Method for producing a winding overhang assembly for an electrical rotating machine

1. A method for producing a winding overhang assembly for an electrical rotating machine, said method comprising:

producing an insulating main body at least partly from a dielectric material;

connecting each of a plurality of conductors of a metal material to the insulating main body via an intermediate layer;

producing the intermediate layer from a material which is different from the dielectric material of the insulating main body and from the metal material of the conductors and which is produced from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof; and

spraying the conductors onto the intermediate layer by a first thermal spraying method.

2. The method of claim 1 , wherein the conductors are sprayed onto the intermediate layer by cod gas spraying as the first thermal spraying method.

3. The method of claim 1 , wherein the intermediate layer is connected to the insulating main body by a positive connection.

4. The method of claim 1 , wherein the intermediate layer is sprayed onto the insulating main body by a second thermal spraying method, in particular by means of cold gas spraying, with the second thermal spraying method differing from the first thermal spraying method.

5. The method of claim 4 , wherein the second thermal spraying method differs from the first thermal spraying method with regard to speed and/or size of particles used in the first and second thermal spraying methods.

6. The method of claim 1 , further comprising arranging the intermediate layer at least partly in grooves of the insulating main body.

7. The method of claim 6 , wherein the grooves of the insulating main body have a profile to effect a positive connection between the intermediate layer and the insulating main body.

8. The method of claim 1 , further comprising applying an electrical insulation onto the conductors to prevent short-circuiting of the conductors.

9. The method of claim 1 , further comprising arranging cooling channels in the insulating main body.

10. The method of claim 1 , further comprising arranging the conductors in at least two planes, in particular in at least two planes which are arranged behind one another in an axial direction.

11. The method of claim 10 , further comprising connecting the conductors in the at least two planes to one another via connecting elements.

12. The method of claim 1 , wherein the dielelectric material of the insulating main body has a dielelectric strength of at least 10 kV/mm.

13. The method of claim 1 , wherein the metal material of the conductors has an electrical conductivity which is higher than an electrical conductivity of the material of the intermediate layer and/or the metal material of the conductors has a strength which is higher than a strength of the material of the intermediate layer.

14. A winding overhang assembly for an electrical rotating machine, comprising:

an insulating main body made at least partly from a dielectric material; and

a plurality of conductors made of a metal material and connected to the insulating main body via an intermediate layer from a material which differs from the dielectric material of the insulating main body and from the metal material of the conductors, with the conductors being sprayed onto the intermediate layer by a thermal spraying method, and with the intermediate layer being made from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof.

15. The winding overhang assembly of claim 14 , wherein the intermediate layer is arranged at least partly in grooves of the insulating main body, said grooves of the insulating main body having a profile to effect a positive connection between the intermediate layer and the insulating main body.

16. The winding overhang assembly of claim 14 , wherein the conductors are arranged in at least two planes, and, further comprising connecting elements configured to connect the conductors in the at least two planes to one another.

17. A stator for an electrical rotating machine, said stator comprising:

a magnetic field-guiding stator element; and

a winding overhang assembly arranged at an axial end of the magnetic field-guiding stator element, said winding overhang assembly comprising an insulating main body made at least partly from a dielectric material, and a plurality of conductors made of a metal material and connected to the insulating main body via an intermediate layer from a material which differs from the dielectric material of the insulating main body and from the metal material of the conductors, with the conductors being sprayed onto the intermediate layer by a thermal spraying method, and with the intermediate layer being made from silver, aluminum, antimony, magnesium, tin, zinc, lead, tantalum or from a mixture and/or from at least one alloy thereof.

18. The stator of claim 17 , further comprising coil rods arranged at least partly in the magnetic field-guiding stator element and connected to the conductors of the winding overhang assembly.

19. The stator of claim 18 , wherein the conductors are arranged essentially perpendicular to the coil rods.

20. An electrical rotating machine, comprising a stator as set forth in claim 17 .