Electrical Energy Converter and Method for Its Manufacture

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The invention is a new type of electrical energy converter—such as electric motors, generators, and transformers—manufactured as a three-dimensional monolithic structure using sintered combinations of conductive, non-conductive, and magnetic materials. This process, which uses a specialized 3D screen-printing and sintering method, enables highly precise, miniaturized energy converters that are easier to produce, require less assembly, and can integrate multiple functions—including cooling, sensors, and intricate wiring—directly into the device's structure.

Use CasesContent extracted from patent full text and abstract with AI.

• Miniaturized electric motors for robotics, medical devices, and precision tools
• Compact generators for portable electronics or energy harvesting
• Custom-shaped transformers for high-density power electronics
• Electric motors operating at high temperatures, such as those used in aerospace, automotive, or industrial environments
• Sensors and actuators integrated into smart machines or devices
• Rapid prototyping and mass production of custom electromagnetic devices
• High-efficiency magnetic bearings for advanced mechanical systems

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces production complexity and assembly steps by creating monolithic, multi-material components
• Enables high-precision manufacturing of small and complex devices
• Allows local customization of material properties (electrical, magnetic, thermal) in three dimensions for performance optimization
• Improves heat dissipation and enables operation at much higher temperatures than conventional designs—up to 700-800°C
• Minimizes or eliminates the use of organic materials, increasing thermal and chemical resistance
• Integrates cooling channels, sensors, connectors, and complex wiring within the same manufacturing process
• Facilitates mass production as well as special prototyping with consistent quality
• Achieves high packing density and efficiency in electromagnetic components, potentially improving power density and overall device performance

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Inventors & Applicants

Patent Abstract

The invention relates to electrical energy converters and to a method for the production thereof. Said electrical energy converters are primarily electric motors and generators. The aim of the invention is to provide electrical energy converters that can be produced very accurately and with reduced complexity. Said aim applies in particular to small-format energy converters. Energy converters according to the invention have a stator and a rotor and/or electric coils. The rotor and/or the stator and/or at least one electric coil is/are designed as a three-dimensional monolithic element and made of electrically conductive, magnetically conductive, magnetically non-conductive, electrically non-conductive, magnetic, and/or magnetizable materials sintered to one other.