WO2023274932A1 - Insulating mask for a stator, stator, electric machine and method for producing a stator - Google Patents

Abstract

The invention relates to an insulating mask (10) for a stator (14), comprising a plurality of individual masks (28), which are designed for use on stator segments (26) of the stator (14), the plurality of individual masks (28) being disposed about an imaginary stator center point (32). According to the invention, each pair of mutually adjacent individual masks (28) is interconnected by means of at least one connecting element (30), the connecting element (30) being designed such that, when the connecting element (30) is in a first state, the two individual masks (28) in question have a predefined tangential first distance (36) from each other and that, when the connecting element (30) is in a second state, the distance between the two individual masks (28) can be changed to a tangential second distance (52), which is greater or less than the first distance (36).

Description

description

title

Insulating mask for a stator, stator, electric machine and manufacturing method for a stator

The invention relates to an insulating mask for a stator according to the species of the independent claim. The invention also relates to a stator and an electrical machine with such an insulating mask and a manufacturing method for a stator with such an insulating mask.

State of the art

The increasing electrification, especially in mobile applications, leads to a need for electrical machines with increased power density. Such machines usually use segmented stators, as this allows shorter overall lengths and higher copper fill factors compared to full-section stators. Segmented stators have the disadvantage that their production is significantly more complex and therefore more error-prone, since significantly more individual parts are brought together and assembled. For example, according to the prior art, two insulating masks must be provided for each segment of the stator, while a full-section stator generally only requires a total of two insulating masks, one for each of the two axial end faces.

Disclosure of Invention

advantages

The present invention describes an insulating mask for a stator, having a plurality of individual masks which are designed for use on stator segments of the stator. The plurality of individual masks is arranged around an imaginary center point of the stator, in particular in a largely circular manner. According to the invention, mutually adjacent individual masks with at least one Connecting element connected to one another, the connecting element being designed in such a way that in a first state of the connecting element the two individual masks in each case have a predetermined tangential first distance from one another and that in a second state of the connecting element the distance between the two individual masks can be changed to a tangential second distance which is greater or less than the first distance.

This has the advantage that the manufacture of the stator can be simplified with such an insulating mask. Due to the fact that the individual masks assigned to a stator segment are connected to one another by means of the connecting elements to form a single insulating mask, only a single insulating mask can be used for a segmented stator for each end face.

A largely circular arrangement is to be understood in particular as an arrangement which deviates from a circular arrangement by less than 20%, preferably less than 10%, particularly preferably less than 5%.

Furthermore, such an insulating mask can have the advantage that in this way all the stator segments can be arranged around an imaginary stator center by means of at least one insulating mask at a predetermined distance from one another—the first distance or second distance. In this way, it is possible to wind the stator segments without an additional tool for positioning or arranging—as is customary in the prior art.

An individual mask should be understood to mean an insulating mask for a stator segment, which is provided at least for the electrical insulation of at least one axial end face of the stator segment from at least one coil winding. A stator segment typically has a stator tooth in each case. An individual mask should advantageously be understood to mean a preferably one-piece component, in particular a component having an insulator. The individual masks are typically components which are predominantly, preferably largely completely, made of plastic. Those are advantageous Individual masks designed to be placed or pushed onto a stator segment, in particular onto one of the axial end faces of the stator segment.

The number of individual masks in an insulating mask advantageously corresponds to the number of stator teeth or stator segments. Two individual masks are preferably provided for each stator segment, which are placed in opposite axial directions from above and below on the stator segment or on the stator tooth, or in other words from above and below on the two axial end faces of the stator segment or stator tooth be put on. However, it is also conceivable for an insulating mask to be arranged on a stator only on one axial end face, preferably on the end face facing the electronics

The individual masks are connected to one another by at least one connecting element to form an insulating mask. The fact that the individual masks are connected to one another by means of a connecting element is to be understood in particular to mean that the individual masks are connected to one another at least in the first state of the connecting element. It is conceivable that the number of connecting elements corresponds to the number of individual masks or to a multiple of the number of individual masks, so that, for example, two adjacent individual masks are connected with one or two connecting elements which only connect precisely these two individual masks. However, it is also conceivable for a connecting element to connect more than two individual masks to one another, for example it is conceivable for a fork-shaped connecting element to have three extensions which are connected to three individual masks. In particular, it is conceivable that a connecting element connects all the individual masks of the insulating mask with one another, for example it is possible for the connecting element to run around the imaginary center point of the stator, in a somewhat circular manner, and to be arranged inside or outside of the individual masks and each of the individual masks on a radially inner or is contacted or connected radially outer point.

Adjacent individual masks are advantageously formed in one piece with the connecting elements connecting them. In this context, one-piece is to be connected, in particular, in a materially bonded manner, such as by a welding process and/or a gluing process etc. and particularly advantageously molded, such as by being produced from a single cast and/or by being produced in a one-component or multi-component injection molding process.

It is also possible for the insulating mask to be formed in several pieces or from a plurality of sections, in particular for the individual masks and the connecting elements to be formed as sections. It is also conceivable that a number of individual masks are formed in one piece with one or two connecting elements. For example, it is conceivable that two individual masks are connected with a connecting piece in a positive or non-positive manner.

The fact that the connecting elements have a first state in which two adjacent individual masks have a predetermined tangential first distance from one another and can be converted into a second state has the advantage that the insulating mask can serve as a holding element over several process steps during production, further simplifying the process.

For example, it is conceivable that in a first state the first distance is large, so that the stator teeth can easily be wound, in particular for needle winding. In the second state, it is possible for the second distance to be reduced to such an extent that the stator segments directly abut or contact one another, so that they assume their final position in the stator and can be fixed in this position relative to one another in a further process step

In principle, it is conceivable that the connecting element is designed in such a way that the distance between the individual masks can be changed in that the connecting element is designed to be movable and/or deformable, in particular plastically or elastically deformable. For example, the connecting element can be designed as a flap mechanism or as an elastic spring element. Such connecting elements can preferably switch between the first state and the second state several times.

It is also conceivable that the connecting element is designed in such a way that the distance between the individual masks can be changed by the connecting element is severed and / or removed, for example by a cutting tool or a punching tool. In this case, there is a first state with a defined first tangential distance when the connecting element connects at least two individual masks. After the connecting element has been severed or removed, the previously connected individual masks can move freely, so that a second state is present in which a second tangential distance can be set by appropriately arranging the individual masks.

Advantageous developments of the insulating mask are possible as a result of the features listed in the dependent claims.

An advantageous embodiment is when the connecting element connects two adjacent individual masks to each other at the tangential first distance and has a separation point, so that the second state can be produced with any tangential second distance by separating the two individual masks at the separation point. This makes it possible to provide a rigid connecting element which ensures the first distance in a particularly reliable manner, for example for winding the coils. Furthermore, the point of separation enables a particularly simple and therefore reliable separation of the two individual masks. The separation point can in particular be designed as a predetermined breaking point, for example by a notch or constriction on the connecting element. It is also conceivable that the predetermined breaking point or separation point is formed by a narrowing on or along the connecting element.

It is also advantageous if the individual masks each have a yoke section arranged radially on the outside, which is designed to cover a yoke area of the stator segment, and that one connecting element is connected to tangential sides of the respective yoke sections that are directed toward one another on two adjacent individual masks. A tangential side is to be understood as meaning the side which is arranged adjacent to the tangential intermediate area between two adjacent individual masks. This enables a compact construction of the insulating mask, which is easy to handle in the manufacturing process. The yoke section is advantageously formed in one piece with the individual mask. It is conceivable that the individual mask has a tooth section arranged radially on the inside, which is designed to cover the stator tooth or a stator tooth end face. The tooth section is advantageously formed in one piece with the individual mask.

The insulating mask is further improved if the at least one connecting element is arranged largely completely outside of an imaginary first radius and largely completely within an imaginary second radius, with the first radius defining the smallest distance between the yoke sections and the imaginary stator center and the second radius defining the largest Defined distance of the yoke sections to the imaginary center of the stator. In other words, there is an advantageous insulating mask when the at least one connecting element is arranged largely completely between the first radius and the second radius. In this way, the at least one connecting element can be separated particularly easily and reliably during manufacture of the stator, particularly in the case of a pre-cut stator, when separating the stator segments, for example when separating the stator segments using wedges. In particular, separation points or predetermined breaking points of the at least one connecting element or connecting elements can be arranged outside of the imaginary first radius and inside of the imaginary second radius.

The fact that an element is arranged largely completely outside or inside an area should be understood in particular to mean that the element is at least 80%, preferably at least 90%, particularly preferably at least 95% of its volume, its mass or its surface outside or inside from the area is located.

An alternative improvement of the insulating mask is possible if the at least one connecting element has at least one protruding section which is arranged outside the second radius or inside the first radius. This is a separation of at least one connecting element or the Connection elements simplified because the cutting tool only has to be guided to the protruding section outside of the stator base area. For example, it is conceivable that the connecting element is separated when it is placed in a tool carrier for the stator or the stator segments. A separation point or predetermined breaking point is advantageously arranged on the protruding section. It is conceivable that the connecting element is arranged largely completely outside the second radius or within the first radius, for example the connecting element can be connected on each side of the individual masks that runs along the second radius or first radius.

An insulating mask in which the at least one connecting element is connected to the yoke sections radially on the outside enables a particularly good winding process. Because the at least one connecting element or the connecting elements is or are connected on the outside, a winding nozzle, for example, can be guided much more easily in an area between two individual masks. In particular, the connecting element can be arranged largely completely outside the second radius in this way. A further advantage of the at least one connecting element or the connecting elements being connected to the yoke sections radially on the outside is that a separation point or predetermined breaking point of the connecting element can be arranged directly on the yoke section. This enables the connecting element to be completely separated from the individual masks.

The fact that the connecting element is connected to the yoke sections radially on the outside should be understood in particular to mean that the connecting element is connected to the individual mask on an outside of the individual mask, which is arranged on the second radius or runs along the second radius.

A variant that can be produced particularly cheaply is when the at least one connecting element is designed as a gating element, preferably having a gating frame and/or a gating spider. The insulating mask is advantageously designed entirely as an injection molded part. The insulating mask particularly advantageously has exactly one connecting element which connects all the individual masks to one another. This has the additional advantage that an optimal injection molding process can be guaranteed. Better quality can be guaranteed in the individual masks because the connecting element, which is separated off during the manufacturing process of the stator, serves as a sprue element. In particular, an optimal injection position can be selected, for example from a mold flow simulation. In addition, an optimal position at which the connecting element is connected to the respective individual masks can be selected so that the individual masks have an optimized structure, for example wall thickness changes due to unfavorably positioned connecting elements can be avoided in this way. Overall, this makes it possible to provide a high-quality, robust and therefore reliable insulating mask.

In advantageous embodiments, the at least one connecting element is designed as a film hinge, with two adjacent individual masks having a tangential end distance when the film hinge is in a first, folded-up state, and two adjacent individual masks having a tangential winding distance in a second, opened-up state of the film hinge. which is greater than the end distance. In this way, the stator segments inserted into the insulating mask can be brought into the winding spacing for winding by opening the film hinge and then brought together again by folding them shut. As a result, the step of severing the at least one connecting element or connecting elements is no longer necessary, which simplifies the manufacturing process.

A further improvement is possible if the insulating mask has a contacting element for electrical contacting on at least one individual mask, in particular a pocket for an insulation displacement connection. This has the advantage that only as many contacting elements as are necessary can be arranged on the insulating mask. For example, the seven pockets for insulation displacement connections (IDC) of a 12/10 pre-cut stator with delta 2-fold parallel connection can be distributed arbitrarily over the twelve individual masks, so that five of the individual masks do not have an IDC pocket. If one were to use an individual insulating mask for each stator segment, as in the prior art, then insulating masks would be needed with and without SKV pockets, each requires a different tool and thus almost twice the tool costs and a significantly more complex manufacturing process. Therefore, insulating masks with SKV pockets are usually always used in the prior art, although not all of them are needed. With the present invention, material can thus be saved compared to the prior art.

In alternative embodiments, contacting elements other than pockets for SKV are also conceivable, for example hot-stacking hooks, which open upwards to accommodate the connecting wires, or two pins, which allow the connecting wires to be clamped so that a connecting board can be contacted,

The insulating mask is further improved if the individual masks have a tooth section which is designed to cover a stator tooth of the stator segment extending out of the yoke region, with grooves running around the tooth section around an imaginary radial axis of tooth extension being formed, which are provided for laying a winding wire . In particular, the grooves can be arranged on the axial end faces of the tooth section. This enables a more reliable winding process. It is also conceivable that the tooth sections each have one or two areas extending in the axial direction, which insulate for at least partial covering and electrical insulation of the stator teeth along the axial direction or intended axis of rotation. In other words, the axially extending areas of the tooth cuts are designed to at least partially cover the stator teeth in the spaces between the stator teeth or in the stator slots and to insulate them electrically from the winding wire.

Alternatively, it is also conceivable that the tooth section only essentially covers the axial end face of the stator teeth and the stator teeth are insulated in the stator slots, for example with insulating paper.

A further improvement is possible if areas of the tooth sections extending in the axial direction have at least partially a smooth surface without grooves, which are used to guide separating wedges, in particular for the Production of pre-cut stators are provided. This enables a more reliable separation of pre-cut stators, since the grooves cannot be damaged by separating wedges or the separating wedges cannot be misguided. It is conceivable that the axially extending areas of the tooth sections have two or more smooth surfaces, each of which is separated by at least one axially extending groove for the winding wire.

Also advantageous is a method for manufacturing a stator from a plurality of separate stator segments, which have a yoke area from which a stator tooth extends radially inwards, characterized by the following steps:

- providing an insulating mask, in particular an insulating mask according to the present invention, having a plurality of individual masks which are arranged around an imaginary center point of the stator, preferably arranged in a largely circular manner and individual masks which are adjacent to one another are connected to one another with at least one connecting element,

- arranging the stator segments in a single mask,

- arranging the stator segments with the stator teeth aligned radially towards the stator center, and with a tangential winding distance between adjacent yoke areas,

- winding of the stator teeth using needle windings, in particular with single-tooth coils,

- Radial compression of the stator segments to a final distance, in particular until the yoke areas of the stator segments touch tangentially,

- Mechanical connection of the individual stator segments.

The method offers the advantage that the process chain for a segmented stator does not differ from the process chain for manufacturing a full-cut stator, apart from cutting into individual teeth in the case of pre-cut stators. This means that existing and tried-and-tested production systems can continue to be used.

In particular, it is also possible that by arranging the separate stator segments around an imaginary stator center point, preferably circular, all the stator segments in one process step are wound with an uninterrupted, fully wound winding wire like a full-cut stator by means of needle winding can be. There is no electrical contact between the individually wound stator segments and the tangential winding distance between the stator segments makes it possible to still achieve a high copper fill factor - as with the winding of individual tooth segments. The connecting wires between the single-tooth coils can advantageously be pressed radially inwards simultaneously with the radial compression of the stator segments in the same tool, so that an additional assembly step for the final positioning of the connecting wires is advantageously eliminated.

Exactly one individual mask is advantageously assigned to each stator segment or each stator tooth. It is conceivable that the stator segments that have already been separated are arranged in the insulating mask or in the individual masks. It is also conceivable that the stator segments which are still connected or at least partially connected to one another in a basic stator body are arranged in the insulating mask or in the individual masks. These are separated before the winding, preferably in one step together with the separation of the individual masks or when the connecting element is transferred into the second state.

In particular, the arrangement of the stator segments in an individual mask should be understood to mean that either individual or isolated stator segments are already arranged in the insulating mask or contiguous individual masks, but it should also be understood that the stator segments are arranged in an interconnected arrangement in the insulating mask are, for example, as a stator base body, in particular pre-cut stator base body, which are separated at a later process step, for example before winding.

When the stator segments are radially compressed in variants with a connecting element designed as a film hinge, the film hinges are folded together so that the individual masks that are adjacent to one another have the tangential end distance from one another. In principle, it is possible for the stator to be produced with one or two insulating masks. In the case of methods with two insulating masks, these can be arranged on the stator segments or on the stator base body in directly consecutive (partial) process steps. Alternatively, the stator segments or the stator base body can first be arranged in the first insulating mask, then further process steps can be carried out, for example the isolation of a pre-cut stator base body, and then the second insulating mask can be arranged.

A manufacturing process is particularly advantageous in which a stator base body that is closed all the way around and is produced using pre-cut technology and has the stator segments, which is arranged in the insulating mask in such a way that the stator segments are each arranged in an individual mask, and when the stator base body is separated to individual stator segments, in particular by means of separating wedges, the insulating mask is separated by separating the at least one connecting element into individual individual masks, which are each arranged on the stator segments, and that the individual stator teeth are then wound. Advantageously, the separation of the stator base body into individual stator segments is carried out with the same process step as the separation of the insulating mask into individual masks, in particular with the same tool. For example, it is conceivable that the separating wedges have a correspondingly arranged cutting element, which separates the connecting elements when the separating wedge is inserted between the stator segments.

With the pre-cut technology, the stator segments are made up of individual layers of laminations. In this case, individual stator segments are punched out of a circumferentially closed layer of laminations using pre-cut technology, so that the adjacent stator segments of each lamina layer remain connected to one another by means of a predetermined breaking point. To do this, the stator segments of each laminated layer are first only partially punched through, and then pushed back into their original axial position in a further step, so that the individual stator segments remain connected to one another only through small plastic deformations. After that, several layers of lamellae are put together axially to form a basic stator body, in particular by means of stamped stacking. The basic stator body is separated into individual stator segments, in particular by separating wedges. According to a preferred embodiment, the stator base body can be inserted into the insulating mask before it is separated, so that the insulating mask is also separated during separation, so that the individual stator segments are provided with the individual masks. After that, these stator segments can be fixed with a segment carrier for winding, and after they have been wound, they can be reassembled radially to form the stator, exactly in the way in which the stator segments were previously connected to one another via the predetermined breaking points.

Alternatively, a production method is advantageous in which a circumferentially closed stator base body produced using pre-cut technology and having the stator segments, which are connected to one another with connecting elements, is arranged in the insulating mask in such a way that the stator segments are each arranged in an individual mask and then the stator base body is separated into individual stator segments, in particular by means of separating wedges. The individual stator teeth are then wound and the insulating mask is separated into individual masks by separating the connecting elements. The connecting elements are preferably separated in a sub-process step during winding, in particular in the winding machine, or directly after winding.

A manufacturing method is also advantageous in which individual or isolated stator segments are arranged in the insulating mask in such a way that the stator segments are each arranged in an individual mask, the stator teeth are then wound and the individual masks are then separated by separating the at least one connecting element. This has the advantage that the insulating mask fixes the stator segments when winding. In particular, the insulating mask functions as a segment carrier.

A winding distance between the individual masks and thus the stator segments is preferably produced via the at least one connecting element or the connecting elements. After winding and separating the at least one Connecting element or the connecting elements, the stator segments can be compressed radially in the individual masks. This variant is conceivable for conventional stator segments or pre-cut stator segments, with the pre-cut stator base body being isolated before the stator segments are arranged in the insulating mask. After winding and separating the at least one connecting element or connecting elements, the pre-cut stator segments can be radially compressed in the individual masks so that the stator segments are joined together exactly as they were previously connected to one another via the predetermined breaking points.

In a further advantageous variant of the method, the at least one, preferably a plurality of connecting elements is designed as film hinges. In this case, two adjacent individual masks have a tangential end distance when the film hinge is in a first folded state. In a second, opened state of the film hinge, two adjacent individual masks have a tangential winding distance that is greater than the final distance. The stator segments are each arranged in individual masks and the stator teeth in the insulating mask are wound with the film hinge or film hinges in the second, unfolded state and after the winding the film hinge or film hinges are folded back into the first state. This variant also has the advantage that the insulating mask fixes the stator segments during winding and, in particular, acts as a segment carrier. In addition, the use of the film hinge or film hinges as connecting elements has the advantage that no cutting or separating tools are required in the manufacturing process.

A particularly advantageous production method is when a circumferentially closed stator base body produced using pre-cut technology and having the stator segments, which are connected to one another with predetermined breaking points, is arranged in the insulating mask in such a way that the stator segments are each arranged in a single mask. When the stator base body is arranged in the insulating mask, the film hinges are in the first, folded state. During the subsequent separation of the stator body into individual stator segments, in particular by means of separating wedges, the film hinges are Insulating mask at least partially opened, and the film hinges then, if necessary, fully opened to the winding of the stator teeth in the second state. After winding, the film hinges can be folded into the first, folded state, so that the pre-cut stator segments are radially compressed in the individual masks, so that the stator segments are joined together exactly as they were previously connected to one another via the predetermined breaking points.

The production method is further improved if the stator segments are mechanically connected to one another after being radially compressed by means of gluing or welding—in particular laser welding—or clamping—and in particular are inserted axially into a stator housing. In this way, the stator segments are firmly fixed to one another. Two adjacent stator segments are advantageously connected to one another on the outer circumference, for example by means of laser welding. Alternatively, the stator segments can also be connected to one another by a form fit, for example by means of a connecting lug on one stator segment with a corresponding recess on the adjacent stator segment, which are correspondingly clamped together. Because the stator segments are inserted into a stator housing, the stator segments are permanently held in an exact position relative to one another. The stator segments can advantageously be pressed into a stator housing. This can be done, for example, by means of thermal shrink presses.

A stator manufactured with an insulating mask according to the present invention and/or with a method according to the present invention is also advantageous. Such a stator enables better copper fill factors and smaller overall lengths - and thus a higher power density - than full-section stators, but can be produced almost as easily as a full-section stator.

A stator in which the outer circumference of the yoke areas has sections in the shape of a circular arc and/or is formed with a flat surface, and in particular the stator segments are composed of individual, axially stacked laminations, has the advantage that in this way the outer diameter of the stator base body can be reduced. In a further variant, flattened areas and approximately circular areas can also alternate in the circumferential direction in order to ensure the exact assembly of the stator segments in a stator base body produced using pre-cut technology.

In advantageous variants, the stator has exactly six or nine or twelve or eighteen stator segments or stator teeth, with all individual tooth coils of the stator segments being connected to one another via a single wound winding wire. In this way, a stator with a high power density can be made available in a small installation space. For example, radially exactly two opposing stator segments are wound directly one after the other, so that the winding wire between the opposing stator segments extends approximately over half the outer circumference of the stator base body.

The stator is advantageously used for an electrical machine in which the rotor has integrated permanent magnets. These permanent magnets can be arranged, for example, like spokes (longitudinal direction of the magnets in the radial direction) or tangentially (longitudinal direction in the circumferential direction). The stator of the electric motor can, for example, be glued inexpensively into a housing part. The stator can preferably be electronically commutated by means of an electronics unit.

The present invention is particularly advantageous for motor topologies of permanent magnet synchronous motors with small stator diameters, in particular less than 35 mm, in particular for example 3/2, 6/4, 9/6, 12/8, 12/10, 12/14, 15/ 10, 18/12, 18/14, 18/16 of the 18/20 topologies.

drawings

The drawings show exemplary embodiments of the insulating mask, the stator and the electrical machine according to the present invention and are explained in more detail in the following description. Show it FIG. 1 shows an electrical machine with a stator with an insulating mask according to the invention,

Figures 2 and 3 detailed views of the insulating mask,

Figures 4 to 9 different variants of the insulating mask,

FIGS. 10 to 14 a variant of the insulating mask in different stages of the manufacturing process,

FIGS. 15 to 18 another variant of the insulating mask in different stages of the manufacturing process,

FIG. 19 detailed views of an individual mask and

FIGS. 20 to 23 different embodiments of contacting elements.

description

The same parts are given the same reference numbers in the different design variants.

FIG. 1 shows an insulating mask 10 according to the present invention in an electrical machine 12 in an exploded view. The insulating mask 10 is arranged on a stator 14 . The electrical machine 12 has a stator housing 16 for accommodating the stator 14 . The electrical machine 10 is designed as an internal rotor machine, in which a rotor (not shown) is arranged inside the external stator 14 .

Furthermore, the electrical machine 10 has an electronics box 18 . Electronics box 18 has electronics, in particular power electronics, which are provided for controlling stator coils of stator 14 . The insulating mask 10 is arranged, for example, on the electronics side, ie on the end face of the stator 14 facing the electronics box 18 . Pockets 22 for the insulation displacement connections (SKV pockets) are formed as contacting elements 21 on the insulating mask 10, into which the winding wire is inserted. The corresponding SKV elements 20 can be inserted into these SKV pockets 22, by means of which the electrical windings of the stator 14 are contacted. The insulating mask 10 has, for example, four contacting elements 21, see Figure 2.

By way of example, the electrical machine 12 is designed as an EC machine with a 6/4 motor topology, which is why the stator 14 has six stator teeth 24 which are each arranged on a stator segment 26 . The rotor, not shown, has four poles.

FIG. 2 shows a detailed view of the insulating mask 10 of the exemplary embodiment illustrated in FIG. The insulating mask 10 has, for example, six individual masks 28 which are connected to one another with connecting elements 30 . FIG. 3 shows the insulating mask 10 in an axial plan view and mounted on the stator 14. FIG. As can be seen clearly, the individual masks 28 are arranged around an imaginary center point 32 of the stator.

In the exemplary embodiment shown in FIGS. 2 and 3, the connecting elements 30 are in a first state and hold the individual masks 28 at a first tangential distance 36. The first tangential distance 36 is, for example, from a tangential extension 38 of the individual mask 28 or of the yoke section.

The stator 14 has a plurality of stator segments 26 , for example six, which each have a stator tooth 24 . The stator segments 26 form a stator base body 34. The outer diameter of the stator base body is for example less than 35 mm. In the exemplary embodiment shown in FIGS. 1 to 3, the stator segments 26 are T-shaped, for example, and have a yoke area radially on the outside, from which the stator tooth 24 with a toothed shaft extends radially inward. Tooth bases are formed at the radially inner end of the tooth shafts, which then form the magnetic poles for the rotor mounted radially inside the stator 14 .

The individual masks 28 are arranged on the stator segments 26 in FIG. In the exemplary embodiment shown, the individual masks 28 have a yoke section 40 radially on the outside, which largely covers the axial end face of the yoke area of the stator segment 26 .

The fact that an element largely covers an area is to be understood in particular to mean that the element covers the area by at least 80%, preferably at least 90%, particularly preferably at least 95%.

A tooth section 42 extends radially inward from the yoke section 40 and largely covers the axial end face of the stator tooth 24 .

For example, the tooth section 42 also has two areas each, which extend along an axial direction on both sides of the stator tooth 24, see Figure 2. In the axial plan view, the individual masks 28 are, for example, T-shaped, matching the geometry of the end face of the stator segments 26 , see Figure 3.

The yoke sections 40 define an imaginary first radius 44 around the imaginary stator center 32 , the first radius 44 defining the smallest distance between the yoke sections 40 and the stator center 32 . Furthermore, the yoke sections 40 also define an imaginary second radius 46 around the imaginary stator center 32 , the second radius 46 defining the greatest distance between the yoke sections 40 and the stator center 32 .

The connecting elements 30 are largely outside of the second radius 46. For example, the connecting elements 30 are U-shaped or designed in the manner of a loop. Connection element 30 is an example arranged largely completely outside of the second radius 46 and thus represents a protruding section 48 of the connecting element 30. The connecting elements 30 each make contact with two individual masks 28 on the radially outer edge of the yoke sections 40. The connecting elements 30 each contact, for example, directly on two adjacent individual masks 28 mutually directed tangential sides of the respective yoke sections 40. Starting from a yoke section 40 of an individual mask, the connecting element 30 shown in Figure 3 initially extends radially outwards and then has a semicircular course over the first tangential distance 36 in the direction of the adjacent individual mask 28 and then extends counter to the radial direction onto the yoke section 40 of the adjacent individual mask 28 and connects to it. The loop-like connecting elements 30 shown in FIGS. 2 and 3 with a section 48 projecting radially outwards can be easily cut off or punched off or detached.

The insulating mask 10 shown in Figures 2 and 3 is particularly suitable for a method for manufacturing a stator 14, in which the insulating mask 10 in a sub-process step when winding the stator teeth 24 in a needle winding machine or needle winding system or directly after winding to be separated. For example, the method for manufacturing the stator 14 could be as follows: inserting the pre-cut stator body 34 in the split state into a cutting tool and separating the pre-cut stator segments 26, for example by double wedges per winding space between the stator teeth 24. The next step is the first lower insulating mask 10 or the one opposite the electronics side is placed in the needle winding tool without contacting elements 21 and then the separate stator segments 26 are inserted into this lower insulating mask 10 . In the next step, the second, upper electronics-side insulating mask 10 with contacting elements 21 is placed on the stator segments 26 . Subsequently, the stator teeth 24 are wound with needle windings and the individual masks 28 are separated by, for example, the connecting elements 30 being severed or severed using a cutting or stamping tool. This wound segments can now be assembled and fixed in a stator assembly system to form the stator.

Figure 4 shows a variant of the embodiment of the insulating mask 10 shown in Figures 2 and 3. The insulating mask 10 shown in Figure 4 has essentially the same properties and features as the insulating mask from Figure 3, the main difference being the shape of the connecting element 30. By way of example the connecting element 30 is arranged largely completely outside of the second radius 46 and thus represents a protruding section 48 of the connecting element 30. The connecting elements 30 each make contact with two individual masks 28 on the radially outer edge of the yoke sections 40. The connecting elements 30 each make contact directly on von two adjacent individual masks 28 mutually tangential sides of the respective yoke sections 40. Starting from a yoke section 40 of an individual mask 28, the connecting element 30 shown in FIG scurved course, which merges into a straight section, which extends essentially in the tangential direction. This is followed by a course of the connecting element 30 in the shape of a quarter circle, which leads into a section which then extends counter to the radial direction towards the yoke section 40 of the adjacent individual mask 28 and contacts or connects with it. In this way, the connecting elements 30 shown in FIG. 4 have a comparable extent in the radial direction to the connecting elements in FIG. 3, but have a significantly greater tangential extent. A greater tangential distance 36 of the individual masks 28 from one another can thus also be provided. For example, in the first state of the connecting elements 30, the tangential distance 36 in the variant shown in Figure 4 is 70% of the tangential extension 38 of the individual mask 28 or of the yoke section 40.

The loop-like or bow-like connecting elements 30 shown in Figure 4 with a radially outwardly projecting section 48 can be easily cut off or punched off or separated. The larger tangential distance 36 compared to the variant in FIG. 3 enables simpler needle winding since the winding tool or the winding nozzle has more tangential space between the stator teeth 24 available. In such variants, the first tangential distance 36 produced by the connecting elements 30 is advantageously chosen such that it corresponds to the necessary distance in the needle winding process. The first tangential distance 36 is advantageously large enough that the needle winding nozzle can pass through the tangential gap between the stator teeth 24 and wind around the stator tooth 24 with the maximum number of turns and even then there is still enough space for the nozzle to pass between the wound teeth .

FIG. 5 shows the insulating mask 10 from FIG. 4 mounted on the stator segments 26 and with the connecting elements 30 already separated or removed . The connecting elements 30 are thus in a second state, in which the individual masks 26 have a tangential second distance 52 from one another, which differs from the tangential first distance 36 in the first state. For example, the stator segments 26 with the individual masks 28 are arranged directly next to one another, the tangential second distance 52 is 22% of the tangential extent 38 of the individual mask 28 or of the yoke section 40.

Figures 6 shows another variant of the insulating mask 10 from Figure 3. The insulating mask 10 shown in Figure 6 has essentially the same properties and features as the insulating mask from Figure 3, the main difference being the shape and type of the connecting element 30. The insulating mask 10 is manufactured using an injection molding process and the sprue or injection frame forms a connecting element 30 which connects all the individual masks 28 to one another. In FIG. 6, the connecting element 30 or the injection frame is designed, for example, as a radially outer injection frame. As can be clearly seen in FIG. 6, the connecting element 30a has a base frame 30a which runs around the imaginary stator center point 32 and is arranged outside the second radius 46 . For example, the base frame 30a has a hexagonal design, with each of the six sides of the base frame being assigned to one of the six individual masks 28 . In variants with n individual masks 28, it is conceivable that the base frame 30a is in the form of an n-gon. However, other geometries are also conceivable, for example a circular or largely circular base frame 30a. For example, the sides of the base frame 30a run along the longitudinal direction or circumferential direction of the respectively assigned individual mask 28 or the assigned yoke section 40.

The connecting element 30 has webs 30b. Two webs 30b extend radially inwards from each side of the base frame 30a, for example. In the first state, both webs 30b are connected to the individual mask 28 assigned to them. The webs 30b contact the individual mask 28 assigned to them at the radially outer edge of the yoke sections 40. The entire connecting element 30 is thus arranged largely completely outside of the second radius 46 and thus represents a completely protruding section 48 of the connecting element 30.

For example, the webs 30b have constrictions 54 at the point of contact with the individual mask 28, at which the webs 30b are constricted or taper to a point on the individual mask 28. By way of example, the webs 30b have a round cross section. The constrictions 28 are designed, for example, as truncated cones, which are connected to an individual mask 28 at their tip. In addition, the webs 30b can have predetermined breaking points 56 at the connection points to the base frame 30a. The webs 30b can thus be easily broken out in the manufacturing process, so that the second state of the connecting element 30, in which the individual masks are freely movable, can be easily produced. FIG. 6 shows an insulating mask 10 in which two individual masks 28 each have a web 30b cut out. Can be clearly seen at the point of detached web 30b, the respective severed predetermined breaking point 56 on the base frame 30a and a separation point 50 on the individual mask 28.

FIG. 7 shows an alternative variant of the insulating mask 10 from FIG. 6. Here, too, the connecting element 30 is produced using an injection molding process, with the sprue forming a connecting element 30 which connects all the individual masks 28 to one another. The embodiment in FIG. 7 differs from the embodiment in FIG. 6 in that the connecting element 30 is not designed as a radially outer injection frame, but as a radially inner injection spider. As can be seen in FIG. 7, the connecting element 30 has a basic axis 30c, which runs along an imaginary axis of symmetry or axis of rotation of the insulating mask 10. In other words, the basic axis 30c runs in the axial direction through the imaginary stator center 32.

For example, six webs 30b extend radially outwards from the basic axis 30c at the stator center point 32 . A web 30b is assigned to each individual mask 28, for example. In the first state, the webs 30b are each connected to the individual mask 28 assigned to them. The webs 30b make contact with the individual mask 28 assigned to them at the radially inner edge of the tooth cuts 42 of the insulating masks. The entire connecting element 30 is thus arranged largely completely within the first radius 44 and thus represents a completely protruding section 48 of the connecting element 30.

The two variants of connecting elements 30 shown in FIGS. 6 and 7 as a casting element from an injection molding process with a section 48 projecting radially outwards or inwards can be easily cut off or punched off or separated.

FIGS. 8 and 9 show an alternative embodiment of insulating mask 10 according to the invention. Such an insulating mask 10 is for a stator 14 with twelve Stator segments 26 or provided with twelve stator teeth 24. For example, such a stator is suitable for a machine with a 12/8, 12/10 or 12/14 topology, ie in particular with a rotor which has eight, ten or 14 poles.

FIG. 8 shows an axial top view of a section of the insulating mask 10 with four visible individual masks 28. FIG.

As can be seen clearly, the connecting elements 30 each have a taper or constriction 54 in the axial plan view. In the radial side view, for example, the upper connecting element 30 arranged closer to the axial end face has a tapering or constriction 54 . This has the advantage that both connecting elements 30 can be separated with a tool with one cut, in particular an axial punching cut, or cut in a cutting tool in one step. A free space behind the respective connecting element 30 is advantageously provided at least in one axial direction, particularly advantageously in both axial directions, so that a complete breakdown or sectioning is possible.

Similar to the previous embodiments, the individual masks 28 are T-shaped in the axial plan view. The individual masks 28 have a yoke section 40 radially on the outside and a tooth section 42 extending radially inward. The yoke sections 40 define the imaginary first radius 44 and the imaginary second radius 46 around the imaginary stator center point 32, which is not shown in Figures 8 and 9.

As can be clearly seen, the two connecting elements 30 are arranged inside the second radius 46 and outside the first radius 44 . In other words, the connecting members 30 are between the mutually facing tangential sides of the respective yoke portions 40 of two mutually adjacent individual masks 28 are arranged. The connecting elements 30 extend in the tangential direction or in the circumferential direction. The connecting elements 30 contact or connect, for example, directly on the mutually directed tangential sides of the respective yoke sections 40 of the two adjacent individual masks 28. In this way, the connecting elements 30 form bridges between the individual masks 28, in the exemplary embodiment shown advantageously two bridges each. The advantage of such a double or multiple number of connecting elements 30 between two adjacent individual masks 28 is the increase in stability and torsional rigidity of the entire insulating mask 10.

For example, in the first state of the connecting elements 30, the tangential first distance 36 in the variant shown in Figure 9 is 16% of the tangential extension 38 of the individual mask 28 or of the yoke section 40.

The second state of the connecting elements 30 can be produced by separating or cutting up the connecting elements 30 .

The embodiment of the insulation mask 10 shown in FIGS. 8 and 9 is particularly well suited for use with a pre-cut stator base body 34. Advantageously, the connecting elements 30 can also be separated into individual stator segments 34 when the pre-cut stator base body 34 is separated, so that stator segments 34 insulated on one or both sides are present and can be wound on.

For example, the method for producing the stator 14 with the insulating mask 10 according to FIGS. 8 and 9 could be as follows: inserting the first lower insulating mask 10 or the opposite side of the electronics side into a separating tool, inserting the pre-cut stator base body 34 in the separated state . In the next step, the second, upper electronic-side insulating mask 10 with contacting elements 21 is placed on the unseparated pre-cut stator base body or its connected stator segments 26 . Then the pre-cut Stator segments 26 isolated, for example by inserting double wedges per winding space between the stator teeth 24, the individual masks 28 being separated by separating the connecting elements 30, for example by a stamping die or a cutting die. The individual masks 28 are preferably separated in the same process step as the separating of the pre-cut stator segments 26 or in a sub-process step of separating the pre-cut stator segments 26. The separated and insulated stator segments 26 are then inserted into the needle winding tool and stator teeth 24 are also wound , preferably in the through-winding process depending on the desired interconnection principle or winding scheme. These wound stator segments 26< can now be assembled and fixed in a stator assembly plant to form the stator.

FIG. 10 shows a variant of the insulating mask 10 from FIGS. 8 and 9. This variant is characterized in that two individual masks 28 that are adjacent to one another are connected to one another with precisely one connecting element 30 . The connecting element 30 is arranged between the first radius 44 and the second radius 46, for example directly at the second radius 46. The connecting element 30 extends in the tangential direction or in the circumferential direction. The connecting element 30 makes contact or connects, for example, directly on the mutually directed tangential sides of the respective yoke sections 40 of the two adjacent individual masks 28. In this way, the connecting element 30 forms a bridge between the individual masks 28. By way of example, the connecting element is designed in the form of a strip, it has an axial extension 58 in the axial direction. For example, this axial extension 58 is about 40% of the first tangential distance 36 of the individual masks 28. The first tangential distance 36 of the individual masks 28 corresponds in particular to a tangential extension of the connecting element 30 or an extension of the connecting element 30 in the circumferential direction. The advantage of a connecting element 30 with a sufficient extension 58 in the axial direction is that in this way the stability and torsional rigidity of the entire insulating mask 10 can be increased.

In the example shown in FIG. 10, the insulating mask 10 has twelve individual masks 28, which are provided for use with twelve stator segments 26 and twelve stator teeth 24, respectively. The insulating mask 10 on the electronics side is shown. The insulating mask 10 has, in particular, seven contacting elements 21 which are arranged on the respective yoke sections 40 of seven individual masks 28 . By way of example, in the variant in FIG. 10, the contacting elements 21 are designed as insulation displacement connection (IDC) pockets. IDC pockets are special SKV pockets 22, which ensure a gas-tight connection between enameled wire and an insulation displacement terminal and thus a particularly reliable electrical connection. The insulating mask 10 shown in FIG. 10 can advantageously be produced using an injection molding process, in which the insulating mask 10 is sprayed on from the inside.

To illustrate the steps of a manufacturing method for a stator 14, FIGS. 11 to 13 show the insulating mask 10 from FIG. 10 together with the stator base body 34 in different phases of the method.

In FIG. 11, the stator base body 34 is already present in the form of individual or isolated stator segments 26, on which the electronics-side insulating mask 10a is arranged on one axial end face and the electronics-facing insulating mask 10b on the other axial end face. The electronics-side insulating mask 10a corresponds to the insulating mask 10 shown in FIG. The insulating mask 10b facing away from the electronics is constructed largely like the insulating mask 10a on the electronics side, but without the contacting elements 21. Both insulating masks 10a, 10b have individual masks 28a, 28b, which are each connected to connecting elements 30a, 30b. Therefore, two adjacent stator segments 26 are connected in total with two connecting elements 30, one on the electronics side Connecting element 30a from the electronics-side insulating mask 10a and to a connecting element 30b facing away from the electronics from the insulating mask 10b facing away from the electronics.

In FIG. 11, the connecting elements 30 are in a first state in which the insulating masks 10 and thus the stator segments 26 are at a first tangential distance 36 from one another. In this state, the insulating masks 10 and stator segments 26 are present in the winding tool, for example.

The first clearance 36 allows the stator teeth 24 to be wound by needle winding. The tangential first distance 36 is a tangential winding distance 60.

FIG. 12 shows the stator segments 26 after the winding and severing of the connecting elements 30. The winding wire is not shown to illustrate the distances. The connecting elements 30 were punched out in the winding tool, for example. After the connecting elements 39 have been severed, they are in a second state in which the distance between the individual masks can be changed. In FIG. 12, the wound stator segments 26 with the individual masks 28 are still in the tangential first state 36 to one another, but this can now be changed.

FIG. 13 shows the wound stator segments 26 after the step of radially compressing the stator segments 26. To illustrate the distances, the winding wire is not shown in FIG. 13 either. Now the stator segments 26 are close together, the tangential second distance 52 is largely zero. The tangential second distance 52 is in particular an end distance 62. In the next method step, the stator segments 26 could be mechanically connected or fixed.

FIG. 14 shows the stator segments 26 with the two insulating masks 10 from the variant in FIG. 11 in a state after the winding and before the connection elements 30 have been separated single tooth winding. For example, the winding wire 63 has a wire diameter of about 1 mm. The wire routing shown in FIG. 14 corresponds, for example, to a delta 2-fold parallel connection. The windings of the different stator teeth 24 are connected to a connecting wire 64 which extends at least in sections in the tangential direction or circumferential direction. After winding, the stator segments 26 are compressed radially until a final condition with a final spacing 62 as shown in FIG. 13, for example, is reached. For this purpose, the winding tool has, for example, bending fingers 65 which are arranged radially on the outside between the stator segments 26 . When the stator segments 26 are pressed together radially, the bending fingers 65 move radially inward towards the imaginary stator center 32 and thereby bend the connecting wires 64 radially inward. In this way, the connecting wires 64 do not protrude to the outside.

FIG. 15 shows a further embodiment of the insulating mask 10 according to the invention. This is structurally very similar to the insulating mask 10 from FIGS. 10 to 14 and also has twelve individual masks 28 by way of example. The essential difference is that the connecting elements 30 between the individual masks are designed as film hinges 66 . In FIG. 15, the film hinges 66 are in the folded first state, in which the individual masks 28 are at the tangential first distance 36 from one another. The tangential first distance 36 here corresponds to the final distance 62.

This variant of the insulating mask 10 is particularly suitable for pre-cut stator base bodies 34. In FIG. 15, the insulating mask 10 is arranged on a pre-cut stator base body 34 with stator segments 26 that have not yet been separated. When separating the stator segments 26, the film hinge 66 can open at least partially. After the separation, the film hinges 66 can be opened completely for the winding. FIG. 16 shows a variation of the insulating mask 10 from FIG. 15, which by way of example has only six individual masks 28 for a stator 14 with six stator segments 26, but has largely the same film hinges 66 as connecting elements 30. FIG. 16 shows the stator segments 26 after winding. the Film hinges 66 are opened in the second state with a tangential second distance 52, which corresponds to the winding distance 60 and is greater than the closed first distance 36. The windings of the various stator teeth 24 are connected to connecting wires 64, which in the opened second state of the film hinges 66 is stretched and the tangential distance between the stator segments 26 is bridged.

FIG. 17 shows the wound stator segments 26 of the embodiment from FIG. 16 after the stator segments 36 have been radially compressed. The tangential first distance 36 corresponds to the final distance 66 at which the stator segments 26 can be mechanically connected. The film hinges 66 remain in the finished, wound stator 14. The film hinge 66 as a connecting element 30 enables a waste-free process chain for the production of the stator 14. Figure 18 is a detailed view of Figure 17 and shows a film hinge 66. As can be clearly seen, the connecting wires 64 in figure 17 bent radially inwards. This can be done, for example, with the help of bending fingers 65 of the winding tool, as shown in FIG. 14 by way of example.

Figure 19 shows detailed views of two variants of individual masks 28.

FIG. 19A shows an individual mask 28 in which the tooth section 42 has grooves 70 running around an imaginary radial axis 68 of tooth extension. The grooves 70 are provided for guiding or laying the winding wire 63 . In FIG. 19A, the grooves 70 are continuous around the tooth portion 42. In FIG.

FIGS. 19B and C show a variant of individual masks 28 in different perspectives, in which grooves 70 are formed on tooth section 42, which are interrupted by smooth surfaces 72 without grooves 70. Two smooth surfaces 72 are arranged on each of the two areas of a tooth section 42 extending in the axial direction. An axially extending portion of a tooth portion 42 is the portion of the tooth section, which in the assembled stator 14 will be arranged in or on a stator slot, i.e. in a tangential gap between two adjacent stator teeth 24. By way of example, the two smooth surfaces 72 on an axially extending region of a tooth section 42 are separated by two grooves 70 Cut. It is also conceivable that the two smooth surfaces 72 are separated from one another by a groove 70 . One or more grooves 70 between the smooth surfaces 72 have the advantage that they stiffen the individual mask 28 .

The other grooves 70, which are formed on the axial end face of the tooth section 42, i.e. the area of the tooth section 42 which is intended to cover the axial end face of the stator tooth 24, end at the transition area to the areas of a tooth section 42 extending in the axial direction. When the stator segments 26 are separated, the wedges for separating them, in particular double wedges, can be applied to these smooth surfaces 72 .

FIG. 20 shows an alternative embodiment of the insulating mask 10 in which the contacting elements 21 are in the form of pins 74 for receiving hot-stacking hooks 76 . Figures 20A and B show two views of the contacting elements 21. Two pins 74 extending in the axial direction are formed on the yoke section 40 of the individual mask 28, on which a winding wire 63 or laying wire is tensioned, which is used for contacting with a hot-stacking hook 76 a wiring board is provided. For this purpose, the wiring board has a hot-stacking hook 76 which is open downwards or in the direction of the contacting element 21 and is provided for gripping the winding wire 63 tensioned between the pins 74 . For this purpose, the hot-stacking hook 76 must be pressed or bent around the winding wire 63 between the two pins 74 during assembly to establish the contact.

FIGS. 21A and B show two views of an alternative variant of an insulating mask, in which the contacting elements 21 are designed as hot-stacking forks 78. Exemplary are the hot-stacking forks 78 up and in Axial direction away from the stator 14. The connecting wires can be inserted into the hot-stacking forks 78 for contacting.

Figure 22 shows a detailed view of contacting elements 21 of an insulating mask 10. The insulating mask 10 shown is largely designed like the variant shown in Figure 2, the main difference lies in the design of the contacting elements 21. In Figure 22, the insulating mask 10 is already on the Stator elements 26 and the stator body 34 are arranged, the stator teeth 24 are wound and the stator elements 26 are compressed radially, the connecting elements 30 are severed. In FIG. 22A, the winding wire 63 is hidden for a better view of the contacting elements 21. FIG. In Figure 22B the connecting wires 64 are shown. The contacting elements 21 are designed as SKV pockets 22 . As can be clearly seen, the SKV pockets 22 have a slot extending in the axial direction, through which a connecting wire 64 is passed radially in each case. It can also be seen that the SKV pockets 22 have guide grooves 80 which are provided for guiding connecting wires 64 in the circumferential direction or tangential direction. The guide grooves 80 are arranged on the radially outer edge of the SKV pockets or on the second radius 46. In particular, the guide grooves 80 extend in the circumferential direction or in the tangential direction. In this way, in particular, the connecting wires 64 can be stretched between two windings of two different stator teeth 24 . In particular, a clean routing of connecting wires 64 is possible in this way, so that the connecting wires do not protrude radially outwards from the stator 14 .

Individual SKV pockets 22 have three guide grooves 80 arranged one above the other in the axial direction, other SKV pockets 22 have two guide grooves 80 arranged one above the other in the axial direction. The number of guide grooves 80 depends on the desired winding scheme or interconnection scheme. The SKV pockets 22 of the variants shown in FIG. 2 also have guide grooves 80 formed thereon. In the variants shown in FIG. 2, the SKV pockets 22 have, for example, four or five guide grooves 80 arranged one above the other in the axial direction. FIG. 23 shows a view of the SKV pockets 22 of the variant shown in FIG. 22 from a different angle. FIG. 23A shows the connecting wires 64, in FIG. 23B the connecting wires 64 are hidden for the sake of clarity. The connecting elements 30 between the individual masks 28 are completely separated, but the separation points 50 are clearly visible. A crash barrier 82 can also be clearly seen in FIG. 23A, which extends from the yoke section 40 of an individual mask 28 in the axial direction. The crash barrier 82 has a similar geometry to the SKV pockets 22 but does not have a pocket for receiving an SKV clamp. The crash barrier 82 has guide grooves 80 and is provided for guiding connecting wires 64 .

Crash barriers 82 with guide grooves 80 can also be clearly seen in the variant shown in FIG. As already explained, the advantage of the insulating mask 10 according to the invention is that it can have fewer contacting elements 21 than individual masks 28 . The individual masks 28 without a contacting element 21 advantageously have a crash barrier 82 with guide grooves 80 . The variants shown in Figures 2 and 4 each have, for example, six individual masks 21 and four SKV pockets 21 and two crash barriers 82. The variant shown in Figure 10 has, for example, twelve individual masks 21 and seven SKV pockets 21 and five crash barriers 82.

Claims

Expectations An insulating mask (10) for a stator (14), comprising a plurality of individual masks (28) which are designed for use on stator segments (26) of the stator (14), the plurality of individual masks (28) being imaginary about one stator center (32), characterized in that adjacent individual masks (28) are connected to one another with at least one connecting element (30), the connecting element (30) being designed in such a way that in a first state of the connecting element (30) the each of the two individual masks (28) have a predetermined tangential first distance (36) from one another and that in a second state of the connecting element (30) the distance between the two individual masks (28) can be changed to a tangential second distance (52) which is greater or is smaller than the first distance (36). 2. Insulating mask (10) according to Claim 1, characterized in that the connecting element (30) connects two adjacent individual masks (28) to one another in the tangential first distance (36) and has a separation point (54, 56), so that through the Separating the two individual masks (28) at the separation point (54, 56) the second state can be produced with any tangential second distance (52). 3. Insulating mask (10) according to one of the preceding claims, characterized in that the individual masks (28) each have a yoke section (40) arranged radially on the outside, which is designed to cover a yoke area of the stator segment (26), and that each has a connecting element (30) is connected to mutually tangential sides of the respective yoke sections (40) of two mutually adjacent individual masks (28). 4. insulating mask (10) according to any one of the preceding claims, characterized in that the at least one connecting element (30) largely is arranged completely outside of an imaginary first radius (44) and largely completely within an imaginary second radius (46), the first radius° (44) defining the smallest distance between the yoke sections (40) and the imaginary stator center (32) and the second radius (46) defines the greatest distance between the yoke sections (40) and the imaginary stator center (32). 5. Insulating mask (10) according to one of the preceding claims, characterized in that the at least one connecting element (30) has at least one protruding section (48) which is arranged outside the second radius (46) or inside the first radius (44). . 6. Insulating mask (10) according to one of the preceding claims, characterized in that the at least one connecting element (30) is connected to the yoke sections (40) radially on the outside. 7. Insulating mask (10) according to one of the preceding claims, characterized in that the at least one connecting element (30) is designed as a gating element, preferably having a gating frame (30a, 30b) and/or a gating spider (30b, 30c). 8. Insulating mask (10) according to one of the preceding claims, characterized in that the at least one connecting element (30) is designed as a film hinge (66), with two adjacent individual masks (28) in a first, folded state of the film hinge (66) one have a tangential end distance (62) and wherein two adjacent individual masks (28) have a tangential winding distance (60) in a second, unfolded state of the film hinge (66) which is greater than the end distance (62). 9. insulating mask (10) according to any one of the preceding claims, characterized in that at least one individual mask (28) has a contacting element (21) for electrical contact, in particular a pocket (22) for a Insulation displacement connection. 10. Insulating mask (10) according to one of the preceding claims, characterized in that the individual masks (28) have a tooth section (42) which is designed to cover a stator tooth (24) of the stator segment (26) extending from the yoke area, wherein Grooves (70) running around an imaginary, radial tooth extension axis (68) are formed around the tooth section (42) and are provided for laying a winding wire (63). 11. Insulating mask (10) according to claim 10, that areas of the toothed sections (42) extending in the axial direction have at least partially a smooth surface (72) without grooves (70), which are used to guide separating wedges, in particular for the production of pre-cut - Stators (14) are provided. 12. A method for producing a stator (14) from a plurality of separate stator segments (26) which have a yoke area from which a stator tooth (24) extends radially inwards, characterized by the following steps: Providing an insulating mask (10), in particular an insulating mask (10) according to one of the preceding claims, having a plurality of individual masks (28) which are arranged around an imaginary stator center (32) and mutually adjacent individual masks (28) with at least one connecting element (30) are interconnected, arranging the stator segments (26) in an individual mask (28), arranging the stator segments (26) with the stator teeth (24) aligned radially towards the stator center point (32) and with a tangential winding spacing (60) between adjacent yoke regions (40) Winding the stator teeth (24) using needle windings, in particular with single-tooth coils, Radial compression of the stator segments (26) into an end distance (62), in particular until the yoke areas of the stator segments (26) touch tangentially, Mechanically connecting the individual stator segments (26). 13. The method according to claim 12, wherein a circumferentially closed stator base body (34) produced by means of pre-cut technology, having the stator segments (26), which is arranged in the insulating mask (10) in such a way that the stator segments (26) each are arranged in an individual mask (28), and when the stator base body (34) is separated into individual stator segments (26), in particular by means of separating wedges, the insulating mask (10) is separated into individual individual masks (28) by separating the at least one connecting element (30). , which are each arranged on the stator segments (26), and that the isolated stator teeth (24) are then wound. 14. The method according to claim 12, wherein individual or isolated stator segments (26) are arranged in the insulating mask (10) in such a way that the stator segments (26) are each arranged in an individual mask (28), and then the stator teeth (24) are wound and then the individual masks (28) are separated by separating the at least one connecting element (30). 15. The method according to claim 12, wherein the at least one connecting element (30) is designed as a film hinge (66), with two adjacent individual masks (28) having a tangential end spacing (62) when the film hinge (66) is in a first folded state and wherein two adjacent individual masks (28) have a tangential winding distance (60) in a second, opened state of the film hinge (66) which is greater than the final distance (62), the stator segments (26) each being in individual masks (28) are arranged and the stator teeth (24) in the insulating mask (10) are wound with the at least one film hinge (66) in the second, unfolded state and after winding the film hinge (66) is folded back into the first state. 16. The method according to claim 15, wherein a circumferentially closed stator base body (34) produced using pre-cut technology and having the stator segments (26) which are connected to one another with predetermined breaking points is arranged in the insulating mask (10) in such a way that the stator segments (26) are each arranged in an individual mask (28), with the film hinges (66) being present in the first, folded state when the stator base body (34) is arranged in the insulating mask (10), and then when the stator base body (34 ) to individual stator segments (26), in particular by means of separating wedges, the film hinges (66) of the insulating mask (10) at least partially open, and the film hinges (66), if necessary, for winding the stator teeth (24) are fully opened in the second state . 17. The method according to any one of claims 12 to 16, characterized in that the stator segments (26) are mechanically connected to one another after the radial compression by gluing or welding or clamping - and in particular are inserted axially into a stator housing (16). 18. Stator (14) produced with an insulating mask (10) according to one of Claims 1 to 11 and/or with a method according to one of Claims 12 to 17. 19. Stator (14) according to claim 18, characterized in that the yoke regions (40) are formed on their outer circumference arcuate sections and / or with a flat surface, and in particular the stator segments (26) are composed of individual axially stacked laminations. 20. Stator (14) according to claim 18 or 19, characterized in that the stator (14) has exactly six or nine or twelve or eighteen stator segments (26) or stator teeth (24), in particular all Single-tooth coils of the stator segments (26) are connected to one another via a single wound winding wire (63). 21. Electrical machine (12) with a stator (14) according to any one of claims 18 to 20, characterized in that radially inside the stator (14). Rotor having permanent magnets is rotatably mounted - and in particular the stator (14) can be electronically commutated by means of an electronic unit (18).