Sintered Rotor Material Layers for Thin Laminations and Low Eddy Loss
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Solution Overview
Problem
Conventional methods for producing sheets for dynamoelectric rotary machines are limited by the inability to create sheets thinner than 100 µm and result in significant waste due to cutting or punching from large sheets.
Innovation Solution
A method involving the application of a suspension with a binder and solid particles through a template to form a green body, followed by debinding and sintering to create a material layer with a thickness between 0.5 and 500 µm, allowing for thinner, more precise sheets with reduced waste, and the use of insulation materials for electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling processes are used to produce sheets, then sheets can be manufactured with standard thickness, but sheets thinner than 100 μm cannot be produced
Solution Approach 1:
The invention changes the fundamental manufacturing approach from mechanical rolling to a deposition process using suspension applied through a stencil. This parameter change enables production of sheets with thickness between 0.5-500 μm,突破ing the 100 μm lower limit of conventional rolling processes while maintaining manufacturability through a different technological route.
Solution Approach 2:
The invention replaces the mechanical rolling system with a chemical/physical deposition system. Instead of using rollers and mechanical pressure to form sheets, the process uses suspension application, debinding, and sintering to create thin sheets, thereby achieving thicknesses impossible with conventional mechanical rolling.
2Shape
If sheets are cut or punched from large sheets, then sheets can be formed to required shapes, but significant waste is generated
Solution Approach 1:
The invention applies segmentation by using a stencil to define the exact shape and outline of each sheet before deposition. The suspension is applied only where needed through the stencil openings, creating individually shaped sheets directly without requiring cutting or punching from larger parent sheets, thus eliminating shape-related material waste.
Solution Approach 2:
The stencil serves as a preliminary action tool that pre-defines the shape and outline of sheets before the actual deposition process. By preparing the stencil with the desired shape pattern in advance, the invention ensures that material is deposited only in the required shapes from the beginning, preventing waste that would occur with subsequent cutting or punching operations.
3Loss of energy
If material layers are made thinner to reduce eddy current losses, then electrical efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The invention changes the manufacturing parameters to enable precise control of very thin layers (0.5-500 μm). The suspension concentration, application method through stencil, debinding process, and sintering parameters are all optimized to achieve consistent thin layer formation, making it feasible to produce layers thin enough to reduce eddy current losses while maintaining manufacturing precision.
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
Enables the production of thinner, more efficient material layers with reduced eddy current losses and improved electrical insulation, suitable for high-performance applications in dynamoelectric rotary machines and other energy converters.
Implementation Method 1
Applying a suspension, comprising at least one binder and solid particles, through a stencil onto a base surface to obtain a green body
Implementation Method 2
expelling the binder from the green body, in particular by debinding
Implementation Method 3
creating a permanent cohesion of the solid particles by heating and/or by compaction, in particular by sintering
Data Source
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AI summary
The invention relates to a method for producing a material layer (1) with a layer thickness (d) of between 0.5 and 500 µm, comprising the steps of: applying a suspension, comprising at least one binder and solid particles, through a template onto a base area to obtain a green body, driving out the binder from the green body, in particular by means of debindering, and creating a permanent cohesion of the solid particles by heating and/or by means of compaction, in particular by means of sintering. The invention also relates to a material layer (1), a method for producing a material layer structure (9) for a rotor (11) of a dynamoelectric rotary machine (15), a material layer structure (9), a rotor (11) of a dynamoelectric rotary machine (15) comprising such a material layer structure (9) and also a dynamoelectric rotary machine (15) comprising such a rotor (11).