Method for producing a magnetic material layer
In a method for producing a material layer by an additive process, a first suspension with binding agent and solid particles is applied through a first template onto a base area to obtain a first green body, thereby reproducing by the first template a first material region of a first material to form a magnetic flux-conductive region with a first magnetic permeability μr>50. A second suspension with binding agent and solid particles is applied through a second template onto a base area to obtain a second green body, thereby reproducing by the second template a second material region of a second material to form a flux-blocking region with a second magnetic permeability μr<5. The first and second green bodies are joined and a permanent, material-bonded cohesion between the first and second green bodies and the solid particles is created by heating and/or by compaction.
1. A method for producing a material layer composed of a first green body and a second green body for a dynamoelectric rotary machine by an additive process, said method comprising:
producing the first green body by applying a first suspension having a first binding agent and first solid particles through a first template onto a base area, thereby creating a first material region with a first magnetic permeability μ r >50 to form a magnetic flux-conductive region;
producing the second green body by applying a second suspension having a second binding agent and second solid particles through a second template onto the base area, thereby creating a second material region with a second magnetic permeability μ r <5 which is lower than the first magnetic permeability;
debindering the first and second green bodies;
joining the first and second debindered green bodies to one another; and
creating a permanent, material-bonded cohesion between the first and second debindered green bodies and the first and second solid particles by thermosetting or sintering.
2. The method of claim 1 , wherein the solid particles comprise metal particles.
3. The method of claim 1 , wherein the solid particles of the first suspension comprise magnetic particles, wherein the solid particles of the second suspension comprise amagnetic particles.
4. The method of claim 1 , further comprising applying an insulation material to the material layer on at least one layer side.
5. A material layer for a dynamoelectric rotary machine, said material layer comprising:
a first magnetic flux-conductive material region constructed as a first green body from a first material with a first magnetic permeability μ r >50;
a second flux-blocking material region constructed as a second green body from a second material with a second magnetic permeability μ r <5 which is lower than the first magnetic permeability;
wherein the material layer is produced by debindering the first and second green bodies, and joining the first and second debindered green bodies to one another by a permanent, material-bonded cohesion generated by thermosetting or sintering between the first and second green bodies.
6. The material layer of claim 5 , configured for use in a rotor of the dynamoelectric rotary machine, said material layer having a layer center point coinciding with an axis of rotation of the rotor.
7. The material layer of claim 5 , further comprising varnish applied on at least one layer side of the material laver.
8. The material layer of claim 7 , wherein the varnish is a thermosetting varnish.
9. The material layer of claim 5 , further comprising a further material layer applied to the material layer for strengthening the material layer.
10. The material layer of claim 5 , further comprising a third region having permanent magnetic material, said permanent magnetic material being connected with a material bond to the first material or to the second material.
11. The material layer of claim 6 , wherein the magnetic flux-conductive material region forms a plurality of magnetic poles, wherein each pole is located between two flux-blocking regions in a circumferential direction.
12. The material layer of claim 11 , wherein a width of the flux-blocking region, viewed in the rotational direction, at an external periphery of the material layer, corresponds to between 1% and 50% of a pole pitch, wherein a radial depth of a pole corresponds to >10% of a circular arc length of the pole pitch.
13. The material layer of claim 11 , wherein the magnetic flux-conductive region is forms a plurality of magnetic poles, wherein as viewed in a plane of the material layer structure, magnetic flux-conductive regions alternate with flux-blocking regions in a radial direction of the material layer structure from a center to a magnetic pole and have a shape of an arc.
14. The material layer of claim 13 , wherein a width of the magnetic flux-conductive region, viewed in the rotational direction, at an external periphery of the material layer, corresponds to between 1% and 50% of a pole pitch.