Granted Patent B2

US 12,463,481 · App. 18/138,326 · Granted Nov 4, 2025

Inventors: Florian Braunbeck (Bietigheim-Bissingen, DE); Tobias Engelhardt (Stuttgart, DE); Patrick Knecht (Stuttgart, DE); Johannes Lange (Dettenheim, DE); Peter Wurster (Wiggensbach, DE)

Assignee: Dr. Ing. h. c. F. Porsche AG

H02K1/32

Abstract

Claims (17)

1 . A method for manufacturing a rotor ( 1 ) of an electric motor ( 20 ), the rotor ( 1 ) having a rotor shaft receptacle opening ( 22 ) configured to receive a stator ( 8 ) of the electric motor ( 20 ) so that the rotor ( 1 ) is rotatable relative to the stator ( 8 ) about an axis of rotation corresponding to a longitudinal axis ( 2 ) of the rotor ( 1 ), the rotor ( 1 ) further having a rotor sheath ( 23 ) outward of the rotor shaft receptacle opening ( 22 ), and a cooling device ( 4 ) having cooling channels ( 11 ) formed between the rotor shaft receptacle opening ( 22 ) and the rotor sheath ( 23 ) of the rotor ( 1 ), the method comprising:

using a tool for forming individual blades ( 9 ) that have pockets for receiving permanent magnets, the tool having tool cores for forming passage openings ( 12 ) in the individual blades ( 9 ) during production of the individual blades ( 9 ) with each of the passage openings ( 12 ) being between two of the pockets for receiving the permanent magnets;

joining the individual blades ( 9 ) side-by-side along the longitudinal axis ( 2 ) of the rotor ( 1 ) so that the respective passage openings ( 12 ) of the blades ( 9 ) align to form the cooling channels ( 11 ) of the cooling device ( 4 ); and

applying a plastic sealing to surround the passage openings ( 12 ) that form the cooling channels ( 11 ).

2 . The method of claim 1 , further comprising introducing a plurality of permanent magnets into the pockets.

3 . A rotor ( 1 ) of an electric motor ( 20 ), comprising:

a rotor shaft ( 3 );

a rotor body ( 21 ) having a rotor shaft receptacle opening ( 22 ) in which the rotor shaft ( 3 ) is mounted, a rotor sheath ( 23 ) surrounding the rotor body ( 21 ) outward of the rotor shaft opening ( 22 ), and first and second end faces ( 14 , 18 ) facing away from one another at opposite ends of the rotor body ( 21 ), the rotor body ( 21 ) being formed from blades ( 9 ) arranged on the rotor shaft ( 3 ) side-by-side in an axial direction of the rotor shaft ( 3 );

magnetic field-inducing components ( 10 ) arranged in the rotor body ( 21 ) between the rotor shaft receptacle opening ( 22 ) and the rotor sheath ( 23 ); and

a cooling device ( 4 ) that comprises a supply channel ( 5 ), a drainage channel ( 6 ) and cooling channels ( 11 ) formed in the rotor body ( 21 ) between the rotor shaft receptacle opening ( 22 ) and the rotor sheath ( 23 ) at positions adjacent the magnetic field-inducing components ( 10 ), the cooling channels ( 11 ) being formed by passage openings ( 12 ) that penetrate the blades ( 9 ), the passage openings ( 12 ) of the blades ( 9 ) being aligned and being sealed by a plastic sealing material to form the cooling channels ( 11 ) that extend parallel to the axial direction of the rotor shaft ( 3 ).

4 . The rotor ( 1 ) of claim 3 , wherein the cooling channels ( 11 ) are arranged between the magnetic field-inducing components ( 10 ).

5 . The rotor ( 1 ) of claim 3 , wherein the cooling device ( 4 ) further comprises a manifold portion ( 16 ) formed on the first end face ( 14 ) of the rotor ( 1 ) and connected to the cooling channels ( 11 ) in a perfusable manner.

6 . The rotor ( 1 ) of claim 3 , wherein the drainage channel ( 6 ) is formed in the rotor shaft ( 3 ).

7 . The rotor ( 1 ) of claim 3 , wherein the drainage channel ( 6 ) is perfusably connected to the cooling channels ( 11 ) by a further annular channel ( 19 ).

8 . The rotor ( 1 ) of claim 7 , wherein the further annular channel ( 19 ) is on the second end face ( 18 ).

9 . The rotor ( 1 ) of claim 3 , wherein the magnetic field-inducing components ( 10 ) are permanent magnets.

10 . The rotor ( 1 ) of claim 3 , wherein the magnetic field-inducing components ( 10 ) are windings.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (17)