Stator for an electric motor, and method for manufacturing a stator

Abstract

The invention relates to a stator (1) for an electric motor, the stator having a basic shape, the basic shape consisting of a single-piece insulating material (14), and the stator (1) comprising a first end region (5), a second end region (6), and a core region (7) arranged between the first end region (5) and the second end region (6), electrical conductors (4) for coil windings being embedded in the insulating material (14), the electrical conductors (4) extending within the insulating material (14) of the first end region (5) and of the second end region (6) substantially in the transverse direction (11) and within the insulating material (14) of the core region (7) in the longitudinal direction (12), the core region (7) having, in the longitudinal direction (12), at least one sequence of alternately arranged first core layers (8) and second core layers (9), the insulating material (14) in the first core layer (8) being formed as a column structure (10) and in the second core layer (9) being formed as a planar structure (21), and ferromagnetic material (13) for forming stator teeth (3) between the column structures (10) made of insulating material (14) being arranged in the first core layers (8). The invention also relates to a method (100) for manufacturing a stator (1).

Description

[0001] Description

[0002] Stator for an electric motor and method for producing a stator

[0003] The patent application claims priority from the German patent application

[0004] 10 2024 109 316.1 , the disclosure content of which is hereby incorporated by reference.

[0005] Stators for electric motors are an essential component in drive systems and are used in a wide variety of applications, for example in industrial machines or electric vehicles. The stator is one of the core components in an electric motor. A magnetic field is generated in the stator, which serves to set a rotor in rotation. Typically, coils consisting of electrical wires are wound around a ferromagnetic stator tooth for this purpose. In order to increase the efficiency of stators, for example, it is desirable to optimize coil winding techniques. Even modern coil winding techniques often only offer limited options for the geometric arrangement of the electrical wires and also restrict the geometric design of the stator teeth. After the electrical wires have been wound, the stator is encapsulated with insulating material to protect the winding.Subsequently, further manual manufacturing steps often have to be performed to achieve the desired dimensions and tolerances for the stator. Consequently, complex and diverse manufacturing technologies are required for stator production. Stator production often also involves manual manufacturing steps.

[0006] It is therefore an object of the invention to provide an improved stator for an electric motor and an improved method for producing a stator.

[0007] The object is achieved by a stator according to claim 1 and by a method for producing a stator according to claim 9. Advantageous embodiments are specified in the dependent claims.

[0008] According to one aspect of the invention, a stator for an electric motor is provided with a basic shape that has a through opening in the longitudinal direction for receiving a rotor. The basic shape consists of an integrally formed insulating material, and a plurality of coils are provided in the basic shape radially circumferentially with respect to the longitudinal direction. The coils have electrical lines in the form of coil windings, and the stator has a first end region, a second end region, and a core region arranged between the first end region and the second end region. The electrical lines of the coil windings are embedded in the insulating material. In addition, the electrical lines of the coil windings run essentially in the transverse direction in the insulating material of the first end region and the second end region, and in the longitudinal direction in the insulating material of the core region.The core region has at least one sequence of alternating first core layers and second core layers in the longitudinal direction. The two outer core layers of the core region adjacent to the first end region and the second end region, respectively, are first core layers. The insulation material is formed as a columnar structure in the first core layer and as a planar structure in the second core layer. Ferromagnetic material for forming stator teeth is arranged between the columnar structures in the first core layer.

[0009] This makes it possible to achieve the technical advantage of providing an improved stator for an electric motor. For this purpose, the stator has a one-piece basic shape made of insulating material and, in the core region, has a sequence of alternating first and second core layers. In the first core layer, the insulating material is designed as a columnar structure, and the electrical lines are embedded in the insulating material in the longitudinal direction. In the second core layer, the insulating material is designed as a planar structure. Ferromagnetic material for forming stator teeth is provided between the columnar structures in the first core layer. Eddy currents can arise in the stator teeth due to the induced magnetic field of the electrical lines. To reduce the eddy currents, the insulating material is designed as a planar structure in the second core layer.This can achieve the advantage that the stator has a more homogeneous and stable magnetic field in the core area.

[0010] In other words, the ferromagnetic material for the stator teeth in the first core layers is designed to have so-called slots. The area between the slots filled with insulating material can then be viewed as a columnar structure. The term "columnar structure" should be understood as an approximately columnar configuration of the insulating material, with the cross-section of this columnar structure being able to have any possible cross-sectional shape (square, round, trapezoidal, etc.). The term "columnar structure" can be understood as an analogy for the essentially longitudinally extending region of the insulating material within the slots of the stator teeth in the first core layers.The columnar structure should also be understood as not being completely filled with insulating material, i.e., across its entire cross-section, but also serving as embedding and insulation for the electrical lines running within it. The surface structure in the second core layer should be understood as a surface extending essentially across the entire cross-section of the stator, which is formed essentially across the entire layer thickness of the second core layer. As with the columnar structure, the surface structure is designed such that the electrical lines are embedded within it.

[0011] Furthermore, this embodiment offers the advantage that the stator has a very compact design and can be manufactured using an additive manufacturing process thanks to the longitudinally running electrical lines and the layered structure within the core area. Thus, the structure and design of the stator make it possible to reduce manufacturing costs while simultaneously providing an efficient stator that is less susceptible to eddy currents. The stator can be manufactured, for example, using an additive screen printing process.

[0012] In a further embodiment, the first and second end regions each have a first end region layer and a sequence of several second end region layers and third end region layers in the longitudinal direction, as viewed from the outside. The electrical lines of the coil windings are embedded in the insulating material of the second end region layers in the transverse direction and interconnected, and are embedded in the insulating material of the third end region layers in the longitudinal direction.

[0013] This offers the technical advantage that the special design of the stator allows it to be manufactured entirely using an additive manufacturing process. Consequently, it is not necessary to plan for manual production steps for the stator. Furthermore, this embodiment makes it possible to dispense with the need for additional encapsulation for the stator in the first and second end regions. Stator insulation is already achieved by creating the basic shape from the insulation material. Furthermore, this embodiment allows the individual coils to be interconnected in any desired manner. Furthermore, additional connection steps for the coils, such as soldering, can be reduced. Manufacturing using an additive manufacturing process, particularly screen printing, also prevents faulty connection of the coils.In addition, a compact design and a significant reduction of the winding head can be achieved, in contrast to conventional stators.

[0014] In a further embodiment, electrical connections for the electrical lines are provided in the first and / or second end region, wherein the electrical connections protrude from at least one of the end region layers. The electrical connections can protrude radially or axially from the basic shape, thus enabling electrical connection of the coils.

[0015] This offers the technical advantage that, in addition to the basic shape, the stator teeth, and the coils made of electrical wires, the electrical connections for the coils can also be manufactured. By providing the electrical connections in the layers of the first and / or second end region, a further reduction in the winding head of the stator can be achieved with respect to the height of the first and / or second end region. This significantly reduces the space required for the stator, and the electric motor can be built accordingly shorter. Furthermore, complex and time-consuming connection of the coils by crimping, soldering, or welding can be eliminated.

[0016] In a further embodiment, a thermally conductive material is provided in the first end region and / or the second end region. The thermally conductive material is arranged at a distance from the electrical lines and at least partially surrounds the electrical lines.

[0017] This embodiment offers the advantage that improved heat dissipation of the stator can be provided. Typically, the insulating material in the first and / or second end region has only low thermal conductivity. Through the additional use of a thermally conductive material in the first and / or second end region, heat generated by the operation of the stator in the first and / or second end region can be better dissipated to the environment or adjacent components. Furthermore, the thermally conductive material in the first and / or second end region can be produced in one manufacturing process, i.e. together with the insulating material and the electrical lines. In a further embodiment, the first core layer has a first layer thickness and the second core layer has a second layer thickness. The second layer thickness of the second core layer is smaller than the first layer thickness of the first core layer.

[0018] This embodiment offers the advantage that, on the one hand, the eddy currents in the stator teeth can be reduced by a thinner design of the second core layer made of insulating material and, on the other hand, a sufficiently strong magnetic field can be realized in the stator teeth by the greater design of the first layer made of ferromagnetic material.

[0019] In a further embodiment, the first end region and / or the second end region and / or the core region have a notch and / or a nose extending in the longitudinal direction at a radial end region.

[0020] This embodiment offers the technical advantage that the stator can be mounted in a housing so that it cannot twist. Since the stator should be mounted as stably as possible in a housing, and should not perform any rotational or translational movement, it is advantageous to provide a notch or a lug. If the stator has a notch, a lug complementarily formed on a housing can then engage in the notch to form a positive connection between the stator and the housing, which secures the stator in its position relative to a housing. If the stator has a lug, this can then engage in a notch complementarily formed on a housing to form a positive connection between the stator and the housing, which secures the stator in its position relative to a housing. Multiple notches and / or lugs can also be formed on the stator.

[0021] In a further embodiment, the stator has a housing at the radial end region, wherein the housing is made of a metallic material.

[0022] This offers the technical advantage of providing a housing in addition to the stator. Furthermore, the stator and housing can be manufactured as a single component. This offers the advantage that the stator does not need to be subsequently installed in a housing. Furthermore, the housing can be manufactured to precisely match the shape of the stator. Alternatively, the outer casing of the stator can also be coated and / or painted.

[0023] This also offers the advantage that the stator does not have to be subsequently installed in a housing to protect it from external influences.

[0024] In a further embodiment, the electrical lines of the coil windings have different wire cross-sections in the longitudinal direction within the basic shape, wherein the electrical lines have a larger cross-sectional area in at least one edge region.

[0025] This allows for the technical advantage of providing a significantly improved fill factor within the windings, thus increasing the stator's performance. By combining different wire cross-sections, the available installation space can be optimally utilized. Furthermore, the larger wires in a peripheral area can further increase the fill factor. This allows for a particularly effective and powerful stator.

[0026] According to a second aspect of the invention, a method for manufacturing a stator for an electric motor is proposed. The stator has a basic shape with a through-opening in the longitudinal direction for accommodating a rotor. A plurality of coils are provided in the basic shape, extending radially around the longitudinal direction. The coils have electrical leads in the form of coil windings. The basic shape consists of a one-piece insulating material. The method comprises the following steps:

[0027] - Creating a first end region by applying insulating material in layers, wherein the electrical lines of the coil windings are embedded in the insulating material substantially in the transverse direction;

[0028] - Creating a core region on the first end region by applying insulating material in layers, wherein the electrical lines of the coil windings are embedded in the insulating material in the longitudinal direction, and wherein the core region is created in the longitudinal direction from an alternating sequence of first core layers and second core layers, wherein a first core layer is created adjacent to the first end region, wherein the insulating material is formed as a column structure in the first core layer and as a surface structure in the second core layer, wherein ferromagnetic material for forming stator teeth is arranged between the column structures made of insulating material in the first core layers;

[0029] - Creating a second end region, adjacent to a first core layer, by applying insulating material in layers, wherein the electrical lines of the coil windings are embedded in the insulating material substantially in the transverse direction.

[0030] With the proposed method, a stator can be manufactured in a simple and efficient manner using an additive manufacturing process. Advantageously, a one-piece basic shape can be created from insulating material. The core region is created from at least two different core layers. The electrical lines in the first core layer are embedded in a column structure made of insulating material. In the second core layer, the insulating material is formed as a surface structure. It can therefore be achieved that by using different layers, an improved manufacturing process for a stator can be provided. The special formation of the insulating material in the core layers can advantageously reduce eddy currents that can form in the stator teeth.

[0031] In a further embodiment, the first and the second end region in the longitudinal direction, each viewed from the outside, have a first end region layer and a sequence of several second end region layers and third end region layers, wherein the electrical lines of the coil windings are embedded in the insulating material of the second end region layers in the transverse direction and interconnected, and wherein the electrical lines of the coil windings are embedded in the insulating material of the third end region layers in the longitudinal direction.

[0032] This offers the technical advantage that a complex winding overhang geometry can be efficiently manufactured in the first and second end regions using the process. By using the different layers, even complex interconnections in the winding overhang of the stator can be integrated in a space-saving and efficient manner. The interconnections in the winding overhang can, for example, be designed as a star connection, delta connection, or zigzag connection. However, any other type of interconnection can also be created using the manufacturing process. In a further embodiment, the process is carried out as an additive screen printing process. A separate screen is used for each of the end region layers to apply the insulation material and an electrically conductive material for the electrical lines. Furthermore, a first screen is used for the first core layer and a second screen for the second core layer.The first screen is used to apply the electrically conductive material for the electrical wires of the coil windings, the insulation material, and the ferromagnetic material for forming the stator teeth. The second screen is used to apply the electrically conductive material for the electrical wires of the coil windings and the insulation material.

[0033] This offers the technical advantage of allowing the two end sections and the entire core area, including the stator teeth, electrical wires, and insulation material, to be created in a single process. This makes it possible, for example, to create different cross-sectional shapes for the electrical wires. Furthermore, the electrical wires are insulated during production. It also eliminates the need for complex coil winding.

[0034] The term "screen" does not necessarily refer to a single, formed component. Rather, a screen for a layer can also consist of several individual screens and / or inserts or templates for a screen, so that the different materials to be applied are applied using an individual screen and / or insert or template specific to the respective material and its precise placement. Thus, the screen for each layer can consist of a single or multiple individual screens and / or inserts or templates.

[0035] In a further embodiment, the layers are created by applying several layers to form a layer, wherein the sieve of one layer is used to create several layers of a layer, wherein after creation of each layer a consolidation process is carried out, wherein the layers are layered in the longitudinal direction and applied in the transverse direction until a defined layer height for the layer is reached.

[0036] This offers the technical advantage of allowing the layer heights to be precisely adjusted to the required installation space. This provides considerable design freedom for the stator. Furthermore, the stator can be manufactured more efficiently and in a more space-efficient manner, as the layers can be fabricated by applying the layers to the defined and required layer heights.

[0037] The invention is explained in more detail below with reference to the figures. These show:

[0038] - Fig. 1 is a perspective view of a stator according to an embodiment;

[0039] - Fig. 2 is a perspective view of a cross-section of the stator according to the section plane T of Fig. 1;

[0040] - Fig. 3 is a sectional view of the stator according to the section plane S of Fig. 1;

[0041] - Fig. 4 is a side view in partial section of the stator;

[0042] - Fig. 5 schematic exemplary cross-sections of the cutting planes A, B, C and D from Fig. 3 of the first end region of the stator;

[0043] - Fig. 6 schematic exemplary cross-sections of the cutting planes E, F and G from Fig. 3 of the first end region of the stator;

[0044] - Fig. 7 schematic exemplary cross-sections of the cutting planes H and I from Fig. 3 of the core area of ​​the stator;

[0045] - Fig. 8 schematic exemplary cross-sections of the cutting planes J, K, L and M from Fig. 3 of the second end region of the stator;

[0046] - Fig. 9 schematic exemplary cross-sections of the cutting planes N, O and P from Fig. 3 of the second end region of the stator; Fig. 10 a schematic exemplary cross-section of the cutting plane H from

[0047] Fig. 3 of the first core layer or third core layer of the stator in a further embodiment;

[0048] - Fig. 11 shows a schematic exemplary cross-section of the section plane B from Fig. 3 of the first end region of the stator in a further embodiment;

[0049] - Fig. 12 shows a schematic exemplary cross-section of the section plane B from Fig. 3 of the first end region of the stator in yet another embodiment;

[0050] - Fig. 13 is a schematic exemplary cross-section of the section plane B from Fig. 3 of the first end region of the stator in yet another embodiment;

[0051] - Fig. 14 shows a partial area of ​​an enlarged, schematic sectional view of the core area of ​​the stator in a further embodiment;

[0052] - Fig. 15 exemplary different embodiments of the electrical lines in a winding region of the core region;

[0053] - Fig. 16 is a schematic representation of a method for manufacturing the stator.

[0054] Fig. 1 shows a perspective view of a stator 1 according to an embodiment.

[0055] The stator 1 is exemplarily designed as a hollow cylinder, wherein the stator 1 extends in a longitudinal direction 12. The stator 1 has a plurality of coils 2 and a plurality of stator teeth 3 radially circumferentially. In this exemplary embodiment, the stator 1 has twelve coils 2 and twelve stator teeth 3. The stator 1 can also have more or fewer coils 2 and stator teeth 3. For example, two, four, or sixteen coils 2 and stator teeth 3 can be provided. Furthermore, the stator 1 has a first end region 5, a second end region 6, and a core region 7. The coils 2 consist of electrical lines 4 and surround the stator teeth 3 in the form of coil windings.

[0056] The electrical lines 4 for the coils 2 consist of an electrically conductive material and are made of copper, for example.

[0057] Furthermore, the stator 1 has a one-piece base made of an insulating material 14. Electrically insulating materials can be used as the insulating material 14. For example, ceramics or plastic can be used.

[0058] The radially arranged coil windings of electrical lines 4 are embedded in the basic form of the insulating material 14. In the core region 7, the electrical lines 4 run within the insulating material 14 in the longitudinal direction 12.

[0059] The stator 1 can, for example, be used to drive a rotor or armature of an electric motor (not shown here). To do this, a magnetic field is induced in the stator teeth 3 by means of the coils 2 through the electrical lines 4.

[0060] Fig. 2 shows a perspective view of a cross section of the stator 1 according to the section plane T of Fig. 1.

[0061] The illustration according to Fig. 2 shows the first end region 5 and a part of the core region 7. The first end region 5 borders the core region 7 in the longitudinal direction 12. The electrical lines 4 run in the core region 7 in the longitudinal direction 12 and are arranged in the form of a winding, radially encircling and surrounding the stator teeth 3.

[0062] In this embodiment, a winding of the electrical lines 4 is illustrated with eight turns as an example. More or fewer turns can also be used for a winding. Thus, the electrical lines 4 can form two turns or even twenty turns. Furthermore, the electrical lines 4 for the coil windings are again embedded in the basic form of the insulating material 14 in the first end region 5 and the core region 7.

[0063] Fig. 3 shows a sectional view of the stator 1 along the sectional plane S of Fig. 1. The stator 1 is additively manufactured, for example, starting with the first end region 5, followed by the core region 7, and finally the second end region 6. Known additive manufacturing methods can be used for this purpose. The inventive structure of the stator 1 is described below based on its production using an additive screen printing process, although a stator 1 according to the invention is not limited to this specific manufacturing method.

[0064] As is common with additive manufacturing processes, the stator 1 consists of a plurality of individual layers 28, of which only one layer 28 is shown in Fig. 3 as an example by means of dotted lines. The individual layers 28 build upon one another in the longitudinal direction 12 until the finished stator 1 is created.

[0065] Each layer 28 has a uniform layer thickness 29, which can, for example, be in a range of 0.05 to 0.25 mm. However, the individual layer thicknesses 29 can also vary within this range from layer 28 to layer 28. Two or more different materials can also be used for each layer 28 in order to form the respective components in the respective layer 28.

[0066] Depending on the selected manufacturing process, the two or more different materials can be introduced into the respective layer 28 in a single process step or in several consecutive process steps. After the production of a layer 28, it may be necessary for the materials applied in layer 28 to first be dried and / or, if necessary, sintered and / or subjected to a further process step. This process step can generally also be referred to as a solidification process. Then, the manufacturing process for the subsequent layer 28 in the longitudinal direction 12 begins. One or more layers 28 can then form a layer 36.

[0067] A layer 36 is characterized, for example, by the fact that the cross-section in the longitudinal direction 12 of all layers 28 of this layer 36 is identical or nearly identical. If the cross-section and / or the material composition change from one layer 28 to the next, this can be considered a change from one layer 36 to the subsequent layer 36.

[0068] In a screen printing process, all layers 28 of a layer 36 use an identical screen. As soon as the screen is changed or a differently designed screen is used, a change from one layer 36 to a subsequent layer 36 occurs. The term “identical screen” should not be understood here as a single component designed as a screen. Rather, a screen for a layer 36 can also consist of several individual screens and / or inserts or stencils for a screen, so that in each layer 28, the individual different materials to be applied are applied using an individual screen and / or insert or stencil specific to the respective material and the exact placement of the respective material. Thus, the described identical screen for each layer 36 can consist of a single or a plurality of individual screens and / or inserts or stencils.

[0069] Accordingly, the different first layers 15 of the first end region 5 are first produced layer 28 by layer 28. Then, the first core layer 8 and the second core layer 9 of the core region are produced layer 28 by layer 28, whereby the first core layer 8 and the second core layer 9 can be repeated at a desired frequency to form the stator 1 with a desired length. Subsequently, the second layers 16 of the second end region 6 are produced layer 28 by layer 28.

[0070] First, the production of the second layers 16 of the second end region 6 will be discussed in more detail below. The description can be applied to the production of the first layers 15 of the first end region 5, so that, to avoid repetition, only the second end region 6 will be discussed here. For the sake of simplicity, the description also takes place opposite to the longitudinal direction 12, i.e., in the reverse production sequence, provided that the stator 1 is manufactured in the longitudinal direction 12, layer 28 by layer 28.

[0071] A first end region layer 30 has a fourth layer thickness 33. The first end region layer 30 consists entirely of the insulation material 14 and is formed by repeatedly producing individual layers 28 until the desired fourth layer thickness 33 is reached.

[0072] A second end region layer 31 consists, for example, of the electrically conductive material for forming electrical lines 4 and of the insulating material 14. In the second end region layer 31, the electrical lines 4 run essentially in the transverse direction 11 and can even be made to protrude from the actual stator 1, for example, to form electrical connections 17, which are shown by way of example in Fig. 8 b), Fig. 8 d) and Fig. 9 b).

[0073] For the production of the second end region layer 31, it may also be necessary to form several layers 28 until the desired fifth layer thickness 34 of the second end region layer 31 is achieved. The fifth layer thickness 34 can, for example, be in a range from 0.05 to 4 mm. The electrical lines 4 are shown here as an example with a square cross-section. However, the electrical lines 4 can also have any other shape in cross-section, and within a stator 1, the cross-section of the electrical lines 4 can also vary as desired.

[0074] A third end region layer 32 consists, for example, of the electrically conductive material for forming electrical lines 4 and of the insulating material 14. In the third end region layer 32, the electrical lines 4 run essentially in the longitudinal direction 12.

[0075] For the production of the third end region layer 32, it may also be necessary to form several layers 28 until the desired sixth layer thickness 35 of the third end region layer 32 is reached. The sixth layer thickness 35 can, for example, be in a range of 0.5 to 4 mm.

[0076] As can be seen in Fig. 3, there can be one or more first end region layers 30, second end region layers 31 and / or third end region layers 32 in both the first end region 5 and the second end region 6, wherein in particular second end region layers 31 and third end region layers 32 alternate as viewed in the longitudinal direction 12 and wherein electrical lines 4 of second end region layers 31 can be connected to electrical lines 4 of third end region layers 32 in order to form a desired electrical interconnection of the electrical lines 4.

[0077] If a plurality of second end region layers 31 are formed in the first end region 5 and / or second end region 6, the respective second end region layers 31 do not necessarily have to be identical. If a plurality of third end region layers 32 are formed in the first end region 5 and / or second end region 6, the respective third end region layers 32 do not necessarily have to be identical. A core region 7 is formed between the first end region 5 and the second end region 6 of the stator 1. The core region 7 is also produced using individual layers 28. In the core region 7, a first core layer 8 and a second core layer 9 alternate repeatedly, such that a stator 1 can be produced in the desired length.

[0078] The first core layer 8 consists, for example, of the electrically conductive material to form electrical lines 4, of the insulating material 14 and of a ferromagnetic material 13.

[0079] The ferromagnetic material 13 can be, for example, iron or an iron alloy, in particular an iron-silicon alloy with an increased silicon content or an iron-cobalt alloy with an increased cobalt content.

[0080] The electrical lines 4 extend within the first core layer 8 essentially in the longitudinal direction 12 and are embedded in a column structure 10 made of the insulating material 14. Viewed in cross-section, the insulating material 14 is formed over an entire first layer thickness 19 of the first core layer 8, directly adjacent to the electrical lines 4, so that the respective electrical line 4 is insulated from other electrical lines 4 and / or the ferromagnetic material 13.

[0081] The cross-sectional area of ​​the first core layer 8 not filled with electrical lines 4 and the insulating material 14 is filled with the ferromagnetic material 13.

[0082] The first layer thickness 19 of the first core layer 8 is, for example, 0.3 to 0.5 mm, so that at least two layers 28 must be formed to form the first core layer 8. The ferromagnetic material 13 of the individual first core layers 8 together forms the stator teeth 3 of the stator 1.

[0083] As described, a second core layer 9 is always formed between two subsequent first core layers 8. The second core layer 9 consists of the electrically conductive material for forming electrical lines 4, and the insulating material 14. The electrical lines 4 of the second core layer 9 are then always connected to associated electrical lines 4 of a first core layer 8, so that the electrical lines 4 in the core region 7 are always continuous in the longitudinal direction 12. The cross-sectional area of ​​the second core layer 9 not filled with electrical lines 4 is completely filled with the insulating material 14 in the form of a surface structure 21.

[0084] Viewed in cross-section, the insulating material 14 is thus formed over an entire second layer thickness 20 of the second core layer 9, adjacent to the electrical lines 4, so that the respective electrical lines 4 are insulated from other electrical lines 4. The second layer thickness 20 of the second core layer 9 is, for example, 0.05 to 0.15 mm, so that at least one or possibly even two layers 28 must be formed to form the second core layer 9. Thus, the first layer thickness 19 of the first core layer 8 is many times thicker than the second layer thickness 20 of the second core layer 9.

[0085] Depending on the external structural and / or electrical conditions, an optimized layer thickness ratio between the first layer thickness 19 of the first core layer 8 and the second layer thickness 20 of the second core layer 9 can be formed due to the additive manufacturing process.

[0086] Eddy currents can form in the stator teeth 3 due to the induced magnetic field. To reduce the eddy current within the stator teeth 3, the insulating material 14 is provided as a surface structure 21 in the second core layer 9. Thus, in this embodiment, the layered structure in the core region 7 allows the stator 1 to exhibit reduced eddy currents compared to conventional stators.

[0087] Fig. 4 shows a side view in a partial section of the stator 1.

[0088] The left half of the stator 1 is shown in its entirety, including the first region 5, second region 6, and core region 7. For clarity, only the electrical lines 4 are shown in the right half of the stator 1. Also shown are sectional planes A to P, which will be discussed in more detail in connection with Figs. 5 to 9. Figs. 5 and 6 show schematic example cross-sections of the first layers 15 of the first end region 5.

[0089] The cross-sections shown serve to illustrate an exemplary layered structure of the stator 1 in the first end region 5. The first end region 5 of the stator 1 can, for example, as described, be produced by means of an additive manufacturing process and is realized by applying a plurality of layers 28 layer by layer, wherein the layers 28 are applied running in a longitudinal direction 12. One or, depending on the desired layer thickness, several layers 28 then result in a layer 36 of the stator 1, as described in detail in connection with Fig. 3. In this example, the structure of the first layers 15 is explained for the embodiment of a stator 1 with twelve coils 2, which have eight turns of electrical lines 4. By way of example, seven different first layers 15 are used for this purpose in the first end region 5.

[0090] Section plane AA in Fig. 5 a) shows a first end region layer 30 as the first layer 15 of the first end region 5, wherein the basic shape of the insulating material 14 is formed as a hollow cylinder in a surface structure 21. The basic shape can also have any shape other than a hollow cylinder, so that all considerations made in connection with a hollow cylinder also apply to any other shape of the stator 1.

[0091] The section plane BB in Fig. 5 b) shows a second end region layer 31 as the first layer 15 of the first end region 5. The second end region layer 31 extends in the longitudinal direction 12 and adjoins the first end region layer 30. In the second end region layer 31, the basic shape is again made of the insulating material 14. Furthermore, a plurality of electrical lines 4 are provided in the transverse direction 11 in the second end region layer 31 in order to form a desired interconnection of the individual coils 2.

[0092] In this exemplary embodiment, three electrical lines 4 per coil 2 are formed in the second end region layer 31 in the transverse direction 11, with twelve coils 2 being provided as an example. The second end region layer 31 is not limited to having three electrical lines 4 for each of twelve coils 2. For example, two electrical lines 4 may also be provided for each of two, three, or even sixteen coils 2. The number of electrical lines 4 for the coils 2 depends on the required number of turns and the available installation space.

[0093] The sectional plane CC in Fig. 5 c) shows a third end region layer 32 as the first layer 15 of the first end region 5. The third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the second end region layer 31 described in connection with Fig. 5 b). The third end region layer 32 again comprises the insulating material 14 from which the basic shape is made. Furthermore, the electrical lines 4 are provided in the third end region layer 32, wherein the electrical lines 4 from the second end region layer 31 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0094] The sectional plane DD in Fig. 5 d) again shows a second end region layer 31 as the first layer 15 of the first end region 5. This second end region layer 31 is arranged in the longitudinal direction 12 adjacent to the third end region layer 32 described in connection with Fig. 5 c). The second end region layer 31 again has the insulating material 14 from which the basic shape is made. The electrical lines 4 from the previously described third end region layer 32 are guided further in the longitudinal direction 12 through the second end region layer 31. Between the electrical lines 4 running in the longitudinal direction 12, three further electrical lines 4 are arranged in the transverse direction 11 for each coil 2.

[0095] The sectional plane EE in Fig. 6 a) again shows a third end region layer 32 as the first layer 15 of the first end region 5. This third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the second end region layer 31 described in connection with Fig. 5 d). The third end region layer 32 again has the insulating material 14 from which the basic shape is made. Furthermore, the electrical lines 4 are also provided in this third end region layer 32, wherein the electrical lines 4 from the preceding second end region layer 31 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0096] The sectional plane FF in Fig. 6 b) again shows a second end region layer 31 as the first layer 15 of the first end region 5. This second end region layer 31 is arranged in the longitudinal direction 12 adjacent to the third end region layer 32 described in connection with Fig. 6 a). The second end region layer 31 again has the insulating material 14 from which the basic shape is made. The electrical lines 4 from the previously described third end region layer 32 are guided further in the longitudinal direction 12 through the second end region layer 31. Between the electrical lines 4 running in the longitudinal direction 12, two further electrical lines 4 are arranged in the transverse direction 11 for each coil 2.

[0097] The sectional plane GG in Fig. 6 c) again shows a third end region layer 32 as the first layer 15 of the first end region 5. This third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the second end region layer 31 described in connection with Fig. 6 b). The third end region layer 32 again has the insulating material 14 from which the basic shape is made. Furthermore, the electrical lines 4 are also provided in this third end region layer 32, wherein the electrical lines 4 from the preceding second end region layer 31 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0098] Following the first end region 5, the core region 7, which was previously described in Figures 2, 3 and 4, can then be constructed.

[0099] In this exemplary embodiment, a layered structure for the first end region 5 of a stator 1 was described. Eight turns of electrical conductors 4 are provided for a coil 2 as an example. The number of turns can also vary. Depending on the complexity or number of turns, the number of first layers 15 used can also differ from the previously described example.

[0100] Fig. 7 a) schematically shows an exemplary cross section of the first core layer 8 of the core region 7. Fig. 7 b) schematically shows an exemplary cross section of the second core layer 9 of the core region 7.

[0101] The section plane HH in Fig. 7 a) shows a first core layer 8.

[0102] A plurality of stator teeth 3 made of the ferromagnetic material 13 are formed radially around the first core layer 8. The stator teeth 3 are shaped internally as a type of groove. The electrical lines 4 surround the stator teeth 3 in the slots in the form of coils 2. The electrical lines 4 are each surrounded by a thin-walled jacket made of the insulating material 14, so that each of the electrical lines 4 is insulated from the adjacent electrical lines 4, but also from the ferromagnetic material 13 of the stator 1. The basic shape made of the insulating material 14 extends within the first core layer 8 as a column structure 10. The individual electrical lines 4 can have any shape in cross-section, so that they preferably almost completely fill the slots of the stator 1 formed by the ferromagnetic material 13.

[0103] Section plane II in Fig. 7 b) shows a second core layer 9, in which the basic shape of the insulating material 14 is formed as a hollow cylinder in the form of a surface structure 21. In the second core layer 9, the electrical lines 4 are also surrounded by the insulating material 14. It can be seen that in this embodiment, the second core layer 9 does not contain any ferromagnetic material 13.

[0104] The electrical lines 4 run in the first core layer 8 and the second core layer 9 in the longitudinal direction 12 and are also provided at the same positions within the cross sections.

[0105] Fig. 8 and Fig. 9 show schematic exemplary cross sections of the second layers 16 of the second end region 6.

[0106] The cross-sections shown serve to illustrate an exemplary layered structure of the stator 1 in the second end region 6. The second end region 6 of the stator 1 can, for example, as described, be produced using an additive manufacturing process and is realized by applying a plurality of layers 28 layer by layer, wherein the layers 28 are applied running in a longitudinal direction 12. One or, depending on the desired layer thickness, several layers 28 then result in a layer of the stator 1, as described in detail in connection with Fig. 3. In this example, the structure of the second layers 16 is explained for the embodiment of a stator 1 with twelve coils 2, which have eight turns of electrical lines 4. By way of example, seven different second layers 16 are used for this purpose in the second end region 6.

[0107] The second end region 6 is provided in the longitudinal direction 12 adjacent to the core region 7 of the stator 1 described in connection with Fig. 7. The sectional plane JJ in Fig. 8 a) shows a third end region layer 32 as the second layer 16 of the second end region 6. The third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the first core layer 8 described in connection with Fig. 7 a). The third end region layer 32 has the insulating material 14 formed in a surface structure 21, from which the basic shape is made. Furthermore, the electrical lines 4 are provided in the third end region layer 32, wherein the electrical lines 4 from the first core layer 8 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0108] The sectional plane KK in Fig. 8 b) shows a second end region layer 31 as the second layer 16 of the second end region 6. The second end region layer 31 is arranged in the longitudinal direction 12 and adjoins the third end region layer 32. In the second end region layer 31, the basic shape is again made of the insulating material 14. Furthermore, a plurality of electrical lines 4 are provided in the transverse direction 11 in the second end region layer 31. Furthermore, an electrical connection 17 is provided. The electrical connection 17 projects beyond a radial end region 22 of the stator 1 and is designed in the transverse direction 11. In the second end region layer 31, the electrical lines 4 for the coils 2 are interconnected.

[0109] The sectional plane LL in Fig. 8 c) again shows a third end region layer 32 as the second layer 16 of the second end region 6. This third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the second end region layer 31 described in connection with Fig. 8 b). The third end region layer 32 again has the insulating material 14 from which the basic shape is made. Furthermore, the electrical lines 4 are also provided in this third end region layer 32, wherein the electrical lines 4 from the preceding second end region layer 31 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0110] The sectional plane MM in Fig. 8 d) shows a further second end region layer 31 as the second layer 16 of the second end region 6. This second end region layer 31 is arranged in the longitudinal direction 12 and adjoins the previously described third end region layer 32. In the second end region layer 31, the basic shape is again made of the insulating material 14. Furthermore, a plurality of electrical lines 4 are provided in the transverse direction 11 in the second end region layer 31. Furthermore, an electrical connection 17 is again provided. The electrical connection 17 also projects beyond the radial end region 22 of the stator 1 and is designed in the transverse direction 11. In the second end region layer 31, the electrical lines 4 for the coils 2 are interconnected.

[0111] The sectional plane NN in Fig. 9 a) again shows a third end region layer 32 as the second layer 16 of the second end region 6. This third end region layer 32 is arranged in the longitudinal direction 12 adjacent to the second end region layer 31 described in connection with Fig. 8 d). The third end region layer 32 again has the insulating material 14 from which the basic shape is made. Furthermore, the electrical lines 4 are also provided in this third end region layer 32, wherein the electrical lines 4 from the preceding second end region layer 31 are guided from their radial ends in the longitudinal direction 12 through the third end region layer 32.

[0112] The sectional plane 0-0 in Fig. 9 b) shows a further second end region layer 31 as the second layer 16 of the second end region 6. This second end region layer 31 is arranged in the longitudinal direction 12 and adjoins the previously described third end region layer 32. In the second end region layer 31, the basic shape is again made of the insulating material 14. Furthermore, a plurality of electrical lines 4 are provided in the transverse direction 11 in the second end region layer 31. Furthermore, a further electrical connection 17 is again provided. The electrical connection 17 also projects beyond the radial end region 22 of the stator 1 and is designed in the transverse direction 11. In the second end region layer 31, the electrical lines 4 for the coils 2 are interconnected.

[0113] The sectional plane PP in Fig. 9 c) shows, as the second layer 16 of the second end region 6, a further first end region layer 30, in which the hollow cylindrical basic shape is formed from the insulating material 14. This first end region layer 30 is arranged in the longitudinal direction 12 adjacent to the previously described second end region layer 31.

[0114] This exemplary embodiment shows how a winding head for a stator 1 can be constructed using a layer system consisting of, for example, seven layers. The structure was shown as an example for a stator 1 with twelve coils 2 and eight turns of electrical lines 4. Additionally, three electrical connections 17 are integrated into the second end region 6. It goes without saying that the structure allows for different embodiments depending on the number of coils 2 and turns. The layered structure also enables the entire second end region 6 of the stator 1 to be manufactured using an additive manufacturing process, in particular a screen printing process.

[0115] Fig. 10 shows a schematic exemplary cross section of the section plane HH from Fig. 3 of the first core layer 8 of the stator 1 in a further embodiment.

[0116] The essential structure of the first core layer 8 or third core layer 10 shown in Fig. 10 has already been described in connection with the description of Fig. 7 a), so it will not be discussed again here to avoid repetition. Only the differences will be described.

[0117] In contrast to the embodiment according to Fig. 7 a), in the embodiment according to Fig. 10, the stator teeth 3, which consist of the ferromagnetic material 13 and form the receptacle for the electrical lines 4, are not designed as grooves, but as closed chambers. Due to the layered construction of the stator 1 using the additive manufacturing process, such a structure can be easily manufactured, since the electrical lines 4 can be manufactured directly and do not have to be subsequently attached to the stator teeth 3. Such a closed structure of the stator teeth 3 with individual chambers for the electrical lines 4 reduces the proximity losses in the electrical lines 4.

[0118] Fig. 11 shows a schematic exemplary cross-section of the section plane BB from Fig. 3 of the first end region of the stator in a further embodiment.

[0119] The essential structure of the second end region layer 31 shown in Fig. 11 has already been described in connection with the description of Fig. 5 b), so it will not be discussed again here to avoid repetition. Only the differences will be described. By way of example, a thermally conductive material 18 is arranged radially outwardly spaced from the electrical lines 4. The thermally conductive material 18 can be made of copper or an aluminum alloy, for example.

[0120] In this embodiment, the thermally conductive material 18 completely surrounds the electrical lines 4 in a ring shape. The thermally conductive material 18 is not limited to completely surrounding the electrical lines 4 in a ring shape. It can also only partially surround the electrical lines 4 or surround them in sections. The thermally conductive material 18 can also be provided in further layers 36 of the first end region 5. It can also be provided in each of the first layers 15 of the first end region 5. Furthermore, the thermally conductive material 18 can also be provided in the second layers 16 of the second end region 6. The second layers 16 in the second end region 6 can all also comprise the thermally conductive material 18. The thermally conductive material 18 can preferably serve to dissipate heat generated by the stator 1 to an environment and / or an adjacent component.

[0121] Fig. 12 shows a schematic exemplary cross-section of the section plane BB from Fig. 3 of the first end region 5 of the stator 1 in yet another embodiment.

[0122] The essential structure of the second end region layer 31 shown in Fig. 12 has already been described in connection with the description of Fig. 5 b), so it will not be discussed again here to avoid repetition. Only the differences will be described. For example, a notch 23 can be provided at a radial end region 22. Alternatively or additionally, a nose 24 can also be provided at a radial end region 22.

[0123] Furthermore, it is possible for the notch 23 and / or the nose 24 to be provided in all first layers 15 of the first end region 5. It is also possible for the notch 23 and / or the nose 24 to be provided in all core layers of the core region 7. Furthermore, it is conceivable for the nose 24 and / or the notch 23 to be provided in all second layers 16 of the second end region 6.

[0124] It is also possible for the notch 23 and / or the nose 24 to be provided only in selected layers of the first end region 5 and / or the second end region 6 and / or the core region 7. The notch 23 and / or the nose 24 can serve to ensure rotational securing of the stator 1 in a housing 25 (not shown). Thus, the stator 1 can be inserted into a housing 25 correspondingly designed with a similar web for the notch 23 or a similar groove for the nose 24 and does not need to be further secured in a form-fitting and / or force-fitting manner against unauthorized rotation in the housing 25. This eliminates further assembly steps. Fig. 13 shows a schematic example of a cross-section of the section plane BB from

[0125] Fig. 3 of the first end region 5 of the stator 1 in yet another embodiment.

[0126] The essential structure of the second end region layer 31 shown in Fig. 12 has already been described in connection with the description of Fig. 5 b), so that it will not be discussed again here to avoid repetition. Only the differences will be described. In this embodiment, the second end region layer 31 additionally has a metallic material 27 adjacent to the radial end region 22 of the base body. The metallic material 27 makes it possible to form a housing 25. The metallic material 27 for the housing 25 can be, for example, aluminum or an aluminum alloy.

[0127] In this embodiment, the metallic material 27 for the housing 25 has a quadrangular cross-section. The housing 25 can have any possible geometric cross-section. It is not limited to being quadrangular. The cross-section of the housing 25 can also be round or oval. If it is intended to form a housing 25 from a metallic material 27 for the stator 1, each of the first layers 15, second layers 16, and core layers of the core region 7 has the metallic material 27 adjacent to the radial end region 22. Consequently, the housing 25 extends over the entire longitudinal direction 12 of the stator 1. This offers the advantage that the stator 1 can be manufactured together with the housing 25 in a single manufacturing process, for example using an additive screen printing process.

[0128] Fig. 14 shows a partial area of ​​a schematic sectional view of the core area 7 in a further embodiment.

[0129] The essential structure of the embodiment shown in Fig. 14 has already been described in connection with the description of the first core layer 8 and the second core layer 9 according to Fig. 3. The core region 7 again has the first core layer 8 and the second core layer 9. The electrical lines 4 run in the longitudinal direction 12 through the first core layer 8 and the second core layer 9 and are each surrounded by a thin-walled sheath made of the insulating material 14.

[0130] In the first core layer 8, the ferromagnetic material 13 is again provided for the stator teeth 3 and the insulation material 14 runs as a column structure 10. In the second core layer 9, the insulation material 14 is again provided as a surface structure 21.

[0131] In this embodiment, in addition to the insulating material 14, connecting webs 26 are also provided in the second core layer 9. These connecting webs 26 run in the longitudinal direction 12 and consist of the ferromagnetic material 13. The connecting webs 26 can serve to amplify the magnetic field induced in the first core layers 8. For this purpose, the connecting webs 26 run across the entire second layer thickness 20 of the second core layer 9. Thus, the connecting webs 26 partially connect the ferromagnetic material 13 of a first core layer 8 to the ferromagnetic material 13 of a second core layer 8. In this embodiment, it can advantageously be achieved that eddy currents are reduced and, at the same time, an induced magnetic field and the mechanical strength are increased.

[0132] Fig. 15 shows exemplary different embodiments of the electrical lines 4 in a winding region 37 of the core region 7.

[0133] Fig. 15 a) shows a sectional view HH of the first core layer 8. A winding region 37 is shown. The winding region 37 comprises the electrical lines 4 extending in the longitudinal direction 12 in the core region 7 and the insulating material 14. In this exemplary embodiment, eight electrical lines 4 with round cross-sections are provided in the winding region 37.

[0134] In the following figures 15 b) - 15 d), three further possibilities for the arrangement and geometric design of the electrical lines 4 in the winding area 37 are described by way of example.

[0135] Fig. 15 b) shows by way of example that the electrical lines 4 in the winding region 37 can also have an oval cross-section and that significantly more than eight electrical lines 4 can be provided. In addition, the electrical lines 4 in the winding region 37 can also have different cross-sections, for example to further increase the fill factor of the winding region 37. It is also possible, as shown in Fig. 15 c), for the electrical lines 4 to have a hexagonal cross-section. Furthermore, it would also be conceivable for the electrical lines 4 within the winding region 37 to have oval and hexagonal cross-sections.

[0136] Using the additive manufacturing process, in particular the screen printing process, the electrical lines 4 can be manufactured in a wide variety of cross-sectional shapes, and combined cross-sections can also be realized. This makes it possible to achieve a higher fill factor for a winding area 37 than with conventional stators.

[0137] Fig. 15 d) shows a further possible embodiment for the winding region 37 of the stator 1. In this case, the electrical lines 4 are designed, by way of example, with a round cross-section. In addition, an electrical line 4 in the winding region 37 has increased insulation 38. The electrical line 4 provided with the increased insulation 38 is the first turn within the winding region 37. The increased insulation 38 can, for example, compensate for increased pulse voltages during converter operation of the stator 1. A significantly higher dielectric strength for the stator 1 can therefore be achieved with an approximately constant fill factor. According to an embodiment not shown, the electrical lines 4 can have a larger cross-section in an edge region 39. By increasing the cross-section in the edge region 39, the fill factor for the winding region 37 can be further increased.

[0138] Fig. 16 shows a schematic representation of a method 100 for producing a stator 1 .

[0139] The method 100 is an additive manufacturing method. This manufacturing method makes it possible to produce a stator 1 with a plurality of coils 2, stator teeth 3, and a one-piece base mold made of the insulation material 14 for an electric motor. The method 100 is carried out by applying several layers 36 layer by layer in the longitudinal direction 12.

[0140] In a first method step 110, a first end region 5 is produced by layer-by-layer application of insulating material 14. Electrical lines 4 are embedded in the insulating material 14, essentially in the transverse direction 11. The electrical lines 4 can also be created together with the insulating material 14 during the layer-by-layer application of the layers 36; in particular, this can be achieved using the additive screen printing process, which has already been described in detail in connection with Fig. 3.

[0141] In a second method step 120, a core region 7 is created on the first end region 5 by applying insulating material 14 in layers. In this case, the electrical lines 4 of the coil windings are embedded in the insulating material 14 in the longitudinal direction

[0142] 12. The core region 7 is formed from at least a first core layer 8 and a second core layer 9. The insulation material 14 is formed as a columnar structure 10 in the first core layer 8 and as a surface structure 21 in the second core layer 9.

[0143] The ferromagnetic material 13 is arranged between the column structures 10 in the first core layer 8 to form stator teeth 3. The electrical lines 4 and the stator teeth 3 can also be created by applying the layers 36 layer by layer, together with the insulating material 14. In particular, this can be achieved using the additive screen printing process, which has already been described in detail in connection with Fig. 3.

[0144] A first screen is used for the first core layer 8 and a second screen for the second core layer 9. The first screen is used to apply the insulating material 14 for forming the column structure 10, the ferromagnetic material 13 for forming the stator teeth 3, and the electrically conductive material for forming the electrical lines 4. The second screen is used to apply the insulating material 14 for forming the surface structure 21 and the electrically conductive material for forming the electrical lines 4.

[0145] In a third method step 130, a second end region 6 is produced by layering insulating material 14. Electrical lines 4 are embedded in the insulating material 14 essentially in the transverse direction 11. The electrical lines 4 can also be created together with the insulating material 14 during the layer-by-layer application of the layers 36; in particular, this can be achieved using the additive screen printing process, which has already been described in detail in connection with Fig. 3. The first end region 5 and the second end region 6 can each have, viewed from the outside, a first end region layer 30 and a sequence of several second end region layers 31 and third end region layers 32. The electrical lines 4 of the coil windings can be embedded in the insulating material 14 of the second end region layers 31 in the transverse direction 11 and interconnected.In the third end region layers 32, the electrical lines 4 of the coil windings can be embedded in the insulation material 14 in the longitudinal direction 12. The first end region 5 and the second end region 6 can also be created, in particular, using the additive screen printing process, so that in an advantageous embodiment, it is possible to manufacture the entire stator 1 in a single process.

[0146] In method 100, the layers 36 can preferably be created by applying multiple layers 28 to form a layer 36. The screen of a layer 36 can be used to create multiple layers 28 of a layer 36. After each layer 28 has been created, a consolidation process can be performed. The layers 28 are applied in the transverse direction 11, and the layers 28 are layered in the longitudinal direction 12 until a defined layer thickness for the layer 36 is achieved.

[0147] The method 100 is an efficient method for producing a stator 1 having a geometrically complex shape and consisting of multiple materials in a simple manner, particularly by means of a screen printing process. The layered construction allows for the creation of a wide variety of geometric shapes that are not feasible using conventional manufacturing methods.

[0148] It goes without saying that the first to third method steps 110, 120, 130 can be carried out in any order.

[0149] Although the invention has been described above using specific embodiments, the person skilled in the art can also implement embodiments not disclosed or only partially disclosed without deviating from the essence of the invention.

[0150] (1) Stator

[0151] (2) Coil

[0152] (3) Stator tooth

[0153] (4) Electrical line

[0154] (5) First end area

[0155] (6) Second end area

[0156] (7) Core area

[0157] (8) First core layer

[0158] (9) Second core layer

[0159] (10) Column structure

[0160] (11) Transverse direction

[0161] (12) Longitudinal direction

[0162] (13) Ferromagnetic material

[0163] (14) Insulation material

[0164] (15) First layers

[0165] (16) Second layers

[0166] (17) Electrical connections

[0167] (18) Thermally conductive material

[0168] (19) First layer thickness

[0169] (20) Second layer thickness

[0170] (21) Surface structure

[0171] (22) Radial end area

[0172] (23) Notch

[0173] (24) Nose

[0174] (25) Housing

[0175] (26) Connecting bridge

[0176] (27) Metallic material

[0177] (28) Location

[0178] (29) Layer thickness

[0179] (30) First end-area layer

[0180] (31) Second end-area layer

[0181] (32) Third end-area layer

[0182] (33) Fourth layer thickness

[0183] (34) Fifth layer thickness (35) Sixth layer thickness

[0184] (36) Layer

[0185] (37) Winding area

[0186] (38) Insulation

[0187] (39) Marginal area

[0188] (A) Section plane A

[0189] (B) Section plane B

[0190] (C) Section plane C

[0191] (D) Section plane D

[0192] (E) Section plane E

[0193] (F) Section plane F

[0194] (G) Section plane G

[0195] (H) Section plane H

[0196] (I) Section plane I

[0197] (J) Section plane J

[0198] (K) Section plane K

[0199] (L) Cutting plane L

[0200] (M) Section plane M

[0201] (N) Section plane N

[0202] (O) Section plane O

[0203] (P) Cutting plane P

[0204] (S) Section plane S

[0205] (T) Section plane T

[0206] (100) Procedure

[0207] (110) Creating the first end area

[0208] (120) Creating the core area

[0209] (130) Creating the second end area

Claims

Claims 1. Stator (1) for an electric motor, having a basic shape which has a through-opening in the longitudinal direction (12) for receiving a rotor, wherein a plurality of coils (2) are provided radially circumferentially in the basic shape with respect to the longitudinal direction (12), wherein the coils (2) have electrical lines (4) in the form of coil windings, wherein the basic shape consists of a one-piece insulating material (14) and the stator (1) has a first end region (5), a second end region (6) and a core region (7) arranged between the first end region (5) and the second end region (6), wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14),wherein the electrical lines (4) of the coil windings run in the insulating material (14) of the first end region (5) and the second end region (6) substantially in the transverse direction (11) and in the insulating material (14) of the core region (7) in the longitudinal direction (12), wherein the core region (7) has at least one sequence of alternatingly arranged first core layers (8) and second core layers (9) in the longitudinal direction (12), wherein the two outer core layers of the core region (7) adjacent to the first end region (5) and the second end region (6) respectively are first core layers (8), wherein the insulating material (14) is formed as a column structure (10) in the first core layer (8) and as a surface structure (21) in the second core layer (9), and wherein ferromagnetic material (13) for forming stator teeth (3) is provided between the column structures (10) made of insulating material in the first core layers (8). (14) is arranged., 2. Stator (1) according to claim 1, wherein the first end region (5) and the second end region (6) in the longitudinal direction (12), viewed from the outside, each have a first end region layer (30) and a sequence of several second end region layers (31) and third end region layers (32), wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) of the second end region layers (31) in the transverse direction (11) and interconnected, and wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) of the third end region layers (32) in the longitudinal direction (12).

3. Stator (1) according to claim 2, wherein electrical connections (17) for the electrical lines (4) are provided in the first end region (5) and / or the second end region (6), wherein the electrical connections (17) protrude from at least one end region layer.

4. Stator (1) according to one of claims 1 to 3, wherein a heat-conducting material (18) is provided in the first end region (5) and / or the second end region (6), wherein the heat-conducting material (18) is arranged at a distance from the electrical lines (4) and at least partially surrounds the electrical lines (4).

5. Stator (1) according to one of the preceding claims, wherein the first core layer (8) has a first layer thickness (19) and the second core layer (9) has a second layer thickness (20), wherein the second layer thickness (20) of the second core layer (9) is smaller than the first layer thickness (19) of the first core layer (8).

6. Stator (1) according to one of the preceding claims, wherein the first end region (5) and / or the second end region (6) and / or the core region (7) have a notch (23) and / or a nose (24) extending in the longitudinal direction (12) at a radial end region (22).

7. Stator (1) according to one of the preceding claims, wherein the base body is surrounded at a radial end (22) by a housing (25), wherein the housing (25) consists of a metallic material (27).

8. Stator (1) according to one of the preceding claims, wherein the electrical lines (4) of the coil windings have different wire cross-sections in the longitudinal direction (12) of the basic shape, wherein the electrical lines (4) have a larger cross-sectional area in at least one edge region (39).

9. Method (100) for producing a stator (1) for an electric motor, wherein the stator (1) comprises a basic shape which has a through-opening in the longitudinal direction (12) for receiving a rotor, wherein in the basic shape, relative to the longitudinal direction (12), a A plurality of coils (2) are provided, wherein the coils (2) have electrical lines (4) in the form of coil windings, wherein the basic shape consists of a one-piece insulating material (14), wherein the method (100) comprises the following steps: - creating (110) a first end region (5) by applying insulating material (14) in layers, wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) substantially in the transverse direction (11); - Creating (120) a core region (7) on the first end region (5) by applying insulating material (14) in layers, wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) in the longitudinal direction (12), and wherein the core region (7) is created in the longitudinal direction (12) from an alternating sequence of first core layers (8) and second core layers (9), wherein a first core layer is created adjacent to the first end region, wherein the insulating material (14) is formed as a column structure (10) in the first core layer (8) and as a surface structure in the second core layer (9), wherein ferromagnetic material (13) for forming stator teeth (3) is arranged between the column structures (10) made of insulating material in the first core layers (8); - Creating (130) a second end region (6), adjacent to a first core layer (8), by applying insulating material (14) in layers, wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) substantially in the transverse direction (11).

10. The method (100) according to claim 9, wherein the first end region (5) and the second end region (6) in the longitudinal direction (12), each viewed from the outside, have a first end region layer (30) and a sequence of several second end region layers (31) and third end region layers (32), wherein the electrical lines (2) of the coil windings are embedded in the insulating material (14) of the second end region layers (31) in the transverse direction (11) and interconnected, and wherein the electrical lines (4) of the coil windings are embedded in the insulating material (14) of the third end region layers (32) in the longitudinal direction (12).

11. The method (100) according to claim 10, wherein the method (100) is carried out as an additive screen printing process, wherein for each of the end region layers (30, 31, 32) a separate sieve is used for applying the insulating material (14) and an electrically conductive material for creating the electrical lines (4), and wherein a first sieve is used for the first core layer (8) and a second sieve is used for the second core layer (9), wherein the electrically conductive material for the electrical lines (4) of the coil windings, the insulating material (14) and the ferromagnetic material (13) for forming stator teeth (3) are applied with the first sieve and the electrically conductive material for the electrical lines (4) of the coil windings and the insulating material (14) are applied with the second sieve.

12. The method (100) according to claim 11, wherein the layers are created by applying a plurality of layers (28) to form a layer (36), wherein the screen of a layer (36) is used to create a plurality of layers (28) of a layer (36), wherein after creation of each layer (28) a solidification process is carried out, wherein the layers (28) are layered in the longitudinal direction (12) and applied in the transverse direction (11) until a defined layer thickness for the layer (36) is achieved.

Images