DE102021210974A1 - Electrical machine and method for inserting at least one electrical conductor assembly into at least one slot of a stator or rotor for an electrical machine - Google Patents

Abstract

Method for inserting at least one electrical conductor assembly (1) into at least one slot (2) of a stator (3) or rotor of an electrical machine (4), the electrical conductor assembly (1) having a plurality of conductor elements (5 ), in particular fibers and/or yarns, and an insulation (7) based on at least one duroplast (6). It is proposed that the individual conductor elements (5) be encased in the thermoset (6), the thermoset (6) being only partially crosslinked after encasing, that the conductor elements (5) encased with the thermoset (6) in the partially crosslinked state are connected to a composite (8), that the composite (8) made up of the conductor elements (5) encased with the thermoset (6) in the partially crosslinked state is inserted into the at least one groove (2) and that the thermoset ( 6) is fully thermally cross-linked in order to form the insulation (7) of the electrical conductor assembly (1). Furthermore, an electrical machine (4) is specified, in which such an electrical conductor assembly (1) is inserted in at least one slot (2) of a stator (3) or rotor,

Description

State of the art

The invention relates to a method for inserting at least one electrical conductor assembly into at least one slot of a stator or rotor used for an electrical machine, the electrical conductor assembly having a plurality of conductor elements based on carbon nanotubes and/or graphene with insulation based on at least one duroplast . Furthermore, the invention relates to an electrical machine with a stator or a rotor, wherein at least one electrical conductor assembly is introduced into at least one slot of the stator or rotor using such a method.

In addition, the invention relates to a method for fixing the end winding so that it is present as a rigid composite in the required position after full thermal crosslinking of the thermoset.

Alternative electrical conductor materials are based on carbon nanotubes and/or graphene plates. The electrical conductivity of carbon nanotubes and graphene sheets exceeds the conductivity of copper. However, the macroscopic conductor materials based on the molecular building blocks (carbon nanotubes and/or graphene plates), which i.a. as films, tapes and yarns, copper and aluminum are still inferior in terms of electrical conductivity and have therefore not been used to date.

In addition to their low density (approx. 2 g/cm ³ - copper 8.95 g/cm ³ ), these alternative electrical conductor materials are characterized by their flexibility, which allows these conductor materials to change their cross-section in accordance with the effects of external forces. In a package consisting of many individual conductors, for example, the packing density can be increased to such an extent that there are hardly any cavities left. This is not possible for copper conductors because of their radial stiffness. For this reason, the so-called plug-in or bar winding, which consists of one or more solid copper conductors, is used with copper conductors instead of many individual conductors.

Graphene films or carbon nanotube films can be produced as a conductor material by various methods. Carbon nanotube (CNT) conductor materials can be manufactured as follows: In WO 2007/015710 A2 the production of CNT ribbons from so-called CNT forests is shown. The tapes are electrically conductive and are characterized by high elongation at break and high tensile strength. An alternative manufacturing process for CNT tapes is presented in U.S. 8,999,285 B2 described. Here the production takes place through the synthesis of a CNT aerogel. This is processed into a ribbon as it leaves the reactor. Another manufacturing process for ribbons based on carbon nanotubes is WO 2013/034672 disclosed. The carbon nanotubes are dispersed in a super acid and then processed into fibers or ribbons by wet spinning.

Conductor materials based on graphene can be produced as follows, with graphite being the only raw material used for commercially interesting production variants. In the form of films or tapes, production can take place, for example, as follows: In CN 108892134A Graphite powder is wet-chemically intercalated and oxidized to graphene oxide using the so-called Hummers method. The purified graphene oxide dispersion is then processed into a film and subsequently reduced into a graphene film by heat treatment. In CN 107221387A the graphene film is produced directly from an aqueous dispersion. After applying the graphene film to a substrate and drying it, the next step is to remove the dispersant that made the aqueous dispersion possible. In DE102020200325A1 is produced using a spinneret whose geometry ensures that the graphene platelets are aligned parallel to the film planes.

For fibers or yarns, the production can be done as follows: The production of fibers from graphene is in U.S. 8,999,212 B2 disclosed. Graphene is obtained by one-sided axial cutting of carbon nanotubes. After that, the graphene is dispersed in a superacid and then processed into fibers by wet spinning.

Particularly preferred for the production of graphene fibers is the production of graphene oxide, which is obtained from graphite by wet-chemical oxidation, such as. B. the Hummers method is produced. Since this manufacturing route uses graphite as a raw material, the raw material costs are 1-2 orders of magnitude lower compared to the above process. Such manufacturing processes are CN 105603581A , CN 105544016A and CN 105544017A disclosed. At the end of the manufacturing process, thermal treatment at temperatures of up to 3000°C is necessary to increase the electrical conductivity.

The insulation of graphene-based conductors, such as films, fibers, and yarns, can be WO 18177767 A1 , by fluorination of the surface layer, which turns into an insulator and thereby electrically shields the film. In addition, electrical insulation can also be achieved by applying polymers, as shown in WO13051761A1 is shown. Furthermore, in DE102019220214A1 shows how insulation can be achieved using layers of boron nitride.

Such electrical conductors can be used in electrical motors, as described in WO18233897 A1 or WO18158003 is shown.

Endless fibers are obtained by the spinning processes presented above. These endless fibers are processed into yarns. Techniques such as twisting or braiding can be used. The aim of all these processes is to combine the endless fibers into one unit, the yarn. This enables further processing, such as covering with an insulator or winding as an electrical conductor in a rotor.

All known techniques for forming endless fibers or yarns made of graphene and/or carbon into a yarn with a larger cross-section, such as twisting, weaving or braiding, have the disadvantage that the yarn remains pliable. This is a deficiency in the prior art when the conductor is routed through the slots or around the poles of a stator or rotor of an electric motor in such a way that an overhang occurs.

From the U.S. 9,520,213 B2 the coating of a conductive yarn made of carbon nanotubes or graphene with a duroplastic or an epoxy resin is known.

Disclosure of Invention

The method according to the invention with the features of claim 1 and the electric machine according to the invention with the features of claim 11 have the advantage that an improved design and mode of operation are made possible.

Advantageous developments of the method specified in claim 1 and of the electrical machine specified in claim 11 are possible as a result of the measures listed in the dependent claims.

In particular, it is made possible for an overhang of a conductor assembly based on yarns made of graphene and/or carbon nanotubes, also referred to as a winding head, to be stiffened after completion of the winding, so that it no longer moves around the conductor assembly during operation due to the magnetic fields that are created or is deformed.

In this way, a composite of conductor elements can be created that has been coated with partially cross-linked duroplast. This composite, which is still soft, can be introduced into the engine as an electrical conductor and then harden there, so that the flexible conductor elements are then transformed into a rigid composite.

The insulation is preferably not only to be found on the outside of the composite, but also in the composite between the conductor elements that are encased with the duroplast. This is advantageous because, after full thermal crosslinking, it not only creates electrical insulation from the rotor or stator, but also electrical insulation of the conductor elements from one another, which is highly effective against current displacement effects, and a matrix that gives the composite structural strength gives.

It is advantageous that the insulation is designed in such a way that the electrical conductor assembly is designed to be rigid. This prevents deformation or movement, particularly at the end winding, during operation.

It is advantageous that at least one thermolatent catalyst, in particular at least one adduct of boron trifluoride with amines, more particularly BF ₃ -monoethylamine, and/or at least one quaternary phosphonium compound and/or a dicyandiamide, is admixed to the thermoset. This can support and/or accelerate complete crosslinking.

It is advantageous that the individual conductor elements are encased in the duroplast by means of an immersion baud. In this way, the conductor elements can be advantageously encased in a simple manner in the respective application.

It is advantageous that the individual conductor elements are encased with the duroplast by a spraying process. In the respective application, an advantageous implementation of the method with an optimized use of the production factors can thereby be made possible.

It is advantageous that the individual conductor elements are encased with the duroplast by a pultrusion process. This allows special advantages to be realized. In particular, the duroplast can be applied with good adhesion and/or thinly. A low thermal resistance can also be realized as a result. Especially when the conductor element is designed as a yarn, it is advantageous that only the yarn is insulated or is coated and there is no infiltration by the insulation material in the yarn, which can be achieved by the pultrusion process.

Whether an infiltration takes place depends to a small extent on the procedure. The ability of the resin to wet the yarn and, in particular, the viscosity of the resin are decisive for the infiltration. The lower the viscosity, the more resin can infiltrate into the yarn.

It is advantageous that the individual conductor elements are encased with the duroplast in the liquid state. As a result, air inclusions or cavities can be avoided as far as possible.

It is advantageous that the duroplast is formed from a resin system which has at least one resin based on tetraglycidyldiaminodiphenylmethane and/or an epoxy resin of the novolac type and a hardener based on microencapsulated imidazole and/or diaminodiphenylsulfone. As a result, the system can still be sufficiently low-viscous at a certain mixed viscosity, for example 750 mPa*s, at an advantageous processing temperature, for example 25°C.

It is advantageous that the composite of the conductor elements encased with the thermoset in the partially crosslinked state is encased in a silicone tube and that the composite of the conductor elements encased with the thermoset in the partially crosslinked state, encased with the silicone tube, is inserted into the at least one groove. As a result, the composite can be further stabilized, in particular for insertion into the groove.

The electric machine, in particular the electric drive machine for motor vehicles, advantageously comprises at least one electrical conductor assembly that is inserted into at least one slot of a stator or rotor, the electrical conductor assembly having a plurality of conductor elements based on carbon nanotubes and/or graphene and a conductor element based on at least one Has thermoset based insulation. Since the conductor element can be encased in duroplast, a matrix then forms from the duroplast in the conductor assembly, which matrix holds the conductor assembly together.

character list

• 1 eine mit einem teilvernetzten Duroplast umhülltes Leiterelement 5, die Fasern oder Garne mit niedrigem Durchmesser sind, in einer schematischen Schnittdarstellung zur Erläuterung eines Verfahrens entsprechend einem Ausführungsbeispiel der Erfindung;
• 2 die in 1 dargestellte, mit einem teilvernetzten Duroplast umhüllten Leiterelemente entsprechend einer abgewandelten Ausgestaltung;
• 3 einen als Garn ausgestalteten Verbund aus mehreren in 1 dargestellten Leiterelementen in einer schematischen Schnittdarstellung zur Erläuterung des Verfahrens entsprechend dem Ausführungsbeispiel;
• 4 den in 3 dargestellten Verbund entsprechend der abgewandelten Ausgestaltung;
• 5 den in 3 dargestellten Verbund, der zusätzlich mit einem Elastomerschlauch umhüllt ist, in einer schematischen Schnittdarstellung zur Erläuterung des Verfahrens entsprechend dem Ausführungsbeispiel;
• 6 den in 5 dargestellten Verbund, der zusätzlich mit einem Elastomerschlauch umhüllt ist, entsprechend der abgewandelten Ausgestaltung und
• 7 eine auszugsweise, schematische Schnittdarstellung einer Nut eines Stators einer elektrischen Maschine, in die der in 5 dargestellte, mit dem Elastomerschlauch umhüllte Verbund als elektrischer Leiterverbund eingelegt ist, um eine Wicklung des Stators zu bilden.

Preferred exemplary embodiments of the invention are explained in more detail in the following description with reference to the attached drawings, in which corresponding elements are provided with the same reference symbols. Show it:

• 1 a conductor element 5 sheathed with a partially cross-linked duroplast, which are fibers or yarns with a small diameter, in a schematic sectional view for explaining a method according to an embodiment of the invention;
• 2 in the 1 illustrated conductor elements covered with a partially cross-linked duroplast according to a modified embodiment;
• 3 a composite designed as a yarn consisting of several in 1 illustrated conductor elements in a schematic sectional view to explain the method according to the embodiment;
• 4 the in 3 composite shown according to the modified embodiment;
• 5 the in 3 shown composite, which is additionally covered with an elastomer tube, in a schematic sectional view to explain the method according to the embodiment;
• 6 the in 5 shown composite, which is additionally covered with an elastomer tube, according to the modified embodiment and
• 7 a partial, schematic sectional view of a slot of a stator of an electrical machine, in which the 5 is inserted as an electrical conductor assembly in order to form a winding of the stator.

Embodiments of the invention

Based on 1 until 7 a method for inserting at least one electrical conductor assembly 1 into at least one slot 2 of a stator 3 or rotor of an electrical machine 4 is explained. Here is at hand 1 , 3 , 5 and 7 described an embodiment. 2 , 4 and 6 show a modified design.

1 shows a conductor element 5, which is covered by a partially cross-linked duroplast 6, in a schematic sectional view to explain the method according to the embodiment. The conductor element 5 can be designed as a continuous fiber 5 or yarn 5 . The conductor element 5 is based on carbon nanotubes and/or graphene. The electrical conductor assembly 1 ( 6 ) then has several such conductor elements 5, with finally an insulation 7 based on the duroplastic 6 ( 7 ) is formed. In a modified embodiment, conductor elements 5, which are yarns with a small cross-section, can also be used and which consist, for example, of several fibers, are encased with the partially cross-linked duroplast 6. The fibers and such yarns with a small cross-section are possible configurations for a conductor element 5 based on carbon nanotubes and/or graphene.

If the individual conductor elements 5 are covered with the duroplast 6, as is shown in 1 is shown, then this is done in such a way that the duroplast 6 is only partially crosslinked after the encapsulation. In the preferred embodiment, the cross section of the conductor elements 5 is round.

The individual conductor elements 5 can be encased with the duroplastic 6 by means of an immersion bath, a spraying process or a pultrusion process. Depending on the configuration of the method, the thermoset 6 can be applied in the liquid state.

2 shows the in 1 illustrated conductor element 5 encased with a partially cross-linked duroplast 6 according to a modified embodiment. Here, the cross section of the conductor element 5 is star-shaped. Yarns can also be produced with almost any cross section, for example by braiding, weaving or moulding.

3 shows a composite 8 of several in 1 illustrated conductor elements 5 in a schematic sectional view to explain the method according to the embodiment. The composite 8 can be designed as a yarn 8 . In this case, the conductor elements 5 are encased in the partially crosslinked state with the duroplast 6 and connected to form the composite 8 .

The conductor elements 5 based on graphene and/or carbon nanotubes, which consist of endless fibers or yarns formed from them with a smaller cross section and the partially crosslinked duroplast 6, are further processed into the composite 8 in the form of a yarn 8 with a larger cross section. The conductor elements 5 are limp and deform during the production of the yarn 8 . It is particularly advantageous if this is done before twisting, weaving or braiding, as is also the case at hand 1 respectively 2 is described. It is even more advantageous if the continuous fibers 5 or yarns with a smaller cross section are processed directly into a conductor assembly 1 in which they are guided parallel to the longitudinal axis of the yarn. This causes the effective line length of the filaments 5 to be shortened and the packing density of the filaments 5 in the yarn 8 to be increased. In addition to the resulting increase in the electrical conductivity of the conductor assembly 1, the assembly 8 is also easier to deform, which is an advantage for the processability when producing the winding.

Such a composite 8 can thus be produced, for example, by coating the yarns with a smaller cross section or endless fibers 5 with the crosslinkable duroplast 6 by means of an immersion bath or by spraying. This composite 8 can then be passed through a conical hole. As a result, the endless fibers 5 are compacted into a yarn 8 and the duroplast 6 is partially crosslinked, so that the composite 8 is still deformable. Depending on the choice of the geometry of the cross section, the yarn 8 made of parallel endless fibers 5 can have a cross section with a round, oval, triangular, square, rectangular, trapezoidal or star-shaped geometry, for example.

4 shows the in 3 shown composite 8 according to the modified embodiment, wherein the cross sections of the individual conductor elements 5 are star-shaped.

5 shows the in 3 shown composite 8 in a schematic sectional view to explain the method according to the embodiment, wherein the composite 8 is additionally covered with an elastomer tube 9. In this case, the composite 8 has the duroplast 6 in the partially crosslinked state. The elastomer hose 9 can be a silicone hose 9 . The composite 8 encased with the elastomer tube 9 can then be inserted into the groove 2 in this form. In a modified embodiment, the elastomer hose 9 can also be omitted.

The composite 8 encased with the elastomeric tube 9 can be produced by hose extrusion with simultaneous continuous feeding of the composite 8 into the elastomeric tube 9 being formed. This ensures that the composite 8 does not disintegrate, improves the workability during winding and also prevents the composite 8 from sticking to itself when stored on a spool or that the thermoset on the surface sticks to the thermoset of the next Location networked.

The encasing of the composite 8 with a silicone hose 9 is particularly advantageous. This can be produced by hose extrusion with simultaneous continuous feeding of the composite 8 into the extruded silicone hose 9 .

6 shows the in 5 shown composite 8, which is additionally covered with an elastomer tube 9, according to the modified embodiment.

7 shows a partial, schematic sectional view of the slot 2 of the stator 3 of the electrical machine 4. Here, the in 5 shown compound 8, which is covered with the elastomer tube 9, inserted as an electrical conductor compound 1 in the groove 2. The representation is to be understood as an example. In particular, other conductor assemblies corresponding to the conductor assembly 1 can also be inserted. Furthermore, the conductor assembly 1 can also be inserted in several windings. Thus, a winding of the stator 3 can be formed.

In one exemplary embodiment, the yarns 8 or yarn bundles 8 can be pressed in or wound and then, if there is no winding tension, depending on the installation situation, optionally heated to 120° C. under mechanical pressure and cured. The yarns 8 nestle against the groove 2 without a gap. Insulating paper is not necessary if the dielectric strength of the elastomer or silicone hose 9 is sufficient for the potential difference that is present.

If the composite 8 is made up of the conductor element 5 encased with the duroplast 6 in the partially crosslinked state, the fibers or yarns with a small diameter, in which at least one groove 2 is inserted, heat treatment then takes place. As a result, the duroplast 6, which is in the partially crosslinked state, is thermally fully crosslinked. As a result, the insulation 7 of the electrical conductor assembly 1 is then formed. The electrical conductor assembly 1 then has a plurality of conductor elements 5 based on carbon nanotubes and/or graphene and an insulation 7 based on the duroplast 6 . The insulation 7 can then be designed in such a way that the electrical conductor assembly 1 is designed to be rigid. The conductor is designed to be rigid if the crosslinking of the insulation of the conductor elements with the insulation of adjacent conductor elements during full thermal crosslinking leads to a rigid composite.

A thermolatent catalyst can be added to the duroplast 6, which supports and accelerates the full crosslinking during the heat treatment. In one possible embodiment, an adduct of boron trifluoride with amines, in particular BF ₃ monoethylamine, and/or at least one quaternary phosphonium compound and/or a dicyandiamide can be admixed as a catalyst.

In one possible embodiment, the thermoset 6 may be formed from a resin system comprising a tetraglycidyldiaminodiphenylmethane-based resin and a novolac-type epoxy resin and microencapsulated imidazole and diaminodiphenylsulfone-based hardeners.

• Ep604: 50,
• Ep1032: 50,
• HX3722: 25 und
• DDS: 20.

A preferred exemplary embodiment for a possible implementation of method steps of the method is specified below. An example of the composition of a resin system in parts by weight can be given as follows, where HX3722 and DDS are the hardeners:

• Ep604: 50,
• Ep1032: 50,
• HX3722: 25 and
• DDS: 20.

• Ep604: Tetraglycidyldiaminodiphenylmethan, Japan Epoxy Resins Co., Ltd.;
• Ep1032: Epoxidharz vom Typ Novolac (siehe US 2003/0135011 A1 , Formel(I));
• HX3722: Mikroverkapseltes Imidazol, Asahi-Ciba Co., Ltd.; und
• DDS: Diaminodiphenylsulfon, Wakayama Seika Kogyo Co., Ltd.

The chemical composition is:

• Ep604: Tetraglycidyldiaminodiphenylmethane, Japan Epoxy Resins Co., Ltd.;
• Ep1032: Novolac type epoxy resin (see U.S. 2003/0135011 A1 , formula (I));
• HX3722: Microencapsulated Imidazole, Asahi-Ciba Co., Ltd.; and
• DDS: Diaminodiphenylsulfone, Wakayama Seika Kogyo Co., Ltd.

With its mixed viscosity, this system is sufficiently low in viscosity. Depending on the selection and mixing ratio of the components, a mixed viscosity can vary, with a mixed viscosity of around 750 mPas at 25° C., for example, still being considered to be sufficiently low in viscosity. The components of the epoxy resin system mentioned above are heated to 25 °C and then mixed in the specified ratio. The mixture is placed in a container. This has a double jacket by means of which the mixture is tempered to 25°C. There is a deflection roller in the container, which is positioned in such a way that the endless fibers 5 can be guided continuously through the epoxy resin system in the container. A continuous immersion bath is thus realized.

As soon as the continuous fibers 5 emerge from the immersion bath, they are drawn through a device, the first part of which consists of a metal segment which has a conical hole 5 cm long with a circular cross-section. The diameter of the hole is 5mm at the beginning and 1.5mm at the end. This is followed by a 2 cm long hole in the metal segment, which has a circular cross-section with a diameter of 1.5 mm. This first metal segment is cooled to 20°C. Another metal segment follows the first metal segment. This is thermally separated from the first metal segment by an insulating layer. The hole in the second metal segment is 50 cm long and has a circular cross section with a diameter of 1.5 mm. This second metal segment is heated to keep it at a temperature of 80°C. When the continuous fibers 5 are drawn through these two metal segments, they are compacted by the cone in the first metal segment and formed into a yarn 8 in the second metal segment by the partial thermal crosslinking of the epoxy resin system, in which the continuous fibers 5 are arranged parallel to one another. The dwell time of the yarn in the second metal segment is 2 s. The yarn 8 is then encased in a silicone hose 9 by coextrusion.

Post-crosslinking can be suppressed in this composite for weeks by storage at temperatures < 0°C after production, thus ensuring adequate deformability and thus processability. Once the winding has been made from the composite, it must be thermally post-treated so that the maximum temperature resistance of 180°C is achieved. For this purpose, the component is heat-treated. The epoxy resin system is fully crosslinked through temperature stages of 30 minutes at 100°C and 30 minutes at 145°C and 30 minutes at 180°C. The composite is then so stiff that it can no longer be deformed by magnetic forces during operation

As a result, the conductor elements 8 can be continuously coated with curable resin. The conductor elements 8, which lie in the groove, are bonded to one another by the resin after the heat treatment. This differs from casting with a resin. As a rule, cavities between the conductor elements cannot be completely avoided both in the case of casting and in the case of the proposed method. If the proposed method is used, a conductor element is usually always coated with resin in the area of the cavities, while the conductor elements adjoining the cavities are not partially coated with resin during casting

In another preferred embodiment, the insulation may be made using a pultrusion process, as described below.

Conductor elements 5 in the form of yarns and tapes based on carbon nanotubes (CNT) or graphene are conductor materials that have high tensile strength in the axial direction but at the same time are pliable in the radial direction. In order to leverage the full potential of CNT yarns and tapes in terms of their flexibility and the associated design freedom for electrical conductors (extremely small bending radii, very high tensile stress, very high winding speed and so on), the electrical insulation layer should be as flexible and adhesive as possible be that even with very small bending radii the insulation layer does not tear or become detached. At the same time, the insulating layer should be as thin as possible in order to achieve low thermal resistance. The insulation layer is therefore applied as evenly as possible and thinly in one process step with short process times.

The CNT yarn or other electrically conductive fibers 5 can be insulated by means of pultrusion. This is particularly advantageous if a yarn with a smaller cross section is used instead of a fiber 5 . It is important here that only the yarn is insulated or coated and that the insulation material does not infiltrate the yarn. Furthermore, the viscosity of the material can be fine-tuned to the process in order to enable coating or insulation on the one hand and to prevent infiltration on the other. Infiltration would reduce the electrical conductivity in the yarn itself. It is also possible to specify how high the maximum porosity of the yarn/tape should be so that the reaction only takes place on the surface and not in the core of the yarn/tape. A reaction in the core is to be avoided as this can impair the electrical conductivity. It is advantageous that a particularly thin, temperature-resistant and highly elastic insulation layer is produced by the pultrusion. The process is easily scalable.

In addition, when using silicones, especially liquid silicones, the surface has a very low coefficient of friction. If used without further coating, this offers great advantages in relation to the possible winding speed and the ability to achieve a high packing density of the winding even in complicated geometries of the winding pocket, especially in winding processes. In addition to silicone, all thermoplastic materials as well as thermoplastic elastomers can be applied to the yarn as an insulator by pultrusion.

In addition to the method already described, several yarns can also be lined up next to each other and still be insulated individually. This creates a wide conductor track that can be easily wound around a coil. Other arrangements, for example one on top of the other, are also possible and still easy to wind due to the high degree of bending of the yarn. For example, the yarns can be fed crosswise into the tool and covered with the insulating layer. It is particularly advantageous for the electrical conductivity that the fiber is not infiltrated with an insulator. For this purpose, the fiber can be strongly cooled to reduce the viscosity of the To increase the insulator on the fiber and thereby prevent infiltration.

Another option is to heat the fiber with electricity and thus ensure rapid hardening on the fiber surface.

The invention is not limited to the exemplary embodiments described.

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

• WO 2007015710 A2 [0005]
• US8999285B2 [0005]
• WO 2013034672 [0005]
• CN 108892134A [0006]
• CN 107221387A [0006]
• DE 102020200325 A1 [0006]
• US8999212B2 [0007]
• CN 105603581A [0008]
• CN 105544016A [0008]
• CN 105544017A [0008]
• WO 18177767 A1 [0009]
• WO 13051761 A1 [0009]
• DE 102019220214 A1 [0009]
• WO 18233897 A1 [0010]
• WO 18158003 [0010]
• US 9520213 B2 [0013]
• US20030135011A1 [0049]

Claims (12)

Method for inserting at least one electrical conductor assembly (1) into at least one slot (2) of a stator (3) or rotor of an electrical machine (4), the electrical conductor assembly (1) having a plurality of conductor elements (5 ), in particular fibers and/or yarns, and an insulation (7) based on at least one duroplastic (6), characterized in that the individual conductor elements (5) are encased with the duroplastic (6), the duroplastic (6) only partially cross-linked after encapsulation, that the conductor elements (5) encased with the thermoset (6) in the partially cross-linked state are connected to form a composite (8), that the composite (8) consists of the encapsulated with the thermoset (6) in the partially cross-linked state Conductor elements (5) are inserted into the at least one groove (2), that the duroplast (6), which is in the partially crosslinked state, is thermally fully crosslinked in order to form the insulation (7) of the electrical conductor assembly (1). and that the insulation (7) is designed in such a way that the electrical conductor assembly (1) is designed to be rigid. procedure after claim 1 , characterized in that the duroplast (6) electrically insulates the conductor element (5) and thus causes the current displacement effect to be effective only in the cross section of the conductor elements (5) and no longer in the cross section of the composite (8). procedure after claim 1 or 2 , characterized in that at least one thermolatent catalyst, in particular at least one adduct of boron trifluoride with amines, more particularly BF ₃ -monoethylamine, and/or at least one quaternary phosphonium compound and/or a dicyandiamide, is added to the thermoset (6). Procedure according to one of Claims 1 until 3 , characterized in that the individual conductor elements (5) are covered by an immersion bath with the partially cross-linked duroplast (6). Procedure according to one of Claims 1 until 3 , characterized in that the individual conductor elements (5) are covered by a spraying process with the partially cross-linked duroplast (6). Procedure according to one of Claims 1 until 3 , characterized in that the individual conductor elements (5) are covered by a pultrusion process with the partially cross-linked duroplast (6). Procedure according to one of Claims 1 until 6 , characterized in that the individual conductor elements (5) are covered with the partially cross-linked duroplast (6) in the liquid state. Procedure according to one of Claims 1 until 7 , characterized in that the thermoset (6) is formed from a resin system which has at least one resin based on tetraglycidyldiaminodiphenylmethane and/or an epoxy resin of the novolac type and a hardener based on microencapsulated imidazole and/or diaminodiphenylsulfone. Procedure according to one of Claims 1 until 8th , characterized in that the composite (8) made up of the conductor elements (5) encased with the duroplast (6) in the partially cross-linked state is encased in an elastomer hose (9), in particular a silicone hose (9), and that the elastomer hose (9) encased assembly (8) made up of the conductor elements (5) encased with the duroplast (6) in the partially cross-linked state, is inserted into the at least one groove (2). Procedure according to one of Claims 1 until 9 , characterized in that the composite (8) consisting of the conductor elements (5) encased with the duroplast (6) in the partially crosslinked state is fixed in the area of the end winding in such a way that after full thermal crosslinking there is a rigid composite, with a Elastomer hose (9), in particular a silicone hose (9) and in particular cable ties are used. Electrical machine (4), in particular an electric drive unit for motor vehicles, having at least one electrical conductor assembly (1) which is inserted in at least one slot (2) of a stator (3) or rotor, the electrical conductor assembly (1) having a plurality of carbon nanotubes and / or Graphene-based conductor elements (5) and at least one thermoset (6) based insulation (7) and wherein the electrical conductor composite (1) by a method according to one of Claims 1 until 9 formed and in which at least one groove (2) is inserted. Electric machine after claim 11 , characterized in that the end winding is designed and/or supported in such a way that it is present in the required position as a composite after full thermal crosslinking.

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