Fraunhofer-gesellschaft Zur Foerderung Der Angewandten Forschung E.v.

Fraunhofer-gesellschaft Zur Förderung Der Angewandten Forschung E.v.

Matthias Busse

Franz-Josef Wöstmann

Michael Heuser

Lukas Stumm

Christian Soltmann

Franz-Josef Woestmann

Ingo Bardenhagen

Katharina Koschek

Marc Soto

Julian Schwenzel

Christian Weck

Thorsten Müller

Franz-Josef WÖSTMANN

Joachim Thielke

A method for producing a coil includes casting; a semi-finished product in a cavity of a casting tool and the coil is formed following a demolding of the semi-finished product by shaping this semi-finished product, wherein the form of the semi-finished product may be derived from a shape of the finished coil by stretching along a longitudinal axis of the coil and/or by bending this longitudinal axis, and wherein the semi-finished product, during the shaping, is bent and compressed so that windings of the coil already present in the semi-finished product are brought closer to one another at least in some regions and are brought into an arrangement along the longitudinal axis of the finished coil, wherein the product, whilst being shaped, is twisted or bent by no more than a right angle over the course of each individual turn.

Coil and method and tool for producing coil

A permanent mold can include mold halves which can be joined together on a mold separation plane. The mold halves of the permanent mold are joined together such that the permanent mold has a cavity, which defines the shape of the helix or the shape of a bent-up helix, when the permanent mold is joined together. The specified helix or the bent-up helix has a flattened profiled winding cross-section which has two opposite flat faces, an outer face and an inner face opposite the outer face. The mold separation plane runs at least partly along the flat faces from the inner face to the outer face, wherein the permanent mold has a bulge which extends along the mold separation plane and protrudes into the cavity at least in a region in which the mold separation plane runs along one of the flat faces such that the cast body is provided with recesses on the flat faces.

Method for producing a helix and permanent mold for casting a helix

A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

Method for producing a spiral-shaped body with a compressed spiral

The invention relates to a casting mould for producing helical cast bodies (), in particular coils, springs or spirals, having a mould () in the form of a permanent mould which determines the outer contour of the helical body and consists of a ceramic material or is coated by a ceramic material; a supporting tool (), which supports the mould () from outside; and a mould core (), which defines the continuous opening within the helical body () and consists of a ceramic material or is coated by a ceramic material, the mould core being formed in particular as a core puller.

Casting mould for producing helical cast bodies

A method for producing a helical casting pattern. The method including: providing a pattern body having a longitudinal axis, a cavity extending in the direction of the longitudinal axis, and a pattern body wall that surrounds the cavity; providing a processing tool for creating a recess; arranging the pattern body and the processing tool such that the processing tool extends at least partially through the pattern body wall in the radial direction with respect to the longitudinal axis; and rotatably driving at least one of the processing tool and the pattern body about one of the longitudinal axis of the pattern body and an axis parallel thereto, relative to one another, with a relative movement between the pattern body and the processing tool in a direction parallel to the longitudinal axis being produced one of continuously or at least intermittently during or in alternation with the relative rotational movement.

Method for producing a helical casting pattern

A method for producing a helix includes a step of providing a permanent mold with mold halves which are joined together on a mold parting line. The method additionally has a step of joining together the mold halves of the permanent mold such that the permanent mold has a cavity, which defines the shape of the helix or the shape of a bent-up helix, when the permanent mold is joined together, wherein the helix or the bent-up helix has a flattened profiled winding cross-section which has two opposite flat sides, an outer side and an inner side opposite the outer side, and the mold parting line runs at least partly along the outer side and/or the inner side and/or edges of the profiled winding cross-section.

Method of forming a helix, permanent mold for forming a helix, and helix

The invention relates to a coil-tooth module and to a method for the production thereof. A prefabricated coil is filled with a metallic powder, and this powder is subsequently pressed to form a tooth, so that a coil-tooth module is created, in which the tooth directly abuts the coil.

Coil-tooth module and method for the production thereof

The present application creates a roller molding method for producing a spiral structure or a coil, in particular a spiral structure for use in electric machines, wherein material is supplied between a first roller and a second roller running opposite thereto, wherein the first roller has first teeth, and the second roller has second teeth, said first and/or second teeth having tooth flanks with cavities for receiving the supplied material, wherein the teeth are designed and aligned such that the cavity of at least one tooth is at least temporarily delimited by the surface of a tooth of the other roller when the rollers are rotating such that the supplied material is molded between the teeth into a portion of the spiral structure or the coil.

Roller molding method for producing a spiral structure

The invention relates to a method for producing a helical metal body (), in particular made of aluminum or an aluminum alloy. A blank is first produced in a primary shaping process, a metal forming process, or in a removal process, in particular a machining process, and one or more recesses () are then introduced into the blank using a removal process, said recesses defining a circumferential coil, the adjacent windings thereof being mutually spaced, in particular electrically insulated from one another.

Method for the production of a helical metal body

A roller casting method produces a spiral structure, in particular a spiral structure for use in electric machines. Molten metal is supplied between a first roller and a second roller miming opposite thereto, wherein the first roller has first teeth, and the second roller has second teeth, said first and/or second teeth having tooth flanks with cavities for receiving the supplied molten metal. The teeth are designed and aligned such that the cavity of at least one tooth is at least temporarily delimited by the surface of a tooth of the other roller when the rollers are rotating such that the supplied molten metal is molded between the teeth while cooling and is molded into a section of the spiral structure.

Roller casting method and system for producing a spiral structure

A casting core for casting moulds can include a central core and a core shroud arranged around the central core. The core shroud containing contains or consists of ceramic particles bound to a binder. The central core contains ceramic particles bound to a binder, wherein the ceramic particles of the central core contain at least one component, which exhibits, at a temperature in a range from 100&#xb0; C. to 1500&#xb0; C., a thermally induced phase transformation, and/ or at least two components, the thermal expansion coefficients of which at 20&#xb0; C. differ by at least 5&#xb7;10K

Casting core for casting molds and method for the production of same

The present invention relates to a casting core for casting molds, wherein the casting core contains or consists of ceramic particles bound with a silica sol. The casting core has a pore structure, in which the average pore size of the pores increases at least in sections from the outside to the inside in the casting core. The present invention also relates to a method for producing the casting core according to the invention and to the use of the casting core according to the invention.

Casting core for casting molds and method for the production thereof

The present invention relates to a solid-state battery, particularly a lithium-ion solid-state battery, composed of one or more battery cells, which have an ion-conducting solid matrix () as solid electrolyte, which matrix is embedded between two electrodes (). The proposed solid-state battery is characterized in that the solid matrix () is formed form camphor, 2-adamantanone or a mixture of one of the two with one or more other substances. Owing to the use of camphor or 2-adamantanone, the solid electrolyte is mechanically stable and has good ionic conductivity in a wide temperature range.

Solid-state battery based on an ion-conductive matrix composed of camphor or 2-adamantanone

Disclosed herein are systems and methods for production and use of a casting mold for casting components. The casting mold comprises at least one casting mold frame made of metal and/or of an alloy, and also one or more ceramic casting mold inserts introduced into the at least one casting mold frame. The casting mold insert(s) have the negative contour or part of the negative contour of a component to be produced or of the combination of a component to be produced with one or more casting cores.

Casting mold for casting components and method for the production thereof

Disclosed herein is a casting core for casting molds, the casting core comprising an inner core and an outer core arranged around the inner core. The outer core contains or consists of ceramic particles bound with a binder. The inner core contains ceramic particles bound with a binder and additionally one or more placeholder elements. The placeholder element(s) is/are at least partially thermally decomposable. Also disclosed is a method for producing the casting core and use of the casting core.

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Bremen, Germany

Matthias Busse