# US 11,451,121 B2 · Method for producing a material layer and a material layer structure for a dynamoelectric rotary machine

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- Number: US 11,451,121 B2
- Document ID: US11451121B2
- Status: Granted
- Kind: B2
- Application number: 17/259,841
- Filed: 2019-07-10
- Published: 2021-10-14
- Granted: 2022-09-20
- Earliest claimed: 2018-07-13
- Assignees: Siemens Aktiengesellschaft
- Applicants: Siemens Aktiengesellschaft
- Inventors: Reiner Seufert; Rolf Vollmer
- Web page: https://patentgrep.com/patent/US11451121B2

## CPC

- H02K 15/02: of stator or rotor bodies
- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B22F 10/10: Formation of a green body
- B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- H02K 1/02: characterised by the magnetic material
- H02K 1/04: characterised by the material used for insulating the magnetic circuit or parts thereof
- Y02P 10/25: Process efficiency
- Y10T 29/49012: Rotor
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

In a method for producing a material layer with a layer thickness between 0.5 and 500 μm, a suspension with a binding agent and solid particles is applied through a template onto a base area for obtaining a green body. The binding agent is driven out of the green body and a permanent cohesion of the solid particles is created by heating and/or by compaction.

## Claims

### Claim 1

A method for producing a shaped material layer having an outer perimeter and a centrally arranged substantially round material cut-out, without further machining, said method comprising:
providing a template having an annular cutout complementary to the outer perimeter of the shaped material layer and to the centrally arranged substantially round material cut-out of the shaped material layer,
applying, with a scraper, a suspension with a binding agent and solid particles through the template onto a base area for obtaining a green body having the outer perimeter and the centrally arranged substantially round material cut-out and a layer thickness between 0.5 and 500 μm,
driving the binding agent out of the green body, in particular by debindering; and
creating a permanent cohesion of the solid particles by at least one of heating, compaction, and sintering, thereby producing the material layer with the outer perimeter and the centrally arranged substantially round material cut-out and the layer thickness between 0.5 and 500 μm without further machining.

### Claim 2 (depends on 1)

The method of claim 1, further comprising applying insulation material to the material layer on at least one layer side.

### Claim 3 (depends on 1)

The method of claim 1, further comprising applying insulation material to the material layer on both layer sides.

### Claim 4 (depends on 1)

The method of claim 1, further comprising applying a varnish, in particular thermosetting varnish, to the material layer.

### Claim 5 (depends on 1)

The method of claim 1, wherein the solid particles comprise particles of et least one of an electrically and magnetically conductive material.

### Claim 6 (depends on 1)

The method of claim 1, wherein the solid particles comprise particles from soft-magnetic material.

### Claim 7 (depends on 1)

The method of claim 1, wherein the suspension is pseudoplastic.

### Claim 8 (depends on 1)

A material layer produced by a method as set forth in claim 1, said material layer having a layer thickness between 0.5 and 500 μm, in particular between 10 and 100 μm, and comprising:
a soft-magnetic material; and
an insulation material on at least one layer side of the material layer.

### Claim 9 (depends on 8)

The material layer of claim 8, wherein the insulation material is applied on both layer sides of the material layer.

### Claim 10 (depends on 8)

The material layer of claim 8, wherein the insulation material is varnish, in particular thermosetting varnish.

### Claim 11 (depends on 8)

The material layer of claim 8, configured with a further material layer applied to the material layer for strengthening the material layer.

### Claim 12 (depends on 8)

The material layer of claim 8, wherein the material layer has a material cut-out arranged substantially centrally.

### Claim 13 (depends on 1)

A method for producing a material layer structure for a rotor of a dynamoelectric rotary machine, said method comprising:
additive manufacturing of a first material layer produced by a method as set forth in claim 1 such that the first material layer comprises at least one material ply;
applying an insulation material to the first material layer;
additive manufacturing of a second material layer such that the second material layer comprises a material ply;
applying an insulation material to the second material layer; and
joining the first and second material layers
to mutually strengthen the first and second material layers.

### Claim 14 (depends on 13)

The method of claim 13, further comprising applying through additive manufacturing additional material layers of a number sufficient to produce the material layer structure, with each of the material layers having a layer thickness of 0.5 to 500 μm.

### Claim 15 (depends on 13)

A material layer structure for a rotor of a dynamoelectric rotary machine, said material layer structure comprising a plurality of material layers arranged one above the other and produced by a method as set forth in claim 13, each said material layer having a layer thickness between 0.5 and 500 μm and including a soft-magnetic material and an insulation material on at least one side of the material layer.

### Claim 16 (depends on 15)

The material layer structure of claim 15, wherein the insulation material is applied on both layer sides of the material layer.

### Claim 17 (depends on 15)

The material layer structure of claim 15, wherein the insulation material is varnish, in particular thermosetting varnish.

### Claim 18 (depends on 15)

The material layer of claim 15, wherein the material layer has a material cutout arranged substantially centrally.

### Claim 19 (depends on 1)

The method of claim 1, wherein the solid particles comprise metal particles.