Multicomponent Magnetic Sheets With Recessed Additive-Filled Regions
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Solution Overview
Problem
Existing methods for producing magnetic sheets for electric machines face challenges in achieving warp-free and dense sintering, particularly with materials that are chemically incompatible or have different shrinkage rates, limiting the composition and stackability of multicomponent magnetic sheets.
Innovation Solution
The method involves using a flat, nonmagnetic sheet with recessed regions filled via additive manufacturing using soft-magnetic materials, allowing for material-bonded connections and enabling the production of multicomponent sheets with chemically incompatible components, and allowing for greater freedom in composition and stack arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stencil printing and sintering methods are used to produce multicomponent magnetic sheets, then the manufacturing process is established and repeatable, but the ability to achieve warp-free and dense sintering is limited, particularly with chemically incompatible materials
Solution Approach 1:
The magnetic sheet is divided into a base sheet component and additive components applied subsequently. The base sheet provides structural stability while additive components are deposited in recessed regions, allowing different materials to be combined without requiring complete sintering of all components together, thus enabling chemically incompatible materials to coexist.
Solution Approach 2:
The base sheet is prepared in advance with recessed regions before the additive manufacturing step. This preliminary preparation allows the base sheet to be pre-formed and stabilized, providing a stable substrate that supports subsequent additive materials and enables better control over the final sintering process.
2Adaptability or versatility
If multiple components are printed sequentially onto a carrier plate for collective thermal treatment, then multicomponent sheets can be produced, but the sintering process becomes complex and difficult to control for warp-free and dense results
Solution Approach 1:
The manufacturing process is segmented into separate stages: base sheet preparation, additive deposition in recessed regions, and controlled thermal treatment. This segmentation allows each stage to be optimized independently, reducing overall process complexity while maintaining multicomponent capability.
Solution Approach 2:
Different regions of the magnetic sheet have different properties: the base sheet provides structural support while recessed regions contain additive components with specific magnetic properties. This local differentiation allows tailored material properties in different areas without requiring complex global sintering control.
3Adaptability or versatility
If chemically incompatible materials are used in multicomponent magnetic sheets, then material versatility is improved, but traditional sintering methods cannot achieve dense and warp-free results
Solution Approach 1:
The magnetic sheet structure is segmented into a stable base sheet and additive components in recessed regions. This segmentation allows chemically incompatible materials to be combined because the base sheet provides structural stability while additives are confined to specific regions, preventing unwanted chemical interactions during sintering.
Solution Approach 2:
The base sheet acts as an intermediary between chemically incompatible additive materials. It provides a stable substrate that isolates the additives from direct chemical interaction, enabling the use of materials that would otherwise be incompatible in traditional sintering processes.
4Ease of manufacture
If stencil printing technology is used to create green bodies from metal powders, then the manufacturing process is established, but the resulting sheets have limitations in achieving dense sinter material
Solution Approach 1:
The base sheet is prepared in advance with recessed regions before additive deposition. This preliminary action creates a pre-formed structure that guides the additive material into precise positions, enabling better control over material distribution and density in the final sintered product.
Solution Approach 2:
The additive material is deposited only in recessed regions of the base sheet, creating local concentrations of magnetic material where needed. This localized approach ensures dense packing of additive particles in specific areas without requiring dense distribution across the entire sheet, improving overall sinter material density.
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
This approach enables the efficient and flexible production of multicomponent magnetic sheets that can be stacked without geometric restrictions, overcoming the limitations of traditional sintering methods and allowing for the creation of electric machines and vehicles with improved magnetic structures.
Implementation Method 1
The additive manufacturing takes place by means of powder deposition welding and/or by means of a wire-based electric arc and/or by means of cold metal transfer
Implementation Method 2
The additive manufacturing takes place by means of powder deposition welding and/or by means of a wire-based electric arc
Implementation Method 3
cold metal transfer, in particular laser-based and/or electric-arc-based
Implementation Method 4
these regions (40) are filled by means of additive manufacturing of a soft-magnetic material (50)
Implementation Method 5
the magnetic sheets (20) are tempered and/or thermally treated and/or debound and/or sintered before they are stacked
Implementation Method 6
This green body is then transformed by thermal treatment, in other words by means of debinding and sintering, into a metallic, structured sheet
Implementation Method 7
the magnetic sheets (20) are rolled before they are stacked
Implementation Method 8
an electrical insulation material (60) is arranged on the magnetic sheet (20) on or along at least one flat extension of the magnetic sheet (20)
Data Source
AI summary
Various embodiments include a method for manufacturing a magnetic sheet comprising: positioning a nonmagnetic sheet with recessed regions; filling the recessed regions with a soft-magnetic material using additive manufacturing; and fixing the soft-magnetic material to the sheet in a material-bonded manner.