Method for assembling pole elements for a rotor of an axial motor

Abstract

The present invention relates to a method for assembling a pole element (20) for a rotor of a shaft flow electric motor, said rotor (1) comprising a body (10) in the form of a disc having at least one seat (30), said pole element comprising a plurality of single magnets (21), said method comprising the following steps: e1) forming a first row (91) of at least two single magnets, and retaining said single magnets using a strip of adhesive material; e2) placing said first row on a support whose curvature is equal or substantially equal to the curvature of a circumferential edge (32) of said seat; e3) forming another row (92) of at least two further single magnets, and retaining said single magnets using another strip of adhesive material; e4) placing said other row on said first row; e5) repeating steps e3) and e4) until assembling said pole element.

Description

Technical Field

[0001] This invention generally relates to the field of electric motors.

[0002] More specifically, the present invention relates to the assembly of magnetic pole elements for the rotor of an axial-flow electric motor.

[0003] This invention has particularly advantageous applications in electric motors used in electric or hybrid vehicles. Background Technology

[0004] An axial-flow motor typically consists of two stators and one rotor, with an air gap separating these two types of components. The rotor carries a series of permanent magnets, while the stators carry a series of coils. When the coils are powered by current, the rotor, which is fixed to the motor's output shaft, experiences a torque generated by the magnetic field (the resulting magnetic flux is the axial flow used in the axial-flow motor).

[0005] To reduce energy losses in the rotor caused by Foucault currents and thus improve motor performance, permanent magnets can comprise multiple small individual magnets. In fact, the losses suffered by a magnet due to Foucault currents are greater than those in an equivalent small single magnet. These individual magnets are closely packed to maximize the volume of the magnetic material relative to the volume of the corresponding pole element, thereby improving motor performance.

[0006] For example, document WO2018172636 describes a structure comprising a single magnet in the form of a polyhedron. The advantage of these single magnets is that they can form a dense network—in this case, a honeycomb structure—while simultaneously possessing a strong magnetic field.

[0007] However, filling the volume of the pole elements with the maximum number of individual magnets while limiting manufacturing costs is complex. In practice, for example, permanent magnets typically have at least one non-linear surface on the outer periphery of the rotor body, thus increasing the volume occupied by the permanent magnets. Therefore, arranging the individual magnets along this non-linear surface creates unused space, which reduces the magnetic efficiency of the pole elements and thus the magnetic efficiency of the rotor. Summary of the Invention

[0008] In order to overcome the above-mentioned shortcomings of the prior art, the present invention proposes to simplify the geometry and arrangement of mass-produced single magnets (single magnets, unit magnets).

[0009] More specifically, according to the present invention, a method is provided for assembling magnetic pole elements for a rotor of an axial current motor, the rotor comprising a body in the form of a disk centered on a rotation axis and extending into a main plane, the body having at least one housing (receiving portion, groove), the magnetic pole elements comprising a plurality of single magnets, the method comprising the following steps:

[0010] e1) Form a first row consisting of at least two single magnets, and use strips of adhesive material to hold the single magnets in the first row;

[0011] e2) The first row is placed on an assembly support whose curvature is equal to or substantially equal to the curvature of the circumferential edge of the receptacle about the axis of rotation, such that the single magnets of the first row are placed along a first line contained in the assembly plane and having a non-zero curvature.

[0012] e3) Form another row consisting of at least two additional single magnets, and hold the single magnets in the other row using a strip of another adhesive material;

[0013] e4) Place the other row on top of the first row such that the single magnets in the other row are placed along another line contained in the assembly plane and having a non-zero curvature;

[0014] e5) Repeat steps e3) and e4) until the magnetic pole components are assembled.

[0015] This method allows individual magnets to be arranged such that they are placed along a line with non-zero curvature relative to the axis of rotation. Therefore, magnetic pole elements assembled in this way exhibit good resistance to mechanical stress and excellent magnetic properties. Furthermore, this method allows for mass production at a lower cost.

[0016] Furthermore, placing individual magnets along lines of non-zero curvature allows them to follow non-linear contours. For example, the first line could be located at the periphery (outer circumference, edge) of the housing, where the curvature is essentially equal to the outer curvature of the body. This reduces the maximum force exerted on each individual magnet when viewed independently. In other words, centrifugal and magnetic forces are optimally distributed across all individual magnets, and the risk of individual magnets detaching is minimized. This improves the rotor's resistance to centrifugal forces.

[0017] Other advantageous and non-limiting features of the method according to the invention are as follows, which may be applied individually or in combination according to all technical possibilities:

[0018] - The assembly support is a part independent of the body, and in step e5), the magnetic pole element is inserted into the housing;

[0019] - In step e5), the magnetic pole element is inserted in such a way that the assembly plane is parallel to the main plane or combined with the main plane (joined together);

[0020] - Before inserting the magnetic pole element into the housing, a step is performed to straighten the side edges of the magnetic pole element;

[0021] – The assembly support belongs to the housing, and the assembly plane is parallel to or connected to the main plane;

[0022] -The method includes the following steps: e6) compressing the magnetic pole element in the main plane and toward the outer periphery of the housing;

[0023] -The method includes the following steps: e7) fixing the magnetic pole element in the housing by injecting a bonding material for coating the single magnet;

[0024] - The method includes a prior step of producing the single magnets by dividing the magnet block into single magnets of substantially the same cuboid form, the single magnets extending along a main direction in their maximum dimension and in a transverse direction perpendicular to the main direction in another dimension;

[0025] - Place or insert the magnetic pole element into the housing such that the principal direction of the single magnet is oriented about the axis of rotation and the lateral direction is oriented tangentially to the first line or the other line;

[0026] - The width of the adhesive strip is less than the length of the single magnet along the main direction.

[0027] Arranging magnets in the cuboid form as described above creates small free spaces that are uniformly distributed within the magnetic pole elements. These free spaces increase permeability, i.e., improve the filling effect when using adhesive materials such as glue or varnish, which allows individual magnets to be bonded together.

[0028] The invention also relates to a rotor as defined in the Technical Field section, wherein at least some individual magnets have the form of cuboids and are placed side by side along adjacent first and second lines, the first and second lines being contained in a principal plane and having an average non-zero curvature about the axis of rotation, wherein the individual magnets placed along the first line are separated from the individual magnets placed along the second line by strips of adhesive material.

[0029] Therefore, due to the present invention, the magnetic pole elements comprise single magnets in the form of cuboids. These single magnets are easy to mass-produce. In fact, for example, it can be achieved by simply breaking or cutting the block along two directions. Due to their cuboid shape, the single magnets can be easily arranged on one side of each other.

[0030] Other advantageous and non-limiting features of the rotor according to the invention are as follows, which may be applied individually or in combination according to all technical possibilities:

[0031] -The single magnet is coated with a bonding material;

[0032] - All of the multiple individual magnets are in the form of cuboids and are distributed along multiple lines;

[0033] - The curvature of the line closest to the body is basically equal to the curvature of the periphery of the container;

[0034] - The curvature of each line is an arc;

[0035] -Single magnets in rectangular parallelepiped form are essentially the same; and

[0036] - The single magnets extend along a principal direction in their maximum dimension and in a transverse direction orthogonal to the principal direction in another dimension, wherein the principal direction of the single magnet is oriented about the axis of rotation and wherein the transverse direction is oriented tangentially to the first line.

[0037] Naturally, different features, variations, and embodiments of the invention can be associated with each other in various combinations, as long as they are not incompatible or exclusive with each other. In particular, in one variation, magnets are first bonded together to form magnetic pole elements, and then the magnetic pole elements are compressed into the rotor structure, for example by means of supports. Attached Figure Description

[0038] The following description, given by way of non-limiting example and with reference to the accompanying drawings, will enable one to understand the composition of the invention and how to implement it.

[0039] In the attached diagram:

[0040] Figure 1 This is a schematic cross-sectional view in the main plane of a rotor assembled according to the present invention, including permanent magnets;

[0041] Figure 2 yes Figure 1 A schematic perspective view of a single magnet of a rotor;

[0042] Figure 3 It is placed along a line. Figure 1 A schematic cross-sectional view of a single magnet;

[0043] Figure 4 yes Figure 1 A schematic cross-sectional view of the peripheral portion of a variant of the magnetic pole element of a rotor;

[0044] Figure 5 It is a block diagram of a series of steps according to the assembly method of the present invention, which enables the assembly of magnetic pole elements into a rotor;

[0045] Figure 6 It is used to form Figure 1 A schematic cross-sectional view of a modified magnet block of a single magnet;

[0046] Figure 7 schematically shown Figure 5 One step of the method, wherein the single magnet is composed of Figure 6Made of magnet blocks;

[0047] Figure 8 schematically shown Figure 5 One step in the method involves forming a row of single magnets;

[0048] Figure 9 schematically shown Figure 5 One step of the method, wherein a single magnet is inserted Figure 1 In the rotor housing;

[0049] Figure 10 schematically shown Figure 5 Another step in the method involves inserting a single magnet. Figure 1 In the rotor housing;

[0050] Figure 11 schematically shown Figure 5 One step in the method involves injecting a binding material;

[0051] Figure 12 This is a schematic cross-sectional view of a single magnet before compression; and

[0052] Figure 13 schematically shown Figure 5 One step in the method involves compressing a single magnet. Detailed Implementation

[0053] Figure 1 The image shows a rotor 1 for an axial-flow motor, which includes a body 10 and multiple magnetic pole elements 20.

[0054] The body 10 has the form of a single disk, and in this sense, it is essentially circumscribed in a cylinder revolving about an axis (hereinafter referred to as the axis of rotation A1). The body 10 extends in a principal plane P orthogonal to the axis of rotation. Here, the principal plane P is... Figure 1 The height of the body 10 (the dimension of the body around the rotation axis A1) is much smaller than its diameter. This height is called the thickness of the body 10. Therefore, the body 10 has two flat (flat) circular surfaces that are parallel to each other and parallel to the main plane P, and perpendicular to the rotation axis A1 of the rotor 1. Here, the main plane P is positioned equidistant from the two circular surfaces.

[0055] like Figure 1 As shown, the body 10 has a central recess adapted to receive a drive shaft extending along the axis of rotation A1. The rotor 1 is configured to be fixed to the drive shaft, which will be driven by the rotor.

[0056] The body 10 can be made of, for example, aluminum, steel, iron, titanium-based materials, or alloys containing these metals, all of which are antimagnetic. For instance, it can be made of a stack of thin metal sheets with a thickness of one millimeter or less. Here, these sheets are curved and radially stacked. They extend over the entire height of the body 10. However, the body 10 can also be made of a composite material reinforced with glass fiber or carbon fiber.

[0057] like Figure 1 As shown, the body 10 has a plurality of recessed seats 30. Here, the body 10 has ten identical seats 30. The seats 30 are regularly distributed around the axis of rotation A1 with a constant angular spacing. This ensures good balance of the rotor 1 during rotation.

[0058] Each housing 30 preferably extends over the entire thickness of the body 10. This has the advantage of providing two opposing working surfaces. Such a rotor 1 can therefore be constructed, for example, by two stators to provide more mechanical power.

[0059] like Figure 1 As shown, each container 30 has a predominantly trapezoidal shape, having two radially extending side edges 31, a circumferential edge 32, and an inner edge 33. Here, the two side edges 31 are straight.

[0060] Here, the circumferential edge 32 is curved. In the main plane P, the circumferential edge 32 defines an arc whose curvature radius is substantially equal to the curvature radius of the outer perimeter 11 of the body 10.

[0061] The inner edge 33 can be a straight line—such as Figure 1 As shown, it may be curved, for example, to fit the central recess of the body 10.

[0062] Overall, each magnetic pole element 20 has the same form (shape), which is the opposite of the form of the receiver 30 into which it is inserted. For example... Figure 1 and 2 As shown, each magnetic pole element 20 is therefore primarily trapezoidal in shape in this case. The thickness of each magnetic pole element 20 (the dimension about the axis of rotation A1) is substantially equal to the thickness of the body 10.

[0063] like Figure 1 As shown, each magnetic pole element 20 includes multiple individual magnets 21. The size of these individual magnets 21 is much smaller than the size of the magnetic pole element 20. Therefore, in this case, each magnetic pole element 20 includes dozens of individual magnets 21. In a variation, the magnetic pole element may include one hundred or hundreds of individual magnets.

[0064] Here, at least some individual magnets 21 have a cuboid shape and are placed side by side along a first line 41 and a second line 42, which are contained in the principal plane P and have an average non-zero curvature about the axis of rotation A1. For example, Figure 2 The image shows a single magnet 21.

[0065] like Figure 4 As shown, single magnets 21 placed along two adjacent lines 40 are separated by strips 50 of adhesive material. In this case, when the single magnets are placed close together, the two lines are adjacent, with one above the other. For example, in Figure 4 In this configuration, the first line 41 is adjacent to the second line 42. In this case, a line thus has one or two adjacent lines. This means that two consecutive rows of single magnets 21 relative to the axis of rotation A1 are separated by strips 50 of rigid adhesive material.

[0066] The adhesive material is typically a strip of glass or carbon fiber mesh covered with glue on one or both sides. The adhesive strip 50 is hereinafter referred to as the "adhesive strip".

[0067] like Figure 3 As shown, the fact that line 40 has a non-zero average curvature means that line 40 is not a straight line. The fact that the average curvature of line 40 about the axis of rotation A1 is not zero means that, in this case, line 40 has a concavity oriented towards the axis of rotation A1. In general, this means that line 40 is curved about the axis of rotation A1.

[0068] "Place along the line" means that at least a portion of the single magnet 21 is located on the line 40. In this case, as... Figure 3 As shown, the portion of the single magnet 21 located on line 40 is preferably the center C of the cross section S of the single magnet 21 in the main plane P.

[0069] The magnetic pole element 20 also includes a bonding material 22 that ensures adhesion between the individual magnets 21. In this example, the bonding material 22 covers the individual magnets 21. The bonding material 22 is, for example, a composite plastic resin, glue, or varnish.

[0070] Here, as Figure 1 As shown, all individual magnets 21 are cuboid in shape. Furthermore, all individual magnets 21 are distributed along several lines 40. Here, all lines 40 are contained within the principal plane P.

[0071] Furthermore, all individual magnets 21 are essentially identical. This facilitates their mass production. The term "essentially" means that a tolerance of 5% to 10% is allowed for differences in size and orientation between individual magnets, for example, by manufacturing individual magnets by dividing large magnet blocks, which is achieved by breaking or sawing.

[0072] The single magnets 21 placed side by side along line 40 form a row of single magnets 21. Therefore, for example, Figure 1 The magnetic pole element 20 includes thirteen rows of single magnets 21 arranged along thirteen lines 40. Figure 1 Only a portion of these lines are marked in the image.

[0073] like Figure 3 and 4 As shown, the placement of the single magnets 21 creates a free space 23. The free space 23 is primarily in the form of an irregularly shaped triangular prism parallel to the rotation axis A1. This free space 23 allows the bonding material 22 to better penetrate between the single magnets 21. The triangular prism shape provides a particularly strong cohesive force to the single magnets 21, resisting the centrifugal force during rotor 1 rotation, thanks to this improved penetration of the bonding material 22.

[0074] like Figure 2 As shown, the rectangular single magnet 21 has six equal faces (2×2), and the angles between the faces are all right angles. The single magnet 21 defines three mutually orthogonal directions U1, U2, and U3. Each direction U1, U2, and U3 is perpendicular to a pair of opposite sides.

[0075] like Figure 2 As shown, these individual magnets 21 extend in a principal direction U3 defined by their larger dimensions. For example, here, the individual magnets 21 extend along direction U3. In this case, the other two directions U1 and U2 are referred to as transverse directions U1 and U2. For example, in this case, the dimensions of these individual magnets 21 in the principal direction U3 are approximately twice the size in the transverse direction U1 and approximately four times the size in the other transverse direction U2. Here, the three directions U1, U2, and U3 define an orthogonal designation.

[0076] Here, the principal direction U3 of the single magnet 21 is oriented about the axis of rotation A1. This means that the lateral directions U1 and U2 are parallel to the principal plane P. The lateral directions U1 and U2 are, in this example, more specifically contained within the principal plane P. Here, the principal dimension U3 of the single magnet 21 is substantially equal to the thickness of the body 10. In this orientation, the single magnet 21 thus extends from one circular surface of the body 10 to another circular surface.

[0077] After the individual magnets 21 are placed in the bonding material 22, this orientation of the individual magnets 21 ensures increased stiffness of the magnetic pole elements 20 about the rotation axis A1. In fact, in this orientation, each individual magnet 21 is fixed by most of its surface, and additionally, along a surface parallel to the stress applied around the rotation axis. Due to this orientation, it is not necessary to clamp the rotor 1 between the fixed discs, which allows for a reduction in the air gap size and improved motor performance.

[0078] Furthermore, here, one of the two lateral directions U1, U2 is tangent to the line 40 along which the single magnet 21 is placed. This means that in this case, as... Figure 3 As shown, one of the two transverse directions U2 is orthogonal to line 40 at the center C of the cross section S of the single magnet 21. Therefore, the other transverse direction U1 is tangent to line 40 at the center C of the cross section S of the single magnet 21.

[0079] Here, the curvature of the outermost circumferential line is substantially equal to the curvature of the circumferential edge 32 of the reservoir 30. The curvature of the line 40 can be increased or decreased by approaching the axis of rotation A1. The curvature of the line closest to the inner edge 33 of the reservoir 30 can, for example, be substantially equal to the curvature of the inner edge. This curvature can, for example, correspond to the curvature of the central recess. The curvature of the line can also remain unchanged.

[0080] The single magnets 21, placed along the outermost circumference, are positioned against the circumferential edge 32 of the housing 30, except for the bonding material 22. Therefore, the row of single magnets 21 follows the non-linear form of the circumferential edge 32, which mainly limits the space loss.

[0081] Here, the curvature of 40 for each line is more specifically an arc.

[0082] like Figure 4 As shown, it can be envisioned that the adhesive strip is longer than a row of individual magnets 21. The individual magnets 21 located at the ends of each row are therefore at least partially separated from the side edges 31 by the adhesive strip.

[0083] The adhesive strip 50 comprises, for example, a glass fiber structure forming the strip, with both sides impregnated with adhesive. More generally, the adhesive strip in this case is a double-sided adhesive strip. The width of the adhesive strip along the main direction U3 is preferably less than the length of the single magnet 21 along the main direction U3. For example, it is at least 20% smaller than the length of the single magnet. This allows the bonding material 22 to adequately cover the single magnet 21, especially when the bonding material 22 hardly surrounds or passes through the adhesive strip. The rotor 1 is therefore more robust during its rotation. However, as Figure 12 and 13 As shown, an adhesive strip whose width is greater than the length of the single magnet along direction U3 can also be used. In this case, the adhesive strip is bent on the surface of the single magnet 21 at the circular surface of the body 10.

[0084] like Figure 8 As shown, the structure of the adhesive strips 50 forms a network that defines the pores 51. Figure 9 and 10As shown, the strip 50 of the adhesive material includes a raised portion 52 on one of its two sides. The pores 51 and the raised portion 52 allow the bonding material 22 to better penetrate between the individual magnets 21. To ensure good penetration of the bonding material 22, the thickness of the raised portion 52, and therefore the thickness of the strip 50 of the adhesive material, is between 1% and 15% of the dimension of the individual magnets 21 in the transverse direction U2.

[0085] Preferably, when the adhesive strip is bent on the surface of the single magnet 21 at the circular surface of the body 10, when the thickness of the adhesive strip is more than two meshes, the mesh of the adhesive strip allows the bonding material 22 to penetrate at least one mesh thickness.

[0086] Now, using Figures 5 to 13 A method for assembling such a magnetic pole element 20 is described.

[0087] Figure 5 A method for assembling magnetic pole elements 20 within a rotor 1 is shown. The method includes the following steps:

[0088] e1) Form a first row 91 consisting of at least two single magnets 21, and use a strip 50 of adhesive material to hold the single magnets 21 in the first row 91;

[0089] e2) Place the first row 91 on an assembly support whose curvature is equal to or substantially equal to the curvature of the circumferential edge 32 of the receptacle 30 about the axis of rotation A1, such that the single magnets of the first row 91 are placed along a first line 41 contained in the assembly plane and having a non-zero curvature.

[0090] e3) Form another row 92 consisting of at least two additional single magnets 21, and fix the single magnets 21 in the other row 92 using a strip 50 of another adhesive material;

[0091] e4) Place the other row 92 on the first row 91 such that the single magnets in the other row 92 are placed along another line 42 contained in the assembly plane and having a non-zero curvature;

[0092] e5) Repeat steps e3) and e4) until the magnetic pole element 20 is assembled.

[0093] Here, "placed on" means that one row is positioned to contact or abut against the assembly support or another row. For example, another row 92 is positioned to contact the adhesive strip of the first row 91.

[0094] Here, in step e5), during the repetition of steps e3) and e4), each new row is placed on top of the previous row, which is the row placed in the previous step e4). Thus, for example, the third row is placed on top of the second row and therefore does not contact the first row. Thus, the other rows are stacked on top of the first row, and then stacked one on top of the other. Advantageously, the adhesive strip thus enables the different rows to remain abutting against each other.

[0095] In one embodiment (not shown in the figure), the assembly support is a different part from the body 10. Therefore, the assembly of the magnetic pole element 20 is performed outside the housing 30. In step e5), the magnetic pole element 20 is thus inserted into the housing 30.

[0096] The assembly support is therefore designed such that the curvature of the surface on which the first row 91 rests is equal to or substantially equal to the curvature of the circumferential edge 32 of the reservoir 30. "Substantially equal to" means equal to with a tolerance of 0 to 5%, that is, here equal to the curvature of the circumferential edge 32 of the reservoir 30 with a maximum tolerance of approximately 5%. The surface of the assembly support on which the first row 91 rests thus has a form similar to the circumferential edge of the reservoir 30.

[0097] Here, the assembly plane is orthogonal to the surface on which the first row 91 is placed on the assembly support. The lines along which each row is placed are contained within this assembly plane.

[0098] Here, in step e5), the magnetic pole element 20 is inserted such that the assembly plane is parallel to or coupled to the main plane P.

[0099] Optionally, before the insertion into the reservoir, a step of straightening the edges of each magnet row is performed so that the pole elements have side edges corresponding to the side edges of the reservoir. This allows for the production of pole elements that uniformly and optimally fill the reservoir. The straightening step is performed using, for example, a water saw or a circular saw. Here, the straightening step is therefore a machining step.

[0100] Figures 6 to 13 One embodiment is shown in which the support belongs to the housing 30, such that the assembly of the magnetic pole element 20 takes place within the housing 30. Therefore, the assembly plane is parallel to or fused with the principal plane P.

[0101] In this case, the assembly support is more specifically the circumferential edge 32.

[0102] therefore, Figures 6 to 13 The assembly method shown includes the following steps:

[0103] e1) Form a first row 91 consisting of at least two cuboid-shaped single magnets 21, and fix the single magnets 21 in the row using adhesive strips;

[0104] e2) Insert the first row 91 into the container 30 at the periphery of the container 30, such that the single magnet 21 in the first row 91 is placed along the first line 41 contained in the principal plane P and having a non-zero curvature about the axis of rotation A1.

[0105] e3) Form another row 92 consisting of at least two additional cuboid-shaped single magnets 21, and fix the single magnets in the other row 92 with another adhesive strip;

[0106] e4) Insert the other row 92 into the housing 30 at the free portion 34, such that the single magnet 21 in the other row 92 is placed along another line 42 contained in the principal plane P and having a non-zero curvature about the axis of rotation A1;

[0107] e5) Repeat steps e3) and e4) until the magnetic pole element 20 is assembled.

[0108] Here, the single magnet 21 is obtained in advance in step e0) by dividing or breaking the magnet block 60. Figure 6 As shown, the magnet block has grooves 61 that facilitate breaking it apart or dividing it into individual magnets 21. In the individual magnets 21... Figure 9 When arranged in rows, these grooves will increase the size of the free space 23, which will subsequently facilitate the penetration of the bonding material.

[0109] like Figure 7 As shown, the three single magnets 21 obtained by this method thus have a substantially cuboid form, having two side grooves 62 extending along the main direction U3. In the transverse directions U1, U2, the size of the side grooves is here less than 10% of the side length of the single magnet 21. Therefore, the single magnet 21 is subsequently described as having a cuboid form.

[0110] Step e1) in Figure 8 As shown in [the image]. Figure 8 In the first row 91, five identical single magnets 21 are placed side by side. Here, the row of single magnets 21 is in a straight line.

[0111] like Figure 8 As shown, it is also conceivable that the individual magnets 21 are connected together using the adhesive strips described above. The adhesive strips make it easy to manipulate the row of individual magnets 21, especially during step e2). During step e1), the adhesive strips are positioned, for example, on the individual magnets 21 aligned on the planar support.

[0112] like Figure 9 As shown, the single magnet 21 of the first row 91 is inserted into the container 30 at the periphery of the container 30—that is, against the circumferential edge 32 of the container 30.

[0113] The number of single magnets 21 placed on each other's sides in step e1) is determined by the length of the circumferential edge 32. This number is preferably determined to be the number of single magnets 21 placed along the circumferential edge 32.

[0114] A single magnet 21 is inserted such that the first line 41 is contained within the main plane P. This is, for example, when a single magnet 21, whose maximum size is substantially equal to the thickness of the body 10, extends from one circular surface to another. In other words, the row of single magnets 21 is centered in the housing 30 about the axis of rotation A1.

[0115] Since the single magnets 21 in the first row 91 are arranged against the circumferential edge 32, the first line 41 naturally has a non-zero curvature about the axis of rotation A1. Here, the curvature of the first line 41 is essentially equal to the curvature of the circumferential edge 32. The curvature of the first line 41 more specifically depicts an arc.

[0116] Because of the adhesive strip, and therefore because of the manipulation of the rows of individual magnets, no special tools are needed, nor is it necessary to position the individual magnets 21 one by one in the container 30. This facilitates their positioning and saves time.

[0117] In step e3), at least two additional single magnets 21 in the form of cuboids are placed to form a second row 92. Here, the additional single magnets 21 are the same as the single magnets 21 in the first row 91.

[0118] As for the first row 91, it is also conceivable to use adhesive strips to connect the other single magnets 21 together.

[0119] Here, the first iteration of step e3) is described, during which the single magnets 21 of the second row 92 are placed along the second line 42.

[0120] In step e4), another single magnet 21 is inserted into the receiver 30 at the free portion 34. Figure 9 As shown, for the second row 92, the free portion 34 is defined by the first row 91. Here, the free portion 34 is defined by the surface of the single magnet 21 in the first row 91, located opposite the circumferential edge 32. Here, the free portion 34 is partially covered using adhesive strips. Therefore, the two rows of single magnets can be easily stacked without specific tools. Here, each row is positioned such that the formed magnetic pole element has a plane of symmetry including the axis of rotation A1.

[0121] like Figure 10 As shown, during the successive iterations of steps e3) and e4), the free portion 34 is defined by the surface of the single magnet 21 in the preceding row opposite the circumferential edge 32.

[0122] In step e4), the additional single magnet 21 is inserted such that another line—for example, a second line 42 in this case—is contained in the principal plane P and has a non-zero curvature about the axis of rotation A1. Here, the curvature of the line is non-zero because the single magnet 21 is arranged against the previous row.

[0123] Here, when the second row 92 is inserted into the receiver 30, the adhesive strip allows the second row 92 to be secured to the first row 91. Generally, the adhesive strip allows the row inserted at the previous row to be secured.

[0124] Here, the number of single magnets 21 placed along the second line 42 is less than or equal to the number of single magnets 21 placed along the first line 41. For example, in Figure 10 In the second row 92, there are four single magnets 21. Generally, the number of single magnets in a line is less than or equal to the number of single magnets in the previous row. In a variation, the number of single magnets can be greater than the number in the previous row.

[0125] For the second row 92 and subsequent rows, the number of single magnets 21 placed to each other's sides in step e3) is determined by the length of the free portion 34. This number is preferably determined to be the maximum number of single magnets 21 placed along the free portion 34.

[0126] Then repeat steps e3) and e4) until the reservoir 30 is filled with the most single magnets 21.

[0127] Regardless of the embodiment, the method herein includes step e6 of compressing the magnetic pole element 20 in the main plane P and toward the periphery of the receptacle 30 (i.e., toward the circumferential edge 32) — i.e., compressing all the single magnets 21 inserted into the receptacle 30.

[0128] Step e6) can, for example, save a considerable amount of space for inserting additional rows against the inner edge 33 of the container 30.

[0129] The method also includes step e7, which involves securing the magnetic pole element 20 in the housing 30 by one of the following methods: thermal curing of an adhesive, paint, or filler material. During this step e7), a bonding material 22, such as glue, varnish, or a material requiring curing, is thus injected around the single magnet 21. Figure 11 As shown, during step e7), in this example, the bonding material 22 is injected into the reservoir 30 using a syringe 70 located in the central recess of the body 10. The bonding material 22 is thus injected through the inner edge 33 of the reservoir 30. This injection method ensures a dimensional chain. As described above, the penetration of the bonding material 22 between the individual magnets 21 is facilitated by the free space 23 between the individual magnets 21, and in this case, also by the structure of the adhesive strip.

[0130] Here, step e6) is performed during step e7). Step e6) of compressing the magnetic pole element 20 is more specifically performed during the hardening of the bonding material 22. These steps are... Figure 12 and 13 As shown in the figure, Figure 12 and 13 The rotor 1 is shown in a cross-section along the axis of rotation A1 containing the rotor.

[0131] like Figure 12 As shown, the composite flange 80, placed on either side of the body 10, clamps the single magnet 21 in the middle in a longitudinal direction parallel to the rotation axis A1. The bonding material 22 is thus injected between and around the single magnets 21. Figure 13 As shown, two pressing elements 81 are then forcibly inserted into either side of the rotor 1 between the magnetic pole element 20 and the body 10 in the longitudinal direction. Here, the pressing elements are inserted between the single magnet and the inner edge 33 of the housing 30. The single magnet 21 is thus pressed against the circumferential edge 32 of the housing 30. The bonding material 22 thus hardens as the single magnet 21 is compressed.

[0132] In one variation, it can be envisioned that single magnets are coated with a bonding material to form magnetic pole elements, and then placed in a housing and pressed together, for example, by supports.

[0133] The present invention is not limited to the embodiments described and shown, and those skilled in the art will know how to provide any variations according to the invention.

Claims

1. A method for assembling a magnetic pole element (20) for a rotor (1) of an axial current motor, the rotor (1) comprising a body (10) in the form of a disk centered on a rotation axis (A1) and extending in a main plane (P), the body (10) having at least one housing (30), the magnetic pole element (20) comprising a plurality of single magnets (21), the method comprising the steps of: e1) Form a first row (91) consisting of at least two single magnets (21) and hold the single magnets (21) in the first row (91) using a strip (50) of adhesive material. e2) The first row (91) is placed on an assembly support having a curvature that is equal to or substantially equal to the curvature of the circumferential edge (32) of the housing (30) about the axis of rotation (A1), such that the single magnets (21) in the first row (91) are placed along a first line (41) which is contained in the assembly plane and has a non-zero curvature. e3) Form another row (92) consisting of at least two additional single magnets (21) and hold the single magnets (21) in the other row (92) using a strip (50) of another adhesive material. e4) Place the other row (92) on the first row (91) such that the single magnet (21) in the other row (92) is placed along another line (42) which is contained in the assembly plane and has a non-zero curvature; e5) Repeat steps e3) and e4) until the magnetic pole element (20) is assembled.

2. The method of claim 1, wherein, The assembly support is a part different from the body (10), and in step e5), the magnetic pole element (20) is inserted into the housing (30).

3. The method of claim 2, wherein, In step e5), the magnetic pole element (20) is inserted such that the assembly plane is parallel to or coupled to the main plane (P).

4. The method of any one of claims 2-3, wherein, The step of straightening the side edges of the magnetic pole element (20) is performed before inserting the magnetic pole element (20) into the housing (30).

5. The method of claim 1, wherein, The assembly support belongs to the housing (30), and the assembly plane is parallel to or connected to the main plane (P).

6. The method according to any one of claims 1 to 3, comprising the following steps: e6) Compress the magnetic pole element (20) within the main plane (P) and toward the circumferential edge (32) of the housing (30).

7. The method according to any one of claims 1 to 3, comprising the following steps: e7) The magnetic pole element (20) is fixed in the housing (30) by injecting a bonding material (22) coated with the single magnet (21).

8. The method according to any one of claims 1 to 3, comprising a previous step of producing the single magnets (21) by dividing a magnet block (60) into substantially identical cuboid-form single magnets (21) extending in their largest dimension along a main direction (U3) and in another dimension along a transverse direction (Ul) perpendicular to the main direction (U3).

9. The method of claim 8, wherein, The pole elements (20) are placed or inserted into the receptacles (30) so that the main direction (U3) of the single magnets (21) is oriented around the rotation axis (Al) and the transverse direction (Ul) is oriented tangentially to the first or the other line (41, 42).

10. The method of claim 8, wherein, The width of the strip (50) of adhesive material is less than the length of the single magnets (21) along the main direction (U3).

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