Laminated sheet with improved insulation for electric machine and method for production thereof

Abstract

The invention relates to an electric machine (1) having a stator (5) with a stack of stator laminations (10) and a rotor (3) with a stack of rotor laminations (13), a sheet for laminations (11, 11a... 11c) of such a stack of laminations (10, 13), and a lamination (11, 11a... 11c) for such a stack of laminations (10, 13), in which an insulating layer (17) made of an electrically insulating material is printed on a soft iron base layer (16), and wherein the insulating layer (17) comprises insulating cutouts (20a, 20b) or non-connected insulating elements (18a... 18d). Further, a vehicle (22) having such an electric machine (1), and a method of manufacturing sheets, laminations (11, 11a... 11c) and laminations stacks (10, 13) of the above type are disclosed.

Description

Technical Field

[0001] This invention relates to a lamination (or corresponding lamination sheet) for a laminated stack body for an electric motor, wherein the sheet comprises a base layer made of soft iron and an insulating layer made of an electrically insulating material. Furthermore, this invention relates to a lamination (or corresponding lamination sheet) for a laminated stack body for an electric motor, wherein the lamination comprises a base layer made of soft iron and an insulating layer made of an electrically insulating material. Furthermore, this invention relates to a laminated stack body comprising a plurality of laminations stacked on top of each other, wherein the laminated stack body is implemented as a stator laminated stack body or a rotor laminated stack body. Further, this invention relates to an electric motor comprising a stator and a rotor rotatable relative to the stator, wherein the stator comprises a stator laminated stack body of the type described above and / or wherein the rotor comprises a rotor laminated stack body of the type described above. Additionally, this invention relates to a vehicle comprising an electric motor of the type described above, wherein the electric motor is configured to propel the vehicle. Finally, the present invention relates to a method for manufacturing a sheet of laminations for a lamination stack for an electric motor, a method for manufacturing a lamination stack for an electric motor, and a method for manufacturing a lamination stack for an electric motor. Background Technology

[0002] The types of sheets, laminations, laminated stacks, motors, vehicles, and methods used for lamination described above are generally known. A laminated stack is formed by or includes stacked laminations and houses windings or magnets for generating magnetic flux. The magnetic flux is guided by the laminations, which are made of soft iron for this purpose. To avoid unwanted electrical short circuits and to prevent unwanted eddy currents, the laminations are coated with an insulating layer. This means that the lamination has a base layer made of soft iron and an insulating layer made of an electrically insulating material. Within the laminated stack, the base layer and the insulating layer are arranged alternately. To reduce the material used in the insulating layer, it is typically made as thin as possible. However, due to the risk of electrical breakdown of the insulating layer, natural boundaries exist, which hinder further reduction in the material used for the insulating layer. Summary of the Invention

[0003] Accordingly, the object of the present invention is to provide an improved sheet, an improved laminate, an improved laminate stack, an improved motor, an improved vehicle, an improved method of manufacturing a sheet, an improved method of manufacturing a laminate sheet, and an improved method of manufacturing a laminate stack. In particular, the amount of material used in the insulating layer should be further reduced without increasing the risk of electrical breakdown.

[0004] The object of the present invention is achieved by a sheet as disclosed in the opening paragraph, wherein an insulating layer is printed onto a substrate and includes insulating cutouts or non-connected insulating elements.

[0005] Furthermore, the object of the present invention is achieved by lamination (or corresponding lamination sheet) as disclosed in the opening paragraph, wherein the insulating layer is printed onto the substrate and includes insulating cutouts or non-connected insulating elements.

[0006] Furthermore, the object of the present invention is achieved by a lamination stack as disclosed in the opening paragraph, wherein the lamination stack comprises a plurality of laminations of the above type stacked on top of each other, and wherein the lamination stack is implemented as a stator lamination stack or a rotor lamination stack.

[0007] Furthermore, the object of the present invention is achieved by an electric motor as disclosed in the opening paragraph, wherein the electric motor includes a stator and a rotor rotatable relative to the stator, wherein the stator includes a stator lamination stack of the type described above and / or wherein the rotor includes a rotor lamination stack of the type described above.

[0008] Furthermore, the object of the present invention is achieved by a vehicle as disclosed in the opening paragraph, wherein the vehicle includes a motor of the type described above, and wherein the motor is configured to propel the vehicle.

[0009] Typically, the insulating layer can be made by printing and sintering an insulating substrate. For example, the insulating substrate can be a powder or paste containing or composed of insulating particles. For example, the insulating substrate, and therefore the insulating layer, can contain, or be composed of, plastics, ceramics, glass, or paper. All these materials can be printed and provide good to excellent electrical insulation. Some of these can be melted, such as ceramics, glass, and thermoplastics.

[0010] The base layer can be provided in the form of a sheet of soft iron, on which the insulating layer is printed. In another variation, the base layer can be made by printing and sintering a soft iron substrate. For example, the soft iron substrate can be a powder or paste containing or composed of soft iron particles.

[0011] In one aspect, the object of the present invention is also achieved by a method for manufacturing a sheet of laminations for a lamination stack for an electric motor, the method comprising the following steps:

[0012] - Provide one roll of soft iron sheet.

[0013] - An insulating layer is printed on a soft iron sheet using an insulating substrate, wherein the insulating layer includes insulating cutouts or non-connected insulating elements, and

[0014] - Heating and sintering the insulation layer.

[0015] This variant involves producing sheets rather than laminations. Here, an insulating layer is printed onto a mild iron sheet, which can be produced using well-known techniques such as sheet rolling. Accordingly, only the insulating layer is printed, not the base layer. In particular, this method is suitable for high-speed, high-volume sheet production.

[0016] On the other hand, the object of the present invention is achieved by a method for manufacturing a lamination stack for an electric motor.

[0017] In case I), the method includes the following steps:

[0018] -Provide sheets of the above types or sheets produced by the above types of methods, and

[0019] - Cut or stamp out stacked sheets from the sheet, or

[0020] In case II), the method includes the following steps:

[0021] -Cut or stamp stacked sheets from soft iron sheets.

[0022] - Print an insulating layer onto an insulating substrate, the insulating layer comprising insulating cutouts or non-connected insulating elements, and

[0023] - Heating and sintering the insulation layer.

[0024] In case I), the laminate itself is cut or stamped from a sheet having the proposed insulating layer. In case II), the cutting or stamping in the first step can also be done using a soft iron sheet produced using well-known techniques (such as sheet rolling), followed by printing the insulating layer. Again, only the insulating layer is printed, without the base layer.

[0025] Furthermore, the object of the present invention is achieved by a method for manufacturing a lamination stack for an electric motor, the method comprising the following steps:

[0026] - Print the base layer using a soft iron substrate, and

[0027] In case A), the method includes the following additional steps:

[0028] - Print an insulating layer onto an insulating substrate, the insulating layer comprising insulating cutouts or non-connected insulating elements, and

[0029] - Heating and sintering the stacked sheets, or

[0030] In case B), the method includes the following additional steps:

[0031] - Heating and sintering the base layer,

[0032] - Print an insulating layer onto an insulating substrate, the insulating layer comprising insulating cutouts or non-connected insulating elements, and

[0033] - Heating and sintering the insulation layer.

[0034] In both cases A) and B), both the substrate and the insulation layer are printed. In case A), the substrate and the insulation layer are cured in a common process step. In case B), the substrate is cured before the insulation layer is printed. In other words, in case B), the substrate and the insulation layer are cured in different process steps, and the insulation layer is printed onto the already cured and rigid substrate.

[0035] If the insulation layer is printed onto a cured and rigid substrate, the temperature used for heating and sintering the insulation layer is more or less freely chosen, as long as the substrate does not melt or substantially does not melt. If the substrate is exposed to this temperature for a very short time, the temperature used for heating and sintering the insulation layer can even be higher than the melting point of the substrate. In particular, case B) is advantageous if plastic or paper is used for the insulation layer. In contrast, in case A), it is advantageous that soft iron and the insulating material have similar melting points. Accordingly, it is thus advantageous to use insulating materials that contain or consist of ceramics and / or glass.

[0036] In a beneficial variant, heating and sintering of the substrate is accomplished by means of induction heating, and heating and sintering of the insulation layer is accomplished by means of heat transfer from the substrate to the insulation layer.

[0037] In this way, the magnetic permeability of the soft iron is used to concentrate heat to the base layer, thereby significantly melting the soft iron particles in the base layer. In contrast, the insulating substrate of the insulating layer is not actively heated, but melts through heat transfer from the base layer to the insulating layer. In some embodiments, the melting point of the soft iron may be significantly higher than that of the insulating substrate. However, with the proposed measures, both the soft iron and the insulating substrate can be sintered in an excellent manner, without overheating the insulating substrate or underheating the soft iron.

[0038] Finally, the object of the present invention is achieved by a method for manufacturing a laminated stack for an electric motor, the method comprising the following steps:

[0039] - Stack multiple sheets of the above type separately, or stack multiple sheets made by the methods of the above type, and

[0040] - The insulating layers of the multiple stacks are interconnected by heating at least locally the insulating layers of the multiple stacks to the melting point of the insulating material.

[0041] Here, the laminations are interconnected to improve the mechanical stability of the lamination stack.

[0042] By using the measures of the present invention, the material used in the insulating layer is further reduced compared to the prior art without increasing the risk of electrical breakdown. Specifically, the substrate is not completely covered by the insulating layer; rather, the insulating layer is printed onto the substrate only in specific areas. Here, the conductive substrates of the stacked sheets are maintained at a distance sufficient to avoid or at least substantially limit electrical breakdown.

[0043] Typically, insulating layers can be formed like an insulating grid or as a pattern of non-connected insulating elements. An insulating grid can be considered a layer with holes, while in another case, rather small, different insulating elements are printed in a pattern. For example, the holes can be oval, circular, elliptical, rectangular, square, polygonal, cross-shaped, or X-shaped. The same applies to the insulating elements, which can also have the shapes described above.

[0044] Advantageously, the thickness of the substrate can range from 100 μm to 400 μm, and / or the thickness of the insulation layer can range from 2 μm to 5 μm. The thickness range of the substrate provides sufficient mechanical stiffness, and the thickness range of the insulation layer provides sufficient distance between adjacent substrates to avoid or at least substantially limit electrical breakdown.

[0045] Another advantage is that the minimum distance between two insulating cuts, or the diameter of the minimum outer circle surrounding one of the non-connected insulating elements, is in the range of 8 μm to 15 μm. In other words, the "residual structure" in the insulating layer is preferably in the range of 8 μm to 15 μm. In this way, the pressure within the stacked wafers is reliably borne by the residual structure of the insulating layer.

[0046] In another advantageous embodiment, the diameter of the largest inner circle within one of the insulating cutouts, or the minimum distance between two non-connected insulating elements, is in the range of 20 μm to 50 μm. In other words, the "open space" in the insulating layer is preferably in the range of 20 μm to 50 μm. In this way, bulk contact between the base layers of adjacent stacks can be avoided. This is especially true in combination with the aforementioned thickness ranges of the base layers and the insulating layers.

[0047] Typically, the base layer (if present) and / or insulating layer can be printed using screen printing, jet printing, or offset printing. When the insulating layer is printed on a soft iron sheet, it is highly advantageous to print the insulating layer on the soft iron sheet in a continuous process (e.g., by offset printing). In this way, the sheets used for lamination can be produced very quickly and in large quantities. Screen printing is particularly suitable for printing the insulating layer on laminations. Screen printing offers moderate speed and moderate output. Jet printing is particularly suitable for fairly complex and fine structured patterns, and is also suitable for printing different insulating substrates onto the base layer. Furthermore, different printing methods can be used in combination. For example, one part of the insulating layer can be printed by screen printing, while another part can be printed by jet printing. Alternatively, the base layer can be printed by screen printing, while the insulating layer is printed by jet printing. In this way, the advantages of specific printing methods can be taken advantage of.

[0048] Typically, insulating elements or insulating cuts can be uniformly distributed. However, in another embodiment, the insulating cuts or non-connected insulating elements have varying densities on the laminations. For example, the density of insulating elements may be higher in regions near the center than in outer regions, and vice versa. Similarly, the density of insulating cuts may be lower in regions near the center than in outer regions, and vice versa. Particularly advantageously, the density of insulating elements in high mechanical stress regions of the laminations is higher than that in low mechanical stress regions. Similarly, the density of insulating cuts in high mechanical stress regions is lower than that in low mechanical stress regions. In this way, more insulating material is present in high mechanical stress regions, and higher loads can be sustained. In cases where the insulating layers of multiple laminations are interconnected by heating the insulating layers of multiple laminations to the melting point of the insulating material, the bonding strength in high mechanical stress regions can be additionally increased by the above measures. For example, more insulating material may be present at the ends of stator teeth or rotor teeth. Attached Figure Description

[0049] The invention will now be described in more detail below with reference to specific embodiments; however, the invention is not limited to these specific embodiments.

[0050] Figure 1 A half-section view of an exemplary motor is shown;

[0051] Figure 2 A front view of an exemplary stator laminate sheet is shown;

[0052] Figure 3 A detailed view of the stator laminated sheets is shown;

[0053] Figure 4 It shows Figure 3 Detailed cross-sectional view of the stator laminated sheet;

[0054] Figure 5 A detailed view of an exemplary pattern with separation points is shown;

[0055] Figure 6 similar Figure 5 However, it has a separation ring as an insulating element;

[0056] Figure 7 similar Figure 5 However, it has a cross-shaped insulating element;

[0057] Figure 8 similar Figure 5 However, it has an X-shaped insulating element;

[0058] Figure 9 A detailed view of a first example of a mesh-shaped insulating layer with square cutouts is shown;

[0059] Figure 10 similar Figure 9 However, it has a circular cut;

[0060] Figure 11 A first example of a dot pattern with varying density is shown;

[0061] Figure 12 similar Figure 11 However, it has an even higher density at the ends of the stator teeth; and

[0062] Figure 13 A schematic diagram of an electric vehicle is shown. Detailed Implementation

[0063] Generally, identical or similar parts are designated with the same / similar names and reference numerals. Features disclosed in the specification apply to parts with the same / similar names and corresponding reference numerals. Indications of orientation and relative positions are related to the associated drawings.

[0064] Figure 1 A half-sectional view of an electric motor 1 is shown. The motor includes a rotor shaft 2 and a rotor 3 mounted thereon, wherein the rotor shaft 2 is rotatably supported by (roller) bearings 4a and 4b about a rotor axis RA. Furthermore, the motor 1 includes a stator 5, a first bearing housing 6, a second bearing housing 7, and a stator housing 8, within which the stator 5 is disposed. The first bearing 4a is disposed in the first bearing housing 6, and the second bearing 4b is disposed in the second bearing housing 7. The first bearing housing 6, the second bearing housing 7, and the stator housing 8 together form a machine housing 9 or at least several parts thereof.

[0065] The stator 5 includes a stator lamination stack 10, which comprises a plurality of stator laminations (or stator lamination sheets) 11 stacked on top of each other along the stator axis or the rotor axis RA, respectively. Additionally, the stator 5 includes stator windings 12 or stator magnets, which are alternatively arranged within the stator lamination stack 10. Similarly, the rotor 3 includes a rotor lamination stack 13, which comprises a plurality of rotor laminations (or rotor lamination sheets) 14 stacked on top of each other along the rotor axis RA. Furthermore, the rotor 3 includes rotor windings or rotor magnets (not shown) arranged within the rotor lamination stack 13.

[0066] Figure 2 A front view of an exemplary stator lamination 11 is shown. The stator lamination 11 has an annular base shape with lamination cutouts 15. The lamination cutouts 15 of the stacked laminations 11 form grooves for receiving stator windings 12. Similarly, the laminations 11 may have closed lamination cutouts 15 that form magnet cavities for receiving stator magnets.

[0067] Figure 3 and Figure 4 A detailed view of the stack 11a is shown. Figure 3 A detailed front view is shown. Figure 4 A detailed cross-sectional view of the laminate 11a is shown.

[0068] The laminate 11a includes a base layer 16 made of soft iron and an insulating layer 17 made of an electrically insulating material, wherein the insulating layer 17 is printed onto the base layer 16, and wherein, in this embodiment, the insulating layer 17 includes non-connected insulating elements 18a. For example, the insulating layer 17 may comprise, or be composed of, plastic, ceramic, glass, or paper. All of these materials can be printed and provide good to excellent electrical insulation. Some of them can be melted, such as ceramics, glass, and thermoplastics. Preferably, the thickness x1 of the base layer 16 is in the range of 100 μm to 400 μm, and / or the thickness x2 of the insulating layer 17 is in the range of 2 μm to 5 μm.

[0069] As in Figure 3 It can be seen in and Figure 5 As can be seen in more detail, the insulating layer 17 can be formed as a pattern 19a similar to the non-connected insulating elements 18a. In this embodiment, the insulating elements 18a are formed as dots arranged in a matrix pattern 19a.

[0070] Preferably, the diameter d1 of the insulating element 18a (which is equal to the smallest outer circle around the insulating element 18a) is in the range of 8 μm to 15 μm.

[0071] Furthermore, it is advantageous that the minimum distances y, y' between two of the non-connected insulating elements 18a are in the range of 20 μm to 50 μm. Within these ranges, particularly within the aforementioned ranges of the thickness x1 of the bonding base layer 16 and / or the thickness x2 of the insulating layer 17, the pressure within the laminate stack 10 can be borne by the insulating elements 18a, and body contact between the base layers 16 of adjacent laminates 11 can be avoided.

[0072] exist Figures 3 to 5 In the example, the insulating element 18a is arranged in a square pattern; however, the insulating element 18a can also be arranged in a rectangular pattern, wherein the horizontal distance y and the vertical distance y' are different, or in any other pattern.

[0073] Figures 6 to 8 Various other different embodiments of the patterns 19b..19d for the non-connected insulating elements 18b..18d are shown. Figure 6 In the middle, the insulating element 18b is ring-shaped, in Figure 7 In the middle, the insulating element 18c is cross-shaped, in Figure 8 In the middle, the insulating element 18d is X-shaped. Furthermore, Figure 8 and Figure 9 The smallest outer circle C1 surrounding the insulating elements 18c and 18d is shown respectively. Preferably, the diameter d1 of the smallest outer circle C1 surrounding one of the non-connected insulating elements 18c and 18d is in the range of 8 μm to 15 μm.

[0074] Figure 9 and Figure 10 An alternative embodiment of the insulating layer 17 is shown. Specifically, the insulating layer 17 includes insulating cutouts 20a, 20b and is formed as insulating meshes 21a, 21b. Figure 9 In the middle, the insulation cut 20a is square, in Figure 10 In the design, the insulating cut 20b is circular. The insulating cuts 20a and 20b are arranged in a square pattern; however, the insulating cuts 20a and 20b can also be arranged in a rectangular pattern, wherein the horizontal distance y and the vertical distance y' are different, or in any other pattern.

[0075] Preferably, the minimum distance z between two of the insulating cuts 20a and 20b is in the range of 8 μm to 15 μm, and / or the diameter of the largest inner circle C2 within one of the insulating cuts 20a and 20b is in the range of 20 μm to 50 μm. Within these ranges, particularly within the aforementioned ranges of the thickness x1 of the bonding base layer 16 and / or the thickness x2 of the insulating layer 17, the pressure within the laminate stack 10 can also be borne by the insulating element 18a, and body contact between the base layers 16 of adjacent laminates 11 can be avoided.

[0076] exist Figure 3In some embodiments, the insulating elements 18a are uniformly distributed. However, this is not a necessary condition, and Figure 11 and Figure 12 An embodiment with varying density of insulating element 18a is shown. Figure 11 In this configuration, insulating elements 18a are arranged along radial rays. Accordingly, the density of insulating elements 18a is higher in the region near the center than in the outer region. Figure 12 In the process, the insulating element 18a is double the density in the region open by the lamination notch 15 or at the end of the stator tooth.

[0077] Generally, it is advantageous that the density of insulating element 18a in the high mechanical stress region of the laminations 11b and 11c is higher than that in the low mechanical stress region of the laminations 11b and 11c. Figure 12 This is the case in the embodiments, and Figure 11 The same applies to some extent in other embodiments. In this way, more insulating material is present in areas of high mechanical stress, and higher loads can be sustained in these areas.

[0078] Similar considerations can be made for the insulation cuts 20a and 20b, which can be uniformly distributed or have varying densities. For example, it is advantageous that the density of insulation cuts 20a and 20b in the high mechanical stress regions of the laminations 11b and 11c is lower than their density in the low mechanical stress regions. In this way, more insulating material is present in the high mechanical stress regions, and these regions can withstand higher loads.

[0079] Various methods can typically be used to produce the insulating layer 17, which are explained below:

[0080] First, the sheets for stacking 11, 11a...11c can be manufactured using the following steps:

[0081] - Provide one roll of soft iron sheet.

[0082] - An insulating layer 17 is printed on a soft iron sheet using an insulating substrate, wherein the insulating layer 17 includes insulating cutouts 20a, 20b or non-connected insulating elements 18a...18d, and

[0083] - Heating and sintering the insulation layer 17.

[0084] These steps involve a method for producing a sheet rather than for producing the laminates 11, 11a...11c themselves, in which the insulating layer 17 is printed onto a sheet of mild iron, which can be produced using well-known techniques such as sheet rolling. In this case, the laminates 11, 11a...11c themselves can be cut or stamped from the sheet. In this embodiment, only the insulating layer 17 is printed, and the base layer 16 is not printed.

[0085] In another, but similar, embodiment, the following steps are used:

[0086] -Laminations of cut or stamped soft iron sheets 11, 11a...11c,

[0087] - An insulating layer 17 is printed on an insulating substrate, the insulating layer including insulating notches 20a, 20b or non-connected insulating elements 18a...18d, and

[0088] - Heating and sintering the insulation layer 17.

[0089] Here, in the first step, the soft iron sheet, which can also be produced using well-known techniques such as sheet rolling, is cut or stamped, and then the insulating layer 17 is printed. Again, only the insulating layer 17 is printed, without the base layer 16. For both variations of this method, it should be noted that the insulating layer 17 can have any structure, particularly... Figures 3 to 12 Any structure depicted herein. It should also be noted that patterns 19a..19d with varying densities and insulating grids 21a, 21b can be printed on soft iron sheets, wherein the laminates 11, 11a..11c are subsequently cut out or stamped out.

[0090] Another alternative method for manufacturing the stacked wafers 11, 11a...11c may include the following steps:

[0091] - Print the base layer 16 using a soft iron substrate, and

[0092] - An insulating layer 17 is printed on an insulating substrate, the insulating layer including insulating notches 20a, 20b or non-connected insulating elements 18a...18d, and

[0093] - Heating and sintering the stacked sheets 11, 11a, 11c.

[0094] In this embodiment, both the base layer 16 and the insulating layer 17 are printed. Here, the base layer 16 and the insulating layer 17 are cured in a common process step.

[0095] In another, but similar, embodiment, the following steps are used:

[0096] - Print the base layer 16 using a soft iron substrate.

[0097] - Heating and sintering the base layer 16,

[0098] - An insulating layer 17 is printed on an insulating substrate, the insulating layer including insulating notches 20a, 20b or non-connected insulating elements 18a...18d, and

[0099] - Heating and sintering the insulation layer 17.

[0100] In this embodiment, both the base layer 16 and the insulating layer 17 are printed. However, the base layer is cured before the insulating layer 17 is printed. In other words, in this embodiment, the base layer 16 and the insulating layer 17 are cured in different process steps.

[0101] Typically, the base layer 16 (if present) and / or the insulating layer 17 can be printed using, for example, screen printing, inkjet printing, or offset printing. In the case where the insulating layer 17 is printed on a soft iron sheet, the insulating layer 17 can be printed on the soft iron sheet in a continuous process (e.g., using offset printing).

[0102] In the case where the base layer 16 is also printed, preferably, heating and sintering of the base layer 16 is accomplished by means of induction heating, and heating and sintering of the insulating layer 17 can be accomplished by means of heat transfer from the base layer 16 to the insulating layer 17.

[0103] When manufacturing the laminated stacks 10, 13 for the motor 1, it is advantageous to interconnect the insulating layers 17 of the plurality of laminates 11, 11a...11c by heating the insulating layers 17 at least locally to the melting point of the insulating material after stacking the laminates 11, 11a...11c. For example, the laminates 11, 11a...11c can be interconnected by means of a baking enamel coating.

[0104] Advantageously, by changing the density of insulating elements 18a..18d or insulating cuts 20a, 20b, bonding strength can be increased in areas of high mechanical stress. For example, more insulating material can be present at the ends of stator or rotor teeth.

[0105] It should be noted that, although Figures 2 to 12 Stator laminations 11, 11a...11c are shown, and although the embodiments have been explained above in the context of stator laminations 11, 11a...11c, the proposed measures are equally applicable to rotor laminations 14, and these rotor laminations 14 having the insulation layer 17 as outlined above can form a rotor lamination stack 13 for rotor 3.

[0106] Figure 13Finally, an electric vehicle 22 with a motor 1 as defined above is shown, which is configured to propel the electric vehicle 22. Specifically, the motor 1 is coupled to an optional gearbox 23, a side axle 24, and finally to a wheel 25. The motor 1 can be configured to permanently power the electric vehicle 22 in a pure electric vehicle, or intermittently, for example, in combination with a combustion engine in a hybrid electric vehicle.

[0107] It should be noted that the present invention is not limited to the embodiments disclosed above, but can be a combination of different variations. In fact, the motor 1 and the electric vehicle 22 may have more or fewer components than shown in the accompanying drawings. It should also be noted that the motor 1 and the electric vehicle 22, or components thereof, are not necessarily drawn to scale in the drawings. Furthermore, this specification may include the subject matter of other independent inventions.

[0108] It should also be noted that the term "comprising" does not exclude other elements, and the use of the articles "a" or "an" does not exclude a plural. Elements described in connection with different embodiments may also be combined. It should also be noted that reference numerals in the claims should not be construed as limiting the scope of the claims.

[0109] Figure Labels

[0110] 1. Motor

[0111] 2. Rotor shaft

[0112] 3 rotors

[0113] 4a and 4b bearings

[0114] 5 stators

[0115] 6 First bearing cover

[0116] 7 Second bearing cover

[0117] 8. Stator housing

[0118] 9. Machine casing

[0119] 10. Stator laminate stack (stator laminate stack)

[0120] 11, 11a...11c laminated sheets (stator laminated sheets)

[0121] 12 stator windings

[0122] 13. Laminated stack (rotor laminated stack)

[0123] 14. Laminated Sheets (Rotor Laminated Sheets)

[0124] 15. Stacked incision

[0125] 16. Grassroots

[0126] 17 Insulation layer

[0127] 18a..18d Insulating elements

[0128] 19a..19d Patterns of non-connected insulating elements / component patterns

[0129] 20a, 20b insulation cuts

[0130] 21a, 21b insulation mesh

[0131] 22 vehicles

[0132] 23 Gearbox

[0133] 24 side axles

[0134] 25 wheels

[0135] C1 is the smallest outer circle surrounding the insulating element.

[0136] The largest inner circle within the C2 cut

[0137] RA axis (rotor axis / stator axis)

[0138] d1 is the diameter of the smallest outer circle surrounding the insulating element.

[0139] d2 is the diameter of the largest inner circle within the cut.

[0140] x1 Thickness of the base layer

[0141] x2 Insulation layer thickness

[0142] y and y' are the minimum distances between non-connected insulating elements.

[0143] z Minimum distance between two incisions

Claims

1. A sheet of laminations (11, 11a...11c) for a laminated stack (10, 13) for an electric motor (1), said sheet comprising a base layer (16) made of soft iron and an insulating layer (17) made of an electrically insulating material, Its features are, - The insulating layer (17) is printed onto the base layer (16) and includes insulating cutouts (20a, 20b) or non-connected insulating elements (18a..18d).

2. A laminated body (10, 13) for use in an electric motor (1) comprising laminated bodies (11, 11a...11c), said laminates comprising a base layer (16) made of soft iron and an insulating layer (17) made of an electrically insulating material. Its features are, - The insulating layer (17) is printed onto the base layer (16) and includes insulating cutouts (20a, 20b) or non-connected insulating elements (18a..18d).

3. The stacked sheets (11, 11a...11c) as described in claim 2, characterized in that, -The base layer (16) is made by printing and sintering a soft iron substrate, and / or - The insulating layer (17) is made by printing and sintering an insulating substrate.

4. The stacked sheets (11, 11a...11c) as described in claim 2 or 3, characterized in that, - The minimum distance (z) between two of the insulating cuts (20a, 20b), or - The diameter (d1) of the smallest outer circle (C1) surrounding one of the unconnected insulating elements (18a..18d) is in the range of 8 μm to 15 μm.

5. The stacked sheets (11, 11a...11c) as described in any one of claims 2 to 4, characterized in that, - The diameter of the largest inner circle (C2) within one of the insulating cuts (20a, 20b), or - The minimum distance (y, y') between two of the non-connected insulating elements (18a..18d) Within the range of 20μm to 50μm.

6. The stacked sheets (11, 11a...11c) as described in any one of claims 2 to 5, characterized in that, The insulating cuts (20a, 20b) or non-connected insulating elements (18a..18d) have varying densities on the laminates (11, 11a..11c).

7. A stacked body (10, 13) comprising a plurality of stacked sheets (11, 11a...11c) according to any one of claims 2 to 6, wherein, The lamination stack (10, 13) is implemented as a stator lamination stack (10) or a rotor lamination stack (13).

8. The stacked body (10, 13) as described in claim 7, characterized in that, - The density of the insulating cutouts (20a, 20b) on the laminate (11, 11a...11c) according to claim 6 in the high mechanical stress region of the laminate (11, 11a...11c) is lower than the density in the low mechanical stress region of the laminate (11, 11a...11c), or - The density of the unconnected insulating element (18a..18d) on the lamination (11, 11a..11c) according to claim 6 is higher in the high mechanical stress region of the lamination (11, 11a..11c) than in the low mechanical stress region of the lamination (11, 11a..11c).

9. An electric motor (1) comprising a stator (5) and a rotor (3) rotatable relative to the stator (5), characterized in that, - The stator (5) comprises a stator lamination stack (10) according to claim 7 or 8, and / or - The rotor (3) includes a rotor lamination stack (13) according to claim 7 or 8.

10. A vehicle (22) comprising the motor (1) as claimed in claim 9, wherein, The motor (1) is configured to propel the vehicle (22).

11. A method for manufacturing sheets of laminations (11, 11a...11c) of a lamination stack (10, 13) for an electric motor (1), the method comprising the steps of: - Provide one roll of soft iron sheet. - An insulating layer (17) is printed on the soft iron sheet using an insulating substrate, wherein the insulating layer (17) includes insulating notches (20a, 20b) or non-connected insulating elements (18a..18d), and - Heating and sintering the insulating layer (17).

12. A method for manufacturing laminations (11, 11a...11c) of a lamination stack (10, 13) for an electric motor (1), In case I), the method includes the following steps: -Provide the sheet according to claim 1 or the sheet produced by the method according to claim 11, and - The stacked sheets (11, 11a..11c) are cut or stamped from the sheet, or In case II), the method includes the following steps: -The stacked sheets (11, 11a..11c) are cut or stamped from soft iron sheets. - An insulating layer (17) is printed on an insulating substrate, the insulating layer comprising insulating notches (20a, 20b) or non-connected insulating elements (18a..18d), and - Heating and sintering the insulating layer (17).

13. A method for manufacturing laminations (11, 11a...11c) of a lamination stack (10, 13) for an electric motor (1), the method comprising the steps of: - Print the base layer (16) on a soft iron substrate, and In case A), the method includes the following additional steps: - An insulating layer (17) is printed on an insulating substrate, the insulating layer comprising insulating notches (20a, 20b) or non-connected insulating elements (18a..18d), and - Heating and sintering the stacked sheets (11, 11a..11c), or In case B), the method includes the following additional steps: - Heating and sintering the base layer (16), - An insulating layer (17) is printed on an insulating substrate, the insulating layer comprising insulating notches (20a, 20b) or non-connected insulating elements (18a..18d), and - Heating and sintering the insulating layer (17).

14. The method according to any one of claims 11 to 13, characterized in that, The base layer (16) and / or the insulating layer (17) are printed by means of screen printing, inkjet printing or offset printing.

15. A method for manufacturing a laminated stack (10, 13) for an electric motor (1), the method comprising the steps of: - Stacking a plurality of stacked sheets (11, 11a...11c) according to any one of claims 2 to 6, or stacking a plurality of stacked sheets (11, 11a...11c) made by the method according to any one of claims 11 to 14, and - The insulating layers of the plurality of laminates are interconnected by heating at least partially the insulating layer (17) of the plurality of laminates (11, 11a..11c) to the melting point of the insulating material.

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