Method for producing an electrical sheet for an electric machine

Patent metadata

Field	Value
Publication number	US-12580462-B2
Application number	US-202217882145-A
Country	US
Kind code	B2
Filing date	Aug 5, 2022
Priority date	Aug 6, 2021
Publication date	Mar 17, 2026
Grant date	Mar 17, 2026

Abstract

An electrical sheet includes an electrical sheet main body produced by additive manufacturing (a 3D screen printing method) from at least a first and a second material. The first and second materials have magnetic properties which differ from one another, and first and second domains are formed in the electrical sheet main body from the first and second materials respectively. An electric machine is also provided. An electric machine and a method for producing an electrical sheet for use in a stator or rotor of an electric machine are also provided.

First claim

What is claimed is:

1 . A method for producing a one- or multi-part electrical sheet including a segmented electrical sheet, wherein an entire electrical sheet main body is formed by additive manufacturing, the method comprising:
defining a target geometry of the electrical sheet main body, wherein the target geometry comprises a distribution of first and second domains of a first material and a second materials, respectively, in the electrical sheet main body; successively layering layers of a first and second coating mass to form a main body blank, wherein the first coating mass consists of a suspension of the first material and the second coating mass consists of a suspension of the second material, the first and second materials having magnetic properties that differ from one another, and wherein the first and second coating masses are layered such that the main body blank has the distribution of the first and second domains of the first and second materials, respectively, corresponding to the target geometry; and sintering the main body blank.

2 . The method according to claim 1 , wherein the sintering is preceded by a drying of the main body blank.

3 . The method according to claim 1 , wherein the main body blank is cooled down following the sintering.

4 . The method according to claim 1 , wherein the main body blank is post-treated, following the sintering or cooling.

5 . The method according to claim 1 , wherein the first and second materials have at least one of different magnetic conductivity and magnetizability.

6 . The method according to claim 1 , wherein the first material and the second material each comprise a metal alloy.

7 . The method according to claim 6 , wherein the first material comprises an iron-cobalt alloy and the second material comprises an iron-silicon alloy.

8 . The method according to claim 1 further comprising:
making a screen configured to be used in 3D Screen printing of the electrical main body and reproduce the target geometry of the electrical sheet main body; and
conveying the first and second coating masses through fabric openings of the screen, wherein the fabric openings from a superordinate passage opening in the screen, wherein the fabric openings form a contour that corresponds to the target geometry, and wherein the first and second coating masses are layered such that the main body blank has the distribution of the first and second domains of the first and second materials.

9 . The method according to claim 8 , wherein the conveying of the first and second materials through the fabric openings of the screen includes using a doctor blade coating method to convey the first and second materials.

10 . The method according to claim 1 further comprising cooling, after the sintering, a formed electrical sheet main body.

11 . The method according to claim 1 , wherein the sintering takes place in a furnace, and wherein the main body blank is arranged on a carrier positioned in the furnace.

12 . A method for producing a one- or multi-part electrical sheet including a segmented electrical sheet, wherein an entire electrical sheet main body is formed by additive manufacturing, the method comprising:
defining a target geometry of the electrical sheet main body, wherein the target geometry comprises a distribution of first and second domains of a first material and a second material, respectively, in the electrical sheet main body, the first material and the second material having magnetic properties that differ from one another, and the first material and the second material each comprising a suspension of a metal alloy; conveying a first coating mass and a second coating mass through openings of a screen to form a main body blank, layering the first and second coating masses such that the main body blank has the distribution of the first and second domains of the first and second materials, respectively, corresponding to the target geometry, the openings of the screen form a contour that corresponds to the target geometry, the first coating mass consists of the first material, and the second coating mass consists of the second material; and sintering the main body blank.

13 . The method according to claim 12 , wherein the openings of the screen form a superordinate passage opening in the screen.

14 . The method according to claim 12 , wherein the conveying of the first coating mass and second coating mass through the openings of the screen includes using a doctor blade to convey the first coating mass and second coating mass.

15 . The method according to claim 12 , wherein the screen is a fine mesh fabric.

16 . The method according to claim 12 , further comprising arranging a template on the screen such that some of the openings of the screen are made impermeable by the template where no coating mass is to be printed according to the target geometry of the electrical sheet.

17 . The method according to claim 16 , further comprising changing a plurality of templates according to the target geometry of each layer to be printed.

18 . The method according to claim 16 , further comprising layering the first coating mass and the second coating mass in a single layer using a multi-part template body.

19 . The method according to claim 12 , further comprising forming a plurality of recesses in the electrical sheet main body during the layering.

20 . The method according to claim 12 , wherein the first material comprises an iron-cobalt alloy and the second material comprises an iron-silicon alloy.

Assignees

• Ford Global Tech Llc

Inventors

• Koch Raphael
• Haeuser Viktor

Classifications

• H02K1/12

  Stationary parts of the magnetic circuit · CPC title

• H02K1/22

  Rotating parts of the magnetic circuit · CPC title

• H02K15/02 Primary

  of stator or rotor bodies · CPC title

• H02K1/06

  characterised by the shape, form or construction · CPC title

• H02K1/02 Primary

  characterised by the magnetic material · CPC title