Electric motor with slanted stator and/or rotor containing at least one layer of a composite material

Patent metadata

Field	Value
Publication number	US-11722018-B2
Application number	US-201917041623-A
Country	US
Kind code	B2
Filing date	Mar 14, 2019
Priority date	Mar 29, 2018
Publication date	Aug 8, 2023
Grant date	Aug 8, 2023

Abstract

An electric motor with a beveled stator and/or rotor has at least one layer of a composite material. The composite material has at least one electrical steel strip layer as carrier and at least one polymer layer. The composite material can be used for reducing acoustic emission in beveled electric motors. A method of reducing acoustic emission in these electric motors is based on the use of the composite material.

First claim

The invention claimed is:

1. An automotive electric drive motor, the electric motor comprising at least one of a skewed stator and rotor containing at least one layer of a composite material, the composite material comprising at least one electrical steel strip layer as carrier and at least one polymer layer, wherein the at least one of a skewed stator and rotor comprises a plurality of lamellae which skew continuously and generate at least one of a skew of a stator pole shoe and a skew of a rotor surface.

2. The skewed electric motor as claimed in claim 1 , characterized in that the composite material includes a further electrical steel strip layer as cover sheet.

3. The skewed electric motor as claimed in claim 2 , characterized in that the polymer layer contains a shear deformation-absorbing polymer.

4. The skewed electric motor as claimed in claim 3 , characterized in that the polymer layer has a layer thickness in the range of 3-20 μm.

5. The skewed electric motor as claimed in claim 4 , characterized in that the electrical steel strip layer has a layer thickness in the range of 50-1500 μm.

6. The skewed electric motor as claimed in claim 5 , characterized in that the composite material has structure-borne sound damping in the range of 0.01-0.2 at 20° C. and 50 Hz; 0.01-0.2 at 20° C. and 500 Hz; 0.01-0.1 at −10° C. and 200 Hz and 0.01-0.3 at 30° C. and 1000 Hz.

7. The skewed electric motor as claimed in claim 6 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz and a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

8. The skewed electric motor as claimed in claim 7 , characterized in that electric motor has a reduction in acoustic emission in the frequency range from 20 to 20 000 Hz of at least 1 dB in comparison to a control.

9. A method of reducing the acoustic emission of a skewed electric drive motor for an automobile, comprising providing a skewed electric motor in an automobile, the electric motor having at least one of a stator and a rotor, wherein:
the at least one of the stator and the rotor contains at least one layer of a composite material, the composite material comprising at least one electrical steel strip layer as carrier and at least one polymer layer; and
the at least one of a skewed stator and rotor comprises a plurality of lamellae which skew continuously and generate at least one of a skew of a stator pole shoe and a skew of a rotor surface.

10. The skewed electric motor as claimed in claim 1 , characterized in that the composite material has structure-borne sound damping in the range of 0.01-0.2 at 20° C. and 50 Hz; 0.01-0.2 at 20° C. and 500 Hz; 0.01-0.1 at −10° C. and 200 Hz and 0.01-0.3 at 30° C. and 1000 Hz.

11. The skewed electric motor as claimed in claim 5 , characterized in that the composite material has structure-borne sound damping in the range of 0.01-0.2 at 20° C. and 50 Hz; 0.01-0.2 at 20° C. and 500 Hz; 0.01-0.1 at −10° C. and 200 Hz or 0.01-0.3 at 30° C. and 1000 Hz.

12. The skewed electric motor as claimed in claim 11 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz and a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

13. The skewed electric motor as claimed in claim 11 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz or a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

14. The skewed electric motor as claimed in claim 13 , characterized in that electric motor has a reduction in acoustic emission in the frequency range from 20 to 20 000 Hz of at least 1 dB in comparison to a control.

15. The skewed electric motor as claimed in claim 12 , characterized in that electric motor has a reduction in acoustic emission in the frequency range from 20 to 20 000 Hz of at least 1 dB in comparison to a control.

16. The skewed electric motor as claimed in claim 1 , characterized in that the composite material has structure-borne sound damping in the range of 0.01-0.2 at 20° C. and 50 Hz; 0.01-0.2 at 20° C. and 500 Hz; 0.01-0.1 at −10° C. and 200 Hz or 0.01-0.3 at 30° C. and 1000 Hz.

17. The skewed electric motor as claimed in claim 6 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz or a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

18. The skewed electric motor as claimed in claim 1 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz or a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

19. The skewed electric motor as claimed in claim 1 , characterized in that the composite material has a specific transmagnetization loss of in the range from 0.7 to 7 W/kg at P1.0; 50 Hz and in the range from 1.9 to 15 W/kg at P1.5; 50 Hz and a polarization in the range from 1.49 to 1.7 T at J2500 and in the range from 1.6 to 1.8 T at J5000, ascertained to DIN EN 60404-2.

20. The skewed electric motor as claimed in claim 1 , characterized in that electric motor has a reduction in acoustic emission in the frequency range from 20 to 20 000 Hz of at least 1 dB in comparison to a control.

21. The skewed electric motor as claimed in claim 1 , characterized in that the stator and/or rotor using the composite material has an iron fill factor in the range of 96-99%.

22. The skewed electric motor as claimed in claim 1 , characterized in that the polymer is a copolymer composed of a copolymerized mixture of at least one alkyl acrylate ester monomer unit and/or alkyl methacrylate ester monomer unit, each of which has an alkyl group having 1 to 12 carbon atoms, a glycidyl monomer unit, an unsaturated carboxylic acid monomer unit and a crosslinker.

Assignees

• Thyssenkrupp Steel Europe Ag
• Thyssenkrupp Ag

Inventors

• Drewes Stephan
• Lewe Tobias
• Herget Florian

Classifications

• H02K1/04 Primary

  characterised by the material used for insulating the magnetic circuit or parts thereof · CPC title

• H02K1/17

  Stator cores with permanent magnets · CPC title

• H02K1/26

  Rotor cores with slots for windings · CPC title

• H02K5/24

  specially adapted for suppression or reduction of noise or vibrations · CPC title