Systems for lamination layers of a rotor

Abstract

System, comprehensive: Electric motor with a rotor having alternating layers, wherein several first layers have a magnetic material and a plurality of second layers have the magnetic material and a non-magnetic material embedded in each of the several second layers.

Description

REFERENCE TO RELATED REGISTRATIONS

[0001] The present application claims priority from U.S. Preliminary Application No. 63 / 665,578 entitled “SYSTEMS FOR LAMINATION LAYERS OF A ROTOR”, which was filed on June 28, 2024. The entire content of the aforementioned application is hereby incorporated by reference for all purposes. TECHNICAL AREA

[0002] The present description refers generally to an electric motor and in particular to the positions of a rotor of the electric motor. BACKGROUND AND DETOUR

[0003] A rotating electric machine can operate in a motor mode, in which power is delivered to a coupled load, such as one or more wheels or other moving components of a vehicle, or in a torque-generating mode, in which the machine's rotation is used to generate electricity. The electric machine may include a cylindrical rotor with a stack of magnetic rotor layers. The rotor can rotate with a rotor shaft when the windings of a stator are energized by a power supply, which may include an energy storage device, such as a battery.

[0004] Due to the high rotational speeds, the rotors may be equipped with structural reinforcements. However, in some cases, these structural reinforcements can impair the functionality of an air gap in the rotor's lamination stack, potentially leading to a loss of electromagnetic power from the electric machine. Therefore, there may be a need for rotor systems other than those currently available.

[0005] The problems described above can be addressed by an electric motor comprising a rotor, wherein the rotor comprises alternating layers, wherein a plurality of first layers comprise a magnetic material and a plurality of second layers comprise the magnetic material and a non-magnetic material embedded in each of the plurality of second layers.

[0006] It should be noted that the above summary serves to present a selection of concepts in simplified form, which are further explained in the detailed description. It does not serve to identify essential features of the claimed subject matter, the scope of which is clearly defined by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to implementations that overcome all the disadvantages mentioned above or in any part of this disclosure. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows an example of a vehicle system; Fig. Figure 2 shows one pole of a rotor with a plurality of poles; Fig. 3A shows a variety of rotor positions; Fig. 3B shows a single pole of the rotor, separated from other positions of the rotor; Fig. Figure 4 shows a first example of a support material arranged in a hybrid layer of the rotor; Fig. Figure 5 shows a second example of the first support material arranged in the hybrid layer of the rotor, or of a second support material arranged on a surface of the rotor; Fig. Figure 6 shows a third example of the first support material arranged in the hybrid layer of the rotor, or of the second support material arranged on the surface of the rotor; Fig. 7 shows an alternative to the first example, which additionally includes a heat management device integrated into the carrier material; Fig. Figure 8 shows a fourth example of a first support material arranged in the position of the rotor; Fig. Figure 9 shows a fifth example of a first support material and a second support material arranged in the position of the rotor; and The Fig. 10A and Fig. Figure 10B shows a second example of an adhesive joint between hybrid and electromagnetic layers of the rotor. DETAILED DESCRIPTION

[0007] The following description relates to systems for an electric motor rotor. The rotor incorporates structural reinforcement in the form of a skeleton structure. The skeleton structure can utilize a high-strength material that supports the magnets and the electromagnetic material (e.g., laminated steel) within the rotor. The rotor can comprise alternating layers of solid electromagnetic material (e.g., laminated steel) and layers of hybrid material. The hybrid material layers can incorporate the high-strength skeleton structure in combination with the electromagnetic material component. The embodiments of the disclosure can position the electromagnetic material where it is desired for efficient rotor operation, while the rotor is reinforced at other locations with non-magnetic material and / or composite materials. The rotor is described in more detail below.

[0008] Fig. Figure 1 shows an example of a vehicle system. Fig. Figure 2 shows one pole of a rotor with a multitude of poles. Fig. Figure 3A shows a variety of rotor positions. Fig. Figure 3B shows a single pole of the rotor, separated from other layers of the rotor. Fig. Figure 4 shows a first example of a support material arranged in a layer of the rotor. Fig. Figure 5 shows a second example of the first support material arranged in the hybrid layer of the rotor, or of a second support material arranged on a surface of the rotor. Fig. Figure 6 shows a third example of the first support material, which is arranged in the hybrid layer of the rotor, and of the second support material, which is arranged on the surface of the rotor. Fig. Figure 7 shows an alternative to the first example, which additionally includes a heat management device integrated into the carrier material. Fig. Figure 8 shows a fourth example of a first support material arranged in the hybrid layer of the rotor. Fig. Figure 9 shows a fifth example of a first support material and a second support material arranged in the position of the rotor. Fig. 10A and Fig. Figure 10B shows an example of an adhesive joint between the hybrid and electromagnetic layers of the rotor.

[0009] Fig. Figure 1 shows a schematic diagram of a vehicle 6 with a drive train 8, which may include a drive motor 54 and a transmission 60. The vehicle 6 may be a passenger car, a commercial vehicle, a heavy-duty vehicle, an all-terrain vehicle, an agricultural vehicle, an aircraft, a boat, or another vehicle system.

[0010] The drive motor 54 can be electrically connected to an energy storage device 58 (e.g., one or more traction batteries, capacitors, fuel cells, combinations thereof, and the like). Furthermore, the drive motor 54 can be configured to operate as a generator under certain conditions, for example, to supply electrical energy for charging the energy storage device 58.

[0011] In one example, the drive machine 54 is an electric machine 54. The electric machine 54 can comprise a stator 51 surrounding a rotor 52. The stator 51 can be supplied with current by the energy storage device 58, which generates an electromagnetic field and sets the rotor 52 in rotation. A shaft can rotate together with the rotor 52 and transmit the power of the electric machine 54 to a gear of the transmission 60.

[0012] In some examples, the vehicle 6 may contain an internal combustion engine (ICE) configured to operate in combination with or independently of the propulsion engine 54. In this way, the vehicle 6 may be configured as a hybrid vehicle in some examples.

[0013] In the illustrated example, the transmission 60 supplies mechanical power to a differential 62 of an axle assembly 53. It is understood, however, that the transmission 60 can additionally or alternatively supply mechanical power to the other axle 64 in the vehicle 6. In other examples, the transmission may be integrated into one of the axles to form an electric axle assembly. In the electric axle example, in some cases an internal combustion engine may supply mechanical power to the other axle. The axle assembly 53 may include a lubrication system, which is described in more detail below.

[0014] The transmission 60 (e.g., a manual transmission) can be configured to receive torque from the drive motor 54 via a shaft (e.g., a drive shaft) and / or other suitable mechanical components. The transmission 60 can transmit torque to the differential 62. The transmitted torque can be moderated based on selective adjustments of a gear engagement on the transmission 60 to achieve a desired vehicle operation. The torque of the transmission 60 can cause the differential 62 to rotate, which in turn drives the axle shafts 66 that are rotationally fixed to the vehicle wheels 55. The vehicle wheels 56 can rotate when the vehicle wheels 55 are in contact with a surface.

[0015] A controller 112 can form part of a control system 114. As shown, the control system 114 receives information from sensors 116 and sends control signals to actuators 181. The sensors 116 can include, for example, a battery level sensor, a clutch activation sensor, one or more position sensors of the electric motor, etc. The controller 112 can receive input data from the sensors, process the input data via a processor, and trigger the actuators in response to the processed input data based on instructions or codes programmed into it, corresponding to one or more routines.

[0016] Fig. Figure 2 shows an embodiment 200 of a section of the rotor 52. Therefore, the components introduced previously are numbered similarly in this and the following figures. The section shown in embodiment 200 can be taken along a plane perpendicular to an axis in which the rotor 52 rotates and comprises a plurality of alternating layers 210. The plurality of alternating layers 210 can form a rotor body of the rotor 52 and can be configured to rotate in response to an electromagnetic field generated by a stator (e.g., stator 51 of Fig. 1) is generated. In one example, the rotor has a cylindrical shape.

[0017] An axis system 290 is shown, comprising an x-axis, a y-axis perpendicular to the x-axis, and a z-axis perpendicular to each of the x- and y-axes. In one example, the x-axis is parallel to a transverse direction, the y-axis is parallel to a vertical direction, and the z-axis is parallel to an axial direction. The rotor 52 can rotate about an axis parallel to the z-axis, and the section can be recorded along a plane parallel to the xy-plane.

[0018] The multitude of alternating layers 210 can comprise a first layer 212 and a second layer 214, which alternate with each other. In one example, the first layer 212 is an electromagnetic layer and the second layer 214 is a hybrid layer. Here, the first layer 212 is interchangeably referred to as the electromagnetic layer 212 and the second layer 214 is interchangeably referred to as the hybrid layer 214.

[0019] The electromagnetic layer 212 can comprise an electromagnetic material. In one example, the electromagnetic material can be laminated steel. The hybrid layer 214 can contain a support element 216 and the electromagnetic material, e.g., the laminated steel. In one example, the support element 216 extends only within one plane of the hybrid layer 214. The support element 216 can be integrally arranged within the hybrid layer 214 and be in planar contact with adjacent layers of the electromagnetic layer 212. The support element 216 can be embedded in the hybrid layer 214 and extend in a radial direction. In one example, the hybrid layer 214 can be identical to the electromagnetic layer 212, except for the inclusion of the support element 216. The support element 216 is described in more detail below.

[0020] The electromagnetic layer 212 and the hybrid layer 214 can alternate with each other. The electromagnetic layer 212 and the hybrid layer 214 can alternate in the axial direction.

[0021] Thus, each iteration of the electromagnetic layer 212 is in planar contact with the hybrid layer 214 and does not touch any other iteration of the electromagnetic layer 212. Similarly, each iteration of the hybrid layer 214 is in planar contact with the electromagnetic layer 212 and does not touch any other iteration of the hybrid layer 214. In this way, the two layers are nested within each other. The orientation of each layer of the electromagnetic layer 212 and the hybrid layer 214 can be identical, with each layer extending radially, perpendicular to the axial direction. In one example, the layers are uniform in the radial direction and alternate only in the axial direction.

[0022] The electromagnetic layer 212 and the hybrid layer 214 can contain one or more recesses in which a plurality of magnets 218 can be arranged. The plurality of magnets 218 can be configured to respond to the electromagnetic field generated by the stator and to cause the rotor 52 to rotate. The plurality of magnets 218 is arranged in Fig. 3B is described in more detail. It becomes clear that the support element and the alternating hybrid and magnetic layers can be used in various rotor and motor topologies and are not limited to the use of magnetic materials.

[0023] Fig. Figure 3A shows a side view 300 of the plurality of alternating layers 210. As shown in the figure, adjacent layers are in planar contact with each other. Each individual layer of the electromagnetic layer 212 or the hybrid layer 214 extends in the axial direction without interruption by the other layer.

[0024] The Fig. 10A and Fig. Figure 10B shows an example of a location where adhesive is used to bond adjacent layers from a plurality of alternating layers 210. In this example, a first plurality of adhesives 1058 can be arranged on the hybrid layer 214. The first plurality of adhesives 1058 can be shaped to match a shape of the hybrid layer 214. Thus, each of the first plurality of adhesives 1058 can cover the hybrid layer 214 and at least part of its support element 216. In one example, sections of the support element 216 located between recesses in the hybrid layer 214 can be left uncoated with an adhesive from the first plurality of adhesives 1058.

[0025] A second array of adhesives 1078 can be arranged on the electromagnetic layer 212. The second array of adhesives 1078 can be shaped to match a shape of the electromagnetic layer 212. Thus, each of the second array of adhesives 1078 can cover the electromagnetic layer 212. The array of magnets 218 and the recesses of the electromagnetic layer 212 must not be covered by the second array of adhesives. When the electromagnetic layer 212 is aligned with and pressed against the hybrid layer 214, the first array of adhesives 1058 and the second array of adhesives 1078 can physically bond to each other. In some examples, the array of alternating layers 210 can be bonded to each other additionally or alternatively.

[0026] In this way, the first variety of adhesives 1058 and the second variety of adhesives 1078 can be arranged on surfaces of the electromagnetic layer 212 and the hybrid layer 214, respectively, parallel to the radial direction. When the surfaces of the electromagnetic layer 212 and the hybrid layer 214 are pressed together, a seal can be formed, and the adhesives can create a permanent bond that prevents separation of the two layers. There must be no other connections or closures holding the two layers together. Thus, the first variety of adhesives 1058 and the second variety of adhesives 1078 are the only connecting elements that join the electromagnetic layer 212 to the hybrid layer 214.

[0027] Fig. Figure 3B shows an embodiment 350 of a single position (e.g., of a single pole) of the rotor (e.g., of the rotor 52 of Fig. 1) In an example, a single layer of the electromagnetic layer 212 is shown from the front, parallel to the axial direction of the rotor. The electromagnetic layer 212 can comprise a first body 352, a second body 372, and a third body 382. The support element 216 is free through an air gap between the first body 352 and the second body 372, as well as between the second body 372 and the third body 382. The support element 216 can be arranged in a plane parallel to or outside a plane of the electromagnetic layer 212. Thus, the support element 216 lies parallel to the electromagnetic layer 212. In this way, the Fig. 3B shows the support element 216 in an adjacent hybrid layer, which is in planar contact with the one in Fig. The electromagnetic layer 212 shown in Figure 3B is located there. The support element 216 is not contained in the electromagnetic layer 212.

[0028] The first body 352 can be separated from the second body 372 by a first air gap 362. The second body 372 can be separated from the third body 382 by a second air gap 364. In this way, the electromagnetic layer 212 can comprise three different parts separated from each other by the air gaps.

[0029] The first body 352 can have a C-shape with prongs 358 and 359 at its outermost ends. That is, the first body 352 can have two spaced-apart outermost ends connected by arms 356, 357 extending from a curved body 354. The width of the arms 356, 357 can increase away from the outermost ends. The outermost ends can have prongs 358 and 359 pointing towards the second body 372. The shape of the first body 352 is described in more detail below.

[0030] The second body 372 can have a V-shape with points 378, 379 at its outermost ends. That is, the second body 372 can have two spaced-apart outer ends connected by arms 376, 377 extending from a central body 374. The width of the arms 376, 377 can increase away from the outermost ends. The outermost ends can have points 378, 379 pointing towards the third body 382.

[0031] The third body 382 can have a curved trapezoidal shape. The curved trapezoidal shape can comprise a straight top 383, a straight first angled side 384, and a straight second angled side 385, the angled sides being connected to a curved base 386 at separate curved edges. The curved base 386 can point in a direction away from the second body 372. Thus, the straight top 383 can point towards the second body 372 and be closer to the second body 372 than the curved base.

[0032] The array of magnets 218 can be arranged within the first air gap 362 and the second air gap 364. The array of magnets 218 in the first air gap 362 can be identical in shape and size to the array of magnets 218 in the second air gap 364. Additionally or alternatively, the array of magnets 218 in the first air gap 362 can have a different shape, size, and / or orientation than the array of magnets 218 in the second air gap 364. As shown, the array of magnets 218 does not obstruct the view of the support element 216 along the z-axis.

[0033] Fig. Figure 4 shows a first example of a hybrid layer 400. The hybrid layer 400 can be identical to the hybrid layer 214 of Fig. 2. The hybrid layer 400 can comprise a multitude of bodies connected to each other via a support element 430. The support element 430 can be identical to the support element 216 made of Fig. 2 be.

[0034] The set of bodies can comprise a first pair, a second pair, and a third pair. The first pair can include a first body 402A and a second body 402B. The second pair can include a third body 412A and a fourth body 412B. The third pair can include a fifth body 422A and a sixth body 422B. Each body in a pair can be a reflection of the other. For example, the first body 402A is a reflection of the second body 402B. The third body 412A is a mirror image of the fourth body 412B. The fifth body 422A is a mirror image of the sixth body 422B.

[0035] The first body 402A can have a first side 403A, a second side 404A, a third side 405A, a fourth side 406A, a fifth side 407A, and a sixth side 408A. The first side 403A can be angled towards the sixth side 408A and the second side 404A. The second side 404A can be curved and extend from the first side 403A to the third side 405A. The third side 405A can be linear and extend to the fourth side 406A. In one example, the third side 405A is the largest side of the first body 402A. The fourth side 406A can be essentially perpendicular to the third side 405A and extend to the fifth side 407A. The fifth side 407A and the fourth side 406A can form a prong of the first body 402A. The sixth side 408A extends from the fifth side 407A to the first side 403A. The sixth side 408A is approximately perpendicular to the fifth side 407A and obtusely angled to the first side 403A.

[0036] The second body 402B can comprise a first side 403B, a second side 404B, a third side 405B, a fourth side 406B, a fifth side 407B, and a sixth side 408B. The first side 403B, the second side 404B, the third side 405B, the fourth side 406B, the fifth side 407B, and the sixth side 408B are identical to, and can reflect, the first side 403A, the second side 404A, the third side 405A, the fourth side 406A, the fifth side 407A, and the sixth side 408A, respectively, of the first body 402A.

[0037] The support element 430 can be physically connected to the first side 403A of the first body 402A and the first side 403B of the second body 402B at a first section 431. The first section 431 can have a first side 431A in planar contact with the first side 403A and a second side 431B in planar contact with the first side 403B. A curved base 431C can extend between the first side 431A and the second side 431B and correspond to a curvature of the second side 404A and the second side 404B.

[0038] A first air gap 442 can be arranged between the first body 402A and the third body 412A. A second air gap 444 can be arranged between the second body 402B and the fourth body 412B. A second section 432 of the support element 430 can be located next to the first air gap 442 and the second air gap 444. The second section 432 can have a narrower width than the first section 431, measured along the x-axis. The second section 432 can comprise a first side 432A and a second side 432B. The first side 432A and the second side 432B can have a J-shape. That is, the first side 432A and the second side 432B can have a curved shape, for example, a concave shape, which can increase the first air gap 442 and the second air gap 444.The first side 432A can extend from the first side 431A of the first section 431 to a first side 433A of a third section 433 of the support element 430. The second side 432B can extend from the second side 431B of the first section 431 to a second side 433B of the third section 433.

[0039] The first side 433A of the third section 433 can be in planar contact with a first side 413A of the third body 412A. A second side 414A can extend from the first side 413A at an angle less than perpendicular. The first side 413A and the second side 414A can each be linear, with one length of the second side 414A being greater than one length of the first side 413A. A third side 415A can extend from the second side 414A at an angle less than perpendicular. The third side 415A can meet a fourth side 416A at an acute angle, forming a prong of the third body 412A. The prong of the third body 412A can point in a similar direction to the prong of the first body 402A, both pointing toward the fifth body 422A.

[0040] A fifth side 417A can extend from the fourth side 416A at a substantially perpendicular angle and connect with the first side 413A at an angle greater than perpendicular. The fourth body 412B can comprise a first side 413B, a second side 414B, a third side 415B, a fourth side 416B, and a fifth side 417B, which are identical to and mirror the first side 413A, the second side 414A, the third side 415A, the fourth side 416A, and the fifth side 417A, respectively. The first side 413B of the fourth body 412B can be in planar contact with the second side 433B of the third section 433.

[0041] A third air gap 446 can be arranged between the third body 412A and the fifth body 422A. A fourth air gap 448 can be arranged between the fourth body 412B and the sixth body 422B. A fourth section 434 of the support element 430 can be located next to the third air gap 446 and the fourth air gap 448. The fourth section 434 can have a smaller width than the first section 431 and the third section 433. The width of the third section 433 can be smaller than the width of the first section 431.

[0042] The fourth section 434 can comprise a first side 434A and a second side 434B. The first side 434A and the second side 434B can have a J-shape. That is, the first side 434A and the second side 434B can have a curved shape, for example, a concave shape, which can enlarge the third air gap 446 and the fourth air gap 448. The first side 434A can extend from the first side 433A of the third section 433 to a first side 435A of a fifth section 435 of the support element 430. The second side 434B can extend from the second side 433B of the third section 433 to a second side 435B of the fifth section 435. A third side 435C can extend in a straight line from the first side 435A to the second side 435B. The width of the fifth section 435 can be greater than the width of the fourth section 434 and the second section 432.The width of the fifth section 435 may be less than that of the third section 433 and the first section 431.

[0043] The first side 435A can be in planar contact with a first side 423A of the fifth body 422A. A second side 424A can extend at an acute angle to the first side 423A. A third side 425A can extend at an acute angle from the second side 424A and at a right angle from the first side 423A. The third side 425A can be curved. The first side 423A and the second side 424A can be straight. The sixth body 422B can have a first side 423B, a second side 424B, and a third side 425B that are identical to and mirror the first side 423A, the second side 424B, and the third side 425B of the fifth body 422A, respectively.

[0044] The support element 430 can be located in the center of the hybrid layer 400. Thus, the support element 430 can be positioned distal to the outer surfaces of the bodies, such as the third side 405A, the third side 405B, the fourth side 406A, the fourth side 406B, the third side 415A, and the third side 415B. The support element 430 and the hybrid layer 400 can form a single, continuous piece. The non-magnetic material (e.g., the support element 430) has a symmetrical shape with a reduced width near the air gaps of the plurality of second layers. In some examples, the width can be greater. For clarity, the third side 405A and the third side 405B are represented as edges in this application. The third sides 405A and 405B can be repeated cyclically to form a 360-degree rotor.

[0045] Fig. Figure 5 shows a second example 500 for the hybrid position 400. The second example 500 can differ from the first example of Fig. 4. The second example 500 also includes a second support element 532 and a third support element 534, which are arranged along an outer part and / or circumference of the hybrid layer 400. In an example such as the second example 500, the support element 430 is a first support element. The second support element 532 can be connected to the fourth side 406A of the first body 402A, the third side 415A of the third body 412A, and the third side 425A of the fifth body 422A. Fig. 4. The third support element 534 can be connected to the fourth side 406B of the second body 402B, the third side 415B of the fourth body 412B, and the third side 425B of the sixth body 422B of Fig. 4 must be connected. The second support element 532 and the third support element 534 must not touch the support element 430.

[0046] The support element 430, the second support element 532, and the third support element 534 can contain identical materials, for example, a carbon fiber composite. Additionally or alternatively, the support element 430, the second support element 532, and the third support element 534 can contain a different non-magnetic material designed to impart desired stiffness and strength to the hybrid layer 400. In one example, one or more of the support elements 430, the second support element 532, and the third support element 534 can contain a mixture or layers of a rigid material, such as the carbon fiber composite, together with a thermally conductive material, such as graphite. In this way, cooling and / or heating can be achieved via a section of the support element 430, the second support element 532, and / or the third support element 534.

[0047] Fig. Figure 6 shows a third example 600 for the hybrid position 400. The third example 600 can be derived from the first example. Fig. 4 and the second example 500 from Fig. 5. The third example 600 differs in that it includes a second support element 630. The second support element 630 can be connected to the fourth side 406A of the first body 402A, the third side 415A of the third body 412A, the third side 425A of the fifth body 422A, the fourth side 406B of the second body 402B, the third side 415B of the fourth body 412B, the third side 425B of the sixth body 422B, and the third side 435C of the fifth section 435 of the support element 430. The second support element 630 can be in planar contact with the support element 430. In one example, the second support element 630 can encircle the entire rotor.

[0048] The support element 430 and the second support element 630 can contain identical materials, such as a carbon fiber composite. Additionally or alternatively, the support element 430 and the second support element 630 can contain a different non-magnetic material designed to impart a desired stiffness to the hybrid layer 400.

[0049] Fig. Figure 7 shows a fourth example 700 for the hybrid position 400. The fourth example 700 can differ from the first to third examples in the Fig. 4, Fig. 5 to Fig. Example 6 differs in that the fourth example 700 contains a heat transfer element 730 embedded in the support element 430. The heat transfer element 730 may include a conduit for conveying a fluid. Additionally or alternatively, the heat transfer element 730 may contain thermally conductive materials. In this way, cooling and / or heating can be performed via a section of the support element 430, which can improve the temperature control of the rotor.

[0050] Fig. Figure 8 shows a fifth example 800 of a hybrid layer 810. The hybrid layer 810 can comprise the first body 402A, which is physically connected to the second body 402B via a support element 830 and a bridge 812. The bridge 812 can extend from the first side 403A of the first body 402A to the first side 403B of the second body 402B. The bridge 812 can have a top surface 814 extending from the first side 403A to the first side 403B. The bridge 812 can also have a bottom surface 816 extending from the second side 404A and the second side 404B. The bottom surface 816 can have a curvature that is complementary to a curvature of the second side 404A and the second side 404B, such that the radius of curvature is uniform. In one example, the first body 402A, the second body 402B and the bridge 812 are a single piece.

[0051] The support element 830 can comprise a first section 832 having a first side 832A that is in planar contact with the first side 403A. The first section 832 can also have a second side 832B that is in planar contact with the first side 403B. The first section 832 can further comprise a third side 832C that is curved and extends from the first side 403A to the first side 403B and is in planar contact with the top surface 814 of the bridge 812.

[0052] The support element 830 can also include a second section 834 with a first side 834A and a second side 834B. The first side 834A and the second side 834B can have a J-shaped curvature. Additionally or alternatively, the first side 834A and the second side 834B can be recessed to increase the size of the first air gap 442 and the second air gap 444, respectively.

[0053] The support element 830 can also include a third section 836. The third section 836 can have a first side 836A that is in planar contact with the first side 413A of the third body 412A. The third section 836 can also have a second side 836B that is parallel to the first side 836A and is in planar contact with the first side 413B of the fourth body 412B. A top surface 836C of the third section 836 can be in planar contact with a bridge 824 that connects the third body 412A to the fourth body 412B. The bridge 824 can connect the bridge 824 to a fifth body 822. The fifth body 822 can have a first surface 822A that faces the third air gap 446 between the first surface 822A and the fifth side 417A. The fifth body 822 may also have a second side 822B, which is opposite the fourth air gap between the second side 822B and the fifth side 417B.The fifth body 822 can further have a third surface 822C which is curved and corresponds to an arc shape of the fourth side 406A, the fourth side 406B, the third side 415A and the third side 415B.

[0054] In one example, the first body 402A, the second body 402B, the third body 412A, the fourth body 412B, the fifth body 822, and the support element 830 form a single, connected part. In some examples, the fifth body 800 may additionally or alternatively contain additional support elements connected to one or more of the fourth body 406A, the fourth body 406B, the third body 415A, and the third body 415B.

[0055] Fig. Figure 9 shows a sixth example 900 for the hybrid position 810. The sixth example 900 can be compared to the fifth example 800 with the hybrid position 810. Fig. 8 modify such that the fifth body 822 is connected to a bridge 912 via a second support element 930. This means that the third body 412A and the fourth body 412B can be connected to each other by the bridge 912.

[0056] A second support element 930 can be shaped similarly to the support element 830. In one example, the second support element 930 can be smaller than the support element 830. The second support element 930 can be connected to a side of the bridge 912 opposite the support element 830. In another example, the bridge 912 can separate the support element 830 from the second support element 930. In this way, the non-magnetic material is discontinuous and arranged at different locations within the hybrid layer 810.

[0057] The second support element 930 can comprise a first section 932 with a first side 932A in planar contact with the first side 413A of the third body 412A. The second support element 930 can further comprise a second side 932B, which extends parallel to the first side 932A and is in planar contact with the first side 413B of the fourth body 412B. The second support element 930 can further comprise a third side 932C, which is in planar contact with the bridge, the third side 932C being perpendicular to and extending from the first side 932A and the second side 932B.

[0058] The second support element 930 can also comprise a second section 934 with a first side 934A and a second side 934B. The first side 934A can face the third air gap 446 and have a concave shape. The second side 934B can face the fourth air gap 448 and have a concave shape.

[0059] The second support element 930 can further comprise a third section 936 with a first side 936A in planar contact with a fourth side 822D of the fifth body 822. The third section 936 can also have a second side 936B in planar contact with a fifth side 822E of the fifth body 822. The third section 936 can further comprise a third side 936C in planar contact with a sixth side 822F of the fifth body 822. The sixth side 822F can be perpendicular to the fourth side 822D and the fifth side 822E.

[0060] The first body 402A, the second body 402B, the support element 830, the third body 412A, the fourth body 412B, the second support element 930, and the fifth body 822 can be a single, contiguous piece. The sixth example 900 can also include additional support elements and / or thermal features that complement the one described in the Fig. Examples 5-7 are similar.

[0061] In the Fig. Figures 1-10B show example configurations with the relative positioning of the various components. If these elements are in direct contact with each other or directly coupled, they can be described as being in direct contact or directly coupled, respectively, in at least one example. Similarly, elements shown side by side or adjacent to each other can be described as being adjacent to each other or adjacent to each other, respectively, in at least one example. For instance, components that are in planar contact with each other can be described as being in planar contact. As another example, elements that are separated from each other, with only a gap between them and that have no other components, can be described as such in at least one case.In yet another example, elements that are displayed above / below each other, on opposite sides, or to the left / right of each other can be described as such, relative to one another. Furthermore, in at least one example, as shown in the figures, a topmost element or the highest point of an element can be referred to as the "top" of the component, and a bottommost element or the lowest point of the element can be referred to as the "bottom" of the component. The terms top / bottom, upper / lower, and above / below used here can refer to a vertical axis of the figures and be used to describe the positioning of elements within the figures relative to each other. Thus, in one example, elements displayed above other elements are arranged vertically above the other elements.As a further example, the shapes of the elements depicted in the figures can be described as such (e.g., circular, straight, flat, curved, rounded, chamfered, angled, etc.). Furthermore, the depicted elements that intersect each other can be described as intersecting elements or as mutually intersecting elements in at least one example. In addition, an element depicted within or outside another element can be described as such. It is understood that one or more components described as "substantially similar and / or identical" may differ from each other according to manufacturing tolerances (e.g., within 1-5% deviation). Fig. 2-10B are shown approximately to scale.

[0062] The disclosure also provides support for a system comprising an electric motor with a rotor, the rotor comprising alternating layers, wherein a plurality of first layers comprise a magnetic material and a plurality of second layers comprise the magnetic material and a non-magnetic material embedded in each of the plurality of second layers. In a first example of the system, the magnetic material is laminated steel. In a second example of the system, which optionally includes the first example, the non-magnetic material is a carbon fiber composite. In a third example of the system, which optionally includes one or both of the first and second examples, the alternating layers are bonded with an adhesive. In a fourth example of the system, which optionally includes one or more or each of the first through third examples, the non-magnetic material comprises a thermally conductive element.In a fifth example of the system, which optionally includes one or more or each of the first four examples, the non-magnetic material is physically connected to separate portions of the magnetic material of a second layer of the plurality of second layers. In a sixth example of the system, which optionally includes one or more or each of the first five examples, the non-magnetic material is discontinuously arranged in different regions of a second layer of the plurality of second layers.

[0063] The disclosure also provides a support for a rotor for an electric motor, comprising a plurality of first layers alternating with a plurality of second layers, each first layer of the plurality of first layers comprising only a magnetic material, and each second layer of the plurality of second layers comprising the magnetic material and a non-magnetic material that joins separate pieces of the magnetic material. In a first example of the system, the non-magnetic material is embedded in the magnetic material of the plurality of second layers. In a second example of the system, which optionally includes the first example, a thermally conductive material is embedded in the non-magnetic material. In a third example of the system, which optionally includes one or both of the first and second examples, the non-magnetic material is arranged centrally or radially within the plurality of second layers.In a fourth example of the system, which optionally includes one or more or each of the first three examples, the non-magnetic material is arranged along an outer circumference of the plurality of second layers. In a fifth example of the system, which optionally includes one or more or each of the first four examples, the non-magnetic material is bonded to the magnetic material. In a sixth example of the system, which optionally includes one or more or each of the first five examples, the non-magnetic material surrounds an entire circumference of the rotor. In a seventh example of the system, which optionally includes one or more or each of the first six examples, the plurality of second layers is identical in shape and size to the plurality of first layers.

[0064] The disclosure also provides a support for an electric motor comprising a plurality of first layers containing a magnetic material and a plurality of second layers comprising the magnetic material and a non-magnetic material bonded to the magnetic material, wherein the plurality of first layers is nested with the plurality of second layers. In a first example of the system, each first layer from the plurality of first layers is a single piece, and each second layer from the plurality of second layers is a contiguous piece comprising several pieces of the magnetic material bonded to at least one piece of the non-magnetic material. In a second example of the system, which optionally includes the first example, the non-magnetic material comprises one or more pieces and is arranged along a middle portion and an outer portion of the plurality of second layers.In a third example of the system, which optionally includes one or both of the first and second examples, the plurality of first layers and the plurality of second layers are identical in shape and size. In a fourth example of the system, which optionally includes one or more or each of the first through third examples, the non-magnetic material at least partially surrounds a perimeter of the plurality of first layers and the plurality of second layers.

[0065] The following claims highlight in particular certain combinations and subcombinations that are to be considered novel and not obvious. These claims may refer to "one" element or "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements, with two or more such elements neither required nor excluded. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application. Such claims, whether they have a broader, narrower, the same, or different scope than the original claims, are also to be considered as being included in the subject matter of the present disclosure. 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 patent literature

[0000] US 63 / 665,578

[0001]

Claims

[1] System, encompassing: Electric motor with a rotor having alternating layers, wherein several first layers have a magnetic material and a plurality of second layers have the magnetic material and a non-magnetic material embedded in each of the several second layers. [2] System according to claim 1, wherein the magnetic material is laminated steel. [3] System according to any of the preceding claims, wherein the non-magnetic material is a carbon fiber composite. [4] System according to one of the preceding claims, wherein the alternating layers are joined together by an adhesive. [5] System according to one of the preceding claims, wherein the non-magnetic material comprises a thermally conductive element. [6] System according to one of the preceding claims, wherein the non-magnetic material is physically connected to separate parts of the magnetic material of a second layer from the plurality of second layers. [7] System according to one of the preceding claims, wherein the non-magnetic material is discontinuous and is arranged in different regions of a second layer of the plurality of second layers. [8] Rotor for an electric motor, comprising: a plurality of first layers alternating with a plurality of second layers, each first layer of the plurality of first layers comprising only a magnetic material and each second layer of the plurality of second layers comprising the magnetic material and a non-magnetic material that joins separate pieces of the magnetic material. [9] Rotor according to claim 8, wherein the non-magnetic material is embedded in the magnetic material of the plurality of second layers. [10] Rotor according to claim 8 or 9, wherein a thermally conductive material is embedded in the non-magnetic material. [11] Rotor according to one of claims 8 to 10, wherein the non-magnetic material is arranged centrally or radially within the plurality of second layers. [12] Rotor according to one of claims 8 to 11, wherein the non-magnetic material is arranged along an outer circumference of the plurality of second layers. [13] Rotor according to any one of claims 8 to 12, wherein the non-magnetic material is bonded to the magnetic material. [14] Rotor according to any one of claims 8 to 13, wherein the non-magnetic material surrounds the entire circumference of the rotor. [15] Rotor according to any one of claims 8 to 14, wherein the plurality of second layers is identical in shape and size to the plurality of first layers.

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