Method for manufacturing a laminated core for an electrical machine - Patent Application 20070122997

Abstract

In a method for manufacturing a laminated core (1) of an electric machine, metal sheets (4, 5) based on an iron material are alloyed with an alloy material (16) containing silicon by heat treatment, whereby aluminum-based foil sheets (6, 7) having aluminum oxide foil layers (8, 9) and each at least partially coated with the alloy material before the heat treatment are arranged between the metal sheets (4, 5).

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a laminated core of an electrical machine. [Background technology]

[0002] EP 3511429 A1 discloses a method for producing a laminated core, in which the metal sheets of the initial laminated core are coated with a foil coating having an aluminum and / or silicon mass fraction of at least 20%. This initial laminated core is then heat treated to obtain a laminated core, which has a silicon content of at least 6.5% by mass. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] European Patent Application Publication No. 3511429 Summary of the Invention [Means for solving the problem]

[0004] The method according to the invention for producing a laminated core with the features of claim 1 has the advantage that it allows for the subsequent alloying of the metal sheets of the laminated core of an electric machine and the subsequent production of insulating layers on or between the metal sheets of the laminated core at low cost. In this way, inexpensive electrical sheets with low aluminum and silicon contents, for example less than 4.0% by weight, can be alloyed by heat treatment to higher aluminum and silicon contents, for example between 4.0 and 8.5% by weight, at least in the region near the surface.

[0005] Furthermore, the electrical resistivity of the laminated core laminations can be advantageously increased without excessively impairing the soft magnetic properties, thereby improving the efficiency of the electric machine. According to the invention, in a first step, foil sheets are provided, each comprising an aluminum support foil and a natural or produced insulating layer, such as an aluminum oxide foil layer, formed on the support foil, and each having a foil coating on at least one side of the foil sheet, the foil coating comprising an alloying material, an adhesive binder for adhering the alloying material to the foil sheet, and in particular further powdered aluminum oxide.

[0006] Furthermore, in a second step, the metal sheets of the laminated core are provided, which are not particularly electrically insulated, as opposed to conventional forms in which they are electrically insulated. If the metal sheets have a lacquer insulation, it must be removed, as this may hinder diffusion and may undesirably allow carbon from the lacquer layer to penetrate the metal sheets.

[0007] In a third step, the metal sheet laminates and foil sheet laminates are stacked alternately, with at least one foil sheet located between each adjacent metal sheet laminate. Furthermore, in a fourth step, the laminate of the metal sheet and the foil sheet is heated, for example, heat-treated, - with the melting of the support foil, aluminum from the support foil of the foil sheet diffuses to a certain depth into the metal of the respective adjacent metal sheet, and alloying material from the foil coating of the foil sheet diffuses to a certain depth into the metal of the respective adjacent metal sheet to form alloyed regions; - The aluminum oxide foil layer of the foil laminate or aluminum oxide from the foil coating of the foil laminate remains and forms an insulating layer between the metal laminates.

[0008] Advantageously, the shape and / or area of ​​the foil sheets correspond to the shape and / or area, respectively, of the metal sheets, thereby achieving a particularly advantageous design with regard to the geometry of the individual layers.

[0009] Advantageously, the aluminum-based foil sheet is cut or cut from an aluminum foil, the aluminum foil having at least one aluminum oxide foil layer on at least one side and / or the aluminum foil being at least partially coated with an alloy material on at least one side. Therefore, in particular, such aluminum foil can already be coated in an upstream production process, for example, before being wound up. Here, it is also advantageous that the foil coating is not too thick, which can allow for advantageous adhesion and winding.

[0010] It is also advantageous if the alloy material is at least partially applied to at least one side of the foil sheet using an adhesive binder, particularly a paste, and / or a polysaccharide, particularly xanthan. The alloy material is preferably in powder form. This ensures a reliable bond of the powdered alloy material to the aluminum foil. Here, silicon powder, and optionally also aluminum oxide powder, can be mixed with water and, for example, xanthan. This mixture can be applied to at least one side of the aluminum foil, for example, using a compressed air spray gun. During subsequent drying, the water evaporates, and the xanthan remaining in the mixture ensures good adhesion of the powder. This can be done on one or both sides of the aluminum foil.

[0011] It is advantageous to at least partially place at least one foil sheet between adjacent metal sheets. When alloying metal sheets, a substantial increase in the silicon mass fraction is achieved, but it is advantageous that the silicon and aluminum mass fractions do not become too large. This essentially means that the amount of aluminum (in metallic form) is not too high compared to the amount of silicon contained in the foil coating. When a double-sided coated foil is inserted between adjacent metal sheets, the amount of silicon can be easily increased without increasing the thickness of the foil coating too much. This ensures reliable adhesion of the foil coating to both sides of the aluminum foil, among other things. On the other hand, it has the advantage that the total thickness of the aluminum oxide foil layers can be easily doubled. Therefore, it is possible to achieve, in particular, the formation of an insulating layer of aluminum oxide between the electrical sheets during heat treatment in the manufactured laminated core. Furthermore, it is also possible to limit the aluminum mass fraction, particularly to reduce or completely prevent the increase in magnetostriction that occurs with increasing aluminum fraction.

[0012] It is advantageous for at least two foil sheets to be at least partially interposed between adjacent metal sheets. When alloying the metal sheets, a substantial increase in the silicon mass fraction is achieved, but it is advantageous for the silicon and aluminum mass fractions not to become too large. This essentially means that it is advantageous for the amount of aluminum (in metallic form) to not become too large compared to the amount of silicon contained in the foil coating. When multiple foil sheets are inserted between adjacent metal sheets, on the one hand, the amount of silicon can be easily increased without increasing the thickness of the foil coating too much. This ensures reliable adhesion of the foil coating to the target surface, especially of the aluminum foil. On the other hand, it has the advantage that the total thickness of the aluminum oxide foil layer can be easily increased. This prevents the aluminum oxide foil layer from being partially scraped off or otherwise partially peeled off, for example, during handling. Therefore, it is possible to achieve, in particular, the formation of an insulating layer of aluminum oxide in the manufactured laminated core. Furthermore, it is also possible to limit the aluminum mass fraction, particularly to reduce or completely prevent the increase in magnetostriction that occurs with an increase in the aluminum fraction. This can be achieved, for example, by using two foil sheets instead of a single foil sheet, where the two foil sheets have the same total thickness as the single foil sheet. For example, instead of one foil sheet having a thickness of 10 μm, two foil sheets each having an aluminum oxide foil layer, each 5 μm thick, can be used, thereby doubling the total thickness of the aluminum oxide foil layer.

[0013] It is also advantageous to select the thickness of the foil sheet and the alloying material and optional electrically insulating solid applied to the foil sheet so that, after heat treatment, at least a portion of the surface of the metal sheet, at least near the surface, has a silicon mass fraction of at least about 6.5% and silicon and aluminum mass fractions of 8.5% or less. This, in particular, can eliminate magnetostriction, thereby resulting in low pressure sensitivity and high magnetic permeability. Near-surface alloying can, for example, involve an edge region or area of ​​about 500 μm. This is advantageous because eddy currents also occur near the surface at high frequencies. In this case, the core region can be advantageously free of silicon and / or aluminum or with a small silicon and / or aluminum mass fraction, thereby providing the material of the electrical sheet in the core region with toughness and therefore high mechanical load-bearing capacity. Preferably, the silicon and aluminum mass fractions are 8.5% or less. Here, the starting material for the metal sheet can be formed, for example, with a silicon mass fraction of about 3%. The mass fraction of silicon is then further increased by heat treatment, preferably to a mass fraction of 6.5% with respect to silicon.

[0014] In a further possible embodiment, the thickness of the foil and the alloy material and optionally the electrically insulating solid applied to the foil are advantageously selected so that, after the heat treatment, at least on a portion of the surface of the metal sheet, at least near the surface, the mass fraction of silicon is between about 4% and about 5%, and the mass fractions of silicon and aluminum are less than or equal to about 8.5%. This configuration allows the use of inexpensive materials for the metal sheet. In particular, metal sheets made of materials that are substantially free of silicon can be used. The mass fraction of silicon can then be increased by heat treatment.

[0015] The increase in the silicon mass fraction is preferably not carried out into the core region of the sheet metal, since the heat treatment required for this would normally also change the grain size, thus avoiding any change in grain size.

[0016] It is advantageous for the foil sheets to have a thickness of about 5 μm to about 10 μm, preferably as thin as possible. For example, a 1 μm aluminum oxide foil layer can be provided. A desired number of foil sheets can be inserted between the metal sheets. This allows for convenient handling, particularly since at least partial peeling of the aluminum oxide foil layer can be reliably avoided. The advantage of the aluminum oxide foil layer of the aluminum foil is that it forms an electrically insulating layer between the electrical sheets during heat treatment. In the case of powder, this risk is high in locations that are not sufficiently electrically insulated. Furthermore, this form allows for a relatively thin foil coating without undesirably increasing the mass fraction of aluminum in the metal sheets after heat treatment.

[0017] It is also advantageous to heat-treat the metal sheets between which the coated foil sheets are placed, prior to the alloying heat treatment, at a temperature between about 150°C and 500°C for about 1 hour to about 2 hours. This ensures decomposition of the adhesive binder or polysaccharide. Here, the heat treatment can be carried out in the presence of hydrogen. At, for example, 400°C, xanthan is decomposed into, for example, water, carbon monoxide, carbon dioxide, and methane, and is therefore removed. Subsequent heat treatment, for example, at 1250°C, allows silicon and aluminum to diffuse into the metal sheets. Once the silicon and aluminum have completely diffused, aluminum oxide remains between the metal sheets as an electrically insulating layer.

[0018] In laminated cores for rotors, it is advantageous for the foil sheets to be partially coated with alloying material so that the radially outer portions of the laminated core foil sheets are provided with more alloying material than the radially inner portions of the foil sheets. In particular, this allows for reduced alloying to be achieved near the shaft, where the material remains tough, while at locations further from the shaft, higher alloying can be achieved, increasing the specific electrical resistivity and therefore reducing remagnetization losses.

[0019] Similarly, in a laminated core for a stator, it is advantageous if the foil sheets are partially coated with an alloy material, the alloy material being located closer to the radially inner portion of the foil sheets than to the radially outer portion of the foil sheets.

[0020] Preferred exemplary embodiments of the present invention will now be described in more detail with reference to the accompanying drawings, in which corresponding elements are designated with the same reference numerals, and in which: [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a partial schematic cross-sectional view of an aluminum foil structure according to an exemplary embodiment. FIG. [Figure 2] FIG. 2 illustrates the aluminum foil shown in FIG. 1 with a foil coating according to an exemplary embodiment. [Figure 3] FIG. 3 is a schematic diagram showing the aluminum foil shown in FIG. 2 in a partially rolled-up state. [Figure 4] 4A is a partial schematic cross-sectional view of the structure of a laminated core according to an exemplary embodiment during manufacture, the left portion representing the cross-section of the laminated core before heat treatment, and the right portion representing the cross-section of the laminated core after heat treatment, the cross-section being indicated by IV in FIG. 4A. [Figure 4A] FIG. 2 is a schematic view of the entire laminated core. [Figure 5] 1 during manufacture in a modified form, prior to heat treatment, and similar to FIG. 4, showing a cross section of the entire laminated core. [Figure 6] 3 is a plan view of a coated foil sheet for the laminated core shown in FIG. 1 or FIG. 2 according to a possible configuration. [Figure 7] 3 is a diagram showing the laminated core shown in FIG. 1 or 2 in a completed manufacturing state after heat treatment. FIG. [Figure 8A] 1 is a phase diagram illustrating the present invention, showing a diagram for an austenite stabilizer; FIG. [Figure 8B] 1 is a phase diagram illustrating the present invention, showing a diagram for eutectic formers; FIG. [Figure 8C]1 is a phase diagram illustrating the present invention, showing a diagram of ferrite forming elements; FIG. DETAILED DESCRIPTION OF THE INVENTION

[0022] 1 shows, in a partially schematic cross-sectional view, the structure of an aluminum foil 11 according to an exemplary embodiment. The aluminum foil 11 has an aluminum oxide foil layer 8. Furthermore, the aluminum foil 11 has a support foil 10, which is not oxidized and therefore consists of pure aluminum.

[0023] 2 shows the aluminum foil 11 shown in FIG. 1 with a foil coating 17 according to an exemplary embodiment. The foil coating 17 is formed from an alloying material 16 and is applied to one of the faces 12, 13. The alloying material 16 includes silicon, and preferably consists at least substantially of silicon. The foil coating 17 may include additional components. A configuration in which the aluminum foil 11 is as thin as possible with a foil coating 17 that includes an alloying element such as silicon is advantageous.

[0024] Figure 3 is a schematic diagram of the aluminum foil 11 shown in Figure 2 in a partially rolled state, where the foil coating 17 is not shown for ease of illustration. Thin foil sheets 6, 7 are cut from the aluminum foil 11, and then each thin foil sheet 6, 7 is coated with a foil coating 17.

[0025] The aluminium foil 11 can then be fed so that one or both sides 12, 13 of the aluminium foil 11 are provided with an aluminium oxide foil layer 8. Thus, depending on the configuration, there may be an aluminium oxide foil layer 8, 9 on only one of the sides 12, 13 or alternatively on both sides 12, 13. The aluminium foil 11 may be present wound up on a roll 18, which is shown diagrammatically.

[0026] Preferably, the aluminum oxide foil layer 8 is on only one of the faces 12,13 and the silicon-based foil coating 17 is on only one of the faces 12,13. FIG. 4 shows in a partially schematic cross-sectional view the structure of a laminated core 1 according to an exemplary embodiment during manufacture.

[0027] Here, reference numeral 4 indicates a cross section of the entire laminated core 1, as indicated by IV in FIG. 4A. The laminated core 1 can in particular be used in the rotor 2 (FIG. 6) or stator of an electric machine 3. Such a rotor 2 can then comprise a plurality of such laminated cores 1. The laminated core 1 is particularly suitable for an electric machine 3 that functions as an electric drive motor 3 for an automobile.

[0028] To manufacture the laminated core 1, the following method steps are carried out according to the invention. In a first step, foil sheets 6, 7, 10, 11 are provided, each of which comprises an aluminum support foil 10, i.e., aluminum foil, and a natural or produced insulating layer 8, in particular an aluminum oxide foil layer 8, formed on the support foil 10, and which each has a foil coating 17 on at least one side 12, 13. The foil coating 17 comprises an alloying material 16, such as silicon, an adhesive binder, and in particular further powdered aluminum oxide.

[0029] In a subsequent second step, the metal laminations 4, 5 of the laminated core 1 are provided, which are not particularly electrically insulated. In a subsequent third step, the metal sheet laminates 4, 5 and the foil sheets 6, 7, 11 are alternately stacked so that at least one foil sheet 6, 7, 11 is located between each adjacent metal sheet laminate 4, 5.

[0030] In a subsequent fourth step, the stack of metal sheets 4, 5 and foil sheets 6, 7, 11 is heated, in particular heat-treated, a) as the support foil 10 melts, aluminum from the support foil 10 of the foil sheets 6, 7, 10, 11 diffuses into the metal of the adjacent metal sheets 4, 5 at a specific depth, and alloying material 16 from the foil coating 17 of the foil sheets 6, 7, 11 diffuses into the metal of the adjacent metal sheets 4, 5 at a specific depth 25, 26 to form alloyed regions 23, 24; b) Aluminum oxide (Al2O3) from the aluminum oxide foil layer 8 or foil coating 17 of the foil laminae 6, 7, 11 remains and forms an insulating layer 27 between the metal sheet laminae 4, 5.

[0031] The heating in the fourth step can be performed, for example, by radiation and / or convection, by induction or by the flow of an electric current through the metal sheets 4, 5. The laminated core 1 comprises metal sheets 4, 5, 5' based on an iron-based material.

[0032] During manufacture, at least one foil sheet 6, 7 is disposed between adjacent metal sheet laminates 4, 5, 5', respectively. In the exemplary embodiment shown in Figure 1, foil sheet 6 is disposed between metal sheet laminates 4, 5, and foil sheet 7 is disposed between metal sheet laminates 4, 5'.

[0033] Preferably, the entire roll or coil of aluminum foil 11 is coated and rewound. During the manufacture of the laminated core 1, which is carried out by stacking alternate metal sheet laminates (electrical sheets) 4, 5 and aluminum foil, the foil laminates 6, 7 are cut or cut from the aluminum foil roll 11 and placed between the metal sheet laminates 4, 5, 5'.

[0034] In the illustrated form, the foil sheet 6 comprises one aluminium oxide foil layer 8 on each of its two sides 12, 13. In addition, a foil coating 17 is applied to both sides 12, 13 of the foil sheet 6.

[0035] After heat treatment, the state shown on the right side of Figure 4 is achieved. The silicon and aluminum have now diffused into the alloy zones or regions 23 and 24 of the metal sheets 4 and 5, respectively, increasing the volume of the metal sheets 4, 5, and 5'. The aluminum can now form a eutectic with the silicon, which facilitates diffusion. Aluminum oxide 8 remains between the layers 4, 5, and 5'.

[0036] FIG. 5 shows the structure shown in FIG. 1 as manufactured in a modified form. Similar to FIG. 4, a cross section of the entire laminated core is shown. In this form, foil sheets 6, 7 can be cut from aluminum foil 11 and multiple foil sheets, e.g., two foil sheets 6, 7, can be placed between adjacent metal sheets 4, 5. This has the advantage that, when the aluminum foil 11 used comprises a pure aluminum layer 10, e.g., half its thickness, a larger amount of aluminum oxide and / or alloy material 16 can be introduced between adjacent metal sheets 4, 5. This allows for correspondingly larger amounts of aluminum oxide and / or alloy material 16 to be introduced without significantly impairing handling. For simplicity, the layer structure of the foil sheets 6, 7 is not shown in FIG. 5. The layer structure of the foil sheets 6, 7 is obtained in a similar manner to the form described with reference to FIG. 1. The foil sheets 6, 7 are preferably much thinner than the foil coating 17 containing the alloy material 16.

[0037] The foil coating 17 may comprise an adhesive binder and / or polysaccharide, in particular xanthan, by means of which the alloying material 16 is applied to the upper surface 14 of the aluminum foil 11 and thus to the foil sheets 6, 7. However, in a modified form, the alloying material 16 can also be applied as an aqueous suspension. However, application by adhesive binder and / or polysaccharide has the advantage of allowing a more uniform and consistent application, even to complex geometries, onto the metal sheets 4, 5, which are usually already punched. A further advantage is that the powdered alloying material 16 does not fall off the aluminum foil 11 and foil sheets 6, 7 after drying.

[0038] The adhesive binder or polysaccharide can be removed by a heat treatment prior to the alloying heat treatment, which can be carried out in a hydrogen atmosphere at a temperature in the range of about 150°C to 500°C for about 1 to about 2 hours.

[0039] Further modifications are possible. For example, more than two foil sheets 6, 7 can be arranged between adjacent metal sheets 4, 5. Furthermore, it is also possible to realize structural variations within the laminated core 1. For example, it is not always necessary to provide a foil sheet 6, 7 between adjacent metal sheets, and it is not always necessary to provide the same number of foil sheets 6, 7 between adjacent metal sheets. However, a uniform structure of the laminated core is preferably realized during manufacturing.

[0040] The thickness of the aluminum foil 11, and thus the foil sheets 6 and 7, and the morphology and composition of the foil coating 17, particularly the alloying material 16, are selected so that, after heat treatment, at least a portion 20 of the surface 21 of the metal sheet 5, at least near the surface, has a silicon mass fraction of at least about 6.5% and a silicon and aluminum mass fraction of not more than 8.5%. This also applies to the metal sheet 4. In a modified embodiment, a silicon mass fraction of between about 4% and about 5% and a silicon and aluminum mass fraction of not more than about 8.5% can be selected. The alloying of the metal sheet 5 can be carried out over the entire surface 21 of the metal sheet 5. However, alloying can also be carried out only on a portion 20 of the surface 21 of the metal sheet 5, as will be described below with reference to FIG. 6.

[0041] FIG. 6 shows a plan view of the coated foil sheet 6 arranged on the metal sheet 5 for the laminated core 1 shown in FIG. 1 or 2, according to a possible configuration for the rotor 2. Here, portion 20 is the radially outer portion 20, where eddy currents may occur at least substantially during operation. Therefore, a higher alloying is beneficial here to prevent losses due to eddy currents. Another portion 22 is the radially inner portion 22 of surface 21. Portions 20, 22 of the metal sheet 5 correspond to portions 20', 22' of the foil sheet 6. Here, the foil sheet 6 can be provided with a foil coating 17 such that the foil coating 17 is only present on portion 20' of the foil sheet 6. This means that, after manufacturing, portion 20 of the metal sheet 5 achieves a higher alloying than the other portion 22 of the metal sheet 5. In particular, this allows the iron material in portion 22, where the metal sheet 5 is pressed, for example, against a shaft, to have a higher mechanical load-bearing capacity.

[0042] Here, the silicon in portion 20 does not lose its volume after diffusing into the iron of electrical sheet 5, resulting in a corresponding increase in the thickness of electrical sheet 5, thereby ensuring that no void formation occurs in portion 22. To compensate for this, an inert powder such as aluminum oxide powder can be used, for example, in portion 21.

[0043] The configuration described with reference to FIG. 6 for the rotor 2 can be realized in a similar but reversed manner for the laminated core 1 acting as the stator. FIG. 7 shows the laminated core 1 shown in FIG. 5 in its completed state. Similarly, the laminated core 1 shown on the right side of FIG. 4 can be obtained. The heat treatment used for alloying, which can be carried out at temperatures ranging from 950°C to 1250°C, preferably from 1000°C to 1100°C, for 10 to 30 minutes, achieves diffusion of silicon and aluminum into the thin metal sheets 4, 5. This diffusion is preferably near the surface, resulting in an average penetration depth 25, 26 of less than half the thickness of the thin metal sheets 4, 5. An aluminum oxide layer 27 remains between the thin metal sheets 4, 5 as an insulator 27, the thickness 28 of which can be determined in advance. The cores 29, 30 of the thin metal sheets 4, 5 are less or almost completely alloyed with respect to the alloy material 16.

[0044] In one possible embodiment, the aluminum foil 11 can have a thickness of approximately 5 μm to approximately 10 μm. However, in a modified embodiment, for example, an aluminum foil 11 anodized on both sides can have a foil thickness of 0.03 mm and an oxide layer thickness of 5 to 6 μm. For example, an alloy material 16 in the form of silicon powder having an average particle size of 1 to 5 μm is particularly suitable for such a foil thickness of 0.03 mm. Similarly, for a foil thickness of, for example, 5 μm, silicon powder having an average particle size of 1 to 5 μm and, optionally, aluminum oxide powder having an average particle size of 0.5 μm can be used. The aluminum foil 11 can have, for example, an aluminum oxide foil layer having a thickness of 1 μm and a metallic aluminum layer having a thickness of 4 to 5 μm.

[0045] In a modified form, the aluminum oxide foil layer of the aluminum foil 11, and thus of the foil sheets 6, 7, can also be omitted when, in addition to the alloy material 16, aluminum oxide is applied to the aluminum foil 11 by means of a foil coating 17. Here, the aluminum oxide can be aluminum oxide powder. In principle, it is also possible to use an aluminum foil 11 that comprises at least one aluminum oxide foil layer 8, 9 and a foil coating 17 that further comprises aluminum oxide.

[0046] Other electrically insulating solids, preferably used as electrically insulating powders, can also be used as the electrically insulating component of the foil coating 17, as long as they are stable and do not melt in the hydrogen atmosphere, especially up to 1250°C. In the hydrogen atmosphere, a significant reduction in aluminum oxide occurs above 1300°C, up to 20% by mass fraction. At a heat treatment temperature of 1250°C, the aluminum oxide is reduced by up to 7%. Silicon oxide (SiO2) and mullite (Al (4+2x) Si (2-2x) O (10-x) , where x=0.17 to 0.59), is also stable and does not melt in a strongly reducing hydrogen atmosphere up to 1250° C. Preferably, oxides of aluminum and silicon are used to form the insulator 27.

[0047] The foil sheets 6, 7 can be punched out of the aluminum foil 11 to the same shape as the metal sheets 4, 5 before being stacked on the laminated core 1. However, it is also possible to stack the foil sheets 6, 7 unpunched between the metal sheets 4, 5. After stacking, the excess foil can then be removed. It is also possible that the excess foil is not removed and melts off during the heat treatment.

[0048] In the completed manufacturing state, for example, the aluminum oxide layer 27, which functions as an insulator 27, at least partially has fine channels perpendicular to the layer plane, which are typical of an anodized aluminum oxide layer. Here, further, the layer structure of the aluminum oxide layer 27 may consist of multiple thin sub-layers.

[0049] 8A, 8B, and 8C, the effect of a suitable alloying element X on the size of each austenite domain in each FeX phase diagram is shown, where the concentration (wt%) of each alloying element X is plotted on the x-axis and the temperature T is plotted on the y-axis.

[0050] Figure 8A is a phase diagram illustrating the present invention, showing a diagram related to an austenite stabilizer. As shown in the schematic phase diagram, with manganese as an austenite stabilizer, the austenite phase (γ) is stabilized at lower temperatures as the manganese concentration increases. The diagram shows room temperature as the lower temperature limit.

[0051] In Figure 8A, an exemplary behavior according to the present invention is shown according to line Y, illustrating the effect of austenite stabilization during the course of heat treatment. Due to the diffusion of the austenite stabilizer into the respective metal sheets 4, 5, the austenite in the heated metal sheets 4, 5 is stabilized so that upon cooling of the metal sheets 4, 5, the austenite does not transform back to ferrite according to the phase diagram.

[0052] FIG. 8B shows a phase diagram for explaining the present invention, showing a diagram for eutectic forming materials. As shown in the schematic phase diagram, with copper as a eutectic former, the austenite phase becomes stable at lower temperatures as the copper concentration increases. However, this does not allow stability down to room temperature. Rather, at a certain copper concentration, a minimum temperature value occurs at which the austenite phase is still stable. This region, where austenite is stable even at low temperatures significantly below A3, allows the austenite to nearly freeze upon cooling and thus be preserved upon further cooling to room temperature. Thereafter, as the copper concentration increases further, the temperature at which the austenite phase becomes stable also increases. This makes it increasingly difficult, and eventually impossible, to nearly freeze austenite upon cooling. Further increases in copper concentration reach a concentration at which the formation of the austenite phase in iron is no longer possible.

[0053] FIG. 8C is a phase diagram for explaining the present invention, showing a diagram relating to ferrite forming elements. As shown in the schematic phase diagram, ferrite (α) is the stable phase at room temperature due to ferrite-forming elements such as silicon or aluminum. This means that austenite is stable only when low concentrations of ferrite-forming elements are present at the same time as high temperatures. Therefore, austenite cannot freeze out on cooling, as it will transform to ferrite at higher temperatures.

[0054] The invention is not limited to the exemplary embodiments described above.

Claims

1. 1. A method for manufacturing a laminated core, in particular for the subsequent alloying of the metal sheets (4, 5) of a laminated core (1) and for the subsequent production of insulating layers (8, 9) on or between the metal sheets (4, 5) of said laminated core (1) of an electric machine, in particular a stator or rotor, comprising: - providing foil sheets (6, 7, 10, 11) each comprising an aluminum support foil (10) and a natural or produced aluminum oxide foil layer (8), each having a foil coating (17) on at least one side (12, 13), said foil coating (17) comprising an alloy material (16), in particular silicon, an adhesive binder, and in particular further powdered aluminum oxide; - providing the metal sheets (4, 5) of said laminated core (1) in particular without electrical insulation; - stacking the metal sheets (4, 5) and the foil sheets (6, 7, 11) alternately so that at least one foil sheet (6, 7, 11) is located between each adjacent metal sheet (4, 5); - heating, in particular heat treating, the laminate of metal sheets (4, 5) and foil sheets (6, 7, 11), a) aluminum from the support foil (10) of the foil thin sheets (6, 7, 10, 11) diffuses into the metal of the adjacent metal sheet thin sheets (4, 5) as the support foil (10) dissolves, and the alloy material (16) from the foil coating (17) of the foil thin sheets (6, 7, 11) diffuses into the metal of the adjacent metal sheet thin sheets (4, 5) at specific depths (25, 26) to form alloy regions (23, 24); b) the aluminum oxide from the aluminum oxide foil layer (8) or the foil coating (17) of the foil laminae (6, 7, 11) remains and forms an insulating layer (27) between the metal sheet laminae (4, 5); method.

2. 2. The method according to claim 1, wherein the shape and / or area of ​​the foil sheets (6, 7, 11) correspond to the shape and / or area of ​​the metal sheet sheets (4, 5).

3. 2. The method according to claim 1, characterized in that the aluminum-based foil sheets (6, 7, 10, 11) are cut or are cut from an aluminum foil (11), the aluminum foil (11) being provided with the aluminum oxide foil layer (8, 9) on at least one side and / or the aluminum foil (11) being at least partially coated or will be coated with the alloy material (16) on at least one top side (14, 15).

4. A method as described in claim 3, characterized in that the alloy material (16) is or is at least partially applied to the at least one upper surface (14, 15) of the foil sheet (6, 7, 10, 11) by means of an adhesive binder, in particular a paste, and / or by means of a polysaccharide, in particular xanthan.

5. 2. The method according to claim 1, wherein at least two of said foil sheets (6, 7, 10, 11) are at least partially arranged between adjacent sheet metal sheets (4, 5).

6. 2. The method of claim 1, wherein the thickness of the foil (6, 7, 10, 11) and the alloy material (16) and optionally the electrically insulating solid applied to the foil (6, 7, 10, 11) are selected such that, after the heat treatment, at least a portion (20) of the surface (21) of the metal sheet (4, 5), at least near the surface, has a mass fraction of silicon of at least about 6.5% and a mass fraction of silicon and aluminum of not more than about 8.5%, or at least near the surface, has a mass fraction of silicon between about 4% and about 5% and a mass fraction of silicon and aluminum of not more than about 8.5%.

7. 2. The method of claim 1, wherein the foil sheets (6, 7, 10, 11) have a thickness of about 5 μm to about 10 μm.

8. 2. The method according to claim 1, wherein the heat treatment of the metal sheets (4, 5) between which the foil sheets (6, 7, 10, 11) are arranged, which is carried out before the heat treatment for alloying, is carried out in a range of about 150°C to 500°C for 1 hour to about 2 hours.

9. 2. The method according to claim 1, wherein in a laminated core for a rotor, the foil sheets (6, 7, 10, 11) are partially coated with the alloy material (16), and the alloy material is provided closer to the radially outer portions (20') of the foil sheets (6, 7, 10, 11) than to the radially inner portions (22') of the foil sheets (6, 7, 10, 11).

10. 10. The method according to claim 9, characterized in that in a laminated core for a stator, the foil sheets (6, 7, 10, 11) are partially coated with the alloy material (16), and the alloy material is provided closer to the radially inner portion (22') of the foil sheets (6, 7, 10, 11) than to the radially outer portion (20') of the foil sheets (6, 7, 10, 11).

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