Electroforming assemblies for electrical machines

Abstract

An electrical machine and method of forming includes electroforming a first set of metal laminates having a first predetermined geometry. The method also includes arranging an insulating layer between each in the first set of metal laminates in a stack to define a layered component having the first predetermined geometry.

What is claimed is: 
     
         1 . A method of forming an electrical machine, the method comprising:
 electroforming a first set of metal laminates having a first predetermined geometry; and   arranging an insulating layer between each in the first set of metal laminates in a stack to define a layered electrical machine component having the first predetermined geometry.   
     
     
         2 . The method of  claim 1 , further comprising electroforming a second set of metal laminates having a second predetermined geometry. 
     
     
         3 . The method of  claim 2 , further comprising simultaneously electroforming the first and second sets of metal laminates. 
     
     
         4 . The method of  claim 2  wherein the first predetermined geometry comprises a rim connected to an inner hub via a set of spokes. 
     
     
         5 . The method of  claim 4  wherein the second predetermined geometry comprises an outer rim connecting multiple radial spokes. 
     
     
         6 . The method of  claim 2 , further comprising separating one of the first set of metal laminates or one of the second set of metal laminates from a remainder of a batch to define a scrap part. 
     
     
         7 . The method of  claim 6 , further comprising recycling the scrap part to form additional metal laminates during an additional electroforming process. 
     
     
         8 . The method of  claim 1 , further comprising forming at least one exposed region on a base sheet prior to the electroforming, wherein the at least one exposed region has the first predetermined geometry. 
     
     
         9 . The method of  claim 8  wherein the forming at least one exposed region further comprises at least one of applying a mask to the base sheet or forming a recess in the base sheet. 
     
     
         10 . The method of  claim 8 , further comprising applying a conductive treatment to the at least one exposed region prior to the electroforming. 
     
     
         11 . The method of  claim 1  wherein the insulating layer has the first predetermined geometry. 
     
     
         12 . The method of  claim 1  wherein the layered electrical machine component comprises one of a rotor or a stator in a turbine engine. 
     
     
         13 . A method of forming an electrical machine, the method comprising:
 electroforming a set of metal stator portion laminates having a first predetermined geometry;   arranging a first insulating layer between each in the set of metal stator portion laminates to define a layered stator in the electrical machine;   electroforming a set of metal rotor portion laminates having a second predetermined geometry; and   arranging a second insulating layer between each in the set of metal rotor portion laminates to define a layered rotor in the electrical machine.   
     
     
         14 . The method of  claim 13 , further comprising forming at least one first exposed region on a base sheet prior to the electroforming a set of metal stator portion laminates, wherein the at least one first exposed region has the first predetermined geometry. 
     
     
         15 . The method of  claim 14  wherein the forming at least one first exposed region further comprises at least one of applying a mask to the base sheet or forming a recess in the base sheet. 
     
     
         16 . The method of  claim 15 , further comprising forming at least one second exposed region on the base sheet, wherein the at least one second exposed region has the second predetermined geometry. 
     
     
         17 . The method of  claim 16 , further comprising applying a conductive treatment to the at least one first exposed region or the at least one second exposed region. 
     
     
         18 . The method of  claim 13 , further comprising simultaneously electroforming the set of metal stator portion laminates and the set of metal rotor portion laminates and separating the sets after the simultaneously electroforming. 
     
     
         19 . The method of  claim 13  wherein the first predetermined geometry includes a rim connected to an inner hub via a set of spokes, and wherein the second predetermined geometry includes an outer rim connecting multiple radial spokes. 
     
     
         20 . An electrical machine, comprising:
 a set of electroformed metal laminates having a predetermined geometry; and   a set of insulating layers arranged between adjacent metal laminates;   wherein the set of electroformed metal laminates and the set of insulating layers define a stack forming at least one of a rotor or a stator.