ELECTROMECHANICAL COMPOSITE COMPONENT AND METHOD FOR PRODUCING SAME

Abstract

An electromechanical composite component having a sleeve and a magnet device positioned therein, which is compressed out of a powdered material containing magnetic particles, and at least one cover, which closes the sleeve in a sealed fashion at the end. The magnet device is affixed in the sleeve in a frictionally engaging way in that a molded body, which is compressed out of the magnetic material, is inserted into the sleeve with sliding friction and produces a frictionally engaging press-fitted connection in the sleeve as it relaxes.

Claims

1. An electromechanical composite component (1) having a sleeve (2) and a magnet device positioned therein, which is compressed out of a powdered material containing magnetic particles, and at least one cover (6), which closes the sleeve (2) in a sealed fashion at the end, the composite component comprising: the magnet device is affixed in the sleeve (2) in a frictionally engaging way with a molded body compressed out of the magnetic material and inserted into the sleeve (2) with sliding friction and producing a frictionally engaging press-fitted connection in the sleeve (2) as it relaxes.

2. The composite component according to claim 1, wherein the wall thickness of the sleeve (2) is at most 0.5 mm, in particular at most 0.2 mm.

3. The composite component according to claim 2, wherein an optional axle (5) that extends through the at least one cover (6) is guided concentrically by the sleeve (2) and the magnet device.

4. The composite component according to claim 3, wherein the at least one cover (6) is affixed to an associated end of the sleeve (2) in a fluid-tight fashion and the optional axle (5) and is affixed to the sleeve (2) by flanging.

5. The composite component according to claim 4, wherein the at least one cover (6) is welded to the associated end of the sleeve (2) and the optional axle (5) in a fluid-tight fashion by laser welding.

6. The composite part according to claim 5, wherein the at least one cover (6) is fixed in position by being injection molded or extrusion coated onto the sleeve (2) and the optional axle (5).

7. The composite component according to claim 6, wherein the sleeve (2) is of a metal or a plastic material, in particular glass fiber-reinforced plastic or a carbon fiber-reinforced plastic.

8. The composite component according to claim 7, wherein the optional axle (5) is of a metal or a ceramic material.

9. The composite component according to claim 8, wherein the magnet device has a cylindrical magnet body (3) with a solid cross-section or annular cross-section.

10. The composite component according to claim 8, wherein a filler body is inserted concentrically into the magnet body (3).

11. A method for producing a composite component (1) having a sleeve (2) and a magnet device positioned therein, in which a molded body is compressed out of a powdered material containing magnetic particles and after insertion of the molded body, the sleeve (2) is closed in a sealed fashion on at least one end, the method including inserting the compressed molded body into the sleeve (2) with sliding friction and when relaxed becomes fixed in position in a frictionally engaging way, producing a press-fitted connection in the sleeve (2).

12. The composite component according to claim 1, wherein an optional axle (5) that extends through the at least one cover (6) is guided concentrically by the sleeve (2) and the magnet device.

13. The composite component according to claim 1, wherein the at least one cover (6) is affixed to an associated end of the sleeve (2) in a fluid-tight fashion and the optional axle (5) and is affixed to the sleeve (2) by flanging.

14. The composite component according to claim 1, wherein the at least one cover (6) is welded to the associated end of the sleeve (2) and the optional axle (5) in a fluid-tight fashion by laser welding.

15. The composite part according to claim 1, wherein the at least one cover (6) is fixed in position by being injection molded or extrusion coated onto the sleeve (2) and the optional axle (5).

16. The composite component according to claim 1, wherein the sleeve (2) is of a metal or a plastic material, in particular glass fiber-reinforced plastic or a carbon fiber-reinforced plastic.

17. The composite component according to claim 2, wherein the optional axle (5) is of a metal or a ceramic material.

18. The composite component according to claim 1, wherein the magnet device has a cylindrical magnet body (3) with a solid cross-section or an annular cross-section.

19. The composite component according to claim 17, wherein a filler body is inserted concentrically into the magnet body (3).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] This invention is explained in greater detail in view of exemplary embodiments with reference to the drawings, wherein:

[0019] FIG. 1A shows a first exemplary embodiment of an electromechanical composite component, for example, for a rotor of an electric machine, with a magnet device in the form of a thin-walled permanent magnet inserted into a sleeve, in a perspective view that is open at one end;

[0020] FIG. 1B shows a perspective view of another embodiment of a composite component with a magnet device inserted into a thin-walled sleeve and a central axle;

[0021] FIG. 2A shows a perspective view of another embodiment of a composite component with a magnet device inserted into a thin-walled sleeve, end covers, and a central axle;

[0022] FIG. 2B shows a perspective view of another embodiment of a composite component with a magnet device inserted into a thin-walled sleeve, end covers, and a central axle; and

[0023] FIG. 3 shows a composite component in a disassembled state.

DETAILED DESCRIPTION OF THE INVENTION

[0024] FIG. 1A shows a composite component 1 with a cylindrical sleeve 2, into which a magnet body 3 of a magnet device is inserted and which is closed at its one end, the rear end in the figure, with a cover, in the form of a bottom 7 in this case, and is open at its other end, the front end in this case. The bottom 7 has a central through opening concentric to the sleeve 2 for an axle 5 such as a shaft of the kind that is used, for example, for the construction of a rotor of an electric machine. The bottom 7 can be formed onto the sleeve 2 of one piece with it or can be placed onto it as a separate component in the form of a cover 6, as shown in FIG. 3, and be mounted onto the relevant terminal edge of the sleeve 2 in a sealed fashion. Correspondingly, the front end is also provided with or has a cover 6, which is mounted onto the relevant terminal edge of the sleeve 2 in a sealed fashion. If an optional axle 5 is used, then a sealed connection is also produced between the bottom 7 or the cover 6 and the optional axle 5, so that for example when used in a liquid, this liquid does not penetrate into the interior of the sleeve 2 where it could damage the magnet body 3.

[0025] The magnet body 3 is inserted into the sleeve 2 by being inserted using the method that is described in detail in PCT Patent Reference WO 2013/110755 A1 mentioned at the beginning, and has or includes a pressed molded body made of powdered material with magnetic particles distributed in it. The molded body that is pressed in a female die is inserted into the sleeve with an exact fit with sliding friction and after being positioned on the inside of the sleeve 2, becomes pressed firmly into place in a frictionally engaging way against the inner surface thereof as it relaxes, without requiring the use of an additional glue layer. The frictionally engaging press-fitted connection also does not require any heating. The pressed molded body in this case can have an annular or solid, for example circular, cross-section and its outer circumference is matched to the inner circumference of the sleeve 2. If the cross-section of the molded body is annular, then a filling body or inner body 4 can be fitted into its interior, such as shown in FIG. 3.

[0026] The pressed molded body is axially compressed, for example by a factor of 2 to 3, relative to its loose filling state in the female die. The factor or compressing pressure is chosen as a function of the material composition and can also be above this range. Because of the compressed density, the molded body relaxes or breathes in the sleeve 2 after the removal of the press tool or tools and is then affixed with a powerful holding force directly against the inner surface of the sleeve 2. In addition, the inner surface of the sleeve 2 can be provided with or have gripping structures for producing a fixing or catching action.

[0027] The composite component 1 that is formed in this way by the fixing of the molded of or body composed of the magnetic material in the sleeve 2 is closed in a sealed fashion by the end covers 6 or by a cover 6 and the bottom 7, as demonstrated by the exemplary embodiment shown in FIGS. 2A and 2B. For example, the cover or covers 6 according to FIG. 2A can be injection molded in a sealed fashion onto the sleeve 2 that is provided with the magnet body 3 or magnet device or can be welded at the circumference to the relevant terminal edges of the sleeve 2.

[0028] An advantageous connecting method is also a flanging between the edge region of the cover 6 or covers 6 and the terminal edge regions of the sleeve 2. Thus, edge regions of the sleeve 2 and cover 6 that extend axially alongside each other are bent over together or one is bent over the other by 180 one time or multiple times, possibly with the interposition of a sealing compound.

[0029] As FIG. 1B shows, the magnet body 3, if it is embodied as annular in cross-section, can have an inner body 4 inserted into it already during the production of the pressed molded body in the female die or subsequently after the insertion of the molded body into the sleeve 2. The inner body 4 can be placed separately onto the optional axle 5 and fastened to it or can be embodied of one piece or integrally to it, as is also shown in FIG. 3.

[0030] The optional axle 5 or shaft can correspondingly be already used in the production of the pressed molded body in the female die or subsequently, after the insertion of the molded body into the sleeve 2.

[0031] The wall of the sleeve 2 preferably is of or consists of nonmagnetic or non-magnetizable material, it being possible to use a nonmagnetic or non-magnetizable material such as GFK or CFK.

[0032] With the thin-walled embodiment of the sleeve 2, it is possible during the joining process, in particular during the relaxing of the molded body as it expands or breathes, a certain expandability of the wall can also be used, which then, thanks to an inwardly directed exertion of elastic forces, promotes the frictionally engaging connection and the compact design of the composite component.