Method for manufacturing a rotor for an electric machine

Abstract

The invention relates to a method for manufacturing a rotor (1) for an electric machine comprising a body (10) and at least one magnet (20), which is carried by the body and which comprises at least one first unitary magnet (21) and at least one second unitary magnet (22), the method comprising the following steps: - forming the first unitary magnet by depositing a magnetic material on a support (30) distinct from the body; - fixing the support with respect to the body.

Description

TITLE OF THE INVENTION: METHOD FOR MANUFACTURING A ROTOR FOR AN ELECTRIC MACHINE TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates generally to electrical machines.

[0002] It relates more particularly to a method of manufacturing a rotor for an electric machine with radial or axial flux.

[0003] It also concerns a rotor manufactured using this process.

[0004] The invention finds a particularly advantageous application in electric motors for electric or hybrid motor vehicles. STATE OF THE ART

[0005] An electrical machine typically consists of a stator and a rotor. The rotor carries a series of large permanent magnets, while a series of coils are carried by the stator. When the coils are energized with an electric current, the rotor, which is secured to the output shaft of the electrical machine, is subjected to a torque resulting from the magnetic field.

[0006] From the document "Novel Multi-layer Design and Additive Manufacturing Fabrication of a High Power Density and Efficiency Interior PM Motor, 2020 IEEE Energy Conversion Congress and Exposition (ECCE), 2020, pp. 3601 - 3606, M. Ibrahim, F. Bernier and J. -M. Lamarre" we know of rotors in which the permanent magnets are formed by dynamic cold projection, a process better known as "cold spraying". Since the projection is carried out "cold", typically between 100 °C and 200 °C, it does not deform the rotor body. It also allows the large permanent magnets to be fixed directly to the rotor body and thus eliminates the need for an additional magnet fixing step. Finally, because they are formed by cold projection on the rotor body, the magnets are firmly fixed to the latter.

[0007] However, these large permanent magnets are subject to energy losses due to eddy currents flowing through them when the electric machine is in operation, which limits the performance of the electric machine. PRESENTATION OF THE INVENTION

[0008] In order to overcome the aforementioned drawback of the state of the art, the present invention proposes to segment these large permanent magnets into a plurality of unit magnets while forming them by depositing a magnetic material. Preferably, said material is also metallic.

[0009] More particularly, the invention proposes a method for manufacturing a rotor for an electrical machine comprising a body and at least one magnet which is carried by the body and which comprises at least one first unitary magnet and at least one second unitary magnet, said method comprising the following steps: - formation of the first unit magnet by depositing a magnetic material on a support separate from the body; - fixing the support to the body.

[0010] Thus, thanks to the invention, the magnet is divided into several unit magnets. The unit magnets then constitute portions of the magnet which are more electrically insulated from each other than their equivalent in the form of a single monobloc magnet. This makes it possible to reduce eddy currents within the magnet and therefore to reduce energy losses. The performance of the electrical machine is thus increased compared to the use of large monobloc permanent magnets of the prior art.

[0011] According to the invention, the deposition of a magnetic material, preferably also metallic, is an additive manufacturing process, that is to say by adding material, such as the cold projection of a magnetic material, i.e. by dynamic cold projection, or magnetic printing, better known as 3D printing.

[0012] Counterintuitively, the invention therefore proposes to produce unitary magnets by depositing a magnetic material on a support separate from the rotor body. Indeed, although the magnets are not formed directly on the body and their fixing is therefore less resistant to mechanical stresses and more complex than in the prior art, this makes it possible to divide the magnet into unitary magnets and to reduce eddy currents.

[0013] In other words, the increase in the energy performance of the rotor manufactured using the process according to the invention is clearly favoured.

[0014] Other advantageous and non-limiting characteristics of the method of manufacturing a rotor for an electrical machine according to the invention, taken individually or in all technically possible combinations, are the following: - the first unit magnet is formed by cold projection of a magnetic material; - the fixing step comprises positioning a face of the first unit magnet opposite and at a distance of less than 1 mm from a face of the second unit magnet; - the method comprises a step of forming the second unitary magnet by depositing a magnetic material on the body; - the body comprises a stack of metal sheets and in which the second unit magnet is formed by depositing a magnetic material on at least two of said metal sheets; - said at least one second unitary magnet has a shape complementary to that of said at least one first unitary magnet and the fixing step comprises the fitting of said at least one first unitary magnet with said at least one second unitary magnet; - the support is made of a magnetically conductive material and, at the stage of fixing the support, it is planned to position the support on the periphery of the rotor; - the first unit magnet is formed on an inner surface of the support and a step of forming the second unit magnet by depositing a magnetic material on an outer surface of the support opposite the inner surface is provided; - said support is made of an electrically insulating material; - the body comprises at least one housing and, at the stage of fixing the support, it is intended to insert the support into said housing.

[0015] The invention also provides a rotor for an electric machine comprising: - a body; - at least one magnet which is worn by the body; and - a support separate from the body and attached to the body; said magnet comprising at least: - a first unitary magnet which is formed by depositing a magnetic material on the support; and a second unitary magnet.

[0016] Of course, the various features, variations and embodiments of the invention may be combined with each other in various combinations to the extent that they are not incompatible or exclusive of each other. DETAILED DESCRIPTION OF THE INVENTION

[0017] The description which follows with reference to the appended drawings, given as non-limiting examples, will make it clear what the invention consists of and how it can be implemented.

[0018] On the attached drawings:

[0019] Figure 1 is a schematic sectional view of a rotor according to a first embodiment, obtained by means of a manufacturing method according to the invention;

[0020] Figure 2 is a schematic sectional view of a portion of the rotor of Figure 1 prior to the attachment of brackets to the rotor body;

[0021] Figure 3 is a schematic perspective view of a portion of the rotor of Figure 1 prior to the attachment of brackets to the rotor body;

[0022] Figure 4 is a schematic perspective view of an example of unit magnets implemented in a first variant of the first embodiment of the rotor;

[0023] Figure 5 is a schematic perspective view of another alternative embodiment of unit magnets implemented in the first embodiment;

[0024] Figure 6 is a schematic sectional view of a part of another example of a rotor according to the first embodiment, obtained by means of a manufacturing method according to the invention;

[0025] Figure 7 is a schematic perspective view of a support on which unit magnets are deposited for the manufacture of a rotor according to a second embodiment, obtained by means of a manufacturing method according to the invention;

[0026] Figure 8 is a schematic sectional view of a portion of a rotor according to the second embodiment and including the support and unit magnets of Figure 7;

[0027] Figure 9 is a view is a schematic perspective view of another alternative embodiment of the support for the manufacture of a rotor according to the second embodiment;

[0028] Figure 10 is a schematic sectional view of a portion of another example of a rotor according to the second embodiment and including the support of figure 9.

[0029] As a preliminary point, it will be noted that the identical or similar elements of the different embodiments of the invention shown in the figures will, as far as possible, be referenced by the same reference signs and they will not be described each time.

[0030] In Figure 1, there is shown a rotor 1 for an electric machine obtained by means of a manufacturing method in accordance with the invention.

[0031] This rotor 1 is here intended to be part of a radial flux electric machine, this machine hopefully being a motor for propelling an electric or hybrid vehicle. Such a machine comprises a rotor and a stator. The invention is particularly suitable for the manufacture of an electric machine having a wide range of rotational speed values.

[0032] As shown in Figure 1, the rotor 1 comprises a body 10, the shape of which is generally tubular around an axis of rotation A1, and permanent magnets, hereinafter called magnets 20. The body 10 is here made of a ferromagnetic material such as electrical steel.

[0033] For its part, the stator (not shown) also has a tubular shape and surrounds the rotor 1 . In practice, the stator and the rotor 1 are coaxially aligned around the axis of rotation A1 . On its inner face facing the rotor 1 , the stator comprises teeth around which coils of electrically conductive wire are wound. For information, the stator is also compatible with a hairpin winding. When these windings are supplied with electric current, they generate a rotating magnetic field driving in particular the permanent magnets, which allows the rotor 1 to move.

[0034] The invention relates more specifically to the rotor 1.

[0035] As shown in Figure 3, the body 10 of the rotor 1 is formed by a stack of metal sheets 15, for example electrical steel, extending perpendicular to the axis of rotation A1. Thus, for example, the section of the body 1 shown in Figure 1 comprises a single metal sheet 15. Alternatively, the body can be made by compacting a magnetic powder.

[0036] The rotor 1 also comprises a plurality of supports 30. The rotor 1 more specifically comprises a support 30 for each magnet 20, that is to say here sixteen supports 30 and magnets 20. Each support 30 is a separate part of the body 10 in the sense that the material forming the body 10, that is to say here the metal sheets 15, does not form the supports 30. As explained below, this translates here into the fact that the supports 30 are manufactured separately from the body 10 then attached to the latter.

[0037] As shown in Figure 1, each magnet 20 comprises a plurality of unit magnets, i.e., at least two unit magnets. In the example illustrated in Figure 1, each magnet 20 comprises seven unit magnets. Each unit magnet is a single-piece magnet. Here, the term "unit" means that the unit magnets are the smallest single-piece magnetic elements constituting the magnets 20.

[0038] The unit magnets forming a single magnet 20 are arranged side by side. Two unit magnets forming a single magnet 20 arranged side by side are adjacent in the sense that they are located at a very small distance, relative to their respective sizes, from each other. Typically, two adjacent unit magnets are located less than 1 mm from each other.

[0039] As shown in Figure 1, each magnet 20 more specifically comprises first unit magnets 21 and second unit magnets 22. As shown in Figure 2, the first unit magnets 21 are separated from each other. The same is true for the second unit magnets 22. This makes it possible to further reduce the eddy currents within the magnet 20.

[0040] The rotor 1 is manufactured according to a process comprising the following main steps: - formation of the first unit magnets 21 by depositing a magnetic material on the supports 30; - fixing the supports 30 relative to the body 10 or on the body 10.

[0041] Here, the term “formation” is understood to mean a process by which an object, in particular here the first unit magnets 21, acquires its shape. Thus, here, the deposition of the magnetic material gives their shape to the first unit magnets 21 and this directly on the supports 30.

[0042] Preferably, the magnetic material is also metallic. This method more particularly comprises a first step of providing or manufacturing the body 10. Here, the first step comprises cutting the metal sheets 15 to the desired shape, for example the shape shown in FIG. 1, and stacking and fixing the metal sheets to form the body 10.

[0043] The method then comprises a second step of providing or manufacturing the supports 30.

[0044] A third step of the method comprises the formation of the first unit magnets 21 on the supports 30.

[0045] During the third step, the first unit magnets 21 are formed by depositing a magnetic material, preferably also metallic. Here, the term “magnetic” material is understood to mean a material that can be magnetized so that it generates a permanent magnetic field or a material that already has a permanent magnetic field; examples are given below. The first unit magnets 21 are thus formed by additive manufacturing, as opposed to subtractive manufacturing (such as machining). Here, the first unit magnets 21 are more particularly formed by dynamic cold projection of a magnetic material, hereinafter called “cold projection”. Cold projection is a process better known by the English name “cold spray”. It consists of projecting a magnetic powder, preferably also metallic, at a supersonic speed via a gas supplied under pressure and heated.The first unit magnets 25 are thus, by construction, solidly fixed to the supports 30.

[0046] The projected magnetic powder is for example a mixture of two powders: a first magnetic powder having a remanence greater than 700 mT which can be an alloy comprising neodymium, praseodymium, iron or boron, and a second magnetic powder for example of aluminum or copper. For the second powder, the use of aluminum alloy powders, or copper alloys, ferrous alloys or polymer powders is also possible. The mixing ratio between the first powder and the second powder is for example between 1:2 and 9:10. The particle size of the first and second powders is preferably between 5 μm and 40 μm to allow efficient projection.

[0047] A fourth step of the method comprises forming the second unit magnets 22. The second unit magnets 22 may be formed on the body 10 (first mode illustrated in FIG. 1) or on the supports 30 (second mode illustrated in FIG. 7).

[0048] During this fourth step, the second unit magnets 22 are also formed by deposition of a magnetic material and more particularly by cold projection.

[0049] Alternatively, the unit magnets can be formed by other additive manufacturing processes such as 3D printing of magnetic material, for example by depositing magnetic powder and melting it locally using a laser beam.

[0050] The method finally comprises a fifth step of fixing the supports 30 relative to the body 10. The fifth step makes it possible to fix the position of the supports 30 and the magnets 20 relative to the body 10 in accordance with their final position in the electrical machine.

[0051] The first embodiment of the method for manufacturing the rotor 1 according to the invention is shown in Figures 1 to 6.

[0052] This first embodiment is characterized by the fact that, during the fourth step, the second unit magnets 22 are formed directly on the body 10. This means here that the second unit magnets 22 are deposited by cold projection on the metal sheets 15 of the body 10. The second unit magnets 22 are thus firmly fixed to the body 10.

[0053] Remarkably, the second unit magnets 22 each extend over at least two metal sheets 15 of the body 10, which improves the cohesion of the metal sheets 15. Preferably, as shown diagrammatically in FIG. 3, the second unit magnets 22 extend over a large number of metal sheets 15, for example over 10 to 100 metal sheets 15.

[0054] In this first embodiment, the supports 30 are preferably also formed by a stack, along the axis of rotation A1, of metal sheets which are for example made of the same material as that of the body 10. For each support 30, the first unitary magnets then extend over several metal sheets, which improves their cohesion.

[0055] Thus, the supports 30 are made of an electrically conductive material and, as shown in FIG. 1, they are positioned on the periphery of the rotor 1. The supports 30 thus participate in the conduction and channeling of the magnetic fluxes in the rotor 1.

[0056] More precisely, the supports 30 are distributed, here regularly, circumferentially all around the body 10 and at a distance from each other.

[0057] As shown in Figure 3, the first unit magnets 21 rise from an inner surface 31 of the support 10, the inner surface 31 being intended to be oriented towards the body 10 of the rotor 1.

[0058] The second unit magnets 22 rise from a peripheral surface 11 of the body 10. Each peripheral surface 11 of the body 10 is intended to be located opposite one of the supports 30.

[0059] In this first embodiment, for each magnet 20, the second unit magnets 22 more specifically have a shape complementary to that of the first unit magnets 21 so as to fit together as illustrated in FIG. 1. Thus, the first unit magnets 21 form reliefs on the internal surfaces 31 and the second unit magnets 22 form reliefs, of a shape complementary to that of the reliefs formed by the first unit magnets 21, on the peripheral surfaces 11.

[0060] Preferably, for each magnet 20, the first unit magnets 21 and the second unit magnets 22 are more specifically designed to form a tight fit, i.e. with very little free space between them, which makes it possible to maximize the volume of magnetic material. As detailed later, this free space is advantageously filled with an electrically insulating material.

[0061] Alternatively, the first and second unit magnets may interlock to form channels that may be used to cool the rotor.

[0062] To achieve this tight fitting, the first unit magnets 21 and the second unit magnets 22 have similar shapes here, as is the case in the examples illustrated in Figures 3 to 5. In addition, the first unit magnets 21 are regularly spaced on the internal faces 31 and the second unit magnets 22 are regularly spaced in a similar manner, i.e. with the same spacing, on the peripheral faces 11. It will be noted that the unit magnets 21, 22 positioned at the edge of the magnets 20 which may exceptionally have different shapes. As shown in Figures 2 and 3, the first unit magnets 21 and the second unit magnets 22 then fit together by offsetting them by half a spacing.

[0063] In the example illustrated in Figure 3, each unit magnet 21, 22 forms a rectilinear rib extending parallel to the axis of rotation A1. This ensures effective holding of the metal sheets. The section of a unit magnet 21, 22 in a plane perpendicular to the axis of rotation A1 is generally triangular. This section more specifically has the shape of an isosceles trapezoid. The apex of this section, i.e. its side of shorter length, coming into contact with a peripheral surface 11 of the body 10 or the internal surface 31 of a support 30.

[0064] As shown in Figures 2 and 3, the unit magnets 21, 22 have two main faces 23a, 23b rising from the body 10 or a support 30. Once the rotor 1 is assembled, each first unit magnet 21 then has one of its main faces 23a which extends opposite and at a distance of less than 1 mm from the main face 23b of a second adjacent unit magnet 22. The main faces 23a, 23b of two adjacent unit magnets 21, 22 extend parallel to each other.

[0065] Figures 4 and 5 illustrate other variant embodiments of the unit magnets 21, 22. In the example illustrated in Figure 4, the unit magnets 21 extend in length in a wavy, or even sinusoidal, manner. This limits in particular the eddy currents which could circulate between two second unit magnets 22 via the metal sheets 15. This is also valid for the first unit magnets 21 with respect to the metal sheets forming the supports 30. Alternatively, the unit magnets can extend in a sawtooth pattern and have flat faces.

[0066] In the example illustrated in Figure 5, the unit magnets 21, 22 have a more complex shape of a pad with flat faces which are connected to each other by thin walls. This shape further limits the eddy currents compared to the other examples described above.

[0067] In this first embodiment, the second step comprises the manufacture of the supports 30 by cutting and stacking metal sheets.

[0068] In the third step, the first unit magnets 21 are formed on the internal surfaces 31 of the supports 30. The formation of unit magnets 21 of the same shape and regularly spaced simplifies the cold spraying process.

[0069] In the fourth step, the second unit magnets 22 are formed on the peripheral surfaces 11 of the body 10. The fact that the second unit magnets 22 have a shape similar to the first unit magnets 21 simplifies the cold spraying process.

[0070] The fifth step comprises the nesting of the first unit magnets 21 with the second unit magnets 22. The fifth step therefore comprises the positioning of the main faces 23a, 23b of two adjacent unit magnets 21, 22 facing each other.

[0071] In the example illustrated in Figures 1 and 2, the internal surfaces 31 of the supports 30 and the peripheral surfaces 11 of the body 10 (on which the unit magnets are formed) are generally flat. As shown by the arrows in Figure 2, the fitting can therefore be carried out by a rectilinear translational movement of the supports 30 in radial directions, i.e. perpendicular to the axis of rotation A1. A wide variety of shapes is then possible for the unit magnets 21, 21, as shown in Figures 3 to 5. The fitting can also comprise a rotational movement as shown diagrammatically by an arrow in Figure 3.

[0072] In the example illustrated in Figure 6, the internal surface 31 of each support 30 and the peripheral surfaces 11 of the body 10 have curved V-shaped shapes. The supports 30 thus have a generally triangular section in a plane perpendicular to the axis of rotation A1 (corresponding to the plane of Figure 6). It is then provided that the unit magnets 21, 22 also extend in length along the axis of rotation A1 and in a rectilinear manner (as in Figure 3). The positioning of the supports 30 then comprises a translational movement along the axis of rotation A1 relative to the body 10 of the rotor 1. In this configuration, the second unit magnets 22 radially block the first unit magnets 21 and therefore constitute means, for the supports 30, of resisting radial stresses (typically centrifugal forces) when the rotor 1 is rotating.The rotor 1 according to the example illustrated in figure 6 is therefore particularly resistant to mechanical stresses.

[0073] Here, with reference to Figure 2, we introduce an intermediate element of the manufacture of the rotor 1 according to the first embodiment: the “second unit magnets - support” assembly consisting of a support and the second unit magnets which are deposited on the latter in the fourth step.

[0074] The fifth step then comprises fixing the second unit magnet - support assemblies to the body 10. In this first embodiment, the supports 30 are thus fixed relative to the bodies 10 by means of the unit magnets 21, 22.

[0075] Here, the second unit magnet - support assemblies are glued to the body 10. For this, the fifth step comprises the deposition of an adhesive on the first unit magnets 21 and / or the second unit magnets 22 before their fitting together. The adhesive is for example deposited on the main faces 23a, 23b of the magnets unitary 21, 22. The glue is for example an epoxy resin, a two-component glue or a thermosetting glue. The glue is preferably electrically insulating.

[0076] Alternatively, the second unit magnet - support assemblies may be secured to the body by adhesive tape, screws, or external fastening means such as hoops circumferentially surrounding the supports. In this alternative, an electrical insulator is placed between the first and second unit magnets.

[0077] Thus, advantageously, in this first embodiment, the unit magnets 21, 22 of each magnet 20 are therefore separated from each other by a layer of electrically insulating material, here a layer of glue. This layer of insulating material makes it possible to further reduce the eddy currents compared to unit magnets which would be in contact.

[0078] Advantageously, the interlocking of the first unit magnets 21 with the second unit magnets 22 offers large bonding surfaces which makes it possible to securely fix the supports 30 to the body 10. The unit magnets 21, 22 in the form of a stud as illustrated in FIG. 5 offer a larger bonding surface than rectilinear unit magnets 21, 22. Thanks to this large bonding surface, the rotor 1 according to the first embodiment is very resistant to mechanical stresses, in particular to radial stresses.

[0079] A second embodiment of the method for manufacturing the rotor 1 according to the invention is shown in Figures 7 to 10.

[0080] This second embodiment is characterized by the fact that, during the fourth step, the second unitary magnets 22 are also formed on the supports 30. This means that the magnets 20 are integrally formed on the supports 30 and then attached to the body 10. As shown in Figures 8 and 10, the body 10 here comprises housings 12 in which the magnets 20 are intended to be inserted.

[0081] As clearly shown in Figure 7, each support 30 has a thin sheet shape. The thickness of the supports 30 is preferably less than 1 mm, for example it is equal to 0.2 mm. The supports 30 thus have two opposite surfaces: one is the internal surface 31, the other is called the external surface 32.

[0082] Here, with reference to Figure 7, we introduce an intermediate element of the manufacture of the rotor 1 according to the second embodiment: the “magnet - support” consisting of a support and second unit magnets which are deposited on the latter in the third step and in the fourth step.

[0083] In this second embodiment, the second unit magnets 22 are formed on the outer surface 32 of the supports 30. The first unit magnets 21 are formed on the internal surface 31 of the supports 30.

[0084] Preferably, the supports 30 are made of an electrically insulating material, that is to say one which does not conduct electric currents or conducts them very weakly. The supports 30 are for example made of ceramic, for example a ceramic comprising aluminum oxide, glass, stone or concrete.

[0085] Thus, the first unit magnets 21 are particularly well electrically insulated from the second unit magnets 22, which makes it possible to effectively reduce the eddy currents within the magnets 20, more than in the first embodiment.

[0086] An example of rotor 1 according to the second embodiment is illustrated in Figures 7 and 8. As Figure 7 clearly shows, in this example, each support 30 is a plate. To simplify the reading of Figure 7, the support 30 is shown in transparency.

[0087] In this example, on each support 30, the unit magnets 21, 22 form reliefs separate from each other and rising from each of the opposite surfaces of the support 30. The unit magnets 21, 22 more particularly form rectilinear ribs extending parallel to the axis of rotation A1, which subsequently allows the magnet-support assembly to be inserted into a housing 12 along the axis of rotation A1. The section of a unit magnet 21 in a plane perpendicular to the axis of rotation A1 here has the shape of an isosceles trapezoid, except for its ends which are rounded.

[0088] In this example, on each support 30, the base 24a, 24b of the unit magnets 21, 22, that is to say their contact surface with the support 30, extends opposite and at a distance of less than 1 mm from one or two other bases 24a, 24b.

[0089] When the supports 30 are flat, and therefore the unit magnets 21, 22 form reliefs, it is provided that the housings 12 also have reliefs of a shape complementary to that of the unit magnets 21, 22. Thus, for example, the housing 12 illustrated in figure 8 has a section in a plane perpendicular to the axis of rotation A1 whose shape is undulating. Preferably, the magnet assembly - support is inserted into its housing 12 with the clearance, as illustrated in figure 8.

[0090] Another example of rotor 1 according to the second embodiment is illustrated in Figures 9 and 10. As clearly shown in Figure 9 (where only the support 30 is shown), in this example, each support 30 is a plate having filling reliefs 33. The filling reliefs 33 form recesses in each of the opposite surfaces of the support 30. Here, the filling reliefs 33 of the same surface of the support 30 are identical and regularly spaced. Here they form an alternation of hollows and bumps.

[0091] As shown in Figure 10, on each support 30, the unit magnets 21, 22 are formed in the filling reliefs 33. The magnets 20 are thus similar to those of the first embodiment illustrated in Figure 1. Each first unit magnet 21 therefore has one of its main faces 23a which extends opposite and at a distance of less than 1 mm from the main face 23b of an adjacent unit magnet 21. However, in this second embodiment, the insulating material separating the unit magnets 21 from the same magnet 20 is the support 30 itself (and not the layer of glue).

[0092] The filling reliefs 33 may have other shapes, for example shapes suitable for manufacturing the unit magnets 21, 22 as shown in FIGS. 4 or 5.

[0093] In all these examples where the supports 30 have filling reliefs 33, the magnet-support assemblies and the housings 12 preferably have two main flat faces 35 as shown in figure 10.

[0094] In this second embodiment, the first step of the method for manufacturing the rotor 1 also comprises the manufacturing of the body 10 by cutting and stacking metal sheets 15. The metal sheets 15 are cut so as to form the housings 12. Here, the sheets are cut and placed in relation to each other in an identical manner. The housings 12 thus form channels of uniform section extending along the axis of rotation A1.

[0095] The second step includes the supply or manufacture of the supports 30.

[0096] In this second embodiment, during the third step, the first unit magnets 21 are formed on the internal surfaces 31 of the supports 30. The first unit magnets 21 may be formed by rising from the planar inner surfaces 31, as in Figures 7 and 8, or by filling the filler reliefs 33, as in Figures 9 and 10.

[0097] Similarly, in the fourth step, the second unit magnets 22 are formed on the outer surfaces 32 of the supports 30. The second unit magnets 21 may be formed by rising from the planar outer surfaces 32, as in Figures 7 and 8, or by filling the filling reliefs 33, as in Figures 9 and 10.

[0098] It will be noted here that the notion of positioning amounts to forming the second unit magnets 22. The fourth step thus comprises, for each first unit magnet 21, the positioning of a face of a second unit magnet 22 opposite one of the faces of the first unit magnet 21. The facing faces of two adjacent unit magnets 21, 22 may be the main faces 23a, 23b (figures 9 and 10) or the bases 24a, 24b (figures 7 and 8).

[0099] The fifth step includes the positioning, here by insertion, of the magnet-support assemblies in the housings 12.

[0100] Preferably, before insertion, glue is placed on the magnet-support assemblies. Thus, once inserted and once the glue has solidified, the magnet-support assemblies are fixed in the housings 12. In this second embodiment, the supports 30 are thus fixed relative to the body 10 by means of the unitary magnets 21, 22.

[0101] Alternatively, it is possible to fix the magnet-support assembly by other means such as force insertion, screws or retaining parts obstructing the housings.

[0102] The present invention is in no way limited to the embodiments described and shown, but those skilled in the art will be able to provide any variation in accordance with the invention.

[0103] Thus, the two embodiments presented are combinable. For example, it is possible to implement a ceramic plate on which the unit magnets are deposited on a surface, then to stick the opposite surface of the plate on the body and on unit magnets which have been deposited on the body.

[0104] Unit magnets can also extend in directions other than that of the rotation axis, for example in orthoradial directions, i.e. orthogonal to the axis of rotation and to a radial direction.

[0105] It is also possible to provide for the rotor to comprise several layers of magnets manufactured according to the invention stacked radially. This makes it possible in particular to produce a synchronous reluctance motor assisted by permanent magnets. Such a rotor can for example be manufactured by nesting several V-shaped supports, adapted from that shown in Figure 6, one inside the other. Finally, although the figures only illustrate the invention in the context of a rotor for a radial flux electric machine, the invention in its most general formulation is entirely suitable for the manufacture of a rotor for an axial flux electric machine.

Claims

DEMANDS

1. A method for manufacturing a rotor (1) for an electrical machine comprising a body (10) and at least one magnet (20) which is carried by the body (10) and which comprises at least one first unit magnet (21) and at least one second unit magnet (22), said method comprising the following steps: - formation of the first unit magnet (21) by depositing a magnetic material on a support (30) distinct from the body (10); - fixing the support (30) to the body (10).

2. Method of manufacturing a rotor (1) according to claim 1, wherein the first unit magnet (21) is formed by cold spraying of a magnetic material.

3. Method of manufacturing a rotor (1) according to claim 1 or 2, wherein the fixing step includes positioning a face (23a; 24a) of the first unit magnet (21) opposite and at a distance of less than 1 mm from a face (23b; 24b) of the second unit magnet (22).

4. Method of manufacturing a rotor (1) according to any one of claims 1 to 3, comprising a step of forming the second unit magnet (22) by depositing a magnetic material on the body (10).

5. Method of manufacturing a rotor (1) according to claim 4, wherein the body (10) comprises a stack of metal sheets (15) and wherein the second unit magnet (22) is formed by depositing a magnetic material on at least two of said metal sheets (15).

6. Method of manufacturing a rotor (1) according to claim 4 or 5, wherein said at least one second unit magnet (22) has a form complementary to that of said at least one first unit magnet (21) and wherein the fixing step comprises the fitting of said at least one first unit magnet (21) with said at least one second unit magnet (22).

7. Method of manufacturing a rotor (1) according to any one of claims 4 to 6, wherein the support (30) is made of a magnetically conductive material and wherein, at the stage of fixing the support (30), it is provided to position the support (30) on the periphery of the rotor (1).

8. Method of manufacturing a rotor (1) according to any one of claims 1 to 3, wherein the first unit magnet (21) is formed on an internal surface (31) of the support (30) and wherein a step of forming the second unit magnet (22) is provided by depositing a magnetic material on an external surface (32) of the support (30) opposite the internal surface (31).

9. Method of manufacturing a rotor (1) according to claim 8, wherein said support (30) is made of an electrically insulating material.

10. Method of manufacturing a rotor (1) according to claim 8 or 9, wherein the body (10) comprises at least one housing (12) and wherein, at the support fixing step (30), it is provided to insert the support (30) into said housing (12).

11. Rotor (1) for an electrical machine comprising: - a body (10); - at least one magnet that is carried by the body (10); and - a support (30) separate from the body (10) and attached to the body (10); characterized in that said magnet comprises at least: - a first unit magnet (21) which is formed by depositing a magnetic material onto the support (30); and - a second unit magnet (22).

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