DE102021203309A1 - Separating clamping element, stator electric machine and method for manufacturing a stator - Google Patents

Abstract

The invention relates to an insulation displacement element (10), in particular for electrically contacting wires (14), in particular in an electrical machine, the insulation displacement element (10) being fork-shaped and having two legs (24), which are designed to hold a wire (14) together, the two legs (24) being connected to one another via a clamping base (28), and the legs (24) each extending along a press-in direction (18), the legs ( 24) each have a cutting edge (20) on their inner sides (30), and the two legs (24) have a deformed area (12) on their inner sides (30) which, in the press-in direction (18), lies between the cutting edges (20) and the free ends (26) of the two legs (24), the forming area (12) being provided for the plastic deformation of wires (14) and on the inner sides (30) of the two legs (24) two in the direction of the cutting edges (20 ) ouch f forming surfaces (32) running towards one another. It is proposed that the two legs (24) taper at least in sections in the press-in direction (18) towards the free ends (26).

Description

The invention relates to insulation displacement elements, in particular for electrically contacting wires, in particular in an electrical machine according to the species of the independent claim. The invention further relates to a stator and an electrical machine with such an insulation displacement element and a method for producing a stator with such an insulation displacement element.

State of the art

Currently, copper wires from coils of electrical machines for energizing are preferably connected using cold contacting techniques, ie contacting techniques without soldering, welding or the like. A well-known cold contact technique is realized by insulation displacement connections (SKV). In this case, the wire is first placed in a plastic receiving pocket, into which a cutting-clamping element is inserted. The wire is clamped between two limbs of the cutting and clamping element, which has cutting elements at the free ends of the limbs, which strip the wire when it is inserted between the limbs. In this case, the cutting elements and the distance between the legs are typically adapted to the wire diameter, so that the insulation can be reliably stripped and securely clamped between the legs. This has the disadvantage that a special cutting and clamping element has to be used for each wire diameter. the DE 10 2017 210 811 A1 shows and describes an improved clipping element for contacting wires. The cutting and clamping elements shown there have a deforming area on the legs, which first plastically deforms the inserted wires before stripping and can thus compensate for tolerances in the wire diameter. This cutting and clamping element can thus be used to a certain extent for different wire diameters.

The disadvantage is that if the wire diameters are too large, the legs are spread too wide during forming and the legs themselves may be plastically deformed. The consequence of this is that the cutting elements on the legs may be at the wrong distance from one another, so that the wire is no longer stripped correctly. This means that a good electrical connection cannot always be guaranteed. Furthermore, it cannot be ensured that it can be reliably fixed or clamped between the legs. The object of the present invention is to overcome this disadvantage and to provide a cutting and clamping element which can also be used in a wide range of wire diameters and thereby enables a secure clamping effect and good electrical contact.

Disclosure of Invention

advantages

The present invention describes an insulation displacement element, in particular for electrical contacting of wires, in particular in an electrical machine, the insulation displacement element being fork-shaped and having two legs which are designed to jointly accommodate a wire, the two limbs are connected to one another via a clamping base, and the limbs each extend along a press-in direction, the limbs each having a cutting edge on their inner sides, and the two limbs having a deformed area on their inner sides, which in the press-in direction between the cutting edges and the free ends of the two legs is arranged, the forming area being provided for the plastic deformation of wires and having two forming surfaces running towards one another in the direction of the cutting edges on the inner sides of the two legs taper towards the free ends at least in sections.

This has the advantage that the legs are relatively stiff at the base of the clamp and thus provide a strong clamping effect in the area of the wire end position, while the legs become softer and more flexible in the area of the forming area. In this way, a wide widening of the limbs in the forming area can be implemented even with large wire diameters, without the limbs being deformed at the clamping base or in a clamping area. This achieves in particular an at least partial decoupling of the functions of forming the wire and clamping the wire. In particular, wires can be reshaped over a wide range of diameters in this way without negatively influencing the clamping effect of the cutting-clamping element.

Advantageously, the cutting and clamping element has a base section from which the two legs extend in the press-in direction. For example, the base section can have contact to an electrical conductor, for example from a wiring board. A press-in direction is to be understood in particular as the direction in which the cutting-and-clamping element is intended to be pressed onto the wire or into the receiving pocket with the wire. Advantageously extended the pressing-in direction is along an axis of symmetry of the cutting-and-clamping element, which is arranged between the two legs.

The fact that the legs taper at least in sections in the press-in direction is to be understood in particular as meaning that the width of the legs along the press-in direction becomes smaller at least in sections, preferably at least 20% smaller overall, particularly preferably at least 30% smaller. The limbs preferably taper along a section which is at least 50% of the entire longitudinal extension of the limbs in the pressing-in direction, preferably at least 70%, particularly preferably at least 80%.

A clamping area is preferably arranged on the inner sides of the legs on the clamping base, on which the inner sides of the legs are arranged largely parallel to one another, in particular largely parallel to the press-in direction. In particular, the wire end position is arranged in the clamping area.

Largely parallel is to be understood in particular as an alignment of a plane or an axis relative to a reference plane or a reference axis, with the plane and the reference plane or the axis and the reference axis forming an angle of in particular less than 8°, advantageously less than 5° ° and particularly advantageously less than 2° and wherein the plane or the axis is advantageously arranged parallel to the reference plane or the reference axis.

The cutting edges are advantageously arranged opposite one another on the insides of the two legs, ie in particular at the same height with respect to the press-in direction. A cutting edge can be understood in particular as a scraping edge or a blade.

A scraping edge is in particular an edge which is arranged at an angle to the press-in direction and is designed to scrape off the wire. When the wire is passed through the scraping edge, a lacquer coating is removed from the wire and the wire stripped. A part of a copper wire under the lacquer coating can also be removed over a large area. This creates a chip. In particular, a scraping edge creates a contact surface on the wire which can be contacted by the cutting and clamping element.

A blade is provided specifically for cutting the wire. The lacquer coating is cut and the copper wire notched. As a rule, no chips are produced.

The forming area is intended in particular to suitably adapt the cross-section of the inserted wire, if necessary, to the width of the cutting edges. Advantageously, after forming, a wire cross section is larger by a predetermined oversize than the distance between the cutting edges. The excess is selected in such a way that the wire is reliably stripped and a sufficiently large contact surface is created.

Advantageous further developments of the cutting and clamping element are possible as a result of the features listed in the subclaims.

It has proven to be a particularly favorable geometry if the two legs have a first leg width at the clamping base that is greater than a second leg width at the cutting edge, in particular that the second leg width is between 40% and 65%, preferably between 45% and 60%, particularly preferably between 50% and 55% of the first leg width. In this way it can be ensured particularly well that the legs do not widen at the clamping base or in the clamping area, so that a particularly good clamping effect is achieved.

A leg width is advantageously to be understood as a leg width perpendicular to the press-in direction or perpendicular to an axis of symmetry of the cutting-and-clamping element.

A first leg width is to be understood in particular as the leg width which is arranged directly on the clamping base. Alternatively, due to special geometric configurations on the clamping base, the first leg width on the clamping base can also be understood to mean a leg width in a clamping area between the two legs, in which the two inner sides of the legs are aligned largely parallel to one another. A first leg width is particularly advantageously understood to mean the largest leg width in the clamping area, in which the two inner sides of the legs are aligned largely parallel to one another. Particularly advantageously, the first leg width is the leg width in the clamping area, in which the two inner sides of the legs are aligned largely parallel to one another, arranged closest to the base of the clamp.

Advantageously, the second leg width in the forming area is the largest leg width in the forming area; the second leg width is particularly advantageously arranged directly on the cutting edge or on a constriction of the leg to form the cutting edge.

The insulation displacement element is further improved if the respective leg width of the two legs, starting from the base of the clamp and along the press-in direction, largely decreases to the cutting edge. This has the advantage that a particularly good stress distribution along the press-in direction can be achieved when the legs are bent.

The fact that the leg width largely decreases along a specified length should be understood in particular to mean that the leg width decreases, advantageously strictly monotonically, along a length in the press-in direction of at least 80%, preferably at least 90%, particularly preferably at least 95% of the specified length.

If the cutting edge encloses an angle of between 65° and 90°, preferably between 70° and 85°, particularly preferably between 75° and 80°, with the press-in direction, the wire can be stripped particularly efficiently and reliably.

It is advantageous if the shanks are constricted at the cutting edge, with a third shank width advantageously at the constriction of between 25% and 50%, preferably between 30% and 45%, particularly preferably between 35% and 40% of the first shank width amounts to. In this way, the cutting edge in particular can be largely decoupled elastically from the forming area. This means that even the largest wire diameters, which require higher forming forces, can be used without significantly increasing the distance between the cutting edges. Since the forming area no longer has any further function after the joining process, a greater expansion or plastic deformation of the legs can be accepted in this area.

The insulation displacement element is further improved if the insulation displacement element, from the base of the clamp, has a longitudinal extension counter to the press-in direction which is between 65% and 135%, preferably between 85% and 115%, particularly preferably between 95% and 105% % of the first leg width. In other words, this longitudinal extent describes the length of the base section in the pressing-in direction along the axis of symmetry, with the base section being the section from which the two legs extend. In this way, the legs are further reinforced at the base of the clamp so that they cannot be easily deformed. This further contributes to a secure clamping effect, particularly in the clamping area.

A particularly favorable clamp geometry is present when the two legs each have an outer contour on their outer sides, which is largely S-shaped along the press-in direction. This enables a particularly homogeneous or balanced distribution of stress in the leg. As a result, a maximum elastic widening of the legs can be achieved, so that a reliable clamping effect and electrical contacting can be ensured.

It has proven to be advantageous if the two legs with their inner sides in the forming area or the forming surfaces enclose a forming opening angle of between 6° and 16°, preferably between 8° and 14°, particularly preferably between 10° and 12 ° is. During forming, the maximum force that can be applied is limited by the elasticity of the legs, but the force required can be reduced by a smaller forming opening angle. However, this requires a greater longitudinal extension of the legs. In practice, the above values for the forming opening angle offer the best compromise between the total length of the cutting and clamping element and the forming forces that can be applied, with the exact values depending on other influencing factors, in particular the materials selected or the surface roughness.

The insulation displacement element is particularly reliable if the two legs each have a catching area at their free ends, with an inner side in the catching area enclosing a catching opening angle with the press-in direction of between 30° and 55°, preferably between 35° and 50°, particularly preferably between 40° and 45°. In this way, even wires that are not in the middle can be centered and reliably installed.

The reliability is further improved if the two legs each have a catch area at their free ends, in which the legs each have a centering shoulder on their outer sides, which extends outwards largely perpendicularly to the press-in direction, on which the legs each have a fourth leg width between 50 % and 80%, preferably between 55% and 75%, particularly preferably between 60% and 70% of the first leg width. The centering shoulders make it easier and more reliable for the cutting-and-clamping element to be correctly centered and inserted into the receiving pocket.

If a clamping step is formed along the inner sides of the two legs, which is between the cutting edges and the clamping base is arranged, with one inner side in the region of the clamping step enclosing a step opening angle with the pressing-in direction of between 5° and 30°, preferably between 10° and 25°, particularly preferably between 15° and 20°, the clamping and electrical contact of the wire even more reliable. The clamping step is advantageously arranged between the cutting edges and the clamping area. The inner sides of the legs thus run towards one another in sections after the cutting edges against the press-in direction in the direction of the clamping step or the clamping base in the area of the clamping step or run in a funnel shape there. In this way, the wire stripped by the cutting edge is once again somewhat elastically compressed or prestressed by the clamping step before it reaches its end position in the clamping step or on the clamping base. In this way, the wire is arranged in the clamping step or at the clamping base with a spring load or elastic tension, so that the clamping effect is improved.

It is advantageous if a transition area is formed between the clamping step and the cutting edges, in which the inner sides of the two legs extend essentially along the press-in direction, the transition area having a transition length in the press-in direction of between 10% and 35%, preferably is between 15% and 30%, particularly preferably between 20% and 25% of the first leg width. In this way, the functions of cutting or stripping the wire and clamping the wire are decoupled.

The reliability of the insulation displacement element is further increased if a main latching hook and a secondary latching hook are formed on opposite outer sides of the insulation displacement element, which are designed to dig into a receiving pocket, with the main latching hook being arranged in front of the secondary latching hook in the press-in direction and the main locking hook has a first hook length which is between 120% and 240%, preferably between 160% and 220%, particularly preferably between 180% and 200% of a second hook length of the secondary locking hook. This has the advantage that a chip of the receiving pocket scraped off by the main latching hook is pressed into the intermediate area between the main latching hook and the secondary latching hook, so that the secondary latching hook is buried by this chip. This enables a particularly strong hold of the Scheid-clamping element in the receiving pocket.

A hook length is to be understood in particular as a direction of extension of a latching hook perpendicular to the press-in direction or center line of the cutting-and-clamping element. The length of the hook can in particular be between an outermost end point of the latching hook and an imaginary base line from which the latching hook extends out of the base section of the cutting-and-clamping element. For example, a straight line aligned parallel to the press-in direction or center line can be used as a baseline, which runs through a bottom of a valley between the main latching hook and the secondary latching hook. In other words, the base line can run through an imaginary point on the outside of the insulation displacement element, which is arranged in the press-in direction between the main latching hook and the secondary latching hook and is at the shortest distance from the center line.

A stator for an electrical machine is also advantageous, with a stator base body that has coils of an electrical winding, with an insulating mask being arranged on one end face of the stator base body, with each coil being assigned at least one receiving pocket on the insulating mask, into which a wire for Interconnection of the individual coils is inserted, and in each case an insulation displacement element according to the present invention is added to the wire in the receiving pocket. Such a stator can be manufactured in a particularly simple and reliable manner, in particular since hardly any faulty contacts are to be expected during the manufacturing process due to the insulation displacement elements used.

An electrical machine is also advantageous--in particular an electronically commutated electric motor--with at least one insulation displacement element according to the present invention, an electronic unit being arranged for energizing the coils and external connection contacts of the electrical machine being connected by means of the at least one insulation displacement Clamping elements are connected to the coils. Such an electrical machine is characterized by high reliability and operational safety due to the use of the cutting and clamping element according to the invention with its optimized clamping effect over a wide range of wire diameters.

• • eine Isoliermaske wird axial auf eine Stirnfläche des Statorgrundkörpers gefügt
• • danach werden auf den Statorgrundkörper mit dem Draht gewickelte Spulen angeordnet
• • von jeder Spule wird der Draht radial durch eine Aufnahmetasche für ein Schneid-Klemm-Element geführt
• • die Schneid-Klemm-Elemente werden mit den Schenkeln in Axialrichtung in die Aufnahmetaschen eingepresst, wobei die Schenkel beim Einpressen den Draht am Umformbereich zunächst umformen, anschließend den Draht mit den Schneidkanten abisolieren und anschließend den Draht zwischen den Schenkeln einklemmen, insbesondere in einem Klemmbereich.

Also advantageous is a method for manufacturing a stator according to the present invention, characterized by the following method steps:

• • An insulating mask is joined axially onto an end face of the stator base body
• • then coils wound with the wire are arranged on the stator base body
• • The wire from each coil is guided radially through a receiving pocket for an insulation displacement element
• • The insulation displacement elements are pressed with the legs in the axial direction into the receiving pockets, with the legs first forming the wire in the forming area when being pressed in, then stripping the wire with the cutting edges and then clamping the wire between the legs, particularly in a clamping area .

The method is particularly flexible since the same cutting and clamping element can be used for different stators with different wire diameters. The press-in direction is advantageously aligned along the axial direction.

character list

• 1 das Funktionsprinzip von Scheid-Klemm-Element aus dem Stand der Technik,
• 2 und 3 zwei verschiedene Ausführungsformen des Scheid-Klemm-Elements gemäß der vorliegenden Erfindung,
• 4 eine Detailzeichnung einer Ausführungsform eines halben Scheid-Klemm-Elements, halbiert entlang der Symmetrieachse des Scheid-Klemm-Elements,
• 5 eine schematische Detailzeichnung einer Ausführungsform eines halben Scheid-Klemm-Elements,
• 6 und 7 weitere Varianten des Scheid-Klemm-Elements gemäß der vorliegenden Erfindung,
• 8 eine Darstellung des Scheid-Klemm-Element aus 5 beim Anformen und
• 9 eine Schnittansicht entlang Linie IX-IX aus 6 zur genaueren Darstellung der Schneidkanten.

Exemplary embodiments of the cutting and clamping element are shown in the drawings and explained in more detail in the following description. Show it

• 1 the functional principle of the cutting-and-clamping element from the prior art,
• 2 and 3 two different embodiments of the cutting-clamping element according to the present invention,
• 4 a detailed drawing of an embodiment of a half Scheid-clamping element, bisected along the symmetry axis of the Scheid-clamping element,
• 5 a schematic detailed drawing of an embodiment of a half cutting-clamping element,
• 6 and 7 further variants of the cutting-clamping element according to the present invention,
• 8th a representation of the Scheid-Klem element 5 when molding and
• 9 a sectional view along line IX-IX 6 for a more precise representation of the cutting edges.

description

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

1 1 shows such a cutting-and-clamping element 10 from the prior art to clarify the functional principle of a cutting-and-clamping element 10 with a deforming region 12 . The cutting-and-clamping element 10 according to the present invention is based on this element from the prior art and functions according to the same basic principle, but has been further developed and has a significantly improved functionality.

In the 1 a) and 1 b) a wire 14 to be contacted is led to a catch area 16 of the clipping element 10 . The wire 14 is arranged in a pocket (not shown), usually a pocket made of plastic, which is also designed to guide the cutting and clamping element. In this case, the cutting and clamping element 10 is moved or guided along a press-in direction 18 towards the wire 14 .

The clipping element 10 and the wire 14 are aligned with one another by the catching area 16 . The wire 14 is guided into the forming area 12 of the cutting and clamping element 10 . In the forming area 12, the cross section of the wire 14 is plastically formed, see FIG 1 c) . the inside 1 Wire 14 shown has a cross-section or diameter that is too large for the cutting edges 20, since the two cutting edges 20 have a smaller distance from each other than the diameter of the original wire 14. In the forming area 12, the wire 14 is deformed in such a way that it is between the two cutting edges 20 fits.

When the wire 14 is pushed down further, it is pushed past the two cutting edges 20 and the insulation is stripped from them. The now stripped and deformed wire 14 is pushed into a clamping area 22 in which the wire 14 is clamped between two legs 24 of the cutting-clamping element 10, see FIG 1d) .

2 and 3 12 show two embodiments of the clip-on element 10 according to the present invention. In both embodiments, the two legs 24 taper in sections in the press-in direction 18 towards their free ends 26 . In particular, a width of each of the two legs 24 perpendicularly to the press-in direction 18 decreases largely continuously, starting from a terminal base 28 to the cutting edge 20 .

The cutting and clamping element 10 has a base section 70 from which the two legs 24 extend in the press-in direction 18 . In both embodiments, the legs 24 extend from the terminal base 28 in the press-in direction 18. The base section 70 is advantageously of largely rectangular design. The base section 70 connects the two legs 24 to one another. The terminal base is 28 the area between the two legs 24 where the legs 24 meet the base portion 70. The base section 70 and the two legs 24 are advantageously formed in one piece with one another.

A clamping area 22 is formed on the terminal base 28 between the respective inner sides 30 of the two legs 24 . The two inner sides 30 of the legs 24 in the clamping region 22 are advantageously configured largely parallel to one another, advantageously largely parallel to the press-in direction 18. In particular, a clamping gap width, i.e. the distance between the two legs 24 or the inner sides 30 of the legs 24 in the clamping region 22 along the Press-in direction 18 largely constant. For example, the clamping area 22 is designed in the form of a slot.

A cutting area, which has two cutting edges 20 , is arranged on the inner sides 30 from the terminal base 28 in the press-in direction 18 after the clamping area 22 . The two cutting edges 20 are each arranged on the respective inner side 30 of the two legs 24 . The cutting edges 20 are advantageously arranged opposite one another, i.e. in particular at the same height with respect to the press-in direction 18.

Starting from the cutting edges 20 in the pressing-in direction 18 , a deforming region 12 is arranged on the legs 24 and extends along the inner sides 30 . The forming region 12 is advantageously designed in the shape of a funnel. In particular, the forming area 12 or the inner sides 30 of the forming area 12 tapers in the direction of the cutting edges 20 or counter to the press-in direction 18. In particular, the inner sides 30 of the legs 24 in the forming area 12 form forming surfaces 32 which point in the direction of the cutting edges 20 or counter to the press-in direction 18 converge. The deforming surface 32 is designed to contact and deform the inserted wire 14 .

Arranged on the legs 24 or their inner sides 30 , starting from the deformed region 12 in the press-in direction 18 , is a catch region 16 which extends to the free ends 26 of the legs 24 . The inner sides 30 are designed in particular in the shape of a funnel in the catch area 16 . Advantageously, the inner sides 30 in the catch area 16 have a larger opening angle than the inner sides 30 in the forming area 12. In other words, the inner sides 30 in the catch area 30 converge more strongly or steeply or at a flatter angle than in the forming area 12.

Advantageously, the cutting-and-clamping element 10 is designed largely symmetrically along the press-in direction 18 . In particular, the cutting-and-clamping element 10 is mirror-symmetrical to an imaginary center line 34 which extends along the press-in direction 18 and is arranged centrally between the two legs 24 . In this way, the cutting-and-clamping element 10 can also be represented completely by the representation of one half on one side of the center line 34 with only one leg. the 4 and 5 show variants of the sheath-clamping element 10 in such a representation of one half of the sheath-clamping element 10. 4 shows a slightly modified variant of the Scheid-clamping element 10 3 , 5 shows a variant of the Scheid-clamping element 10 with more straight lines which is intended to better illustrate geometric aspects.

in 4 In the example shown, the cutting edge 20 encloses a cutting angle 36 of 72° with the press-in direction 18 or imaginary center line 34 . In the variant in 4 the cutting angle 36 is 90°, for example.

To quantify the tapering of the two legs 24 in sections, a first leg width 38 at the clamping base 28 and a second leg width 40 at the cutting edge 20 can be considered. in the in 4 The variant shown is the second leg width 40 57% of the first leg width 38. In the variant according to 5 the second leg width 40 is 60% of the first leg width 38.

In particular, in the examples shown, the leg width largely decreases in the press-in direction 18 starting from the clamping base 28 to the cutting edge 20 . The inside 30 in the clamping area 22 runs largely parallel to the press-in direction 18. An outside 42 of the leg approaches the inside 30 along the press-in direction 18, so that the leg width along the press-in direction 18 largely decreases. in 4 In the example shown, the outer side 42 approaches the inner side initially with a greater gradient, which flattens out the closer it approaches the cutting edge 20 . In particular, the outside 42 in in 4 Example shown in the clamping area 22 has an outer contour which has a concave shape. At the level of the cutting edge 20 , the leg 24 has an outwardly extending extension, from which the outside 42 approaches the inside 30 again along the press-in direction 18 up to the free end 26 . In particular, the outside has 42 im in 4 Example shown an outer contour which is formed along the press-in direction 18, in particular between the clamping base 28 and the free end 26, S-shaped or has an S-shape.

In the exemplary embodiments shown, the cutting edge 20 is advantageously formed by a constriction 44 of the leg 24 . In particular, the constriction 44 is a recess of the leg 24 which extends largely perpendicularly to the press-in direction 18 or with the cutting angle 36 from the inside 30 into the leg 24 . in 4 In the example shown, a third leg width 46 at the constriction is 46% of the first leg width 38. In the example from 5 the third side width 46 is 44% of the first side width 38.

in 4 In the exemplary embodiment shown, a longitudinal extent 48 of the cutting-and-clamping element 10 counter to the press-in direction 18 is 65% of the first leg width 38. In the exemplary embodiment in FIG 5 is the longitudinal extent 48 of the cutting-and-clamping element 10 against the press-in direction 18 71% of the first leg width 38. In the exemplary embodiment in FIG 2 the longitudinal extension 48 of the cutting-and-clamping element 10 against the press-in direction 18 is 125% of the first leg width 38.

In the forming region 12 the two legs 24 or the two inner sides 30 of the legs 24 or the two forming surfaces 32 of the two legs 24 enclose a forming opening angle 50 . In other words, each leg 24 or its inner side 30 in the forming region 12 or a forming surface 32 together with the press-in direction 18 encloses half a forming opening angle 50 . in 4 example shown, the forming opening angle is 50 14 °. in 5 In the example shown, the forming opening angle 50 is 18° for clarification.

In the catch area 16 , a leg 24 or an inner side 30 of the leg 24 together with the press-in direction 18 enclose a catch opening angle 52 . in 4 example shown, the catch opening angle 52 is 40°. in 5 example shown, the catch opening angle 52 is 41°.

6 FIG. 12 shows a further variant of a cutting-clamping element 10 according to the present invention. In this variant, the legs 24 have centering shoulders 54 on their free ends 26 or on the catch area 16 . The two centering shoulders 54 are each formed on the outer side 42 of the legs 24 and extend outwards largely perpendicularly to the press-in direction 18. The legs 24 each have a fourth leg width 56 of 60% of the first leg width 38 at their respective centering shoulders 54 on.

7 shows another variant with a centering paragraph 54. in the in 7 variant shown, the fourth leg width 56 is, for example, 70% of the first leg width 38.

As in 4 and 5 As can clearly be seen, in these embodiments the inside 30 of the leg 24 in the clamping area 22 is advantageously aligned largely along the press-in direction 18 . In these two embodiments, for example, a clamping step 58 is arranged on the inside 30 of the leg 24 between the clamping region 22 and the cutting edge 20 . In the area of the clamping step 58 , the leg 24 or an inner side 30 of the leg 24 encloses a stepped opening angle 60 together with the press-in direction 18 . in 4 shown embodiment is the step opening angle 60 16 °. In the embodiment of 5 the stepped opening angle 60 is 18°, for example.

In advantageous variants with a clamping step 58, a transition region 62 is arranged between the clamping step 58 and the cutting edges 20. In the transition region 62, the legs 24 or the inner sides 30 of the legs extend essentially along the press-in direction 18 or largely parallel to the press-in direction 18. In the two in the 4 or. 5 example shown, the transition area 62 along the inside 30 has a transition length 64 which is 16% of the first leg width 38 . in 7 shown embodiment, the transition length 64 of the transition area 62 is 20% of the first leg width 38.

7 shows an advantageous variant of the clip-on element 10, wherein the clip-on element 10 has a main latching hook 66 and a secondary latching hook 68 formed on each of its two opposite outer sides 42. The two main latching hooks 66 and secondary latching hooks 68 are advantageously formed on the base section 70 or arranged above the clamping base 28 counter to the press-in direction 18 . The main locking hook 66 on the first outer side 42 is advantageously arranged opposite the main locking hook 66 on the second outer side 42 . The secondary latching hook 68 on the first outer side 42 is advantageously arranged opposite the main latching hook 68 on the second outer side 42 . The fact that a latching hook on the first outer side 42 is arranged opposite the latching hook on the second outer side 42 should be understood in particular to mean that the two latching hooks are each arranged at largely the same height with respect to the press-in direction. To put it another way, it is advantageous if the main latching hooks 66 and/or secondary latching hooks 68 are mirror-symmetrical to one another with respect to the imaginary center line 34 of the cutting-and-clamping element 10 .

The main locking hook 66 is advantageously arranged on the outside 42 in each case next to an associated secondary locking hook 68 . This is to be understood in particular as meaning that the distance between the secondary latching hook 68 and the main latching hook 66 in the press-in direction 18 is less than 150% of the added total extension of the main latching hook 66 and the secondary latching hook 68 in the press-in direction 18, preferably less than 100%, particularly preferably less than 50%. In the exemplary embodiments, each of the main latching hooks 66 is arranged in front of the associated secondary latching hook 68 in the press-in direction 18 . In other words, the main locking hook 66 is further away from the clamping base 28 along the press-in direction 18 than the secondary locking hook 68.

Advantageously, the main locking hook 66 has a greater extension perpendicular to the press-in direction 18 than the secondary locking hook 68. In the in 7 The example shown is a first hook length 72 of the main locking hook 66 which is 190% of a second hook length 74 of the secondary locking hook 68 .

8th Figure 12 illustrates the principle of operation of the clip-on element 10 according to the present invention. A variant of the clipping element 10 is shown which largely corresponds to that in 5 shown embodiment corresponds. In 8th 12 shows a point in time when the cutting-and-clamping element 10 is pressed onto a wire 14, at which the wire 14 contacts the deformed area 12 and is deformed by being pressed in. In comparison to a cutting-and-clamping element from the prior art (see 1c) ) the legs 24 in the forming area 12 are spread outwards to a much greater extent. Due to the fact that the legs 24 taper in the press-in direction 18 and, for example, have a constriction 44 on the cutting edge 20 , the legs 24 are designed to be significantly more flexible or elastic at their free end 26 . In this way, when a larger wire 14 is accommodated in the forming area 12 , the limbs 24 are largely deformed without the distance between the limbs 24 changing in the press-in area 22 or on the clamping base 28 and on the cutting edge 20 . In this way, a precise cut at the correct distance and a secure clamping of the wire 14 can always be guaranteed. In the case of the cutting and clamping elements of the prior art, there is a risk that if the wire diameters are too high, the legs 24 will be spread open along their entire direction of extension and possibly even be plastically deformed. This can have the negative effect that the clamping area is widened too much and can no longer provide a good clamping effect and/or that the cutting edges are too far apart from one another and the wire is not stripped sufficiently well and can no longer be contacted sufficiently well.

9 illustrates an example of the geometry of the cutting edges 20. 9 a) 12 shows a view of the cutting edges 20 from FIG 6 along the line IX-IX, but with a wire 14 already mounted in the clipping element. The wire 14 is a copper wire 78 coated with a layer of lacquer 76. 9 a) shows a preferred embodiment in which the cutting edges 20 are designed as scraping edges. By way of example, the scraping edges have a largely rectangular cross-sectional shape. When the wire 14 is inserted, its surface is scraped off by the scraping edge and a defined chip is removed from the wire 14 . It can be clearly seen that the scraping edges have completely removed the lacquer layer 76 in the contact area with the wire 14 and have removed a surface area of the copper wire 78, so that the scraping edge contacts the copper wire 78 along its entire thickness. This enables a particularly good electrical contact. In addition, a reliable mechanical fixing or clamping of the wire is also possible.

9 b) shows an alternative form of the cutting edges 20, these are designed here as blades. The two surfaces of the blades converge towards the inside, so that the thickness of the blades decreases further towards the inside. In profile, the blades of the embodiment example have a triangular shape. Blades have the advantage that, in contrast to scraping edges, they do not scrape the wire but rather cut it, which requires less effort. The material of the wire is at least partially displaced by the blade when cutting.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102017210811 A1 [0002]

Claims (16)

Insulation displacement element (10), in particular for making electrical contact with wires (14), in particular in an electrical machine, the insulation displacement element (10) being designed in the shape of a fork and having two legs (24) which are used for jointly receiving of a wire (14), the two legs (24) being connected to one another via a clamping base (28), and the legs (24) each extending along a press-in direction (18), the legs (24) each have a cutting edge (20) on their inner sides (30), and wherein the two legs (24) have a deformed area (12) on their inner sides (30) which, in the pressing-in direction (18), lies between the cutting edges (20) and the free ends (26 ) of the two legs (24) is arranged, with the deforming area (12) being provided for the plastic deformation of wires (14) and on the inner sides (30) of the two legs (24) two deforming elements running towards one another in the direction of the cutting edges (20). surfaces (32), characterized in that the two legs (24) taper at least in sections towards the free ends (26) in the press-in direction (18). Insulation displacement element (10). claim 1 , characterized in that the two legs (24) have a first leg width (38) at the clamping base (28) which is greater than a second leg width (40) at the cutting edge (20), in particular that the second leg width (40) is between 40% and 65%, preferably between 45% and 60%, particularly preferably between 50% and 55% of the first leg width (38). Insulation displacement element (10) according to one of the preceding claims, characterized in that the respective leg width of the two legs (24) largely decreases from the clamping base (28) along the press-in direction (18) to the cutting edge (20). Insulation displacement element (10) according to one of the preceding claims, characterized in that the cutting edge (20) has a cutting angle (36) between 65° and 90°, preferably between 70° and 85°, in particular with the press-in direction (18). preferably between 75° and 80°. Insulation displacement element (10) according to one of the preceding claims, characterized in that a constriction (44) of the legs (24) is formed on the cutting edge (20), a third leg width (46 ) is between 25% and 50%, preferably between 30% and 45%, particularly preferably between 35% and 40% of the first leg width (38). Insulation displacement element (10) according to one of the preceding claims, characterized in that the insulation displacement element (10) has a longitudinal extent (48) from the base (28) of the clamp opposite to the press-in direction (18) which is between 65% and 135%, preferably between 85% and 115%, particularly preferably between 95% and 105% of the first leg width (38). Insulation displacement element (10) according to one of the preceding claims, characterized in that the two legs (24) each have an outer contour on their outer sides (42) which is largely S-shaped along the press-in direction (18). Insulation displacement element (10) according to one of the preceding claims, characterized in that the two legs (24) enclose a forming opening angle (50) with their inner sides (30) in the forming region (12) or the forming surfaces (32). , which is between 6° and 16°, preferably between 8° and 14°, particularly preferably between 10° and 12°. Insulation displacement element (10) according to one of the preceding claims, characterized in that the two legs (24) each have a catching area (16) at their free ends (26), with an inner side (30) in the catching area (16 ) encloses a catching opening angle (52) with the press-in direction (18) which is between 30° and 55°, preferably between 35° and 50°, particularly preferably between 40° and 45°. Insulation displacement element (10) according to any one of the preceding claims, characterized in that the two legs (24) each have at their free ends (26) a catch area (16) in which the legs (24) on their outer sides (42) each have a centering shoulder (54) which extends outwards largely perpendicularly to the press-in direction (18), on which the legs (24) each have a fourth leg width (56) of between 50% and 80%, preferably between 55% and 75%, particularly preferably between 60% and 70% of the first leg width (38). Insulation displacement element (10) according to one of the preceding claims, characterized in that a clamping step (58) is formed along the inner sides (30) of the two legs (24) and extends between the cutting edges (20) and the clamping base (28 ) is arranged, where an inner side (30) in the region of the clamping step (58) encloses a step opening angle (60) with the press-in direction (18) of between 5° and 30°, preferably between 10° and 25°, particularly preferably between 15° and is 20°. Insulation displacement element (10). claim 11 , characterized in that between the clamping step (58) and the cutting edges (20) a transition area (62) is formed, in which the inner sides (30) of the two legs (24) extend essentially along the press-in direction (18), wherein the transition area (62) has a transition length (64) in the press-in direction (18) which is between 10% and 35%, preferably between 15% and 30%, particularly preferably between 20% and 25% of the first leg width (38). Insulation displacement element (10) according to one of the preceding claims, characterized in that a main latching hook (66) and a secondary latching hook (68) are formed on opposite outer sides (42) of the insulation displacement element, which are used to dig into a receiving pocket, the main latching hook (66) being arranged in front of the secondary latching hook (68) in the press-in direction (18) and the main latching hook (66) having a first hook length (72) which is between 120% and 240%, preferably between 160% and 220%, particularly preferably between 180% and 200% of a second hook length (74) of the secondary locking hook (68). Stator for an electrical machine, with a stator base body that has coils of an electrical winding, with an insulating mask being arranged on one end face of the stator base body, with each coil being assigned at least one receiving pocket on the insulating mask, into which a wire (14) for connecting the individual coils is inserted, and in each case an insulation displacement element (10) according to one of Claims 1 until 13 is joined to the wire (14) in the receiving pocket. Electrical machine - in particular an electronically commutated electric motor - with at least one insulation displacement element (10) according to one of Claims 1 until 13 , characterized in that an electronics unit is arranged for energizing the coils and external connection contacts of the electrical machine are connected to the coils by means of the at least one insulation displacement element (10). Method of manufacturing a stator Claim 14 , characterized by the following process steps: • an insulating mask is axially attached to an end face of the stator body • then coils wound with the wire are arranged on the stator body • the wire is pulled radially from each coil through a receiving pocket for an insulation displacement element (10) guided • the insulation displacement elements (10) are pressed with the legs (24) in the axial direction into the receiving pockets, the legs (24) first forming the wire (14) in the forming area (12) when pressed in, then the wire with strip the insulation from the cutting edges (20) and then clamp the wire (14) between the legs (24), in particular in a clamping area (22).

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