Electric Motor Layered Components With Ceramic Isolation
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Solution Overview
Problem
Existing methods for producing electric motor components, such as rotors and stators, face challenges in achieving high geometric precision, effective electrical isolation, and increased magnetic flux density while minimizing porosity and mechanical stresses.
Innovation Solution
A method involving the additive manufacturing of alternating layers of plastic/metal and plastic/ceramic filaments, followed by controlled thermal treatment to remove plastic and sinter the metal and ceramic layers separately, resulting in a layered structure with electrically isolated and mechanically connected magnetic flux-conducting layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing methods are used to produce electric motor components, then manufacturing flexibility and geometric complexity are improved, but manufacturing precision and porosity control deteriorate
Solution Approach 1:
The component is divided into multiple layers with different material compositions (metallic layers for magnetic flux conduction, ceramic layers for electrical insulation). Each layer is manufactured separately with controlled parameters, then combined through sintering. This segmentation allows each layer to be optimized for its specific function while maintaining overall geometric precision.
Solution Approach 2:
The patent uses composite material structures where metallic layers (with specific silicon content ≥6.5%) provide magnetic flux conduction paths, while ceramic layers provide electrical insulation. This composite approach enables the component to achieve both geometric complexity from additive manufacturing and functional precision through material property differentiation.
2Reliability
If alternating metallic and ceramic layers are produced, then electrical isolation between conductor layers is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the layered structure: metallic layers serve as both structural components and magnetic flux conductors, while ceramic layers simultaneously provide electrical insulation and structural support. The alternating sequence of these layers creates a integrated structure that achieves electrical isolation without requiring separate insulating components, thereby reducing overall device complexity.
Solution Approach 2:
Different regions of the component have locally optimized properties: metallic layers have high electrical and thermal conductivity for flux conduction, while ceramic layers have low electrical conductivity for insulation. This local quality differentiation within the layered structure achieves effective electrical isolation while maintaining structural integrity and reducing the need for additional complex insulating systems.
3Reliability
If silicon content in metallic material is increased to 6.5% or more, then magnetic flux density is improved, but material processing difficulty increases
Solution Approach 1:
The patent changes the material parameters by specifying metallic layers with silicon content of 6.5% or more, which significantly improves magnetic flux density. The additive manufacturing process parameters (temperature, layer thickness, sintering conditions) are also optimized to accommodate this high-silicon material, making it processable despite its challenging properties. This parameter optimization enables the use of high-silicon materials that would be difficult to process using conventional methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high geometric precision, effective electrical isolation, and increased magnetic flux density, enabling improved performance of electric motors.
Implementation Method 1
the layer assembly is heated to a first temperature level at which plastic is removed from the layers, in particular by diffusion
Implementation Method 2
the layer assembly is brought to a second increased temperature level, the metal of the first-type layer being sintered and an electrically insulating ceramic layer being obtained from the second-type layer
Data Source
AI summary
A component, in particular a stator or a rotor, of an electric motor, in which a layer structure is generated is produced, using additive manufacturing, by:forming, via alternate additive production, a layer assembly having first layers and second layers, each first layer including a filament containing plastic and metal, and each second layer including a filament containing plastic and ceramic;heating the layer assembly a first temperature, at which the plastic is removed from the layers;further heating the layer assembly (2) to a second temperature, whereby the metal of the layer is sintered and an electrically insulating ceramic layer is obtained from the layer.