Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
  • H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
  • B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
  • B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
  • B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
  • B05C5/0254—Coating heads with slot-shaped outlet
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/10—Formation of a green body
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
  • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
  • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
  • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
  • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
  • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
  • H01F41/0206—Manufacturing of magnetic cores by mechanical means
  • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/25—Process efficiency
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49009—Dynamoelectric machine
  • Y10T29/49012—Rotor

Definitions

• the invention relates to a method for producing a material layer with a layer thickness between 0.5 and 500 ⁇ m.
• the magnetic circuit of a dynamoelectric rotary machine includes a stator and a rotor.
• the rotor and the stator represent the power-generating components, also called active parts, of the dynamoelectric rotary machine and have so far been manufactured as laminated cores.
• Today's sheet metal packages comprise sheets which are cut or stamped out from rolled large sheets of soft magnetic material. The sheets are then packaged into a sheet stack.
• the invention is therefore based on the object to improve the produc- tion of sheets for dynamoelectric rotary machines.
• the object is achieved by a material layer according to claim 8 and a method for producing a material layer structure for a rotor of a dynamoelectric rotary according to claim 13.
• the object is moreover achieved by a material layer structure according to claim 15 for a rotor of a dynamo-electric rotary machine, the material layer structure comprising a plurality of material layers arranged one above the other, a rotor of a dynamo-electric rotary machine, having such a material layer structure, such as a dynamo-electric rotary structure Machine.
• the material layer advantageously has the previous functions of a conventional sheet in a conventional rotor laminated core and performs the functions of a sheet.
• An outline of the material layer advantageously corresponds essentially to the outline of a sheet.
• the material layer is advantageously made thinner and / or thinner than a sheet.
• the material layer structure advantageously has the previous functions of a rotor laminated core and performs the functions of a rotor laminated core.
• the material layers are arranged one above the other to create the material layer structure.
• the material layers are preferably arranged in the direction of a rotation axis, in other words: along an axis of rotation, of the material layer structure.
• the material layer preferably has an essentially round, essentially centrally arranged material cutout.
• the material layer structure preferably has a cylindrical material recess along the axis of rotation for connection to a shaft.
• the material layer preferably has a layer thickness between 10 and 100 ⁇ m.
• the suspension is preferably applied with a doctor knife.
• the suspension has at least one binder and solid particles which can be driven off, in particular by means of debinding.
• the binder is preferably an organic binder.
• the binder is preferably such that it completely or almost completely dissociates into gaseous components when heated.
• the solid particles are preferably in the form of a powder.
• a solid particle preferably comprises at least one magnetically and / or electrically conductive material.
• the solid particle preferably has a diameter between 0.1 and 100 ⁇ m.
• the solid particle preferably has a diameter between 0.5 and 10 ⁇ m.
• the powder can comprise solid particles of only one material or a powder mixture comprising at least two different materials.
• the powder can be adjusted in terms of strength, magnetic characteristics, electrical characteristics and heat conduction.
• the solid particles are permanently bonded by heating and / or by means of sealing, in particular by means of sintering.
• Sintering is preferably a thermal process, which is particularly dependent on the materials used. For example, a temperature or a temperature band depends on an alloy of the material, other additives and a desired result (after sintering).
• the template is preferably a template for transferring desired shapes and / or contours and / or patterns and / or recesses etc.
• the template can be used as often as desired.
• the template can be used to form exactly the shape of the material layer that is desired. So there is no waste. Two or more templates can also be used for one layer of material.
• the template can be modified quickly and inexpensively (especially faster than a punching tool).
• Filigree shapes can also be reproduced from the template.
• the material layers with filigree shapes are particularly advantageous for the lightweight construction of dynamoelectric rotary machines, cooling and magnetic scattering.
• an insulation material is applied to the material layer on at least one side of the layer.
• the insulation material is preferably a ceramic, in particular a non-magnetic oxide ceramic, for example zirconium oxide or aluminum oxide.
• the applied insulation material is preferably used for electrical insulation.
• the applied insulation material is preferably used for electrical insulation of a material layer from at least one further material layer if at least two or more material layers are arranged one above the other, in particular to create a material structure.
• the advantageously applied insulation material thus prevents current flow from one layer of material to another layer of material.
• an insulation material is applied to the material layer on both sides of the layer.
• the insulation material is applied to the material layer on only one side of the layer, the material layer is thinner. If the insulation material is applied to the layer of material on both sides of the layer, the layer of material is better insulated.
• a lacquer in particular baking lacquer, is applied to the material layer.
• the varnish in particular baking varnish, can be the insulation material.
• paint and insulation material can also be two different materials.
• the advantageously applied baking lacquer enables particularly good electrical insulation of the material layer, in particular in relation to an adjacent further material layer in a material layer structure.
• the material layer in particular by means of the baking varnish, can be solidified with the adjacent material layer or the neighboring material layers.
• the advantageously applied baking varnish enables a high strength and rigidity of the material layer structure, since the material layers are connected flat. This also reduces vibration and noise.
• the solid particles comprise particles made of electrically and / or magnetically conductive material, in particular metal particles.
• the electrically conductive material is preferably silver, copper, gold, aluminum, tungsten, iron and / or steel and / or their alloys. However, other electrically conductive materials are also conceivable.
• the magnetically conductive material is preferably a ferromagnetic material.
• the solid particles comprise particles of soft magnetic material.
• the soft magnetic material is iron, nickel, cobalt and / or their alloys.
• other magnetically conductive, in particular ferromagnetic, materials are also conceivable.
• the suspension is pseudoplastic. This has the advantage that the suspension is less viscous during application to the base for producing the green body, preferably with the doctor blade, and the desired shape can be optimally transferred through the template. When the job is finished, the green body retains the desired shape.
• the invention also relates to a material layer which is produced in the manner described, the material layer having a layer thickness of between 0.5 and 500 ⁇ m, in particular between 10 and 100 ⁇ m, the material layer having a soft magnetic material, the material layer being on at least one layer side has an insulation material.
• the material layer has an insulation material on both sides of the layer.
• the material layer has lacquer, in particular baked lacquer.
• the material layer can be solidified with at least one further material layer.
• the material layer has an essentially centrally arranged material recess.
• the material recess is preferably essentially circular.
• the material cut-out enables a connection to a shaft.
• the invention also relates to a method for producing the material layer structure for the rotor of the dynamoelectric rotary machine with the following steps: Additive manufacturing of a first layer of material, the first layer of material comprising at least one layer of material,
• the material layer comprises at least one material layer, i.e. just a layer of the solid particles. This makes the material layer particularly thin. In order to maintain a stable material layer, however, two or more layers of material are advantageous.
• the insulation material applied is lacquer, in particular baked lacquer.
• the application of baking varnish is easy and by baking two or more layers of material can be mutually solidified.
• the insulation material, in particular the baking varnish, and the material layer are preferably integrally connected.
• the insulation material is ceramic
• Water glass and other glasses are also conceivable as insulation material.
• a ceramic insulation material can be applied particularly well if a ceramic suspension, comprising ceramic solid particles and an expellable binder, is combined with a Doctor blade is applied to the material layer.
• the ceramic solid particles are preferably in the form of ceramic powder.
• the ceramic solid particles can have magnesium oxide, titanium dioxide, silicon carbide, silicon nitride, boron carbide, boron nitride and / or aluminum nitride. Other materials are also conceivable.
• an oxide ceramic in particular zirconium oxide and / or aluminum oxide, is preferred.
• a ceramic solid particle preferably essentially has a diameter between 0.1 and 2 ⁇ m.
• a suspension which has solid particles with a diameter of 0.5 ⁇ m and a suspension which has ceramic solid particles with a diameter of 1 ⁇ m a 1.5 ⁇ m thin layer of material isolated on one side or a 2.5 ym thin sheet of material is insulated on both sides.
• the material layer has a layer thickness of 1 ⁇ m.
• the ceramic solid particles form at least one material layer. However, two or more layers of material are also possible.
• the ceramic powder can comprise ceramic solid particles exclusively of one material or a ceramic powder mixture comprising at least two different ceramic materials.
• the ceramic solid particles are permanently bonded by heating and / or by means of compaction, in particular by means of sintering.
• the ceramic solid particles are preferably with the solid particles by heating and / or by compression, in particular by means of sintering, permanently connected.
• the permanent connection is preferably a cohesive connection.
• a material layer structure is produced by means of a plurality of material layers with a layer thickness of 0.5 to 500 ⁇ m.
• the material layer structure is suitable for a rotor of a dynamo-electric rotary machine, the material layer structure having a plurality of material layers arranged in the direction of a rotor axis of the material layer structure.
• the rotor of the dynamoelectric rotary machine has such a material layer structure.
• the invention further relates to a dynamoelectric rotary machine having such a rotor.
• the dynamoelectric rotary machine comprises a rotor with a plurality of material layers arranged one above the other.
• the material layers are preferably each individually electrically insulated from one another.
• the arrangement planes are advantageously formed parallel to the direction of the magnetic flux.
• the insulation between the individual layers of material prevents the eddy currents from overlapping into large, lossy eddy currents.
• the invention is preferably used in dynamo-electric rotary machines.
• the inven tion can also with other energy converters, such as. B. transformers, are used.
• the invention is also applicable to a stator of a dynamoelectric rotary machine.
• a plurality of material layers arranged one above the other preferably replace a conventional stator laminated core.
• the invention is particularly well suited for engines that demand high performance and low weight, in particular for aircraft, helicopters and racing cars of the formula E.
• FIG. 6 shows a side view of the dynamoelectric rotary machine.
• FIG. 1 shows the method according to the invention for producing a material layer with a layer thickness between 0.5 and 500 ⁇ m.
• the layer thickness is preferably between 10 and 100 ⁇ m for a stable material layer.
• Template applied to a base to obtain a green body Applied here preferably means: The suspension is applied with a doctor blade to the base.
• the binder is expelled from the green body, in particular by means of debinding.
• step S3 the solid particles are held together permanently by heating and / or by means of sealing, in particular by means of sintering.
• insulation material is applied to a layer side.
• insulation material is applied to the layer side with a squeegee or the layer side is coated with a coating tool or the layer side is immersed in a vessel containing the insulation material.
• the insulation material is preferably lacquer, in particular baked lacquer.
• the insulation material can be applied to the layer side by means of a ceramic suspension comprising at least one binder and ceramic solid particles, and the binder can be expelled, in particular by means of debinding.
• the material layer 1 has the layer thickness d.
• the material layer is preferably in one piece.
• Each material layer 1 preferably has an insulation material on at least one layer side.
• the figure shows an embodiment according to which each layer of material 1 has an insulation material on both sides of the layer.
• the insulation material in the figure is lacquer, especially baked lacquer. This corresponds to a preferred embodiment.
• the insulation material and the material layer are preferably integrally connected.
• the material layer 1 has lacquer 2 with an insulation thickness d2 on an upper layer side and lacquer 3 with an insulation thickness d3 on a lower layer side.
• the material layer 1 it is also possible for the material layer 1 to have a different type of insulation material and additional lacquer. It is also possible for the material layer 1 to have a different type of insulation material on one layer side and lacquer on the other layer side. It is also possible that the material layer 1 has a mixed form of a different type of insulation material and lacquer.
• the figure also shows a centrally arranged material recess 5 (for later connection to a shaft, see FIG. 5).
• a rotation axis R leads through a center point of the material recess 5.
• 3 shows the material layer 1 in a side view.
• the figure shows the thinnest version of the material layer 1, since only one layer of solid particles forms the material layer 1.
• the solid particles are granular material in the figure.
• the solid particles are small spheres which lie next to one another and, preferably by means of the sintering described in FIG. 1, are connected to one another.
• the layer thickness d corresponds to a diameter of a solid particle in the figure.
• the figure also shows only one layer of the insulation material as 2 on the upper layer side and only one layer of the insulation material 3 on the lower layer side.
• the insulation thickness d2 and the insulation thickness d3 correspond in figure to a diameter of a ceramic particle or a paint particle.
• two or more solid particles can also be formed one above the other in the material layer 1.
• Two or more ceramic solid particles can also form the insulation one above the other.
• Two or more solid lacquer particles can also form the insulation one above the other.
• a first material layer is manufactured additively, the first material layer comprising at least one material layer.
• an insulation material is applied to the first layer of material.
• the Isolati onsmaterial is preferably paint, especially baking paint.
• the insulation material can also be ceramic or another substance.
• At least one further material layer is manufactured additively, the at least one further material layer comprising at least one material layer.
• an insulation material is applied to the at least one further material layer.
• step S14 the first and the at least one further material layer are joined together.
• a method step S15 the material layers are solidified on the opposite side. If baking lacquer was applied to the material layers in process steps Sil or S13, the material layers are solidified by baking together.
• Baking here means: The layers of material are preferably glued together using pressure and heat.
• the baking varnish becomes soft due to pressure and heat, the material sticks to each other and hardens. This has the advantage over other connection options such as welding, punching and riveting that the material layers have no material-damaging contact points. In addition, a magnetic flux is not disturbed and there are no material tensions and material deformations.
• the method shown is also suitable for a stator of a dynamoelectric rotary machine.
• 5 shows a rotor 11 of the dynamoelectric rotary machine.
• the rotor 11 has a material layer structure 9.
• the material layer structure comprises a plurality of material layers 1 arranged one above the other along the axis of rotation.
• the material layer structure 9 is connected to a shaft 7.
• the material layer 1 is solidified in the figure with at least one white material layer.
• the figure shows a plurality of material layers 1 solidified together.
• Baking varnish works particularly well because it can be applied in a simple manner. A before then caking the material layers 1 creates a stable and robust connection.
• FIG. 6 shows a side view of the dynamoelectric rotary machine 15.
• the machine 15 has the rotor 11, which comprises the shaft 7 and the material layer structure 9.
• the rotor 11 can rotate in a stator 12 according to the axis of rotation R.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Power Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Materials Engineering (AREA)
• Dispersion Chemistry (AREA)
• Mechanical Engineering (AREA)
• Manufacture Of Motors, Generators (AREA)
• Iron Core Of Rotating Electric Machines (AREA)
• Laminated Bodies (AREA)
• Powder Metallurgy (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

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Citations (2)

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• 2018
  • 2018-07-13 EP EP18183457.3A patent/EP3595148B1/de active Active
• 2019
  • 2019-07-10 WO PCT/EP2019/068480 patent/WO2020011823A1/de not_active Ceased
  • 2019-07-10 EP EP19746005.8A patent/EP3785355B1/de active Active
  • 2019-07-10 JP JP2021500903A patent/JP7247317B2/ja active Active
  • 2019-07-10 KR KR1020217003817A patent/KR102395755B1/ko active Active
  • 2019-07-10 ES ES19746005T patent/ES3023050T3/es active Active
  • 2019-07-10 US US17/259,841 patent/US11451121B2/en active Active
  • 2019-07-10 CN CN201980046880.7A patent/CN112400272B/zh active Active
• 2023
  • 2023-02-03 JP JP2023015384A patent/JP7559101B2/ja active Active

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