Patents by Inventor Rayk GERSTEN

Rayk GERSTEN has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20250377038
    Abstract: A device (12) for mounting a shift element (14) on a transmission shaft (16), has a first unit (18) having a sliding region for enabling axial and/or radial relative movement between the transmission shaft (16) and the shift element (14). The device has a second unit (20) having a compression region for counteracting radial deflection of the shift element (14) when the shift element (14) is subjected to a torque load. The present invention also relates to a corresponding shift element and system.
    Type: Application
    Filed: June 6, 2025
    Publication date: December 11, 2025
    Applicant: ZF Friedrichshafen AG
    Inventors: Marcel Störkle, Bernd Lutz, Maximilian Scheufler, Stefan Renner, Andreas Graf, Martin Weiss, Rayk Gersten
  • Publication number: 20250198510
    Abstract: A vehicle drive unit includes an electric motor with a rotor shaft, a transmission with at least a first shaft and a shift element arranged radially within the rotor shaft. An elastic spring element is arranged on the shift element, and a guide element is arranged spatially between the rotor shaft, the elastic spring element, and the shift element and configured to guide the shift element during a shifting operation. The shift element is arranged to connect at least the first shaft to the rotor shaft in a rotationally fixed manner in a first shifting position to feed a drive power from the electric motor to the transmission, where the elastic spring element is arranged for centering the shift element in the rotor shaft in a no-load state of the electric motor and enables a compensating movement of the shift element in the rotor shaft in a loaded state.
    Type: Application
    Filed: December 13, 2024
    Publication date: June 19, 2025
    Applicant: ZF Friedrichshafen AG
    Inventors: Marcel Störkle, Dominik Erny, Rayk Gersten, Andreas Graf, Maximilian Scheufler, Bernd Lutz
  • Publication number: 20250202315
    Abstract: A rotor for an electrical machine has a rotor arm with a radial outer dimension, a balancing disk with a radial inner dimension, and a connection arrangement having an outer contour on a side of the rotor arm and an inner contour on the side of the balancing disk. The outer contour and the inner contour correspond to one another for axial and radial support, where the connection arrangement for radial support has a first contour section with a radial connection dimension which differs from the outer dimension and the inner dimension. The rotor can have an end fin with at least one projection that extends radially inwards and/or in an axial direction to prevent twisting. The rotor can be part of an electrical machine.
    Type: Application
    Filed: December 13, 2024
    Publication date: June 19, 2025
    Applicant: ZF Friedrichshafen AG
    Inventors: Dominik Erny, Rayk Gersten, Martin Christians, David Rittler
  • Publication number: 20250047176
    Abstract: A device for grounding a rotor carrier is arranged inside of a grounded housing and includes a rotatable rotor carrier extending in an axial direction, a grounding device, and at least one bearing. The rotor carrier is supported by the at least one bearing. The grounding device is arranged on a housing arm next to the bearing and includes an electrically conductive annular carrier element with a central cut out. The carrier element forms a permanent electrically conductive connection to the housing arm at an inside surface of the carrier element. An electrically conductive sliding contact extends radially outward and forms an electrically conductive connection to the rotor carrier at an outer lateral surface of the sliding contact. By way of the sliding contact and the carrier element, an electrical connection is established between the rotor carrier and the housing.
    Type: Application
    Filed: July 31, 2024
    Publication date: February 6, 2025
    Applicant: ZF Friedrichshafen AG
    Inventors: Jacob Schicketanz, Rayk Gersten
  • Patent number: 12212186
    Abstract: A cooling arrangement for cooling a stator for an electric machine. The cooling arrangement comprising a stator fixedly mounted relative to a rotational axis. The stator comprises a stator yoke and stator grooves. Windings are provided in the stator grooves, which form first and second winding heads. First and second fluid rings are provided at opposite ends on the stator yoke. The first fluid ring has a fluid inflow opening from a stator housing. The stator yoke has a plurality of axial stator ducts extending in the axial direction, which enable the inflowing fluid to flow through from the first fluid ring to the second fluid ring, and the second fluid ring redirects some of the fluid.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: January 28, 2025
    Assignee: ZF Friedrichshafen AG
    Inventors: Martin Christians, David Wörzler, Rayk Gersten, Stefan Spühler, Martin Jelinewski, Wolfgang Hübler, Timo Hele, Karlheinz Hoher
  • Publication number: 20240359547
    Abstract: A drive unit has a first electric machine with a first rotor mounted to rotate about a rotation axis. A first stator is coaxially arranged and has a stator core lamination packet with a first coil end forming a first switching side and a second coil end forming a first counter-switching side. A second electric machine is mounted axially close to the first electric machine and has a rotatably mounted second rotor that extends in the axial direction around the rotation axis. A second stator is mounted coaxially with the second rotor and has a second stator core lamination packet with second stator coils having a third coil end forming a second counter-switching side and a fourth coil end forming a second switching side. A housing accommodates the first and second machines, where the first counter-switching side and the second counter-switching side face one another in the axial direction.
    Type: Application
    Filed: August 2, 2022
    Publication date: October 31, 2024
    Applicant: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Renner, Karlheinz Hoher
  • Publication number: 20240348127
    Abstract: A vehicle cooling arrangement includes a first electric machine with a drive output shaft and a first rotor mounted to rotate about a rotation axis and extending axially around the rotation axis. A first stator surrounds the first rotor peripherally. A second electric machine is mounted axially close to the first electric machine and has a second rotor mounted to rotate about the rotation axis and the drive output shaft. A second stator surrounds the second rotor peripherally. A common housing forms a casing for the first and second electric machines and the drive output shaft extends axially through the housing. The first and second electric machines form a coolant circuit having at least one coolant line arranged to cool the first and second rotors and a second coolant line parallel to the first coolant line and arranged to separately cool the first and second stators.
    Type: Application
    Filed: August 10, 2022
    Publication date: October 17, 2024
    Applicant: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Renner, David Wörzler, Stefan Spühler, Martin Christians, Martin Jelinewski, Wolfgang Hübler
  • Patent number: 12101000
    Abstract: Disclosed is a rotor carrier for a rotor of an electric machine. The rotor carrier includes a hollow outer shell that includes a bearing area for a rotor lamination stack, the bearing area extending axially along the rotor carrier. The outer shell extends radially outward in a radial dimension that varies along the bearing area in the axial direction of the rotor carrier (101) in such manner that at the axial end sections of the bearing area exhibits no peak contact pressures between the rotor carrier and the rotor lamination stack when the rotor lamination stack is pressed against the bearing area of the rotor carrier. A rotor including the rotor carrier and the rotor lamination stack is also disclosed.
    Type: Grant
    Filed: February 28, 2022
    Date of Patent: September 24, 2024
    Assignee: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Spühler, Daniel Meindl
  • Publication number: 20240195238
    Abstract: The invention relates to a cooling arrangement (1, 1a) for cooling a stator (2) of an electric machine having a housing (10) and a stator (2), which is arranged fixed about a rotation axis in the housing (10), where the rotation axis defines an axial direction and a radial direction radially relative to the rotation axis. At the respective axial ends of the stator (2) a first cooling fluid ring (8, 8a) is mounted to form a first ring-shaped annular space with the housing (10) and a second cooling fluid ring (9) is mounted to form a second ring-shaped annular space, each of them designed to convey cooling fluid.
    Type: Application
    Filed: December 7, 2023
    Publication date: June 13, 2024
    Applicant: ZF Friedrichshafen AG
    Inventors: Martin Christians, Rayk Gersten, Marcel Schmitt, Wolfgang Hübler
  • Patent number: 11973406
    Abstract: A rotor (1) for an electric machine (25) which comprises a rotor support (2). The rotor support has cylindrical inner and outer shells (3, 4). A magnetic flux-carrying rotor component has first and second end faces (6, 7) and carries the cylindrical outer shell (4). A rotationally shaft section (8) is arranged in an inside space (9) of the rotor support and mounted coaxially with the rotor support. At least in the area of the first end face (6) the outer shell has first teeth which face toward the magnetic flux-carrying rotor component and a first tooth base between respective pairs of first teeth, and at least in the area of the second end face (7) the outer shell (4) has second teeth which face toward the magnetic flux-carrying rotor component and a second tooth base between respective pairs of second teeth. The invention also relates to an electric machine.
    Type: Grant
    Filed: December 16, 2021
    Date of Patent: April 30, 2024
    Assignee: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Spühler, David Wörzler, Martin Christians, Martin Jelinewski, Alexander Baur
  • Patent number: 11962189
    Abstract: A stator (1a, 1 b) for an electric machine. The stator (1a, 1b) is fixedly mounted relative to a rotational axis (Rot). The stator (1a, 1b) comprises a stator yoke (2) that extends in the axial (A) and radial (R) directions. Stator teeth (3), facing toward the rotational axis (Rot), are arranged in a ring shape on the stator yoke (2). The teeth are uniformly spaced apart from one another so that a stator groove (14) is formed therebetween. The stator (1a, 1b) is divided into a first stator section (5) and a second stator section (6). First and second outer walls (9, 10) are provided on the stator yoke (2) and serve to axially support the stator yoke (2). A cooling manifold disk (11) is integrated between the first stator section (5) and the second stator section (6). An electric machine with a stator of that type is also disclosed.
    Type: Grant
    Filed: December 16, 2021
    Date of Patent: April 16, 2024
    Assignee: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, David Wörzler, Stefan Spühler, Martin Jelinewski, Johannes Glückler, Timo Hele, Kai Bornträger
  • Patent number: 11791699
    Abstract: A rotor arrangement (1a, 1b) for an electric machine of a vehicle. The rotor arrangement (1a, 1b) comprises a rotor lamination stack (4) and the rotor arrangement further comprises a rotor support (2a, 2b). The rotor support (2a, 2b) carries the rotor lamination stack (4), which is arranged on the radially outer side (6a, 6b) of the rotor support (2a, 2b). A retaining element is arranged on the outer side (6a, 6b) of the rotor support at the end on the rotor lamination stack (4). The retaining element is a one-piece, closed retaining ring (5a, 5b) with an axial ring width (SR) and with at least a first ring diameter (R1). The first ring diameter (R1) is smaller than or equal to the rotor support diameter (TR), so that the rotor laminate stack (4) is secured axially in a rotationally fixed manner. The invention also relates to two production methods.
    Type: Grant
    Filed: December 16, 2021
    Date of Patent: October 17, 2023
    Assignee: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Spühler
  • Publication number: 20220311295
    Abstract: Disclosed is a rotor carrier for a rotor of an electric machine. The rotor carrier includes a hollow outer shell that includes a bearing area for a rotor lamination stack, the bearing area extending axially along the rotor carrier. The outer shell extends radially outward in a radial dimension that varies along the bearing area in the axial direction of the rotor carrier (101) in such manner that at the axial end sections of the bearing area exhibits no peak contact pressures between the rotor carrier and the rotor lamination stack when the rotor lamination stack is pressed against the bearing area of the rotor carrier. A rotor including the rotor carrier and the rotor lamination stack is also disclosed.
    Type: Application
    Filed: February 28, 2022
    Publication date: September 29, 2022
    Applicant: ZF Friedrichshafen AG
    Inventors: Rayk Gersten, Stefan Spühler, Daniel Meindl
  • Publication number: 20220200406
    Abstract: A rotor (1) for an electric machine (25) which comprises a rotor support (2). The rotor support has cylindrical inner and outer shells (3, 4). A magnetic flux-carrying rotor component has first and second end faces (6, 7) and carries the cylindrical outer shell (4). A rotationally shaft section (8) is arranged in an inside space (9) of the rotor support and mounted coaxially with the rotor support. At least in the area of the first end face (6) the outer shell has first teeth which face toward the magnetic flux-carrying rotor component and a first tooth base between respective pairs of first teeth, and at least in the area of the second end face (7) the outer shell (4) has second teeth which face toward the magnetic flux-carrying rotor component and a second tooth base between respective pairs of second teeth. The invention also relates to an electric machine.
    Type: Application
    Filed: December 16, 2021
    Publication date: June 23, 2022
    Inventors: Rayk GERSTEN, Stefan SPÜHLER, David WÖRZLER, Martin CHRISTIANS, Martin JELINEWSKI, Alexander BAUR
  • Publication number: 20220200420
    Abstract: A rotor arrangement (1a, 1b) for an electric machine of a vehicle. The rotor arrangement (1a, 1b) comprises a rotor lamination stack (4) and the rotor arrangement further comprises a rotor support (2a, 2b). The rotor support (2a, 2b) carries the rotor lamination stack (4), which is arranged on the radially outer side (6a, 6b) of the rotor support (2a, 2b). A retaining element is arranged on the outer side (6a, 6b) of the rotor support at the end on the rotor lamination stack (4). The retaining element is a one-piece, closed retaining ring (5a, 5b) with an axial ring width (SR) and with at least a first ring diameter (R1). The first ring diameter (R1) is smaller than or equal to the rotor support diameter (TR), so that the rotor laminate stack (4) is secured axially in a rotationally fixed manner. The invention also relates to two production methods.
    Type: Application
    Filed: December 16, 2021
    Publication date: June 23, 2022
    Inventors: Rayk GERSTEN, Stefan SPÜHLER
  • Publication number: 20220200370
    Abstract: The invention relates to a stator (1a, 1b) for an electric machine, wherein the stator (1a, 1b) is mounted rotatably around a rotation axis (Rot) by which an axial direction (A) is defined, wherein the stator (1a, 1b) comprises a stator yoke (2) that extends in the axial direction (A) and in a radial direction (R) relative thereto, wherein on the stator yoke (2), along the axial direction (A) stator teeth (3) facing toward the rotation axis (Rot) are arranged in a ring shape, which teeth are uniformly spaced apart from one another in the circumferential direction (U), so that a stator groove (14) is formed between radially adjacent stator teeth (3), and wherein the stator (1a, 1b) is divided axially in the middle into a first stator section (5) and a second stator section (6), wherein on the stator yoke (2), at the end on the first stator section (5) a first outer wall (9) that extends radially and, opposite it, at the end a radially extending second outer wall (10) are provided, each serving as axial suppor
    Type: Application
    Filed: December 16, 2021
    Publication date: June 23, 2022
    Inventors: Rayk GERSTEN, David WÖRZLER, Stefan SPÜHLER, Martin JELINEWSKI, Johannes GLÜCKLER, Timo HELE, Kai BORNTRÄGER
  • Publication number: 20220200371
    Abstract: A cooling arrangement (1) for cooling a stator (2) for an electric machine (23). The cooling arrangement (1) comprising a stator (2) fixedly mounted relative to a rotational axis (Rot). The stator (2) comprises a stator yoke (3) and stator grooves (4). Windings are provided in the stator grooves (4), which form first and second winding heads (5, 6). First and second fluid rings (8, 14) are provided at opposite ends on the stator yoke (3). The first fluid ring (8) has a fluid inflow opening from a stator housing (7). The stator yoke (3) has a plurality of axial stator ducts (15, 18, 22) extending in the axial direction (A), which enable the inflowing fluid to flow through from the first fluid ring (8) to the second fluid ring (14), and the second fluid ring (14) redirects some of the fluid. Furthermore, the invention relates to an electric machine.
    Type: Application
    Filed: December 17, 2021
    Publication date: June 23, 2022
    Inventors: Martin CHRISTIANS, David WÖRZLER, Rayk GERSTEN, Stefan SPÜHLER, Martin JELINEWSKI, Wolfgang HÜBLER, Timo HELE, Karlheinz HOHER
  • Patent number: 11052744
    Abstract: A transmission having a main transmission and a splitter group, and including at least four spur gear planes formed with a countershaft and at least five shifting elements for engaging at least six gears between the transmission input and output shafts. When shifting between gears with the highest and the second-highest gear ratios, a shift occurs in the shifting elements associated with the splitter group but not in the shifting elements associated with the main transmission, whereas when shifting between gears with the lowest and second-lowest gear ratios, a shift occurs in the shifting elements associated with the main transmission but not in the shifting elements associated with the splitter group. An electric machine can be connected by a gearset, and depending on its shift position, the gearset acts as a pre-transmission ratio for the electric machine or as a superimposition transmission.
    Type: Grant
    Filed: January 25, 2018
    Date of Patent: July 6, 2021
    Assignee: ZF FRIEDRICHSHAFEN AG
    Inventors: Johannes Kaltenbach, Johannes Glückler, Christian Mittelberger, Kai Bornträger, Rayk Gersten, Stefan Renner
  • Patent number: 10967725
    Abstract: A transmission for a hybrid drive having transmission input and output shafts, a further transmission input shaft and an electric machine, which drives the further transmission input shaft. A main transmission has first and second partial transmissions with a plurality of gear planes and a pair of concentric fourth shafts, and shift elements. A range group can couple the main transmission and has a planetary gearset with three transmission elements. The first element can couple either of the transmission input shafts via the shift elements. The second element is connected to the transmission output shaft and can couple a gear plane of the partial transmissions via the shift elements. The third transmission element can be fixed to the housing or blocked against the first or second transmission element.
    Type: Grant
    Filed: January 25, 2018
    Date of Patent: April 6, 2021
    Assignee: ZF FRIEDRICHSHAFEN AG
    Inventors: Johannes Kaltenbach, Rayk Gersten, Stefan Renner, Johannes Glückler, Christian Mittelberger, Kai Bornträger
  • Patent number: 10940749
    Abstract: A method of operating a vehicle having a hybrid drive, a transmission with shift elements, a drive output with a brake, a main transmission with input shafts, an output shaft and planetary gear sets (PG1, PG2). The main transmission has five gear planes. One shift element can connect a gear plane to an element of gear set (PG1) adjoining the main transmission. Another shift element couples a further element of gear set (PG1) either to the output shaft or a housing. An electric machine is permanently connected to an element of gear set (PG2). If, while driving with a transmission gear engaged, the drive output brake is engaged for a full brake application, a shift element of the transmission is first relieved by the electric machine and/or a brake assigned to one of the input shafts and then subsequently disengaged to decouple the combustion engine from the drive output.
    Type: Grant
    Filed: November 22, 2016
    Date of Patent: March 9, 2021
    Assignee: ZF FRIEDRICHSHAFEN AG
    Inventors: Michael Preuß, Johannes Kaltenbach, Christian Mittelberger, Johannes Glückler, Stefan Renner, Rayk Gersten