ROBUST MATERIAL LAYERS

Abstract

In a method for producing a material layer by an additive process, a first suspension with binding agent and solid particles is applied through a first template onto a base area to obtain a first green body, thereby reproducing by the first template a first material region of a first material to form a magnetic flux-conductive region with a first magnetic permeability μr>50. A second suspension with binding agent and solid particles is applied through a second template onto a base area to obtain a second green body, thereby reproducing by the second template a second material region of a second material to form a flux-blocking region with a second magnetic permeability μr<5. The first and second green bodies are joined and a permanent, material-bonded cohesion between the first and second green bodies and the solid particles is created by heating and/or by compaction.

Claims

1-17. (canceled)

18. A method for producing a material layer by an additive process, said method comprising: applying a first suspension having a binding agent and solid particles through a first template onto a base area to obtain a first green body, thereby reproducing by the first template a first material region of a first material to form a magnetic flux-conductive region with a first magnetic permeability μr>50; applying a second suspension having a binding agent and solid particles through a second template onto a base area to obtain a second green body, thereby reproducing by the second template a second material region of a second material to form a flux blocking region with a second magnetic permeability which is lower than the first magnetic permeability and is μr<5; joining the first and second green bodies to one another; and creating a permanent, material-bonded cohesion between the first and second green bodies and the solid particles by heating and/or by compaction.

19. The method of claim 17, wherein the permanent, material-bonded cohesion between the first and second green bodies and the solid particles is created by sintering.

20. The method of claim 17, wherein the solid particles comprise metal particles.

21. The method of claim 17, wherein the solid particles of the first suspension comprise magnetic particles, wherein the solid particles of the second suspension comprise amagnetic particles.

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

23. A material layer for a dynamoelectric rotary machine, said material layer comprising: a magnetic flux-conductive region having a first material with a first magnetic permeability μr>50; and a flux-blocking region connected to the magnetic flux-conductive region with a material bond and having a second material with a second magnetic permeability which is lower than the first magnetic permeability and is μr<5.

24. The material layer of claim 23, configured for use in a dynamoelectric rotary reluctance machine.

25. The material layer of claim 23, configured for use in a rotor having a rotational direction about an axis of rotation which is arranged in a layer center point of the material layer.

26. The material layer of claim 23, further comprising insulation material applied on at least one layer side.

27. The material layer of claim 23, further comprising insulation material applied on both layer sides.

28. The material layer of claim 23, further comprising varnish applied on at least one layer side.

29. The material layer of claim 23, wherein the varnish is thermosetting varnish.

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

31. The material layer of claim 23, further comprising a third region having permanent magnetic material, said permanent magnetic material being connected with a material bond to the first material and/or to the second material.

32. The material layer of claim 23, wherein the magnetic flux-conductive region is configured to form poles with a number of poles 2p and arranged so as to adjoin a lower side facing a layer center point at the flux-blocking region, wherein a pole pitch extends in a rotational direction from a center of the flux-blocking region to a center of a next one of said flux-blocking region.

33. The material layer of claim 32, wherein a width of the flux-blocking region, viewed in the rotational direction, at an external periphery of the material layer, corresponds to between 1% and 50% of the pole pitch, wherein a radial depth of a pole corresponds to >10% of a circular arc length of the pole pitch.

34. The material layer of claim 23, wherein the magnetic flux-conductive region is configured to form poles with a number of poles 2p and traversed by the flux-blocking region substantially in the manner of an arc, wherein a pole pitch extends in a rotational direction from a center of the magnetic flux-conductive region to a center of a next one of said magnetic flux-conductive region.

35. The material layer of claim 34, wherein a width of the magnetic flux-conductive region, viewed in the rotational direction, at an external periphery of the material layer, corresponds to between 1% and 50% of the pole pitch.

Description

[0095] The invention is described and explained in more detail below on the basis of the exemplary embodiments shown in the figures. In the drawings:

[0096] FIG. 1 shows the prior art,

[0097] FIG. 2 shows a material layer for a machine, in particular reluctance machine,

[0098] FIG. 3 shows a material layer for an inverse machine, in particular reluctance machine,

[0099] FIG. 4 shows a rotor, having a material layer structure with material layers insulated on both sides,

[0100] FIG. 5 shows a rotor, having a material layer structure with material layers insulated on one side,

[0101] FIG. 6 shows a further material layer, having permanent magnetic material for an inverse reluctance machine,

[0102] FIG. 7 shows a method for producing a material layer, and

[0103] FIG. 8 shows a method for producing a material layer structure.

[0104] FIG. 1 shows the prior art, in other words a metal sheet for a laminated core made from soft-magnetic material 3, which moreover has flux bafflers 5. The flux barriers 5 were stamped from the metal sheet and are filled with air or another gas. The figure moreover shows webs 7, which hold the metal sheet together and stabilize the metal sheet. Furthermore, the figure shows a rotational direction R, a center point M, an axis q and an axis d as well as a material cut-out 12.

[0105] The described reference characters are also applicable to the following figures, provided they are included in the exemplary embodiments, and are not explained again for reasons of clarity.

[0106] FIG. 2 shows a material layer 1 for a machine, in particular reluctance machine. The material layer comprises magnetic flux-conductive regions 9 and magnetic flux-blocking regions 11. The magnetic flux-conductive regions 9 have magnetic, in particular soft-magnetic, material.

[0107] This magnetic material is preferably a material containing iron with a lower coercivity field strength, in particular<50 Nm, with a high saturation, in particular>2 T, and a high permeability, in particular μr>500.

[0108] The magnetic flux blocking regions 11 have amagnetic material. This material is preferably amagnetic, in particular with a permeability<1.5.

[0109] The amagnetic material is preferably steel, in particular stainless steel.

[0110] Steel with the material number 1.4404 is particularly suitable.

[0111] In the figure the regions 9 and 11 are connected to one another with a material bond and are therefore robust and resistant to high rotational speeds. No webs are required.

[0112] The regions 9 and 11 are preferably connected with a material bond by heating and/or by means of compaction, in particular by means of sintering, and form a one-piece component. This is explained in more detail below in the description of the method for production.

[0113] The figure moreover shows segment sections 13, which are air-filled, for instance. In order to avoid a pump effect, which develops with geometrically non-circular rotors, or to avoid noises, the segment sections 13 are alternatively filled with amagnetic material and preferably likewise connected with a material bond to the adjoining regions. The segment sections 13 are filled with amagnetic material even with high rotational speed requirements.

[0114] The segment sections 13, which are filled with amagnetic material, are also preferably connected with a material bond to the regions 9 and/or 11 by heating and/or by means of compaction, in particular by means of sintering, and form a one-piece component.

[0115] In one possible embodiment the amagnetic material is ceramic or a ceramic mixture.

[0116] FIG. 3 shows a material layer 1 for an inverse reluctance machine.

[0117] The material layer 1 has, viewed in the rotational direction R, in each case a magnetic flux-blocking region 11 around the centers of the d-axes. Material/layer 1 has in each case a magnetic flux-conductive region 9 around the centers of the q-axes.

[0118] A pole P is formed by magnetic, in particular soft-magnetic material and is surrounded at least partially by amagnetic material. A pole is therefore, at least partially, surrounded by amagnetic material.

[0119] The figure moreover shows a width B11 of the flux-blocking region 11, viewed in the rotational direction R, and a depth U of the flux-blocking region 11, viewed in the rotational direction R. Eddy current losses can be kept minimal by means of the depth U.

[0120] Furthermore, the figure shows a radial depth T of the pole P.

[0121] The material layer 1 for an inverse reluctance machine is optimized with respect to a magnetic flux course by the embodiment of the regions 9 and 11. The optimization is successful in particular by only regions which are to conduct magnetic flux being provided with magnetic, in particular soft-magnetic material.

[0122] FIG. 4 shows a rotor 2, having a material layer structure 20 with material layers 1 which are insulated on both sides. The figure shows that the material layer structure 20 is linked to a shaft 16. Advantageously the shaft is designed to be amagnetic.

[0123] The rotor 2 rotates in the rotational direction R about an axis of rotation A. The axis of rotation A runs through the center point M in the previous figures.

[0124] Each material layer 1 preferably has an insulation material 8 on at least one layer side. The figure shows an embodiment, according to which each material layer 1 has an insulation material 8 on both layer sides.

[0125] In the figure the insulation material 8 is varnish, in particular thermosetting varnish.

[0126] It is also possible for the material layer 1 to have a different type of insulation material and, in addition, 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 a different type of insulation material and varnish.

[0127] In the figure the material layer 1 is strengthened with at least one further material layer. The figure shows a plurality of material layers strengthened with one another. This produces the material layer structure 20.

[0128] The strengthening is particularly successful as a result of applied thermosetting varnish, since this can be applied easily. An especially subsequent thermosetting of the material layers 1 creates a stable and robust connection.

[0129] FIG. 5 shows a rotor 4, having a material layer structure 21 with insulated material layers on one side. The figure shows an embodiment, according to which each material layer 1 has one insulation material 8 on just one layer side.

[0130] FIG. 6 shows a further material layer 1, having permanent magnetic material for an inverse reluctance machine.

[0131] In the figure the material layer has a region 111 provided with permanent magnetic material. The region 111 can consist fully of permanent magnetic material or have a hybrid form made from amagnetic and permanent magnetic material.

[0132] This is advantageous in that two parallel magnetic circuits can be generated and these can be separated electromagnetically from one another. A first magnetic circuit uses the reluctance force. A second magnetic circuit uses the Lorentz force by means of the permanent magnetic material. In this way the magnetic circuits can complement one another and can overall deliver a larger torque with the same current.

[0133] The regions 9 and 111 are preferably connected with a material bond by heating and/or by means of compaction, in particular by means of sintering, and form a one-piece component.

[0134] The segment sections 13, which are filled with amagnetic material, are also preferably connected with a material bond to the regions 9 and/or 111 by heating and/or by means of compaction, in particular by means of sintering, and form a one-piece component.

[0135] The regions 9, 11 and/or 111 need not be connected with screws. Furthermore, no bonded joints or bindings are required.

[0136] FIG. 7 shows a method for producing a material layer.

[0137] In accordance with the invention the material layer has at least one first material region, having a first material, and at least one second material region, having a second material.

[0138] In a method step S1, a first suspension, having at least one binding agent and solid particles, is therefore applied through a first screen onto a base area in order to achieve a first green body. The first material region is reproduced by the first screen (e.g. the already described region 11 or 111).

[0139] Here “applied” preferably means that the suspension is applied to the base area with a scraper.

[0140] In a method step S2, a second suspension, having at least one binding agent and solid particles, is applied through a second screen onto a base area in order to achieve a second green body. The second material region is reproduced by the second screen.

[0141] Various procedures can now be pursued. The respective binding agent from the first green body and/or the second green body can be driven out before the joining process in a method step S3 (see method step S21) of the first green body and the second green body and/or after the joining process (see method step S31).

[0142] The driving-out of the binding agent is preferably effected by means of debindering.

[0143] In a method step S4, a permanent, material-bonded joining of the two green bodies to one another and the solid particles in the respective green body is created by heating and/or by means of compaction, in particular by means of sintering.

[0144] In a method step S5, an insulation material is applied to the material layer on at least one layer side. The insulation material is preferably a varnish, in particular thermosetting varnish.

[0145] Applied here means preferably that 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 containing the insulation material.

[0146] FIG. 8 a method for producing a material layer structure.

[0147] In method step S11, a plurality of material layers (at least two) is joined. The production of the material layers was described in FIG. 7.

[0148] The material layers advantageously having thermosetting varnish are arranged one above the other in order to form the material layer structure.

[0149] In method step S12, the material layers are thermoset with one another for reciprocal strengthening.

[0150] Here thermosetting means that the material layers are preferably glued to one another by means of pressure and heat. The thermosetting varnish becomes soft as a result of the pressure and heat 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 cause damage to the material. Moreover, a magnetic flux is not disturbed and no material stresses and material deformations appear.

[0151] FIG. 9 shows the dynamoelectric rotary machine, in particular reluctance machine 6. The machine, in particular reluctance machine 6, has a stator 16 and a rotor 2, 4.