing part 7a, and with its opposite second axial contact surface 192 the second end face section 161 of the second housing part 7b. Furthermore, the coupling component 190 abuts with its first radial contact surface 193 the first inner surface section 152 of the first housing part 7a, and with its opposite second radial contact surface 194 the second inner surface section 162 of the second housing part 7b. FAZ-105-PCT 27 09 / 30 / 2025

[0100] Fig. 5 shows the sealing unit 180 in two views: In view a), the sealing unit 180 is shown in a sectional view, with the sealing component 182 visible at both ends of the coupling component 190. The coupling component 190 has the first axial contact surface 191 and the second axial contact surface 192, which, in the assembled state, bear against the end face sections 151 and 161 of the housing parts 7a and 7b, respectively. The first radial contact surface 193 and the second radial contact surface 194 are also shown and ensure the precise radial positioning of the housing parts 7a and 7b.

[0101] View b) of Fig. 5 shows an enlarged detail view of the sealing unit 180 from view a), focusing on the left area of ​​the coupling component 190 from view a). The sealing component 182 is made of an elastomer, while the coupling component 190 is made of metal or fiber-reinforced plastic. The previously described channel with the ventilation recess 185 and the ventilation channel 195 are visible.

[0102] The various systems ensure the precise radial and axial alignment of the two housing parts 7a and 7b relative to each other, especially during the assembly process. Since the housing 8 contains various drive components, and specifically components of the reduction gear 5, which requires multiple gear meshes between different gears, the proposed housing 8 and the proposed sealing unit 180 also contribute to improved and more precise assembly and even greater durability of the e-bike drive unit 1. The sealing unit 180 ensures that the gear meshes of the transmission components are correctly aligned and aligned, which is particularly important for the bevel gear 30 and the gear mesh between the bevel pinion 27 and the ring gear 98.

[0103] Fig. 6 shows various views of individual components of the housing 8 and the sealing unit 180 in detail. View a) of Fig. 6 shows the upper housing section 7b of the housing 8. The sealing surface 155 is clearly visible; this sealing surface 155 is provided for connection with another housing part 7a. View b) of Fig. 6 again shows the lower housing section 7a of the housing 8. This section also has a sealing surface 155, which serves for connection with the upper housing section 7b. FAZ-105-PCT 28 09 / 30 / 2025

[0104] View c) of Fig. 6 illustrates the sealing unit 180, which is used to seal the upper housing section 7b with the lower housing section 7a. The sealing unit 180 consists of the sealing component 182 and the coupling component 190. The sealing component 182 is made of an elastic material that provides a seal between the housing parts 7a and 7b. The coupling component 190 is made of a dimensionally stable material such as metal or fiber-reinforced plastic and serves to precisely align the housing parts 7a and 7b with each other.

[0105] The sealing component 182 is metallurgically bonded to the coupling component 190, preferably by vulcanization. The coupling component 190 is designed such that, in the assembled state, it is in contact with both the upper housing section 7b and the lower housing section 7a, ensuring a functional coupling. This enables precise axial and radial alignment of the housing parts 7a and 7b without the use of dowel pins or sleeves.

[0106] The sealing unit 180 has several through-openings 183 which serve to guide connecting elements 170 such as screws (see Fig. 1). These connecting elements 170 ensure that the housing parts are secured in the axial direction, while the sealing unit 180 itself, with the help of the coupling component 190, already takes care of the adjustment during assembly.

[0107] Axial alignment is ensured by the first axial contact surface 191 and the second axial contact surface 192 (see Figs. 4 and 5) of the coupling component 190, which bear against the end face sections of the housing parts. Radial alignment is achieved by the first radial contact surface 193 and the second radial contact surface 194, which bear against the inner surface sections of the housing parts.

[0108] Fig. 7 shows various views of individual components of the housing 8, including the additional sealing unit 181. View b) again shows the upper housing section 7b of the housing 8, as it is essentially already shown in view a) of Fig. 6. Here, too, the sealing surface 155 is visible, which in the axial direction z serves as a contact surface for the sealing component 182 of the additional FAZ-105-PCT 29 30.09.2025

[0109] Sealing unit 181 serves this purpose. The upper housing section 7b is designed to enable precise alignment and sealing with the housing cover 7c.

[0110] In view a) of Fig. 7, the housing cover 7c, or the third housing part 7c of the housing 8, is shown. The housing cover 7c has several through-openings 183, which serve for the passage of connecting elements 170 (see Fig. 1). A recess 171 is also present, which can be used for the passage of electrical connections, for example, from the e-bike battery to the electric motor. The sealing surface 155 is also visible and serves as a contact surface for the sealing component 182 of the further sealing unit 181.

[0111] View c) of Fig. 7 shows the further sealing unit 181 in a perspective view. The further sealing unit 181 comprises the sealing component 182 and the coupling component 190. The through-openings 183 are arranged in the outer corners of the sealing component 182 and serve to guide connecting elements 170 in the axial direction.

[0112] View d) of Fig. 7 shows a cross-section of the further sealing unit 181. The sealing component 182 consists of an elastic material that serves to seal between the housing parts 7b and 7c. The coupling component 190, which consists of a metallic or electrically conductive plastic material, provides the electrically conductive connection between the housing parts 7b and 7c. The coupling component 190 is bonded to the sealing component 182, preferably by vulcanization.

[0113] The additional sealing unit 181 thus performs both the function of sealing and of providing electrical conductivity between the housing parts 7b, 7c.

[0114] Sealing units 180 and 181 are rotationally symmetrical, which further simplifies component manufacturing, assembly, and sealing. FAZ-105-PCT 30 09 / 30 / 2025

[0115] The coupling components 190 of the sealing unit 180 and the further sealing unit 181 are simultaneously the structural and force-absorbing components of the sealing units 180, 181. This ensures that higher forces, which may be necessary for the mechanical connection of housing parts 7a, 7b or 7b, 7c, do not have to be absorbed or transmitted via the respective sealing components 182, which in turn can improve the durability of the sealing units 180, 181 and thus the service life of the housings 8 and the e-bike drive devices 1.

[0116] Fig. 8 shows an e-bike 4 with a bicycle frame 16 comprising a down tube 17 and a seat tube 18. The bottom bracket area 140 is also shown, with the e-bike drive unit 1 partially positioned in the bottom bracket area. The driven e-bike component 78, in this case a chainring 3, is visible and serves to transmit power to the bicycle chain. The down tube area 142 and the seat tube area 144 are also shown.

[0117] Figure 9 shows a more detailed view of the bottom bracket area 140 of the e-bike 4. The e-bike drive unit 1 is mounted in the bottom bracket area 140, with the chainring 3 and the driven e-bike component 78 visible. The mounting area 146 for the e-bike drive unit 1 provides screw connections 147 for attaching the e-bike drive unit 1 to the bicycle frame 16. The seat tube 18 is also visible in this view.

[0118] Figures 8 and 9 illustrate the integration of the e-bike drive unit 1 into the bicycle frame 16, with the arrangement of the components enabling a compact and efficient use of the available installation space. The e-bike drive unit 1 is designed to ensure both the mechanical connection and the electrical conductivity between the housing parts without requiring additional adjustment elements such as dowel pins or separate sleeves, or any further electrically conductive connecting elements. FAZ-105-PCT 31 09 / 30 / 2025

[0119] Reference symbol

[0120] 1 E-bike drive unit 126 Oil chamber connection section

[0121] 2 electric motor 140 bottom bracket area

[0122] 3 chainring 142 downtube area

[0123] 4 E-Bike 144 Seat tube area

[0124] 5 Reduction gear 146 Mounting or fastening area

[0125] 6 gears, 147 screw connections

[0126] 7a first housing part (lower 151 first end face section (of the first

[0127] Housing section) Housing part)

[0128] 7b second housing part (upper 152 first inner surface section (of the first

[0129] Housing section) Housing part)

[0130] 7c third housing part (housing cover) 155 sealing surfaces (of housing parts)

[0131] 8 Housing 161 second end face section (of the

[0132] 9 Oil second housing part)

[0133] 13 input-side gear stage 162 second inner surface section (of the

[0134] 14 output side gear stage second housing part)

[0135] 15 planetary gears 170 connecting elements

[0136] 16 bicycle frames 171 recess (of the housing cover)

[0137] 17 Down tube 180 Sealing unit

[0138] 18 Seat tube 181 Additional sealing unit

[0139] 23 Planetary gear 182 Sealing component

[0140] 24 Oil bath 183 Through opening

[0141] 25 Sun wheel 185 Ventilation recess

[0142] 26 Ring gear 190 Coupling component

[0143] 27 Conical pinion 191 First axial contact surface

[0144] 28 planetary carrier 192 second axial mounting surface

[0145] 30 Angle gear 193 first radial contact surface

[0146] 31 Motor output shaft 194 second radial mounting surface

[0147] 78 powered e-bike components 195 ventilation channel

[0148] 80 Bottom bracket axle r radial direction

[0149] 84 Input side z Axial direction

[0150] 86 Output side A Axis of rotation of the motor output shaft

[0151] 88 Output shaft of the input-side B axis of rotation of the driven e-bike

[0152] Gear stage component

[0153] 90 Input shaft of the output-side D axis of the input-side gear stage oil chamber section

[0154] 94 Output shaft of the bevel gear E Axis of the output side

[0155] 96 Bevel gear oil chamber section

[0156] 98 Ring gear G Direction of travel

[0157] 100 Input shaft of the planetary gear U axial extent of the cylindrical

[0158] 120 Total oil capacity, sub-area of ​​the outlet side

[0159] 122 inlet side oil room section oil room section

[0160] 124 outlet-side oil storage section

Claims

FAZ-105-PCT 1 30.09.2025 Patent claims 1. Housing (8) for receiving drive components of an e-bike drive device (1), comprising: - a first housing part (7a), in particular a lower housing section (7a); - a second housing part (7b), in particular an upper housing section (7b); and - a sealing unit (180) for sealing the connection of the first housing part (7a) with the second housing part (7b) in an assembly state; characterized in that the sealing unit (180) has both a sealing component (182) and a coupling component (190) that differs from the sealing component (182), wherein the sealing component (182) is configured to form the sealing connection by means of compression between the first housing part (7a) and the second housing part (7b) in the assembly state, and wherein the coupling component (190) is in contact with both the first housing part (7a) and the second housing part (7b) in the assembly state and is configured to ensure a functional coupling between the first housing part (7a) and the second housing part (7b) in the assembly state.

2. Housing (8) according to claim 1, wherein the coupling component (190) is configured for precise alignment between the first housing part (7a) and the second housing part (7b); preferably such that a predetermined axial positioning between the first housing part (7a) and the second housing part (7b) is provided; and / or preferably such that a predetermined radial positioning between the first housing part (7a) and the second housing part (7b) is provided.

3. Housing (8) according to claim 1 or 2, wherein the coupling component (190) is designed to provide an electrically conductive connection between FAZ-105-PCT 2 30.09.2025 is set up in the first housing part (7a) and the second housing part (7b).

4. Housing (8) according to one of the preceding claims, wherein the coupling component (190), viewed in the axial direction (z) and in the assembly state, preferably also in the disassembly state, has a greater axial extent than the sealing component (182).

5. Housing (8) according to one of the preceding claims, wherein the coupling component (190) has a first axial contact surface (191) for bearing in the assembly state in the axial direction (z) against a first end face section (151) of the first housing part (7a) and / or a second axial contact surface (192) for bearing in the assembly state in the axial direction (z) against a second end face section (161) of the second housing part (7b); wherein, preferably, the first axial contact surface (191) is opposite the second axial contact surface (192) and / or the first axial contact surface (191) and the second axial contact surface (192), viewed in the radial direction (r), have the same size.

6. Housing (8) according to one of the preceding claims, wherein the coupling component (190) has a first radial contact surface (193) for contact in the assembly state in the radial direction (r) against a first inner surface section (152) of the first housing part (7a) and / or a second radial contact surface (194) for contact in the assembly state in the radial direction (r) against a second inner surface section (162) of the second housing part (7b); wherein, preferably, the first radial contact surface (193) and the second radial contact surface (194) are arranged on opposite sides of the sealing component (182) when viewed in the axial direction (z) and / or the first radial contact surface (193) and the second radial contact surface (194) are of the same size when viewed in the axial direction (z) and / or the first radial contact surface (193) and the second radial contact surface (194) are arranged at the same height when viewed in the radial direction (r). FAZ-105-PCT 3 30.09.20257.Housing (8) according to one of the preceding claims, comprising a third housing part (7c), in particular a housing cover (7c), and a further sealing unit (181) for sealing the connection of the second housing part (7b) with the third housing part (7c) in an assembly state, wherein the further sealing unit (181) also comprises both a sealing component (182) and a coupling component (190) that differs from the sealing component (182); wherein, in particular, the sealing component (182) is configured to form the sealing connection by means of compression between the second housing part (7b) and the third housing part (7c) in the assembly state, and wherein the coupling component (190) is in contact with both the second housing part (7b) and the third housing part (7c) in the assembly state and is configured to ensure a functional coupling between the second housing part (7b) and the third housing part (7c) in the assembly state.

8. Housing (8) according to claim 7, wherein, in the assembled state, the second housing part (7b) is arranged between the first housing part (7a) and the third housing part (7c), and the first housing part (7a) is connected to the second housing part (7b) with the sealing unit (180) arranged between them, and the second housing part (7b) is connected to the third housing part (7c) with the further sealing unit (181) arranged between them.

9. Housing (8) according to one of the preceding claims, wherein the first housing part (7a) is the lower housing section (7a), and is preferably configured to accommodate a reduction gear (5) of the e-bike drive device (1); and / or wherein the second housing part (7b) is the upper housing section (7b), and is preferably configured to accommodate an electric motor (2) of the e-bike drive device (1); and / or wherein the third housing part (7c) is the housing cover (7c), wherein, preferably, the housing cover (7c) has a recess (171) for making electrical connections. FAZ-105-PCT 4 30.09.2025 10. Housing (8) according to one of the preceding claims, wherein the sealing component(s) (182) has / have at least two, preferably four, through-openings (183) for passing connecting means (170) along the axial direction (z) for connecting the second housing part (7b) to the first housing part (7a) and / or the third housing part (7c) to the second housing part (7b).

11. E-bike drive device (1) for providing assisting torque to a rider of an e-bike (4), comprising: - an electric motor (2) which has a motor output shaft (31); - an e-bike component driven to propel the e-bike (4), in particular a bottom bracket axle, a chainring (3) or a pulley of the e-bike (4), wherein the driven e-bike component (78) is configured to be driven in an assisted state of the e-bike drive device (1) both by the rider's muscle power and by the assisting torque of the e-bike drive device (1); and - a reduction gear (5), wherein the reduction gear (5) connects the motor output shaft (31) of the electric motor (2) to the driven e-bike component; characterized by a housing (8) according to one of claims 1 to 10.

12. E-bike (4) characterized by an e-bike drive device (1) according to claim 11.

13. Sealing unit (180) for sealing a first and a second housing part (7a; 7b) of a housing (8), preferably according to one of claims 1 to 10, for receiving drive components of an e-bike drive device (1), preferably according to claim 11, comprising both a sealing component (182) and a coupling component (190) differing from the sealing component (182), wherein the sealing component (182) forms the sealing connection by means of compression between FAZ-105-PCT 5 30.09.2025 the first housing part (7a) and the second housing part (7b) is configured in an assembly state, and wherein the coupling component (190) is in contact with both the first housing part (7a) and the second housing part (7b) in the assembly state and is configured to ensure a functional coupling between the first housing part (7a) and the second housing part (7b) in the assembly state.

14. Sealing unit (180) according to claim 13, wherein the coupling component (190) is configured for precise alignment between the first housing part (7a) and the second housing part (7b); preferably such that a predetermined axial positioning is provided between the first housing part (7a) and the second housing part (7b); and / or preferably such that a predetermined radial positioning is provided between the first housing part (7a) and the second housing part (7b).

15. Sealing unit (180) according to claim 13 or 14, wherein the coupling component (190) is configured to provide an electrically conductive connection between the first housing part (7a) and the second housing part (7b).

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