Method for manufacturing a functional unit for an electrical machine
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- THYSSENKRUPP STEEL EUROPE AG PATENTE PATENT DEPARTMENT
- Filing Date
- 2018-12-21
- Publication Date
- 2026-07-09
AI Technical Summary
The addition of silicon above 3.5% by weight in iron-based electrical steel sheets adversely affects processability and limits the reduction in sheet thickness, leading to increased core losses and anisotropies in magnetic properties, limiting the design parameters of functional units for electrical machines.
A method using a powder-based additive manufacturing process, such as selective laser melting or laser metal deposition, applies a starting material with controlled silicon content (2.0% to 15.0% by weight) to a substrate, forming functional structures with precise element distribution and thicknesses down to 0.10 mm, eliminating the need for stamping and subsequent annealing.
This method produces functional units with reduced core losses and improved mechanical properties, allowing for smaller-scale, complex geometries without material waste, and comparable magnetic performance to conventionally produced units, while avoiding negative effects of high silicon content.
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Abstract
Description
[0001] The invention relates to a method for manufacturing a semi-finished product for an electric machine. The semi-finished product has at least one functional structure made of an iron-based material. The invention further relates to a method for manufacturing a functional unit for an electric machine. A functional unit can, in particular, be a stator or a rotor.
[0002] Electrical machines, especially electric motors, are well-known in practice. Electric motors have at least one stationary functional unit, called a stator, and one movable functional unit. A rotor, for example, can be used as the movable functional unit. The electric machine also has a housing for positioning the stator and rotor. At least one of the two functional units is magnetically active. Depending on the operating principle of the electric motor, at least one of the functional units can be remagnetized using an alternating electromagnetic field. This results in the requirement that the functional unit should ideally be made of a soft magnetic material and be remagnetizable with minimal remagnetization losses.The remagnetization losses consist in particular of hysteresis losses during the reversal of the elementary magnets of the magnetic material and of eddy current losses due to induced eddy currents within the magnetic material.
[0003] With the aim of minimizing remagnetization losses, a common method for manufacturing functional units of electrical machines is to assemble stators and / or rotors from several laminations into so-called laminated cores. The laminations used are usually referred to as electrical steel sheets. The individual laminations of the cores are partially or completely separated from each other by an electrical insulator in order to reduce eddy current losses during remagnetization within each individual lamination and thus also in the finished functional unit as a whole. To minimize eddy current losses as much as possible, the thinnest possible laminations are used to manufacture the core. Another measure to reduce remagnetization losses is the use of electrical steel sheets, as mentioned above.In this context, the term "electrical steel sheets" refers to sheets whose properties are specifically designed to minimize hysteresis losses. For this purpose, electrical steel sheets exhibit, among other things, a comparatively low density of lattice defects, a comparatively low density of grain boundaries, and comparatively low residual stresses. Another characteristic of electrical steel sheets is their elemental composition, which is also optimized for low hysteresis losses. A well-known method for achieving advantageous properties in iron-based alloys, such as electrical steels, is the addition of silicon.
[0004] As mentioned, the addition of silicon according to the invention leads to the desired reduction in remagnetization losses in iron-based electrical steel sheets. However, the addition of silicon to electrical steel sheets has a detrimental effect on processability at higher silicon contents, particularly above approximately 3.5 wt.% Si content in iron-based electrical steel sheets. The addition of silicon in proportions above approximately 3.5 wt.% is especially disadvantageous for cold processing. One reason for this is that Si contents above approximately 3.5 wt.% lead to the precipitation of brittle phases. Furthermore, hot forming of the electrical steel sheets is only possible to a limited extent or with increased effort at Si contents above approximately 3.5 wt.%.
[0005] Another disadvantage of a high silicon content in iron-based electrical steel sheets is that the previously mentioned, and actually advantageous, reduction in sheet thickness with increasing silicon content becomes increasingly limited. This is because the stamping process commonly used to shape the sheets leads, on the one hand, to anisotropies in the magnetic properties, for example, due to residual stresses. On the other hand, the otherwise common reduction of residual stresses by annealing in thin electrical steel sheets, especially below approximately 0.3 mm, leads to a deterioration of the magnetization properties due to increased oxide formation in the surface areas.
[0006] In summary, the known manufacturing of functional units for an electric machine from electrical steel sheets leads to limitations in the selection of design parameters, in particular the elemental composition of the sheets used and the thickness of the sheets used, due to opposing effects.
[0007] Based on the problems described above, the invention aims to provide functional units for electrical machines in which the aforementioned problems are avoided or at least reduced in their extent.
[0008] The problem is solved by a method having the features of claim 1 for producing a semi-finished product that can subsequently be further processed in the manufacture of a functional unit for an electric machine. The problem is further solved by a method for producing a functional unit for an electric machine having the features of claim 12.
[0009] The method according to the invention provides for the production of a semi-finished product that can be used for further processing into a functional unit for an electrical machine.
[0010] The procedure involves the following steps: A) Providing a substrate, B) Providing a powder as a starting material, C) layer-by-layer application of the starting material onto the substrate until the completion of at least one first functional structure of the functional unit.
[0011] The functional structure of the functional unit can, in particular, be a flat structure already present in its final geometry, at least partially, preferably completely. This flat structure serves as a component of the functional unit to be manufactured later. For example, it can be a flat structure that is provided as part of a rotor or, alternatively, a stator. In other words, the functional structure can, in particular, be a plane of the rotor or the stator. The functional structure thus assumes the role that, in conventionally manufactured functional units, is fulfilled by a sheet of a laminated core, more precisely by a section of a sheet produced by stamping.
[0012] According to the invention, a powder is used as the starting material, which necessarily contains the chemical element Fe, i.e., iron, to provide the magnetic functionality. In addition to unavoidable impurities, optional components may be present, which, besides considering their influence on the magnetic properties, can be selected particularly with regard to the desired mechanical properties of the functional unit to be produced. In particular, the powder may contain C, preferably with a C content of at least 0.003 wt.%, to effect the formation of steel.
[0013] The powder provided as starting material also contains between 2.0 wt.% and 15.0 wt.%, preferably between 3.5 wt.% and 10.0 wt.%, and particularly preferably between 4.0 wt.% and 7.0 wt.% silicon. As already explained, a high silicon content has a positive effect on the magnetic properties, which is attributable, among other things, to its ferrite-stabilizing properties and its resistance-increasing properties, meaning its electrical resistance-increasing properties. A silicon content of 15.0 wt.% should not be exceeded in order to reliably avoid negative effects on the mechanical properties of the functional structure, in particular a reduction in its fracture toughness.
[0014] The substrate serves to support the functional structure to be produced and can be made of any material that remains sufficiently stable, both structurally and chemically, at the temperatures occurring during the production of the semi-finished product. In particular, the substrate can be made of sheet steel. Preferably, the substrate has the same or substantially the same elemental composition as the powder, with the advantage that good adhesion between the substrate and the starting material is achieved when the first layer of the starting material is applied to the substrate.
[0015] Preferably, in addition to the aforementioned silicon content, a proportion of less than 18.8 wt.% of optional components is present. Consequently, this also means that at least 66.2 wt.% of the starting material consists of iron and unavoidable impurities. It has been shown that by selecting such a high iron content, sufficient magnetic properties are always achieved, while at the same time, the permitted addition of a significant proportion of optional components provides sufficient flexibility in adjusting the properties of the functional structure, for example, in adjusting the microstructure and mechanical properties.
[0016] The powder provided as starting material is preferably a powder that exhibits the elemental composition of the first functional structure in the respective weight proportions and is provided in a suitable particle size distribution and with sufficient homogeneity. Alternatively, the powder can be in the form of a defined powder type. Whether the individual powder particles present in the powder exist as elements or are themselves already present in one or more alloys is not essential, as long as the aforementioned elemental compositions are maintained and sufficiently homogeneous mixing of the powder ensures a sufficiently high degree of homogeneity in the particle feed to the substrate.The formation of the final alloy of the functional structure takes place during the application process itself and is ensured by the very high temperatures locally at the application site of the manufacturing processes chosen for the application, which are listed below.
[0017] Preferably, the material is completely melted during application.
[0018] For the application, a powder bed-based or powder nozzle-based additive manufacturing process is used. In particular, selective laser melting, laser beam melting, selective laser sintering, or electron beam melting can be used as a powder bed-based additive manufacturing process. Laser metal deposition can be used as a powder nozzle-based manufacturing process. Each of the aforementioned processes is known per se to those skilled in the art. All of these processes have the advantage that, at the time of application, a sufficient temperature can be achieved at that location by the laser radiation or electron beam used to completely melt the materials during application.
[0019] The use of the aforementioned methods has the advantage that, by providing powders with comparatively high silicon content, even exceeding the aforementioned 3.5 wt%, at least one functional structure with high homogeneity in element distribution, low defect density, and comparatively large grain sizes can be produced. Simultaneously, the production of small-scale structures is possible. In particular, it is possible to produce flat structures, for example, in the previously mentioned geometry of a plate or a part punched from a plate, with thicknesses of less than 0.30 mm down to approximately 0.10 mm. The method according to the invention thus has the advantage of enabling the production of smaller-scale plates than is possible with rolling processes.The functional structure can, for example, be a flat structure with two parallel, planar boundary surfaces spaced between 0.10 mm and 0.30 mm apart. However, due to the additive manufacturing process used, the functional structure can also be a three-dimensional form, thus assuming more complex geometries without requiring any forming processes on an electrical steel sheet.
[0020] Preferably, the powder provided as starting material has the following components (all values in wt.%): Si: 2.0 - 15.0; C: less than, that is: actually less than, 0.1; Mn: up to, that is: less than or equal to, 2.0; S: less than 0.01; Al: up to 15.0; N: less than 0.01; Cu: less than 0.3; Cr: less than 0.5; Mo: less than 0.1; B: less than 0.1; Note: less than 0.01; V: less than 0.1; Ti: less than 0.01; Sn: less than 0.1; Ni: less than 0.1; P: less than 0.1; Co: less than 0.01; Zn: less than 0.01; As: less than 0.03; Ca: less than 0.012; Sn: less than 0.16; Ta: less than 0.01; W: less than 0.02;
[0021] Residual iron and unavoidable impurities.
[0022] It is understood that the remainder refers to the sum of all weight components. 100 This results in wt.%. It is particularly preferred that at least 0.003 wt.% C is present, so that no Fe functional structure is present, but rather a steel functional structure with the corresponding positive properties, especially with regard to strength, which is essential for a rotor, for example, as already mentioned as an application goal.
[0023] The powder preferably consists of particles with a particle size between d10 = 10 µm and d90 = 150 µm, preferably between d10 = 10 µm and d90 = 60 µm or between d10 = 30 µm and d90 = 150 µm.
[0024] Preferably, the substrate is preheated to a deposition temperature before the first functional structure is applied, and this temperature is maintained at least during the application of a first layer of the first functional structure, and preferably during the application of the entire first functional structure. In other words, the substrate is kept at a temperature that is at least equal to the deposition temperature.
[0025] The application temperature is preferably between 400 and 900° Celsius, particularly preferably between 500 and 800° Celsius. Preheating the substrate, especially by supporting diffusion processes and reducing the temperature gradients present during application, promotes low cracking and stress in the first functional structure completed by the application. The first functional structure is preferably applied as a flat structure with a thickness between 0.10 mm and 2.0 mm, particularly preferably between 0.10 mm and 1.00 mm. The term "flat structure" refers to the fact that the first functional structure has the form of a stamped, not formed, sheet, but is not referred to as a sheet due to the different manufacturing method using additive manufacturing.
[0026] One embodiment of the process involves applying the first functional structure and a number of subsequent functional structures sequentially, layer by layer, to the substrate. This means that first, the first layer of each functional structure, including the first and subsequent functional structures, is applied sequentially. Then, the second layer of each functional structure is applied sequentially, and this process is repeated until the final layer of each functional structure has been applied sequentially. It is possible for the first functional structure and the subsequent functional structures to have identical dimensions and to be applied to the substrate in a parallel arrangement.The functional structures arranged on the substrate serve as semi-finished products for the electrical machine and already possess their final geometry, eliminating the need for further processing or post-treatment. Compared to conventional manufacturing (i.e., primarily through stamping and subsequent annealing), there is no significant waste of electrical steel sheets. Furthermore, the elimination of subsequent processing steps, such as stamping, prevents the development of internal stresses that negatively impact the remagnetization losses of the semi-finished product. This reduces manufacturing costs, as, for example, the stamping annealing required by DIN EN 10341 can potentially be omitted, resulting in directly lower production costs.
[0027] The functional structures can be oriented perpendicular to a substrate surface, but it is also conceivable that they are attached to the substrate at a slight angle, for example tilted between 0 degrees and 10 degrees to the orthogonal plane of the substrate.
[0028] Preferably, the functional structures are provided with a predetermined breaking point in the area of their transition to the substrate, so that each individual functional structure or the entirety of the functional structures can be easily removed from the substrate, for example by electrical discharge machining, by mechanical processing or by manual removal.
[0029] According to one embodiment, the first functional structure and the number of further functional structures are all designed in the form of a stator lamination or all in the form of a rotor lamination.
[0030] Each functional structure preferably has a distance of between 0.003 mm and 2.00 mm from each immediately adjacent functional structure. Preferably, all functional structures are arranged equidistantly on the substrate and have distances of between 0.003 mm and 2.00 mm from their respective neighboring functional structures.
[0031] In the case that the functional structures are shaped as stator laminations or rotor laminations, the functional structures are preferably already oriented on the substrate with a common axis of rotation, which is perpendicular to a plane of the respective functional structures, and preferably also to the substrate plane.
[0032] The invention further provides a method for manufacturing a functional unit for an electric machine. The manufacturing of the functional unit for an electric machine is carried out in the following steps: First, a semi-finished product is manufactured using a process of the type mentioned above or one of its further developments. The semi-finished product comprises a substrate and at least one, preferably several, functional structure(s) arranged on the substrate.
[0033] Subsequently, an insulating material is introduced into all spaces between adjacent functional structures to provide at least partial electrical isolation between them. After the insulating material has been introduced, the functional structure assembly, consisting of the functional structures and the insulating material, is separated from the substrate, thus preserving the functional unit.
[0034] The electrically insulating material can be, for example, an electrically insulating plastic. This insulating plastic could be, for instance, a polyvinyl butyral-based plastic, a polyamide, a polyester, or an epoxy resin-based plastic. The plastic is preferably applied to the existing gaps by means of a spraying process and / or dip coating.
[0035] In particular, it may be provided that after the application of the starting material, steps D to F are carried out without additional heat treatment, so that a functionally ready unit, in particular a stator or a rotor, is provided without heat treatment being carried out after the assembly of the individual functional structures.
[0036] The fact that the additively manufactured, preferably vertically constructed, semi-finished products have a rough surface advantageously promotes a strong bond between metal and plastic. Examples:
[0037] The described procedure has been verified through various feasibility studies. Example 1:
[0038] The first feasibility study was carried out to verify suitable magnetic properties in thin plates produced using a method according to the invention by means of laser metal deposition.
[0039] The following steps were performed: Providing two base powders: Powder 1: Mn 1.2 wt.%, Si 0.5 wt.%, remainder iron and unavoidable impurities; Powder 2: Mn 1.2 wt.%, Si 48.76 wt.%, remainder iron and unavoidable impurities. Mixing the powders to create three powders as three different starting materials: Starting material 1: wt.% ratio Fe:Si = 96:4; Starting material 2: wt.% ratio Fe:Si = 94:6; Starting material 3: wt.% ratio Fe:Si = 92:8.
[0040] One and two plates measuring 60 × 60 × 0.35 mm were produced for each of the starting materials using laser metal deposition. 3 as well as for the starting material 3 plates with dimensions 60 × 60 × 0.55 mm 3 manufactured.
[0041] Powder was fed to the substrate using argon in an inert gas bubble in an open system.
[0042] The experimental boundary conditions were chosen as follows: - For starting material 1: Laser power 910 W, feed rate 600 mm / min; powder mass flow 3.8 g / min; track offset = 1 mm; height offset = 0.6 mm; preheating temperature = room temperature; For starting material 2: Laser power 910 W, feed rate 600 mm / min; powder mass flow 3.8 g / min; track offset = 1 mm; height offset = 0.62 mm; preheating temperature = 300 °C; For starting material 3: Laser power 950 W, feed rate 600 mm / min; powder mass flow 3.5 g / min; track offset = 1 mm; height offset = 0.625 mm; preheating temperature = 400 °C.
[0043] The samples are subsequently designated as LMD4, LMD6 and LMD8, with increasing silicon content.
[0044] The following mechanical properties were determined: LMD4: Härte HV 0,5 = 200, LMD6: Härte HV 0,5 = 300, LMD8: Härte HV 0,5 = 400 und Zugfestigkeit R m = 500 MPa .
[0045] Magnetization reversal experiments were carried out, which are described in a subsequent section. Example 2:
[0046] A test specimen measuring 60 × 60 × 0.28 mm was produced using selective laser melting. 3produced, with the following powder properties of the powder produced as starting material: Characteristic Value Chemical analysis Flow rate according to DIN EN 18.70 s / (50 g) Si 6.7 wt.% Mn 0.05 wt.% Cr 0.03 wt.% ISO 4490:2014-11: C 0.01 wt.% Al <0.01 wt.% N 0.006 wt.% P 0.005 wt.% Iron and unavoidable impurities rest Particle size distribution measured with Malvern 2000 d10 = 24.4 µm d50 = 35.8 µm d90 = 51.7 µm
[0047] The following experimental conditions were chosen: Vorwärmtemperatur = 300 ° C , Laserleistung schwankend zwischen 120 W und 170 W; Vorschubgeschwindigkeit = 450 − 700 mm / s . <?page 8=""?>
[0048] The produced sample is subsequently referred to as SLM. Magnetization experiments:
[0049] The manufactured samples were subjected to remagnetization tests according to DIN IEC 60404-3:2010-05. Remagnetization tests were performed at remagnetization frequencies of 50 Hz, 400 Hz, and 1000 Hz. In both cases, the remagnetization was carried out at a magnetic flux density of 1 T.
[0050] As reference samples, conventionally produced, 0.30 mm thick plates from the electrical steel sheets made of the alloys comparative standard grade NO30-16 were used before heat treatment and after annealing for 40 seconds in an oven H2 / Ar atmosphere at 1060 °C as well as M400-50 A without heat treatment.
[0051] The following results were obtained Remagnetization losses in W / kg at 50 Hz, measured at 1 T Magnetization losses in W / kg at 1000 Hz measured at 1 T LMD4 without heat treatment 4,3 164 LMD6 without heat treatment 4,5 165 LMD8 without heat treatment 2, 0 142 SLM without heat treatment 3,5 126 NO30-16 before heat treatment 12 293,9 NO30-16 after heat treatment 1,1 79,8 M400-50 A < 2,5 150 - 200
[0052] The results show that the plates produced using additive manufacturing processes exhibited remagnetization losses that, without prior annealing, were sometimes lower, or at least comparably low, than the reference samples without additional heat treatment. At the same time, the remagnetization losses were at least on the same order of magnitude as those of the heat-treated reference sheet. Furthermore, it was shown that an increased silicon content leads to lower remagnetization losses. Thus, it was demonstrated that functional structures for electrical machines can be produced using additive manufacturing processes that exhibit comparably good properties to functional structures manufactured from electrical steel using conventional methods.
[0053] An exemplary embodiment of the method for manufacturing a functional unit for an electrical machine is described in Fig. 1a) - Fig. 1f) illustrated. Further details, features and advantages of the subject matter of the invention will become apparent from the following description in conjunction with the drawings.
[0054] It is understood that the features mentioned above and explained below can be used not only in the combination specified, but also in other combinations or on their own.
[0055] In a first step, as shown in Fig. 1a), a substrate 1 provided. In an order form 2 A starting material provided as a powder is used. 3 filled and from this a first layer is created 4 of the starting material 3 on the substrate 1 applied. The application of the first layer 4 In the example shown, this is done as in Fig.1b) is shown using a process called laser metal deposition (LMD). A first functional structure is built up layer by layer. 5 applied to the substrate. The first functional structure 5 is in its completed state in Fig. 1c) shown, where the first functional structure in the exemplary representation shown is 5 This concerns a component of a rotor for an electric machine designed as a flat structure. The term "flat structure" refers to the fact that the functional structure 5 in its form corresponds to a part stamped from a sheet of metal, but differs in the way it is manufactured from such a stamped part, since the production of the functional structure 5 was carried out using an additive manufacturing process.
[0056] As in Fig. 1d) shows several functional structures 5a , 5b ,5c , 5d , 5e The functional structures are applied layer by layer sequentially to the substrate, with the shape and fabrication corresponding to those of the first functional structure. Layer by layer sequential application means that the nth layer of each functional structure is applied, followed by the n+1th layer of each functional structure. 5 , 5a , 5b , 5c , 5d , 5e are equidistant on the substrate 1 arranged. The substrate with all its functional structures. 5 , 5a , 5b , 5c , 5d , 5e provides the semi-finished product 6This was produced using an embodiment of the inventive method. Further processing of the semi-finished product into a rotor can be provided. Each functional structure has a predetermined breaking point for manual removal of the semi-finished product. 7 , 8 on, which is independent of the design of the functional structure, for example a recess 7 in a contact area between functional structure 5 and substrate 1 (see Fig. 1e): Top view in the direction of a rotational symmetry axis of the functional structure 5 ) and / or a rejuvenation 8 in a contact area between functional structure 5 and substrate 1 (see Fig. 1f): Supervision towards a level of the functional structure 5 can exhibit a lying straight line.
[0057] In Fig. 2a) is the production of a first layer 4A first functional structure is shown using an additive manufacturing process designed as powder bed-based selective laser melting, wherein the reference numerals shown are those already described in the description. Fig. The meanings explained in section 1 are shown. The first layer is generated after the powder has been applied. 3 by means of local melting using a laser beam 9 , which uses a deflecting mirror 10 is directed towards the area to be melted. Fig. 2b) shows the layer-by-layer sequential application of a number of several functional structures using the example of a first layer, wherein the application of the first layer of all functional structures is followed by the sequential application of the second layer of all functional structures, until the last layer of all functional structures has been applied. Fig. 2b) the application process is currently in the process of applying the first layer 4ethe sixth functional structure, after the first layers had already been formed. 4 , 4a , 4b , 4c and 4d the first five functional structures have been produced. QUOTES INCLUDED IN THE DESCRIPTION
[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited non-patent literature
[0000] DIN IEC 60404-3:2010-05
[0049]
Claims
[1] Method for producing a semi-finished product for the manufacture of a functional unit for an electrical machine, comprising the following steps: A) Providing a substrate (1), B) Providing a powder (3) as a starting material (3) , C) layer-by-layer application of the starting material (3) onto the substrate (1) using a powder bed-based additive manufacturing process or a powder nozzle-based additive manufacturing process until at least one first functional structure (5) of the functional unit is fully assembled, where The powder (3) provided as starting material consists of (each in wt. percent) Si: 2.0 - 15.0; Residual iron, optional components and unavoidable impurities. [2] Method according to claim 1, wherein the powder provided as starting material consists of (each in wt. percent) Si: 2.0 - 15.0; less than 18.8 optional components, Residual iron and unavoidable impurities. [3] Method according to claim 1 or according to claim 2, wherein the powder provided as starting material consists of (in each case in wt. percent) Si: 2.0 - 15.0; C: less than 0.1, preferably less than 0.1 and at least 0.003; Mn: up to 2.0; S: less than 0.01; Al: up to 15.0; N: less than 0.01; Cu: less than 0.3; Cr: less than 0.5; Mo: less than 0.1; B: less than 0.1; Note: less than 0.01; V: less than 0.1; Ti: less than 0.01; Sn: less than 0.1; Ni: less than 0.1; P: less than 0.1; Co: less than 0.01; Zn: less than 0.01; As: less than 0.03; Ca: less than 0.012; Sn: less than 0.16; Ta: less than 0.01; W: less than 0.02; Residual iron and unavoidable impurities. [4] Method according to any of the preceding claims, wherein the powder consists of particles with a particle size between d10 = 10 µm and d90 = 150 µm, preferably between d10 = 10 µm and d90 = 60 µm or between d10 = 30 µm and d90 = 150 µm. [5] Method according to one of the preceding claims, wherein the substrate (1) is kept at a temperature corresponding to at least an application temperature at least temporarily during step C), preferably at least during the application of a first layer (4) of the first functional structure (5), particularly preferably until the assembly of the at least first or all functional structures is completed. [6] Method according to claim 5, wherein the application temperature is between 400 and 900 degrees Celsius, preferably between 500 and 600 degrees Celsius. [7] Method according to one of the preceding claims, wherein the first functional structure (5) is applied as a flat structure with a thickness between 0.10 mm and 2.00 mm, preferably between 0.10 mm and 1.00 mm. [8] Method according to one of the preceding claims, wherein the first functional structure (5) is applied at the position immediately adjacent to the substrate (1) with a predetermined breaking point (7, 8) to enable manual breaking of the first functional structure (5) from the predetermined breaking point or breaking of the first functional structure (5) from the predetermined breaking point by means of a mechanical separation process. [9] Method according to any of the preceding claims, wherein the first functional structure (5) and a number of further functional structures (5a, 5b, 5c, 5d, 5e) are applied layer by layer sequentially to the substrate (1). [10] Method according to one of the preceding claims, wherein the first functional structure (5) and the number of further functional structures (5a, 5b, 5c, 5d, 5e) have identical dimensions and are applied parallel-displaced to the substrate (1). [11] Method according to claim 10, wherein the first functional structure (5) and the number of further functional structures (5a, 5b, 5c, 5d, 5e) are each a stator flat structure or each a rotor flat structure, wherein each of the functional structures (5, 5a, 5b, 5c, 5d, 5e) has a distance of between 0.003 mm and 2.00 mm to each immediately adjacent functional structure, preferably each of the functional structures (5, 5a, 5b, 5c, 5d, 5e) has the same distance of between 0.003 mm and 2.00 mm to each immediately adjacent functional structure. [12] Method for manufacturing a functional unit for an electric machine, wherein D) a semi-finished product (6) with at least two functional structures (5, 5a, 5b, 5c, 5d, 5e) is produced by a method according to one of the preceding claims, which are connected to the same substrate (1), E) an insulating material is introduced into all spaces between adjacent functional structures (5, 5a, 5b, 5c, 5d, 5e) for at least partial electrical insulation, F) after the insulating material is introduced, the functional structure package consisting of the functional structures (5, 5a, 5b, 5c, 5d, 5e) and the insulating material is separated from the substrate (1) and the functional unit is thereby obtained. [13] Method according to claim 12, wherein during step E) an electrically insulating plastic, preferably a polyvinyl butyral-based plastic, a polyamide, a polyester or an epoxy resin-based plastic, is applied by spraying and / or by dip coating. [14] Method according to claim 12 or according to claim 13, wherein, after the application of the starting material without additional heat treatment, steps D) to F) are carried out to provide a functional unit ready for use. [15] Semi-finished product for the manufacture of a functional unit for an electric machine, obtainable according to any one of claims 1 to 11.
Citation Information
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