WO2020126149A1

WO2020126149A1 - Method for producing a semi-finished product for an electric machine, and method for producing a functional unit for an electric machine

Info

Publication number: WO2020126149A1
Application number: PCT/EP2019/077462
Authority: WO
Inventors: Andreas Walter; Andreas Offergeld; Lothar Patberg; Thomas PRETORIUS
Original assignee: Thyssenkrupp Steel Europe Ag
Priority date: 2018-12-21
Filing date: 2019-10-10
Publication date: 2020-06-25
Also published as: DE102018133491A1

Abstract

The invention relates to a method for producing a semi-finished product (6) for producing a functional unit for an electric machine. The following steps are carried out: A) providing a substrate (1), B) providing a powder (3) in an application system (2), and C) applying the starting material (3) onto the substrate (1) in layers using an additive manufacturing method starting with a first layer (4) and continuing until completely constructing at least one first functional structure (5, 5a, 5b, 5c, 5d, 5e). The functional structure can have a recess (7) or a taper (8). The invention additionally relates to a method for producing a functional unit and to a semi-finished product.

Description

Method for producing a semi-finished product for an electrical machine and method for producing a functional unit for an electrical machine

The invention relates to a method for producing a semi-finished product for an electrical machine. The semi-finished product has at least one functional structure made of an iron-based one

Material on. The invention also relates to a method for producing a functional unit for an electrical device

Machine. A functional unit can in particular be a stator or a rotor.

Electrical machines, in particular electric motors, are known from practice. Electric motors have at least one immovable functional unit called a stator and one movable functional unit. A rotor can, for example, be provided as the movable functional unit. For the

Positioning of the stator and rotor shows the electrical

Machine also has a housing. At least one of the two functional units is magnetically active. Depending on

Functioning of the electric motor, the at least one of the functional units can be remagnetized with an alternating electromagnetic field. This results in the requirement that the functional unit should have material that is as soft as magnetic as possible and that it can be remagnetized with the least possible magnetic loss. The magnetic reversal losses consist in particular of hysteresis losses during the polarity reversal

Elementary magnets of magnetic material and out

Eddy current losses due to induced eddy currents within the magnetic material together.

With the objective that magnetization losses

should be as small as possible, has established itself as a common method for producing functional units of electrical machines, stators and / or rotors made of several sheets assemble so-called sheet metal packages. The used

Sheets are commonly referred to as electrical sheets. The individual sheets of the laminated cores are partially or completely separated from one another with an electrical insulator in order to be inside each individual sheet and thus also in the

completed functional unit to reduce total eddy current losses during the remagnetization. To reduce eddy current losses as much as possible, thin sheets are used to manufacture the sheet stack

used. Another measure to reduce the

Magnetic reversal losses consist in the use of electrical sheets already mentioned above. The concept of

In this context, electrical sheet refers to sheet metal, the properties of which are set, among other things, with a view to minimizing magnetic loss. For example, electrical sheets have one for this purpose

comparatively low density of lattice defects, comparatively low density at grain boundaries and comparatively low residual stresses. Another feature of electrical sheets is their element compositions, which are also developed for low magnetic loss, among other things. A known measure to achieve advantageous properties of the electrical sheets in iron-based alloys, for example in electrical steels, is the addition of silicon.

The addition of silicon according to the invention leads to

iron-based electrical sheets, as mentioned, to the desired reduction in magnetic losses. The addition of silicon in electrical sheets has an effect on higher ones

Silicon contents, in the case of iron-based electrical sheets in particular above about 3.5% by weight of Si content, adversely affect the processability. The addition of silicon in proportions above about 3.5% by weight is particularly disadvantageous for cold workability. One of the reasons for this is that Si contents above approximately 3.5% by weight are used to eliminate brittle phases to lead. Hot forming of the electrical sheets is also only possible to a limited extent at Si contents above about 3.5% by weight or with increased effort.

Another disadvantage of a high Si content in

iron-based electrical sheets is that the actually advantageous reduction in sheet thickness mentioned at the outset is increasingly limited with an increase in the Si content. That is it

justifies that that is usually used for shaping

Stamping the sheets on the one hand leads to anisotropies in the

leads magnetic properties, for example due to residual stresses, but on the other hand a conventional

Reduction of the internal stresses by annealing in electrical sheets with small thicknesses, in particular below about 0.3 mm, due to increased oxide formation from edge zones to one

Deterioration of the magnetization properties leads.

In summary, the well-known manufacture of

Functional units for an electrical machine

Due to opposing effects, electrical sheets mean that the selection of the construction parameters, in particular the

Element composition of the sheets used and the thickness of the sheets used, limits are set.

Based on the problems presented, the invention has for its object functional units for

To be able to provide electrical machines in which the problems mentioned are avoided or at least reduced in their extent.

The task is solved with a method with the

Features of claim 1 for the manufacture of a semi-finished product, which can then be further processed in the manufacture of a functional unit for an electrical machine. The object is further achieved with a method for producing a functional unit for an electrical machine with the features of claim 12. The method according to the invention provides for the production of a semifinished product which is further processed into a

Functional unit can be used for an electrical machine.

The procedure includes the following steps:

A) providing a substrate,

B) provision of a powder as starting material,

C) layer-by-layer application of the starting material on the substrate until the completion of at least one first functional structure of the functional unit.

The functional structure of the functional unit can in particular be one that already has the final geometry

at least in sections, preferably completely, flat

Act structure. The flat structure serves as a component of the functional unit to be manufactured later

Functional unit. For example, it can be a flat structure that is provided as part of a rotor, alternatively a stator. In other words, the functional structure can in particular be a plane of the rotor

or the stator. The functional structure thus takes on the role that that of conventionally manufactured

Functional units is taken up by a sheet of a sheet stack, more precisely by a cut-out part of a sheet of the sheet stack produced by stamping.

According to the invention, a powder is used as the starting material

used that for providing the magnetic

Functionality as a mandatory component of the chemical element Fe, i.e. iron. In addition, besides

unavoidable impurities, optional components

be present, which can be selected in addition to taking their influence on the magnetic properties into account, in particular with regard to the desired mechanical properties of the functional unit to be produced. In particular, it can be provided that the powder C, preferably a C content of contains at least 0.003% by weight to cause the formation of steel.

The powder provided as the starting material also has between 2.0% by weight and 15.0% by weight, preferably between 3.5% by weight and 10.0% by weight, particularly preferably between 4.0% by weight. -% and 7.0% by weight, silicon. As already explained at the beginning, a high silicon content has a positive effect on the magnetic properties, which among other things its

ferrite stabilizing properties and its

resistance increasing properties are meant

electrical resistance increasing properties, is to be attributed. A proportion of 15.0 wt .-% silicon should not

exceeded to have negative influences on the mechanical properties of the functional structure, in particular

Lowering their fracture toughness, sufficiently safe too

avoid.

The substrate is used to support those to be manufactured

Functional structure and can be made of any material

be produced that remains structurally and chemically sufficiently stable at the temperatures occurring during the production of the semi-finished product. In particular, the substrate can be produced as steel sheet. The substrate particularly preferably has

the same or substantially the same element composition as the powder with the advantage that good adhesion between the substrate and the starting material is achieved when the first layer of the starting material is applied to the substrate.

In addition to the silicon content mentioned, a proportion of less than 18.8% by weight of optional components is preferred

available. As a consequence, this also means that at least 66.2% by weight of the starting material consists of iron and

unavoidable impurities. It has been shown that by selecting such a high iron content, sufficient magnetic properties are inevitably always achieved, and at the same time by the permitted addition a significant proportion of optional components, there is sufficient flexibility in the setting of the properties of the functional structure, for example in the setting of the structure and the mechanical properties.

The powder provided as the starting material is preferably a powder which

Has element composition of the first functional structure in the respective parts by weight and more suitable

Particle size distribution and sufficient homogeneous distribution is provided. Alternatively, the powder can be present as a defined type of powder. Whether the individual powder particles present in the powder are present as elements or in turn already exist in one or more alloys is not important as long as the element compositions mentioned are adhered to and, due to sufficiently homogeneous mixing of the powder, ensures a sufficiently high homogeneity in the particle feed to the substrate is. The formation of the finally

Existing alloy of the functional structure takes place during the application itself and is ensured by the locally very high temperatures for the

Apply selected manufacturing processes, which are mentioned below.

The material is preferably melted completely during application.

A powder bed-based additive manufacturing process or a powder nozzle-based additive manufacturing process is used for the application. In particular, a selective one can be used as the powder bed-based additive manufacturing process

Laser melting (selective laser melting), a

Laser beam melting, a selective one

Laser sintering (selective laser sintering) or a

Electron beam melting can be used. Laser deposition welding (laser metal deposition) can in particular be used as the powder nozzle-based production method. be provided. Each of the methods mentioned is known per se to the person skilled in the art. All of the methods mentioned have the advantage that at the time of the order at one point at this point due to the laser radiation used

or the electron beam used

sufficient temperature can be reached to completely melt the materials during application.

The use of the methods mentioned has the advantage that with the provision of powders with comparatively high element components of silicon, even greater than the 3.5 wt.% Mentioned, the at least one functional structure with a high homogeneity in the element distribution has a low one

Void density and can be produced with comparatively large grain sizes. At the same time, the production of small-scale structures is possible. In particular, it is possible to produce flat structures, for example in the geometry of a plate or a part punched out from a plate, with thicknesses of less than 0.30 mm up to approximately 0.10 mm. The method according to the invention thus has the

Advantage of providing smaller-scale plates too

enable than is possible with rolling processes. The

Functional structure can be present, for example, as a flat structure that has two planes parallel to one another

Boundary surfaces with a distance between 0.10 mm and 0.30 mm. Because of the additive used

Manufacturing processes, the functional structure can also be designed as a three-dimensional structure and thus take on more complex geometries without any forming processes on one

Electrical sheet are required for this.

The powder provided as the starting material preferably has the following constituents (all details in

Weight -%):

Si: 2.0-15.0;

C: less than, that is: really less than, 0.1; Mn: up to, that is: less than or equal to, 2.0;

S: less than 0.01;

Al: up to 15.0;

N: less than 0.01;

Cu: less than 0.3;

Cr: less than 0.5;

Mo: less than 0.1;

B: less than 0.1;

Nb: less than 0.01;

V: less than 0.1;

Ti: less than 0.01;

Sn: less than 0.1;

Ni: less than 0.1;

P: less than 0.1;

Co: less than 0.01;

Zn: less than 0.01;

As: less than 0.03;

Ca: less than 0.012;

Sn: less than 0.16;

Ta: less than 0.01;

W: less than 0.02;

Balance Fe and inevitable impurities.

It is understood that the rest refers to the fact that the sum of all parts by weight is 100% by weight.

It is particularly preferred that at least 0.003 wt.

The powder preferably consists of particles with a

Particle size between dlO = 10 ym and d90 = 150 ym, preferably between dlO = 10 ym and d90 = 60 ym or between dlO = 30 ym and d90 = 150 ym. Before the first functional structure is applied, the substrate is preferably preheated to an application temperature which is at least during the application of a first layer of the first functional structure, preferably during the application of the

entire first functional structure, is no longer undercut. In other words, the substrate is kept at a temperature that at least corresponds to the application temperature.

The application temperature is preferably between 400 and 900 ° Celsius, particularly preferably between 500 and 800 ° Celsius.

By preheating the substrate, in particular by

Support of diffusion processes and the reduction of the temperature gradients prevailing in the job

Low cracks and low tension due to the orders

completed first functional structure. The first functional structure is preferably applied as a flat structure with a thickness between 0.10 mm and 2.0 mm, particularly preferably between 0.10 mm and 1.00 mm, the term flat structure refers to the fact that the first functional structure is in the form of a punched, not formed, sheet, but

is not referred to as sheet metal due to the different type of manufacture by means of additive manufacturing.

An embodiment variant of the method provides that the first functional structure and a number of others

Functional structures are applied sequentially to the substrate in layers. This is to be understood to mean that the first position of all the functional structures of the first functional structure and the number of others is first in succession

Functional structures is applied, then the second layer of all functional structures is applied sequentially and this procedure is repeated until the last layer of each of all functional structures has been applied sequentially. It can be provided that the first functional structure and the number of others

Functional structures have identical dimensions and applied parallel to the substrate. The functional structures arranged on the substrate serve as

Semi-finished products for the electrical machine and already have their final geometry, so that no further processing or post-treatment is required. In comparison to

Conventional production (that is, in particular by punching and subsequent annealing), there is no high waste of electrical sheets. In addition, the emergence of disadvantageous on the magnetic losses of the

Semi-finished / semi-finished product internal stress by eliminating subsequent processing steps, such as punching, avoided. This reduces the manufacturing costs, for example to DIN EN 10341

required annealing of stamped parts can potentially be dispensed with, which immediately results in lower production costs.

The functional structures can be perpendicular to one

Be oriented substrate surface, but it is also conceivable that they are attached to the substrate in a slight inclined position, for example tilted between 0 degrees and 10 degrees to the orthogonal plane of the substrate.

The functional structures are preferably provided with a predetermined breaking point in the region of their transition to the substrate, so that each individual functional structure or the entirety of the functional structures can be easily removed from the substrate, for example by means of spark erosion, by means of

mechanical processing or by manual removal.

According to one embodiment variant, the first

Functional structure and the number of others

Functional structures all in the form of a stator plate or all in the form of a rotor plate.

Each of the functional structures is preferably at a distance from each immediately adjacent functional structure, which is between 0.003 mm and 2.00 mm. All functional structures are preferably arranged on the substrate in an equidistant manner have distances between 0.003 mm and 2.00 mm from the neighboring functional structures.

In the event that the functional structures are shaped as a stator sheet or as a rotor sheet, the functional structures with a common one are preferably already on the substrate

Rotation axis oriented, which is oriented perpendicular to a plane of the respective functional structures, preferably also in addition to the substrate plane.

The invention further provides a method for producing a functional unit for an electrical machine. The functional unit for an electrical machine is manufactured in the following steps:

First, a semi-finished product is produced using a method of the type mentioned at the beginning or one of its further developments. The semifinished product has a substrate and at least one, preferably a plurality of functional structures arranged on the substrate.

After that, everyone in between neighboring

Functional structures existing spaces

Insulating material for at least partial electrical insulation of the functional structures to one another is introduced. After the insulation material has been inserted, this will go out

Functional structures and the insulating material existing

Functional structure package separated from the substrate, whereby the functional unit is obtained.

The electrically insulating insulating material can be, for example, an electrically insulating plastic. Can be used as an electrically insulating plastic

For example, a plastic based on polyvinyl butyral, a polyamide, a polyester or a plastic based on epoxy resin can be provided. The plastic is preferably introduced into the existing spacing spaces by means of a spraying process and / or by means of a dip coating.

In particular, it can be provided that after the application of the starting material without additional heat treatment Steps D to F are performed so that a

Functional functional unit, in particular a stator or a rotor, is provided without a heat treatment being carried out after the construction of the individual functional structures.

The fact that the additively produced, preferably vertically constructed, semi-finished products have a rough surface advantageously favors a firm connection between metal and plastic.

Examples:

The described procedure has been verified with various feasibility studies.

Example 1 :

The first feasibility study was carried out for

Verification of suitable magnetic properties in the case of thin platelets, which is produced using a method according to the invention by means of laser deposition welding (laser metal deposition).

The following steps were carried out:

1. Provision of two basic powders:

Powder 1: Mn 1.2% by weight, Si 0.5% by weight, balance iron and

unavoidable impurities;

Powder 2: Mn 1.2% by weight, Si 48.76% by weight, balance iron and unavoidable impurities.

2. Mix the powders into three powders as three

various starting materials:

Starting material 1: wt. -% proportions Fe: Si = 96: 4;

Starting material 2: wt. -% proportions Fe: Si = 94: 6;

Starting material 3: wt. -% proportions Fe: Si = 92: 8.

There were 1 and 2 platelets for each of the starting materials by means of laser metal deposition with dimensions of 60 x 60 x 0.35 mm ³ and 3 plates with dimensions of 60 x 60 x 0.55 mm ³ for starting material.

Powder was fed to the substrate with argon in an inert gas bell in an open system.

The experimental boundary conditions were chosen as follows:

- for raw material 1: laser power 910 W,

Feed speed 600 mm / min; Powder mass flow 3.8 g / min; Track offset = 1 mm; Height offset = 0.6 mm; Preheating temperature = room temperature;

for starting material 2: laser power 910 W,

Feed speed 600 mm / min; Powder mass flow 3.8 g / min; Track offset = 1 mm; Height offset = 0.62 mm; Preheating temperature = 300 ° C;

for raw material 3: laser power 950 W,

Feed speed 600 mm / min; Powder mass flow 3.5 g / min; Track offset = 1 mm; Height offset = 0.625 mm; Preheating temperature = 400 ° C.

The samples are referred to as LMD4, LMD6 and LMD8 with increasing silicon content.

The following mechanical parameters could be determined:

LMD4: hardness HV 0.5 = 200, LMD6: hardness HV 0.5 = 300, LMD8: hardness HV 0.5 = 400 and tensile strength R _m = 500 MPa.

Magnetic reversal tests were carried out, which are set out in a subsequent section.

Example 2:

A test specimen 60 x 60 x 0.28 mm ^{3 was} produced using selective laser melting (selective laser melting), the following powder properties being the starting material

produced powder orlagen _V:

The experimental conditions chosen were:

Preheating temperature = 300 ° C, laser power fluctuating

between 120 W and 170 W; Feed rate = 450 - 700 mm / s.

The sample produced is referred to below as SLM.

Magnetic reversal attempts:

With the samples prepared

Magnetic reversal tests according to DIN IEC 60404-3: 2010-05

carried out. Magnetic reversal tests were carried out at 50 Hz, 400 Hz and at 1000 Hz magnetic reversal frequency. The magnetization was carried out in one of the two cases

magnetic flux density of 1 T.

As reference samples, conventionally produced, 0.30 mm thick plates made of the electrical sheets from the alloys of the comparative standard quality NO30-16 before heat treatment and after annealing for 40 seconds in an oven at H2 / Ar atmosphere at 1060 ° C and M400-50 A without Heat treatment used.

The following results were obtained

The result shows that those with additive

Manufacturing process produced platelets

Magnetic reversal losses have shown that without prior annealing, some have lower, but at least comparably low magnetic reversal losses as the reference samples without additional heat treatment. At the same time, the magnetization losses are at least in the order of magnitude of the magnetization losses of the heat-treated reference sheet. It also shows that an increased Si content leads to lower magnetic loss. It was therefore possible to demonstrate that using additive manufacturing processes

Functional structures for electrical machines can be produced that have comparable good properties as

Functional structures made with known methods

Electrical sheets are made. An exemplary embodiment of the method for producing a functional unit for an electrical machine is shown in Figs. la) - lf). More details,

Features and advantages of the object of the invention result from the following description in connection with the

Drawings .

It goes without saying that the features mentioned above and also explained below can be used not only in the respectively specified combination, but also in other combinations or on their own.

In a first step, shown in Fig. La), a substrate 1 is provided. In an application system 2, a starting material 3 provided as a powder is filled and from this a first layer 4 of the starting material 3 is applied to the substrate 1. In the example shown, as shown in FIG. 1b), the first layer 4 is applied by means of build-up welding, also referred to as laser metal deposition. A first functional structure 5 is applied in layers on the substrate. The first functional structure 5 is shown in the finished state in FIG. 1 c), the first exemplary embodiment being shown in the example shown

Functional structure 5 is a component of a rotor designed as a flat structure for an electrical machine. The term flat structure refers to the fact that the functional structure 5 is made of sheet metal

stamped part corresponds, however, in the nature of its

Production differs from such a punched-out part, since the production of the functional structure 5 by means of a

additive manufacturing process.

As shown in Fig. Id), several

Functional structures 5a, 5b, 5c, 5d, 5e are applied sequentially in layers on the substrate, the shape and manufacture corresponding to that of the first functional structure. With the layered sequential orders it is meant that the respective nth layer of each of the functional structures is applied and then the n + lth layer of each of the functional structures is applied. The functional structures 5, 5a, 5b, 5c, 5d, 5e are arranged equidistant on the substrate 1. The substrate with the entirety of the functional structures 5, 5a, 5b, 5c, 5d, 5e represents the semifinished product 6, which was produced using an exemplary embodiment of the method according to the invention. A

Further processing of the semi-finished product into a rotor can be provided. For a manual removal of the semi-finished product, each functional structure has a predetermined breaking point 7, 8, which

is independent of the design of the functional structure, for example a recess 7 in a contact area

between functional structure 5 and substrate 1 (see Fig le):

Supervision in the direction of a rotational symmetry axis

Functional structure 5) and / or a taper 8 in one

Contact area between functional structure 5 and substrate 1 (see FIG. 1f): supervision in the direction of a straight line lying on a plane of functional structure 5).

2a) shows the production of a first layer 4 of a first functional structure by means of an additive designed as a powder bed-based selective laser melting

Manufacturing process shown, the illustrated

Reference symbols which have already been used in the description of FIG. 1

have explained meanings. The first layer is generated after application of the powder 3 by means of local ones

Melting by a laser beam 9, which with a

Deflecting mirror 10 is redirected to the point to be melted. 2b) shows the layer-by-layer sequential application of a number of several functional structures using the example of a first layer, with the application of the first layer of all functional structures followed by the sequential application of the second layer of all functional structures until the last layer of all functional structures has been applied. In Fig. 2b) the application process is just when the first layer 4e of the sixth functional structure after the first layers 4, 4a, 4b, 4c and 4d of the first five functional structures have already been produced.

Claims

1. A method for producing a semifinished product for producing a functional unit for an electrical machine, the following steps being carried out:

A) providing a substrate (1),

B) providing a powder (3) as a starting material

(3),

C) layer-wise application of the starting material (3) on the substrate (1) with a powder bed-based additive manufacturing process or with a powder nozzle-based additive manufacturing process until the completion of at least one first functional structure (5)

Functional unit,

in which

the powder (3) provided as the starting material consists of (each in percent by weight)

Si: 2.0-15.0;

Rest Fe, optional components and unavoidable

Impurities.

2. The method according to claim 1, wherein the as

The raw material provided consists of (each in weight percent)

Si: 2.0-15.0;

less than 18.8 optional components,

Balance Fe and inevitable impurities.

3. The method according to claim 1 or according to claim 2, wherein the powder provided as the starting material consists of (each in percent by weight) Si: 2.0-15.0;

C: less than 0.1, preferably less than 0.1 and

at least 0.003;

Mn: up to 2.0;

S: less than 0.01;

Al: up to 15.0;

N: less than 0.01;

Cu: less than 0.3;

Cr: less than 0.5;

Mo: less than 0.1;

B: less than 0.1;

Nb: less than 0.01;

V: less than 0.1;

Ti: less than 0.01;

Sn: less than 0.1;

Ni: less than 0.1;

P: less than 0.1;

Co: less than 0.01;

Zn: less than 0.01;

As: less than 0.03;

Ca: less than 0.012;

Sn: less than 0.16;

Ta: less than 0.01;

W: less than 0.02;

Balance Fe and inevitable impurities.

4. The method according to any one of the preceding claims, wherein the powder consists of particles with a particle size between dlO = 10 ym and d90 = 150 ym, preferably between dlO = 10 ym and d90 = 60 ym or between dlO = 30 ym and d90 =

150 ym.

5. The method according to any one of the preceding claims, wherein the substrate (1) at least temporarily during the

Step C), preferably at least during the application of a first layer (4) of the first functional structure (5), particularly preferably until the completed construction of the at least first or all functional structures, is kept at a temperature which corresponds to at least one application temperature.

6. The method according to claim 5, wherein the application temperature is between 400 and 900 degrees Celsius, preferably between 500 and 600 degrees Celsius.

7. The method according to any one of the preceding claims, wherein the first functional structure (5) is applied as a flat structure with a thickness between 0.10 mm and 2.00 mm, preferably between 0.10 mm and 1.00 mm.

8. The method according to any one of the preceding claims, wherein the first functional structure (5) is applied to the layer directly adjacent to the substrate (1) with a predetermined breaking point (7, 8) to enable a manual

Aborting the first functional structure (5) from the

Predetermined breaking point or one by means of mechanical

Separation procedure aborting the first

Functional structure (5) from the predetermined breaking point.

9. The method according to any one of the preceding claims, wherein the first functional structure (5) and a number of further functional structures (5a, 5b, 5c, 5d, 5e) are applied sequentially in layers on the substrate (1).

10. The method according to any one of the preceding claims, wherein the first functional structure (5) and the number of further functional structures (5a, 5b, 5c, 5d, 5e) have identical dimensions and are applied to the substrate (1) with a parallel shift.

11. The method of claim 10, wherein the first

Functional structure (5) and the number of others

Functional structures (5a, 5b, 5c, 5d, 5e) are all stator flat structures or all are one

Flat rotor structure, each of the functional structures (5, 5a, 5b, 5c, 5d, 5e) being at a distance between 0.003 mm and 2.00 mm from each immediately adjacent functional structure, preferably each of the functional structures (5, 5a, 5b, 5c, 5d, 5e) to each immediately adjacent

Functional structure the same distance between 0.003 mm and 2.00 mm.

12. A method for producing a functional unit for an electrical machine, wherein

D) with a method according to one of the preceding

Claims a semi-finished product (6) with at least two

Functional structures (5, 5a, 5b, 5c, 5d, 5e) are produced, which are connected to the same substrate (1),

E) into all the spaces between adjacent functional structures (5, 5a, 5b, 5c, 5d, 5e)

Insulating material is introduced for electrical insulation, at least in sections,

F) after inserting the insulating material from the

Functional structures (5, 5a, 5b, 5c, 5d, 5e) and the

Insulating material existing functional structure package is separated from the substrate (1) and the functional unit is thereby obtained.

13. The method according to claim 12, wherein during step E) an electrically insulating plastic, preferably a

Polyvinyl butyral-based plastic, a polyamide

Polyester or a plastic based on epoxy resin is applied by spraying and / or by means of dip coating.

14. The method according to claim 12 or according to claim 13, wherein after the application of the starting material without

additional heat treatment steps D) to F)

be carried out to provide a functional functional unit.

15. Semi-finished product for the production of a functional unit for an electrical machine, available according to one of the

Claims 1 to 11.