METHOD FOR PRODUCING A MATERIAL LAYER AND A MATERIAL LAYER STRUCTURE FOR A DYNAMOELECTRIC ROTARY MACHINE

Abstract

In a method for producing a material layer with a layer thickness between 0.5 and 500 μm, a suspension with a binding agent and solid particles is applied through a template onto a base area for obtaining a green body. The binding agent is driven out of the green body and a permanent cohesion of the solid particles is created by heating and/or by compaction.

Claims

1.-15. (canceled)

16. A method for producing a material layer with a layer thickness between 0.5 and 500 μm, said method comprising: applying a suspension with a binding agent and solid particles through a template onto a base area for obtaining a green body, driving the binding agent out of the green body, in particular by debindering; and creating a permanent cohesion of the solid particles by heating and/or by compaction, in particular by sintering.

17. The method of claim 16, further comprising applying insulation material to the material layer on at least one layer side.

18. The method of claim 16, further comprising applying insulation material to the material layer on both layer sides.

19. The method of claim 16, further comprising applying a varnish, in particular thermosetting varnish, to the material layer.

20. The method of claim 16, wherein the solid particles comprise particles of electrically and/or magnetically conductive material, in particular metal particles.

21. The method of claim 16, wherein the solid particles comprise particles from soft-magnetic material.

22. The method of claim 16, wherein the suspension is pseudoplastic.

23. A material layer produced by a method as set forth in claim 16, said material layer having a layer thickness between 0.5 and 500 μm, in particular between 10 and 100 μm, and comprising: a soft-magnetic material; and an insulation material on at least one layer side of the material layer.

24. The material layer of claim 23, wherein the insulation material is applied on both layer sides of the material layer.

25. The material layer of claim 23, wherein the insulation material is varnish, in particular thermosetting varnish.

26. The material layer of claim 23, configured with a further material layer applied to the material layer for strengthening the material layer.

27. The material layer of claim 23, wherein the material layer has a material cut-out arranged substantially centrally.

28. A method for producing a material layer structure for a rotor of a dynamoelectric rotary machine, said method comprising: additive manufacturing of a first material layer produced by a method as set forth in claim 16 such that the first material layer comprises at least one material ply; applying an insulation material to the first material layer; additive manufacturing of a second material layer such that the second material layer comprises a material ply; applying an insulation material to the second material layer; joining the first and second material layers; and reciprocally strengthening the first and second material layers.

29. The method of claim 28, further comprising applying through additive manufacturing additional material layers of a number sufficient to produce the material layer structure, with each of the material layers having a layer thickness of 0.5 to 500 μm.

30. A material layer structure for a rotor of a dynamoelectric rotary machine, said material layer structure comprising a plurality of material layers arranged one above the other, each said material layer having a layer thickness between 0.5 and 500 μm and including a soft-magnetic material and an insulation material on at least one side of the material layer.

31. The material layer structure of claim 30, wherein the insulation material is applied on both layer sides of the material layer.

32. The material layer structure of claim 30, wherein the insulation material is varnish, in particular thermosetting varnish.

33. The material layer of claim 30, wherein the material layer has a material cut-out arranged substantially centrally.

Description

[0091] The invention is described and explained in more detail below with the aid of the exemplary embodiments shown in the figures, in which:

[0092] FIG. 1 shows the inventive method for producing a material layer with a layer thickness between 0.5 and 500 μm,

[0093] FIG. 2 shows the material layer,

[0094] FIG. 3 shows the material layer in a side view,

[0095] FIG. 4 shows a method for producing a material layer structure for a rotor of a dynamoelectric rotary machine,

[0096] FIG. 5 shows a rotor of the dynamoelectric rotary machine, and

[0097] FIG. 6 shows a side view of the dynamoelectric rotary machine.

[0098] FIG. 1 shows the inventive method for producing a material layer with a layer thickness between 0.5 and 500 μm.

[0099] The layer thickness preferably amounts to between 10 and 100 μm for a stable material layer.

[0100] In method step S1, a suspension having at least one binding agent and solid particles is applied through a template onto a base area in order to obtain a green body. Applied here means preferably that the suspension is applied onto the base area with a scraper.

[0101] In method step S2, the binding agent is driven out of the green body, in particular by means of debindering.

[0102] In method step S3, permanent cohesion of the solid particles is achieved by heating and/or by means of compaction, in particular by means of sintering.

[0103] In method step S4, insulation material is applied to one layer side. Applied here means preferably that the insulation material is applied to the layer side with a scraper or the layer side is coated with a coating tool or the layer side is immersed into a vessel which contains the insulation material.

[0104] The insulation material is preferably varnish, in particular thermosetting varnish.

[0105] Other insulation materials are also conceivable, however. The insulation material can for example be applied to the layer side by means of a ceramic suspension, having at least one binding agent and ceramic solid particles, and the binding agent can be driven out in particular by means of debindering.

[0106] Moreover, there is the possibility of applying an insulation material in a method step S4a (not shown) and in addition varnish, in particular thermosetting varnish, in a method step S4b (not shown).

[0107] If both layer sides are to be provided with insulation material and/or varnish, identified with b? and y, this is accomplished in method step S41.

[0108] If only one layer side is to be provided with insulation material and/or varnish, in a method step S5 the material layer is completed in the method by means of b? and n.

[0109] FIG. 2 shows the material layer 1.

[0110] The material layer 1 has the layer thickness d. The material layer is preferably in one piece.

[0111] Each material layer 1 preferably has an insulation material on at least one layer side. The figure shows an embodiment according to which each material layer 1 has an insulation material on both layer sides. In the figure the insulation material is varnish, in particular thermosetting varnish. This corresponds to a preferred embodiment.

[0112] The insulation material and the material layer are preferably connected with a material bond.

[0113] The material layer 1 has varnish 2 with an insulation thickness d2 on an upper layer side and varnish 3 with an insulation thickness d3 on a lower layer side.

[0114] It is also possible for the material layer 1 to have a different type of insulation material and additionally varnish. It is also possible for the material layer 1 to have a different type of insulation material on one layer side and varnish on the other layer side. It is also possible for the material layer 1 to have a hybrid form comprising other types of insulation material and varnish.

[0115] The figure moreover shows a material cut-out 5 arranged centrally (for subsequent connection to a shaft, see FIG. 5).

[0116] An axis of rotation R runs through a center point of the material cut-out 5.

[0117] The described reference characters are also valid for the following figures, provided they are present in the exemplary embodiments, and are not explained again for reasons of clarity.

[0118] FIG. 3 shows the material layer 1 in a side view.

[0119] The figure shows the thinnest embodiment of the material layer 1, since only one ply of solid particles forms the material layer 1. In the figure the solid particles are granular material. In other words, the solid particles are small beads which lie adjacent to one another and are connected to one another, preferably by means of the sintering described in FIG. 1.

[0120] In the figure the layer thickness d corresponds to a diameter of a solid particle.

[0121] Similarly, the figure only shows one ply of the insulation material 2 on the upper layer side and only one ply of the insulation material 3 on the lower layer side. The insulation thickness d2 and the insulation thickness d3 correspond in the figure to a diameter of a ceramic solid particle or a varnish solid particle.

[0122] Two or more solid particles one above the other can also form the material layer 1, however. Two or more ceramic solid particles one above the other can also form the insulation. Two or more varnish solid particles one above the other can also form the insulation.

[0123] FIG. 4 shows a method for producing a material layer structure for a rotor of a dynamoelectric rotary machine.

[0124] In method step S10, a first material layer is manufactured additively, wherein the first material layer comprises at least one material ply.

[0125] In method step S11, insulation material is applied to the first material layer. Here the insulation material is preferably varnish, in particular thermosetting varnish. The insulation material can however also be ceramic or another material.

[0126] In method step S12, at least one further material layer is manufactured additively, wherein the at least one further material layer comprises at least one material ply.

[0127] In method step S13, an insulation material is applied to the at least one further material layer.

[0128] In method step S14, the first and the at least one further material layer are joined.

[0129] In method step S15, the material layers are strengthened reciprocally. If thermosetting varnish was applied to the material layers in the method steps S11 or S13, the material layers are strengthened with one another by means of thermosetting.

[0130] Here thermosetting means that the material layers are preferably glued to one another by means of pressure and heat. Pressure and heat render the thermosetting varnish soft and the material layers adhere to one another and harden. This is advantageous compared with other connection options such as welding, stamping and riveting in that the material layers have no contact points which damage material. Moreover, a magnetic flux is not disturbed and no material stresses and material deformations occur.

[0131] The method shown is also suited to a stator of a dynamoelectric rotary machine.

[0132] FIG. 5 shows a rotor 11 of the dynamoelectric rotary machine.

[0133] The rotor 11 has a material layer structure 9. In the figure 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.

[0134] The material layer 1 in the figure is strengthened with at least one further material layer. The figure shows a plurality of material layers 11 which are strengthened with one another.

[0135] The strengthening is particularly successful using thermosetting varnish since this can be applied easily. An especially subsequent thermosetting of the material layers 1 creates a stable and robust connection.

[0136] FIG. 8 shows a side view of the dynamoelectric rotary machine 15.

[0137] 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.