DE102023115056A1 - Process for the additive manufacturing of a component with a laminated magnetic core and component manufactured thereby - Google Patents

Abstract

The invention relates to a method for the additive production of a component with a laminated magnetic core. By applying filaments layer by layer, first a green part is produced, then a brown part, and from this the component is produced in a sintering process. Lamellas and insulating layers of the magnetic core are thus produced from electrical sheet filament and insulating material filament. Essential to the invention, it is either provided that a holding structure enclosing the magnetic core is produced from a third filament or that soldering material, which is contained in the electrical sheet filament or in the insulating material filament, connects the lamellae and the insulating layers to one another in a materially bonded manner. Protection is also claimed for a corresponding component and an electric motor with the component.

Description

The invention relates to methods for producing a component with a laminated magnetic core according to the preamble of claims 1 and 2. Furthermore, the invention relates to a method for producing an electric motor, which includes the method according to the invention for the additive production of a component, as well as a component produced according to the method and an electric motor produced according to the method.

Components that have a laminated magnetic core and that can be manufactured using the invention are in particular the stator and the rotor of an electric motor. The laminated magnetic core is also called a laminated core, since the magnetic core is traditionally made from a large number of sheet metal sections that are arranged one above the other and are electrically insulated from one another, for example by means of a separating varnish. The individual sheet metal sections thus form sheet metal laminations of the laminated magnetic core, which, when the manufactured component is later used, ensure that eddy currents, which can arise in particular in the stator or rotor of an electric motor, are minimized. This is because the energy used to create eddy currents in the electric motor cannot be used for the performance of the electric motor and is therefore noticeable as a loss of power, which also has to be dissipated in the form of heat, thus requiring efficient cooling of the electric motor.

The individual sheet metal sections are traditionally punched or laser cut from rolled sheet metal. Such sheet metal sections and sheet metal packages with the sheet metal lamellae formed from these sheet metal sections can in principle be produced cost-effectively in large quantities. However, handling small layer thicknesses is complex and expensive. Therefore, the production of magnetic cores with sheet metal lamellae made from punched sheet metal, which has a layer thickness of less than 1 mm, for example, requires an effort that is no longer justifiable for cost reasons. This results in a certain minimum thickness of the sheet metal lamellae traditionally made from punched sheet metal, which means that a minimum level of eddy currents dependent on this is unavoidable when operating a device with a magnetic core made from this material.

Additive manufacturing processes, also known as 3D printing, can be used to produce laminated magnetic cores that allow greater freedom in the composition of the layers from which the magnetic cores are built. Several processes are known for applying and curing the individual layers. One well-known process is so-called Fused Filament Fabrication (FFF), in which at least one filament is melted and applied layer by layer to create a so-called green part. Each filament contains a plastic matrix and, embedded in it, the material from which the layer to be built up will later be composed. The plastic is removed from the green part in a debinding process, for example chemically, to create a so-called brown part, which then subsequently undergoes the so-called sintering process, whereby the brown part is heated and shrinks in the process. The shrinkage behavior depends on the composition of the filaments used and can be problematic for the cohesion of the layers, especially when layers are adjacent to each other that are made of filaments with very different shrinkage behavior.

A generic method for producing a component according to the invention is known from the German laid-open specification DE 10 2020 130 987 A1 known. In the known process, a layer arrangement is produced from filaments in which electrically and magnetically conductive layers alternate with insulating layers, whereby the layer thickness can be less than 0.15 mm. The electrically and magnetically conductive layers are made from a metallic filament that contains plastic and metal. The insulating layers are made from a ceramic filament that contains plastic and ceramic. The layer arrangement formed from the layers goes through a sintering process and is heated in several stages for this purpose. The layers are firmly interlocked and mechanically firmly connected to one another. An area radially outwardly adjacent to the layer arrangement with the alternating filaments is formed continuously from one of the two filaments and connects the layers formed from this filament to one another. This should limit the choice of material for the filaments in order to prevent the filaments from shrinking too much in the sintering process, which could potentially cause gaps or cracks in the manufactured component. Under these conditions, the material selection of the filaments cannot be optimally adapted to minimize power losses in an electric motor that can be manufactured using the component.

The invention is based on the object of further reducing power losses of an electric motor that can be produced with a generic component and, for this purpose, of providing methods for producing a component with a laminated magnetic core. In particular, appropriate processes are to be specified that allow great freedom in choosing a composition of the filaments for the metallic lamellae and for the insulating layers of the magnetic core that is advantageous for performance, even if this changes the shrinkage behavior in the sintering process. Furthermore, a process for producing an electric motor, a component produced according to the process and an electric motor produced according to the process are to be specified.

The invention solves this problem with a method for additively manufacturing a component according to patent claim 1 and with a method for additively manufacturing a component according to patent claim 2. In addition, the invention solves the problem with a method for producing an electric motor according to patent claim 14, with a component according to patent claim 15 and with an electric motor according to patent claim 16.

According to a first solution to the problem, in a method for the additive production of a component with a laminated magnetic core, which has a plurality of metallic lamellae arranged parallel to one another and electrically insulated from one another, wherein a green part is produced from filaments containing a binding agent by applying and solidifying the filaments layer by layer, wherein the green part is produced with an electrical sheet filament for the construction of the lamellae and with an insulating material filament for the construction of insulating layers between the lamellae, wherein a brown part is produced from the green part in a debinding process by removing the binding agent and wherein the component with the laminated magnetic core is produced from the brown part in a sintering process by heating with associated shrinkage and solidification, it is provided as part of the invention that the component is produced with at least one holding structure at least partially enclosing the magnetic core from a third filament made of a non-magnetic material, wherein the third filament is also applied and solidified in layers to produce the green part and wherein the arrangement of the third filament and the material selected for the third filament are adapted to the thickness and arrangement and the shrinkage behavior of the layers of electrical sheet filament and the layers of insulating material filament that occur during the sintering process, such that the holding structure created from the third filament after the sintering process clamps the lamellae and the insulating layers relative to one another. The holding structure is therefore manufactured together with the magnetic core and subsequently holds the layers of the magnetic core together in the desired manner.

According to a second solution to the problem, in a method for additively manufacturing a component with a laminated magnetic core, which has a plurality of metallic lamellae arranged parallel to one another and electrically insulated from one another, wherein a green part is produced from filaments containing a binding agent by applying the filaments layer by layer and solidifying them, wherein the green part is produced with an electrical sheet filament for the construction of the lamellae and with an insulating material filament for the construction of insulating layers between the lamellae, wherein a brown part is produced from the green part in a debinding process by removing the binding agent and wherein the component with the laminated magnetic core is produced from the brown part in a sintering process by heating with associated shrinkage and solidification, it is provided as part of the invention that in the sintering process, soldering material contained in the electrical sheet filament or in the insulating material filament melts and wets the insulating material formed from the insulating material filament, in particular where it borders on the material formed from the electrical sheet filament, and thereby after completion of the sintering process, at least the lamellae formed from the electrical sheet filament and the adjacent insulating layers formed from the insulating material filament are bonded together. The invention arranges the soldering material directly in the filaments from which layers of the magnetic core are made. The layers are therefore not bonded together in the manner known from so-called sintering soldering by means of additional soldering material applied between the layers.

Both solutions according to the invention to the problem underlying the invention ensure that the metallic lamellae of the magnetic core are and remain securely connected to the insulating layers, namely either by the clamping holding structure or by the material connection of the layers of the magnetic core made with the soldering material in filaments, whereby both the formation of gaps between the layers in the sintering process and any overloading and thus the formation of stress cracks in the magnetic core are counteracted. At the same time, both the metallic lamellae can be made very thin with great freedom in the choice of materials used and the insulating layers between the metallic lamellae can be made very thin, which means that eddy currents during later use of the magnetic core and thus power losses, for example of an electric motor having the magnetic core, can be minimized. This allows powerful electric motors to be built in a space-saving manner. The interfaces between the layers of the magnetic core are particularly especially arranged in planes that are perpendicular to the axis of the magnetic core.

In preferred embodiments of the method, each lamella is formed from exactly one applied layer of the electrical steel filament. The resulting thickness of each lamella after the sintering process is preferably less than 0.04 mm, more preferably less than 0.02 mm, particularly preferably about 0.016 mm.

The electrical steel filament particularly preferably contains iron, in particular in an iron alloy. The iron is either grain-oriented or non-grain-oriented. The binder in the respective filament is preferably a polymer which provides a matrix into which the components of the respective filament remaining after the debinding process are bound.

In a preferred embodiment of the first method according to the invention, it is provided that each outer section of the green part arranged comparatively further outwards, which encloses at least one inner section of the green part arranged comparatively further inwards and formed from a filament, is constructed from a filament with which the respective outer section shrinks at least as much as or more than this inner section in order to connect to the respective inner section in the sintering process. This prevents sections arranged further inwards from shrinking so much in the sintering process that gaps arise between the respective inner and outer sections.

In an advantageous embodiment of the first method according to the invention based on this, the green part is constructed with at least one cavity in the area between the respective clasping areas of the respective outer section. In this case, it is provided in particular that the respective outer section shrinks so much more than the inner section that the at least one cavity closes. The outer section preferably surrounds the inner section in a ring shape at least in the radial direction and more preferably also in a clamping manner in the axial direction of the magnetic core to be produced. The cavity is located in particular between the radial outer side of the magnetic body and the radial inner side of the holding structure.

In an advantageous embodiment of the first method, it is provided that the green part is constructed with at least one cavity in the region between the sections constructed from the third filament, from which the sections of the holding structure enclosing the parts of the magnetic core are produced, and that during the sintering process of the brown part formed from the green part, the sections of the brown part formed from the third filament shrink more, at least between their enclosing sections, than the sections of the brown part formed between these enclosing sections for the formation of the magnetic core from the electrical sheet filament and the insulating material filament, so that the at least one cavity closes.

In particularly preferred embodiments of the first method, the third filament used to construct the holding structure differs from the electrical sheet filament used to construct the magnetic core and from the insulating material filament also used to construct the magnetic core, in particular in its shrinkage behavior. This makes it possible to securely clamp the filaments for the magnetic core with very different shrinkage behavior, even without having to provide gaps when building the layers. In particular, it is provided that the filaments used to construct the magnetic core shrink to comparatively different degrees in the sintering process and that the third filament used to construct the holding structure shrinks less than the more strongly shrinking filament used to construct the magnetic core and shrinks more than the less strongly shrinking filament used to construct the magnetic core.

In embodiments that are advantageous for reasons of weight, the holding structure only clasps the magnetic core at certain points, so that the magnetic core cannot at least come loose from the clasp. In particular, the magnetic core is held in the holding structure in a form-fitting manner. In other embodiments, the holding structure is ring-shaped and engages behind the magnetic core in the axial direction of the magnetic core as a continuous ring. These two embodiments are provided in particular for a rotor of an electric motor if this rotor has the magnetic core. Optionally, the stator of the electric motor can also be designed accordingly.

In a particular embodiment of the first method, the holding structure is designed as a housing which completely or at least partially surrounds the magnetic core. In particular, the holding structure forms the housing of an electric motor. The magnetic core is in particular part of a stator of the electric motor.

In a preferred embodiment of the second method according to the invention, it is provided that the soldering material contains at least one refractory metal or consists of at least one refractory metal. The refractory metal is a high-melting, base metal from the fourth, fifth or sixth subgroup, for example vanadium, chromium or molybdenum. Every refractory metal has a high melting point and a low coefficient of thermal expansion compared to other metals such as iron.

In an advantageous embodiment of the second method, the soldering material is arranged only on the outside of the respective filament, whereby an arrangement of the soldering material in the layer applied from the filament is achieved, which, in particular after the debinding process, promotes the connection of the layers by melting and hardening of the soldering material.

Both methods according to the invention for solving the problem underlying the invention are optionally further developed with further embodiments described below. In the respective method, according to an advantageous embodiment, it is provided that the component is manufactured with a housing. In embodiments in which the holding structure is already designed as a housing, the housing is an additional housing to the holding structure. The housing is preferably manufactured from a further insulating material filament that consists of a non-magnetic material. In particular, it is provided that the further insulating material filament is also applied and solidified in layers to produce the green part. The further insulating material filament used for the construction of the housing is particularly preferably different from the insulating material filament used for the construction of the magnetic core.

According to further particularly preferred embodiments of the invention, the insulating material filament contains ceramic powder. This is used to form the insulating layers from or with ceramic material. The electrical sheet filament for the construction of the metallic layer, on the other hand, preferably contains an iron alloy with at least one alloying element from the group silicon, cobalt and nickel. In the iron alloy, the silicon content is in particular in the range from 4 percent to 20 percent, preferably in the range from 4 percent to 10 percent, or the nickel content in the range from 40 percent to 90 percent or the cobalt content in the range from 10 percent to 70 percent.

Basically, the method according to the invention enables the use of comparatively soft metals compared to traditionally manufactured sheet metal packages because the metallic filaments are applied directly where the individual lamellae are to be arranged, meaning that the lamellae do not have to be moved individually and stacked on top of one another after they have been produced. The use of soft metals leads to low eddy current losses when the correspondingly manufactured magnetic core is used in an electric motor. In particular, the electric motor with the lamellae made from at least one soft metal can reach comparatively high speeds before the eddy current losses eventually increase exponentially.

In further embodiments of the invention, the regions of the brown body made from different filaments and to be joined together in the sintering process have a similar shrinkage behavior to one another in the sintering process. In particular, each region shrinks less than 10 percent, preferably less than 5 percent, more or less than any adjacent region of the brown body.

In a further development of the method according to the invention, further parts, in particular of an electric motor to be produced, are constructed together with the magnetic core. In particular, it is provided that the component is produced with several coils that are positively connected to the magnetic core, wherein the coils are produced from a conductor filament that contains copper in particular, and wherein the conductor filament is also applied and solidified in layers to produce the green part.

In preferred embodiments of the methods, all filaments used in the method are applied in one operation. In particular, individual layers are built up one after the other and the different filaments are applied in sections in these layers if necessary.

In alternative embodiments, the individual components of the component are manufactured in different work steps, i.e. either one after the other or at different times in optionally the same apparatus, and only before the sintering process are the individual parts of the brown part formed from the different filaments assembled, in particular with the help of a template.

The green part is advantageously manufactured with at least one support structure, especially if individual parts of the component are already manufactured in the arrangement for the sintering process in one operation. This makes it possible to manufacture the magnetic core and the housing with overhangs and to prevent the overhangs from sagging during the sintering process by means of the support structure. to counteract. To form the support structure, a further filament, which in particular contains ceramic, is preferably applied. In particular, this further filament is applied in one operation together with the filaments for forming the magnetic core and, if applicable, the holding structure or the housing. The support structure does not form a bond with the component to be manufactured during the sintering process and can therefore be easily removed again after the sintering process.

Furthermore, cooling channels can be formed in the magnetic core, which therefore do not have to be subsequently drilled. In particular, it is intended that the component is manufactured with cooling channels in the magnetic core, whereby the electrical steel filament is applied with gaps that form the cooling channels in the lamellae of the magnetic core. The arrangement of the cooling channels is not limited to geometries that could otherwise be achieved using a drill and is therefore preferably optimized for optimal cooling performance.

The magnetic core is manufactured in particular with grooves. If the magnetic core is part of a stator, the grooves are stator grooves. The shape of the grooves can later influence the response behavior of an electric motor manufactured with the magnetic core. In an advantageous embodiment of the method, the magnetic core is designed with obliquely running grooves. By means of obliquely running grooves, several coils, in particular designed as copper windings, and thus poles of an electric motor manufactured with the magnetic core can be achieved, so that a particularly advantageous response behavior of the electric motor is achieved.

The object according to the invention is also achieved by a method for producing an electric motor. The electric motor has a stator and a rotor. According to the method, a component of the electric motor is additively manufactured in the manner according to the invention, wherein the laminated magnetic core of the component becomes a component of the stator or a component of the rotor of the electric motor.

The object underlying the invention is also achieved by a component that contains a magnetic core, in particular for an electric motor, in which the magnetic core is a component of the stator or rotor of the electric motor. According to the invention, the component is additively manufactured using the inventive method for additively manufacturing a component according to a described embodiment, wherein the magnetic core is laminated. The features of the component result from its manufacture accordingly.

The object underlying the invention is further achieved by an electric motor which has a stator and a rotor and which has a component additively manufactured by means of the inventive method for the additive production of a component according to a described embodiment, wherein the additively manufactured component contains a laminated magnetic core and wherein the laminated magnetic core of this component is a component of the stator or a component of the rotor of the electric motor.

• 1: einen vereinfacht dargestellten Ausschnitt eines mit ersten Schritten des erfindungsgemäßen Verfahrens hergestellten Grünteils, aus dem mit den weiteren Schritten des Verfahrens ein erfindungsgemäßes Bauteil hergestellt wird, in einer Seitenansicht;
• 2: ein erstes mit dem erfindungsgemäßen Verfahren aus dem Grünteil von 1 hergestelltes Bauteil in einer Seitenansicht;
• 3: ein zweites mit dem erfindungsgemäßen Verfahren hergestelltes und als Stator eines Elektromotors ausgebildetes Bauteil mit einem Magnetkern und einer als Gehäuse ausgebildeten Haltestruktur für den Magnetkern in perspektivischer Ansicht;
• 4: das zweite Bauteil von 3 in einer Draufsicht;
• 5: ein dem Magnetkern des zweiten Bauteils von den 3 und 4 ähnelndes drittes mit dem erfindungsgemäßen Verfahren hergestelltes Bauteil in perspektivischer Ansicht;
• 6: das dritte Bauteil von 5 in einer Draufsicht;
• 7: der Magnetkern von den 3 und 4 mit in den Magnetkern eingepassten Spulen in perspektivischer Ansicht;
• 8: den Magnetkern mit der Spule von 7 in einer Draufsicht;
• 9: ein viertes mit dem erfindungsgemäßen Verfahren hergestelltes und als Stator eines Elektromotors ausgebildetes Bauteil mit einem Magnetkern und einer Haltestruktur für den Magnetkern in perspektivischer Ansicht; und
• 10: ein dem Magnetkern des vierten Bauteils von 9 entsprechendes fünftes mit dem erfindungsgemäßen Verfahren hergestelltes und als Stator eines Elektromotors ausgebildetes Bauteil in perspektivischer Ansicht.

Further embodiments emerge from the patent claims, from the attached drawings and from the following description of preferred embodiments of the invention shown in the drawings. In the drawings:

• 1 : a simplified section of a green part produced by the first steps of the method according to the invention, from which a component according to the invention is produced by the further steps of the method, in a side view;
• 2 : a first with the inventive method from the green part of 1 manufactured component in a side view;
• 3 : a second component produced by the method according to the invention and designed as a stator of an electric motor with a magnetic core and a holding structure designed as a housing for the magnetic core in a perspective view;
• 4 : the second component of 3 in a top view;
• 5 : a magnetic core of the second component from the 3 and 4 similar third component produced by the method according to the invention in perspective view;
• 6 : the third component of 5 in a top view;
• 7 : the magnetic core of the 3 and 4 with coils fitted into the magnetic core in perspective view;
• 8 : the magnetic core with the coil of 7 in a top view;
• 9 : a fourth component produced by the method according to the invention and designed as a stator of an electric motor with a magnetic core and a holding structure for the magnetic core in a perspective view; and
• 10 : a magnetic core of the fourth component of 9 corresponding fifth produced by the method according to the invention Component designed as a stator of an electric motor in perspective view.

1 shows a green part 1 produced using the method according to the invention according to an embodiment of the invention. The green part 1 is formed by applying an electrical sheet filament 2, an insulating material filament 3 and a third filament 4 made of a non-magnetic material in layers. The green part 1 consists of an outer section 5, which is formed from layers of the third filament 4, and several inner sections 6, 7, 8, 9, 10, 11, 12 and 13, which are formed in an alternating arrangement of at least one applied layer of the electrical sheet filament 2 and the insulating material filament 3. In particular, the inner sections 6, 8, 10 and 12 are formed by the electrical sheet filament 2, whereas the inner sections 7, 9, 11 and 13 are formed by the insulating material filament 3. The outer section 5 encloses the inner sections 6 to 13, with a cavity 14 being formed between the outer section 5 on the one hand and the inner sections 6 to 13 on the other. The cavity 14 is due to the different shrinkage behavior in the subsequent sintering process of the outer section 5 compared to the block from the inner sections 6 to 13 encloses by the outer section 5.

The lowermost inner section 13 is preferably surrounded by a 1 not shown support structure, which is produced by means of another filament containing ceramic and can be removed again after the sintering process that takes place later, since it does not form a connection with the magnetic core produced from the inner sections 6 to 13. Before the sintering process, the green part 1 is first debindered, i.e. the respective matrix of plastic, which is contained in the filaments 2, 3, 4, is removed. This is done, for example, chemically or alternatively thermally.

The brown part created by the debinding process then goes through the sintering process, during which the materials used shrink, which depends on the material. The material used for the outer section 5 is matched to the materials used for the inner sections 6 to 13 and, in the embodiment shown, also to the size of the cavity 14, in such a way that the cavity 14 closes during the sintering process and the block made up of the inner sections 6 to 13 is clamped between the clasping areas of the outer section 5 with a clamping force which reliably holds the inner sections 6 to 13 between the clasping areas of the outer section 5 and to one another, without excessively stressing the material through tension on the outer section 5 or through pressure in the inner sections 6 to 13.

This is from the green part 1 of 1 The component 15 according to the invention resulting from the debinding process and the sintering process is shown in 2 From the outer section of 1 A holding structure 16 has been created here. The inner sections 6, 8, 10 and 12 of 1 , which are formed from the electrical steel filament 2, have become metallic lamellae 17, 18, 19 and 20. From the inner sections 7, 9, 11 and 13 of 1 , which are made up of the insulating material filament 3, have become insulating layers 21, 22, 23, and 24. The lamellae 17 to 20 are electrically insulated from one another by the insulating layers 20 to 23. In practice, the insulating layer 24 is preferably followed by further lamellae alternating with insulating layers, so that the component 15 can, for example, also have at least 10 lamellae or at least 20 lamellae, in deviation from the exemplary embodiment shown.

The lamellae 17 to 20 together with the insulating layers 21 to 24 form a magnetic core 25 in which the generation of eddy currents is kept small due to the electrical and magnetic decoupling of the lamellae 17 to 20 from one another.

The 3 and 4 show a second component 26 manufactured in accordance with the invention, which is designed as a stator for an electric motor. The component 25 is rotationally symmetrical with an inner free space for the rotor of the electric motor. The holding structure 16 is designed in a ring-shaped manner as a housing, which surrounds the magnetic core 25, which is also designed in a ring-shaped manner, radially on the outside and axially on both sides in a radial edge region of the magnetic core 25. The same reference numerals designate the same or corresponding parts in all figures, even in different embodiments. The magnetic core 25 has recesses or grooves, in particular stator grooves, for receiving coils and is adapted to the shape of the coils to be received, so that any gaps between the coils to be received and the magnetic core 25 are minimized or non-existent. The magnetic core 25 here, as in the case of the component 15, consists of 2 of layers of lamellas and insulating layers, which in 3 are not designated for reasons of clarity and of which 4 only the upper slat or insulating layer is visible.

In the 5 and 6 A third component 27 designed as a stator is shown, which is connected to the magnetic core 25 from the 3 and 4 without the support structure 16. The individual slats and iso The soldering layers were bonded together in a material-locking manner in the sintering process by means of soldering material which was contained in the electrical sheet filament 2 or in the insulating material filament 3, and therefore remain held together without the holding structure 16.

In an alternative to the above-described embodiment from the 5 and 6 An additional housing is provided, which is connected to the housing-formed holding structure 16 by the 3 and 4 but does not necessarily have to hold the individual lamellae and layers of the magnetic core 25 together.

In the 7 and 8 The magnetic core 25 is made of 3 and 4 together with the coils already mentioned, whereby for reasons of clarity only one coil 28 is shown in the 7 and 8 is designated.

9 shows a fourth component 29 designed as a stator, in which the magnetic core 25 is separated from the components 26, 27 and 29 by the 3 to 8 with differently shaped recesses for accommodating coils.

In 10 is a fifth component 30 designed as a stator, which is connected to the magnetic core 25 of the fourth component 29 of 9 without the holding structure 16 designed as a housing. The lamellae and the insulating layers of the magnetic core 25 are connected without the holding structure 16 in a materially bonded manner by the soldering material liquefied in the sintering process. Each recess for a coil 28 is assigned an axially extending groove on the radial outside of the magnetic core 25, one of which is designated by the reference numeral 31. The grooves 31 ensure an improved magnetic flux and lower eddy current losses of an electric motor having the component 30 as a stator.

Different geometries and combinations of the illustrated embodiments are possible within the scope of the invention.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 10 2020 130 987 A1 [0005]

Claims (16)

Method for the additive production of a component (15, 26, 29, 30) with a laminated magnetic core (25) which has a plurality of metallic lamellae (17, 18, 19, 20) arranged parallel to one another and electrically insulated from one another, wherein a green part (1) is produced from filaments containing a binding agent by layer-by-layer application and solidification of the filaments, wherein the green part (1) is produced with an electrical sheet filament (2) for the construction of the lamellae (17, 18, 19, 20) and with an insulating material filament (3) for the construction of insulating layers (21, 22, 23, 24) between the lamellae (17, 18, 19, 20), wherein a brown part is produced from the green part (1) in a debinding process by removing the binding agent and wherein the brown part is produced in a sintering process by heating with the associated shrinkage and solidification, the component (15, 26, 29, 30) is produced with the laminated magnetic core (25), characterized in that the component (15, 26, 29, 30) is produced with at least one holding structure (16) at least partially enclosing the magnetic core (25) from a third filament (4) which consists of a non-magnetic material, wherein the third filament (4) is also applied and solidified in layers to produce the green part (1), and wherein the arrangement of the third filament (4) and the material selected for the third filament (4) is adapted to the thickness and arrangement and the shrinkage behavior of the layers of electrical sheet filament (2) and the layers of insulating material filament (3) occurring in the sintering process, such that the holding structure (16) produced from the third filament (4) after the sintering process has the lamellae (17, 18, 19, 20) and the insulating layers (21, 22, 23, 24) are clamped relative to each other. Method for the additive production of a component (27) with a laminated magnetic core (25) which has a plurality of metallic lamellae (17, 18, 19, 20) arranged parallel to one another and electrically insulated from one another, wherein a green part (1) is produced from filaments containing a binding agent by applying the filaments layer by layer and solidifying them, wherein the green part (1) is produced with an electrical sheet filament (2) for the construction of the lamellae (17, 18, 19, 20) and with an insulating material filament (3) for the construction of insulating layers (21, 22, 23, 24) between the lamellae (17, 18, 19, 20), wherein a brown part is produced from the green part (1) in a debinding process by removing the binding agent, and wherein the brown part is produced from the brown part in a sintering process by heating with the associated shrinkage and solidification. Component (27) is produced with the laminated magnetic core (25), characterized in that in the sintering process, soldering material which is contained in the electrical sheet filament (2) or in the insulating material filament (3) melts and wets the insulating material formed from the insulating material filament (3) and thereby, after completion of the sintering process, at least the lamellae (17, 18, 19, 20) formed from the electrical sheet filament (2) and the respectively adjacent insulating layers (21, 22, 23, 24) formed from the insulating material filament (3) are bonded to one another. procedure according to claim 1 , characterized in that each outer section (5) of the green part (1) which is arranged comparatively further outwards and which encloses at least one inner section (6, 7, 8, 9, 10, 11, 12, 13) of the green part (1) which is arranged comparatively further inwards and each formed from a filament, is constructed from a filament with which the respective outer section (5) for connection to the respective inner section (6, 7, 8, 9, 10, 11, 12, 13) shrinks comparatively at least as much as or more than this at least one inner section (6, 7, 8, 9, 10, 11, 12, 13) in the sintering process. procedure according to claim 3 , characterized in that the green part (1) is constructed with at least one cavity (14) in the region between the respective enclosing regions of the respective outer section (5). Method according to one of the Claims 1 , 3 and 4 , characterized in that the third filament (4) used for the construction of the holding structure (16) differs from the electrical sheet filament (2) used for the construction of the magnetic core (25) and from the insulating material filament (3) also used for the construction of the magnetic core (25), in particular in its shrinkage behavior. procedure according to claim 5 , characterized in that in the sintering process the filaments used for the construction of the magnetic core (25) shrink to comparatively different extents and that the third filament (4) used for the construction of the holding structure (16) shrinks less than the more strongly shrinking filament used for the construction of the magnetic core (25) and shrinks more than the less strongly shrinking filament used for the construction of the magnetic core (25). Method according to one of the Claims 1 and 3 until 6 , characterized in that the holding structure (16) is designed as a housing which completely or at least partially surrounds the magnetic core (25). procedure according to claim 2 , characterized in that the soldering material contains at least one refractory metal or consists of at least one refractory metal. Method according to one of the preceding claims, characterized in that the component (15, 26, 27, 29, 30) is provided with a housing, in particular in the case of the design of the holding structure (16) as a housing according to claim 7 with an additional housing compared to the holding structure (16) designed as a housing, wherein the housing is produced from a further insulating material filament (3) which consists of a non-magnetic material, and wherein the further insulating material filament (3) is also applied and solidified in layers to produce the green part (1). Method according to one of the preceding claims, characterized in that the insulating material filament (3) contains ceramic powder. Method according to one of the preceding claims, characterized in that the electrical sheet filament (2) contains an iron alloy with at least one alloying element from the group silicon and cobalt and nickel. Method according to one of the preceding claims, characterized in that the component (15, 26, 27, 29, 30) is produced with a plurality of coils (28) which are positively connected to the magnetic core (25), wherein the coils (28) are produced from a conductor filament which in particular contains copper, and wherein the conductor filament is also applied and solidified in layers to produce the green part (1). Method according to one of the preceding claims, characterized in that the component (15, 26, 27, 29, 30) is produced with cooling channels in the magnetic core (25), wherein the electrical sheet filament (2) is applied with gaps which form the cooling channels in the lamellae (17, 18, 19, 20) of the magnetic core (25). Method for producing an electric motor having a stator and a rotor, wherein a component (15, 26, 27, 29, 30) of the electric motor is additively manufactured using the method according to one of the preceding claims and wherein the laminated magnetic core (25) of this component (15, 26, 27, 29, 30) becomes a component of the stator or a component of the rotor of the electric motor. Component (15, 26, 27, 29, 30) which contains a magnetic core (25), in particular for an electric motor, in which the magnetic core (25) is a component of the stator or rotor of the electric motor, characterized in that the component (15, 26, 27, 29, 30) is produced by the method according to one of the Claims 1 until 13 is additively manufactured, wherein the magnetic core (25) is laminated. Electric motor comprising a stator and a rotor and which is produced by means of the method according to claim 14 additively manufactured component (15, 26, 27, 29, 30), wherein the additively manufactured component (15, 26, 27, 29, 30) contains a laminated magnetic core (25) and wherein this laminated magnetic core (25) is a component of the stator or a component of the rotor of the electric motor.

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