Method for producing multi-layer material prior to press for laminated component of electric motor

Abstract

A method and system for producing a bonded lamination stack for rotors and stators includes a multi-layer roller feeder that receives an upper layer and a lower layer formed from a sheet material. A first adhesive is applied between the layers prior to combining the layers into a multi-layer sheet of material in a multi-layer roller feeder. Additional adhesives are applied to the multilayer sheet of material prior to stamping the rotor plate and the stator plate from the same section of the multilayer sheet. The rotor plate and the stator plate with the additional adhesive are vertically stacked and bonded together. The adhesive may be applied at specific locations corresponding to the material areas that become the rotor and stator to reduce contamination of the stamping punch. The rotor plate is punched from a material disposed radially inward from the material of the stator plate.

Description

Technical Field

[0001] The present disclosure generally relates to a method of producing a lamination stack assembly from a plurality of stamped materials for electrical components, particularly rotor and stator cores for electric motors. More specifically, the method involves forming a multi-layer arrangement of thin sheet materials joined together by an adhesive in line with and prior to a stamping press used to form the final lamination stack. The present disclosure also describes alternative adhesive types, application methods, and application patterns to form multi-layer components and construct the final lamination stack assembly. Background Art

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] At present, electric motor rotors and stators utilize cores formed of laminations made of multiple stamped electrical steel sheets stacked vertically together. The stamping press is fed with a single sheet and is used to stamp each individual sheet via progressive stamping. Preferably, the laminations are formed from coated electrical steel sheets that are as thin as possible (<1.0 mm) to maintain electromagnetic isolation between the sheets, thereby improving electric motor performance and efficiency. These individual sheets are then stacked and assembled to form a multilayer lamination. Known methods of connecting individual sheets into laminations include mechanical mating via welding or interlocking. It is also used to combine the sheets together to form a rotor or stator core through epoxy adhesives, backing bonded varnishes or other adhesives. The thinness of the material leads to limitations on the effectiveness of mechanical mating or welding techniques, so adhesives are now preferred. The epoxy-based adhesives or backing bonded varnishes currently used require a large amount of thermal curing process, which increases the energy usage and cycle time used to form the finished lamination stack. Therefore, there is a need to improve the rotor or stator lamination production process. Summary of the invention

[0004] An object of the present disclosure is to provide an improved rotor or stator lamination process. In one aspect, the process includes stamping more than one layer with each stroke of a press and bonding the layers together with improved adhesive technology and application methods.

[0005] The disclosed method involves producing a multi-layer arrangement of thin sheet materials joined together by an adhesive prior to further processing in line with a punch press that produces a lamination stack of rotors and stators for an electric motor. The present disclosure also describes alternative adhesive types, application methods, and adhesive application geometries to form multi-layer sheet components and construct a final lamination stack assembly using two or three adhesive application stations.

[0006] The steel sheet material proposed is electrical steel, which is a soft magnetic material with enhanced electrical properties. Due to the increase in silicon content, electrical steel can also be called silicon steel. The typical thickness of the electrical steel used in the lamination application is between 0.10mm thick and 0.50mm thick. The sheet material is provided with a coating (i.e., AISI-ASTM A976-9 standard C3, C5 or C7), which is used to insulate the electrical steel sheet to increase the resistance between the laminations, reduce eddy currents, provide corrosion resistance, and is used as a lubricant during the stamping process. The adhesive and activator proposed in the present disclosure work together with the coating commonly used as described above, and no additional backing is required. The electrical steel sheet used in the process can be non-grain oriented electrical steel (NGOES) or grain oriented electrical steel (GOES), but non-grain oriented electrical steel (NGOES) is preferred in the rotor laminations and stator laminations specifically described in the present disclosure. Optionally, an iron-based low-loss amorphous material can be used when it is in a form with a similar thickness to the silicon steel.

[0007] The adhesive for producing a combination between each layer to form a multilayer structure and to produce a laminate stack in the later stage of the process is formed by anaerobic technology or cyanoacrylate technology. Anaerobic adhesives are solidified in the absence of oxygen, and anaerobic adhesives can be, for example, dimethacrylate, polyurethane acrylate or polyurethane methyl acrylate chemical types. Cyanoacrylate adhesives are derived from ethyl cyanoacrylate and related esters. Alternatively, an activator for improving the combination of anaerobic adhesives can also be used to further improve the curing effectiveness within a shortened time frame. These adhesives and optional activators are selected because they form a strong bond without the need to introduce a temperature significantly higher than room temperature, as seen in backing or epoxy adhesive systems. Due to the work and movement of the material through the multilayer forming device and the laminate forming device process, a heating higher than 40 degrees Celsius is naturally produced in the formed part of the multilayer laminate device. If the additional heat up to 80 degrees Celsius is increased, further curing improvement can be achieved, and this additional heat can be increased via the chamber around the multilayer forming device or the chamber around the laminate assembly before the punching tool. These temperatures and durations are much lower than the temperatures and durations required to cure the thermosetting epoxy and polyester resins used in other laminate assemblies. The disclosed adhesive is applied directly to the face of the coated sheet material or laminate before joining, and can be applied with various dispersion methods. The adhesive can be dispersed onto the surface via a contact method or a non-contact method. Non-contact methods include spraying, applying a thin amount over a larger area, or discharging a specific amount in the form of dots from a nozzle for local application. If a larger area needs to be covered by the adhesive, contact methods including rolling, deposition, screen printing or wiping can also be used.

[0008] On the other hand, in combination with anaerobic adhesives, optional activators can be used to improve curing time, eliminate the need for elevated thermal curing, and improve bonding efficiency between coatings. The proposed activator is solvent-based, such as methacrylate or acetone, which will clean the surface, activate the surface to prepare for contact with the anaerobic adhesive, and evaporate quickly. The activator can be applied to a surface different from the anaerobic adhesive, and the surface can then be put together under pressure. Pressure can be applied from a roller feeder when forming a multi-layer material sheet, or pressure can be applied from the enablement of a press when a laminate assembly is produced. Since the activator and adhesive are applied at different positions in the process, the activator applicator can be positioned in a manner that provides a time delay between applying the activator to the first surface and applying the adhesive to the second surface, so as to further promote adhesion when the surfaces are put together. For example, the activator application can be positioned before the single-layer roller feeder, and the adhesive applicator of the first application station is positioned at a later stage in the process. For example, just before the surface of the upper layer and the surface of the lower layer are connected, the adhesive applicator can be located between the single-layer roller feeder and the multi-layer roller feeder. Application of the activator can be the same contact and non-contact methods as described for the adhesive. When the material faces are brought together for proper bonding, the area where the activator is applied is aligned with the area where the adhesive is applied.

[0009] Two processes for forming a multilayer lamination assembly for a rotor and / or stator are provided. In two non-limiting examples, the multilayer sheet assembly formed has two layers, but the described apparatus and process can be extended in parallel operation within the multilayer lamination device to produce a multilayer material sheet with more than two additional layers. For a two-layer design, a parallel process is used in the first section, wherein two long individual sheets of the wound coil material are processed to ensure that the material is flat and unwound using standard techniques. Each layer of the material enters a first adhesive application station, where the adhesive is applied to the upper surface of the lower material layer, and optionally, an activator is applied to the lower surface of the upper layer of the material. Due to the dilute viscosity of the adhesive, it is preferred that the adhesive is applied to the upper surface of the lower layer, but if the viscosity increases, or the application method allows, the adhesive can also potentially be applied to the lower surface of the upper layer. In this arrangement, the optional activator application surface will be changed to the opposite surface to which the adhesive is applied. The individual layers are put together and compressed between the rollers, which causes the adhesive to tightly bind the layers together to produce a multilayer material sheet. At this point, curing begins within the ambient temperature. The multilayer material sheet is received by a lamination forming device in the form of a single combined sheet, which includes a second adhesive application station or a second adhesive application station and a third adhesive application station, and a punching machine, which is used to punch and cut the single multilayer sheet into individual rotor laminations and stator laminations, which are then assembled into rotor lamination assemblies and stator lamination assemblies or rotor lamination stacks and stator lamination stacks.

[0010] In one aspect, one embodiment of the overall process includes two adhesive application stations. The first adhesive application station is used to bond the multi-layer sheet components together, while the second adhesive application station dispenses adhesive to form a lamination stack from laminations punched from the multi-layer sheets. The second adhesive application station applies adhesive prior to any stamping or blanking operation to produce stator or rotor laminations, and applies adhesive and optional activator to the surface of the multi-layer sheets in various patterns described further.

[0011] On the other hand, another embodiment of the entire process uses the same first adhesive application station to combine the multilayer sheets, but the second adhesive application station and the third adhesive application station are positioned in the stamping tool. The second adhesive application occurs immediately before punching the rotor lamination plate, and the third adhesive application occurs immediately before punching the stator lamination plate. Punching should be understood as the final punching operation that separates the rotor lamination plate or the stator lamination plate from the combined multilayer material sheet. In one aspect, the adhesive is applied to the larger surface or specific area that becomes the rotor lamination plate or the stator lamination plate immediately before the punching operation to reduce contamination of the stamping tool. This adhesive is applied at stations two and three when preparing to produce a stack of laminations to form a rotor lamination assembly and / or a stator lamination assembly. The method of applying the adhesive and the optional activator to various surfaces will be described in further detail, but the intention is to apply the adhesive so as to combine the individual punched sheets together to form the rotor and stator lamination stacks. Because remaining unused scrap of multilayer sheets leaves the lamination forming device, the entire process produces fully bonded stator and rotor lamination stack assemblies in an optimized manner.

[0012] In one aspect, the adhesive application station applies adhesive and optional activator in various ways. It has been previously described how the application system deposits adhesive on the surface of electrical steel in different ways, but the pattern used by the application system can also vary at different adhesive application stations. In each of the pattern designs described in further detail herein, there is a balance between the amount of adhesive used, the precision requirements of the adhesive application position, and the potential adhesive contamination on the stamping tool. If there is isolation loss between the layers at the edge of the lamination, each pattern may also have a different effect on the final function of the electric motor due to the impact on electromagnetic performance. This effect is caused by the generation of burrs on the cutting edge. The adhesive pattern changes from the whole surface of the coil with the adhesive applied to the point combination mode in which the adhesive is only applied to the selected local area in the final stator lamination or rotor lamination. In one aspect, there may be differences in the amount and pattern of the adhesive applied at each adhesive application station in the adhesive application station. In addition, the optional activator can be applied in a patterned method similar to the adhesive, changing between full coverage or local application. In the case of localized application, such as dots, the activator and adhesive are deposited on separate surfaces in a controlled positional manner that will cause alignment and interaction when the separate layers are put together. If a particular adhesive that requires an activator to cure contacts the opposing layer and the activator is not present, proper bonding will not occur. However, in the case of the absence of an activator in the matching area, an adhesive that does not require an activator to cure but can still use an activator can still bond.

[0013] Utilizing these adhesive compositions and application methods without the need for elevated curing temperatures to produce multi-layer sheets prior to introduction into a stamping press provides an efficient and cost-effective method of producing lamination stacks for rotors and stators. Utilizing the described methods, overall production time is reduced while operating costs are reduced because multi-layer material sheets are produced and utilized as blank materials for the laminations and significant elevated temperatures are not required to bond the layers of the lamination assembly together.

[0014] A related aspect of the present disclosure is to form a multi-layer material component in-line with a punch press and feed the multi-layer material component directly to the punch press to form a final lamination assembly.

[0015] A related aspect of the present disclosure is to utilize existing high speed stamping technology to stamp multi-layer constructions, thereby reducing the total cycles required and reducing processing to produce a complete lamination stack assembly.

[0016] A related aspect of the present disclosure is that multi-layer constructions may be formed from two, three, four, or more individual layers, depending on the stamping process and the overall thickness of the individual sheets of material.

[0017] A related aspect of the present disclosure is to form a multi-layer construction from layers of different material thicknesses or material types to produce a non-uniform structure.

[0018] One aspect of the present disclosure is to utilize adhesive technology that cures at room temperature or slightly elevated temperature sufficient to form a multi-layer sheet product in-line with and between the unwinder and punch.

[0019] Related aspects of the present disclosure are those utilizing either an anaerobic adhesive technology type or a cyanoacrylate adhesive technology type.

[0020] A related aspect of the present disclosure is the utilization of a single adhesive type throughout the process of producing rotor laminations and / or stator laminations.

[0021] A related aspect of the present disclosure is to utilize an optional activator applied to the steel sheet material prior to application of the adhesive to initiate cure, thereby improving cure time, reducing the need for high heat cure, and improving bonding effectiveness.

[0022] A related aspect of this disclosure is that the adhesive is applied prior to the roller feeder which joins the individual sheets to produce a stable single combined multi-layer metal sheet construction for further pressing operations.

[0023] A related aspect of this disclosure is that an optional activator is applied earlier in the process than the adhesive to improve bonding in the formation of the multi-layer metal sheets.

[0024] A related aspect of this disclosure is that an adhesive is applied over the individual sheet materials and an optional activator is applied from below the individual sheet materials prior to forming the multi-layer material.

[0025] A related aspect of this disclosure is that the adhesive and / or optional activator is applied from above or below the combined multi-layer materials for laminate construction, depending on the tool design and the accuracy of the adhesive application.

[0026] A related aspect of the disclosure is that the adhesive and / or activator may be applied by non-contact spraying, non-contact deposition or contact deposition and / or a wiping application method or a rolling application method.

[0027] An aspect of the present disclosure is that adhesive application for rotor and stator lamination construction can be applied to all desired surfaces prior to any stamping operation, at an adhesive application station positioned prior to or within a stamping tool.

[0028] One aspect of the present disclosure is that adhesive application for rotor and stator laminations may occur within a stamping tool immediately prior to the blanking operation of the rotor and stator lamination plates.

[0029] A related aspect of the present disclosure is to apply adhesive immediately prior to the blanking operation of the rotor and stator laminations to reduce adhesive contamination of the stamping tool.

[0030] One aspect of the present disclosure is to provide a method of optimizing adhesive application geometry to produce a stable multilayer metal sheet, which can vary according to the adhesive application geometry and adhesive volume for further producing a lamination stack in order to optimize the amount of adhesive used.

[0031] A related aspect of the present disclosure resides in applying adhesive and / or activator with application geometries that vary from full surface bonding to localized bonding locations that include rings of adhesive or spots of adhesive.

[0032] A related aspect of the present disclosure is to position the application of the optional activator on the first sheet layer so that the optional activator will align with the similarly located adhesive applied on the second sheet layer when the first and second sheet layers are brought together to form a multilayer sheet.

[0033] A related aspect of the present disclosure is that the position of the adhesive and / or optional activator application system may be adjusted in the X / Y plane to optimize the adhesive application location on the web material.

[0034] A related aspect of the present disclosure is that the rotor and stator will be made from the same area of ​​sheet material, wherein the rotor lamination geometry will be formed from material radially inward of the material used to form the stator lamination geometry.

[0035] A related aspect of the present disclosure is to connect electrical steel sheet segments between an uncoiler and a straightener using butt welding to further increase production and reduce material handling.

[0036] These features and advantages, as well as other features and advantages of the present invention, will become more readily understood when considered in conjunction with the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The drawings described herein are only used for the purpose of illustrating selected embodiments and are not intended to limit the scope of the present disclosure. The inventive concepts associated with the present disclosure will be more easily understood by referring to the following description in conjunction with the drawings, in which:

[0038] Figure 1 is an overall view of a multi-layer lamination apparatus having two adhesive application stations;

[0039] Figure 2 is an overall view of a multi-layer lamination apparatus having three adhesive application stations;

[0040] Figure 3 is an example of an adhesive applied as a full-surface bond;

[0041] Figure 4 is an example of an adhesive applied as an alternative full-surface bond;

[0042] Figure 5 is an example of an adhesive applied only to the active stator surface / active rotor surface;

[0043] Figure 6 is an example of an adhesive applied as concentric rings to the active stator surface / active rotor surface;

[0044] Figure 7 is an example of adhesive grid point bonding;

[0045] Figure 8 is an example of adhesive point bonding. DETAILED DESCRIPTION

[0046] Example embodiments will now be described more fully with reference to the accompanying drawings. It should be appreciated that only example embodiments are provided so that the present disclosure will be thorough and will fully convey to those skilled in the art the scope ultimately defined by the claims. Many specific details such as examples of specific components, devices and methods are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that certain specific details do not need to be adopted, and that example embodiments can be implemented in many different forms and should not be interpreted as limiting the scope of the present disclosure or claims. In some example embodiments, well-understood processes, well-understood device structures and well-understood technologies are no longer described in detail. It will be further understood that references to specific aspects are optional and do not mean that other aspects are not optional in the absence of such designation. It will also be understood that references to specific aspects are preferred and do not mean that other aspects are not preferred in the absence of such designation.

[0047] Figure 1 An overview of one embodiment of a multi-layer lamination apparatus 20 is provided, which includes a multi-layer forming apparatus 22, which is directly followed by a lamination forming apparatus 24. In this example, the multi-layer forming apparatus 22 is shown joining two layers of sheet material to produce a multi-layer material sheet 26. In this two-layer example, the multi-layer forming apparatus 20 includes an upper layer handling apparatus 28 and a lower layer handling apparatus 40. If additional layers beyond two layers are required, the additional layer handling apparatus as described will be positioned in parallel (e.g., above or below the two layers shown) before the lamination forming apparatus 24 to produce a multi-layer material sheet 26 of three, four, or more layers.

[0048] For the two-layer multilayer material sheet 26 in this example, the upper layer handling device 28 receives the upper electrical coil sheet material 30, which is removed from the coil 34 by the unwinder 32 in combination with the single-layer roller feeder 36 and the coil puller 38 located at the end of the process. Note that the lower layer handling device 40 will receive the lower electrical coil sheet material 42 in a similar manner. The width of the electrical coil sheet materials 30 and 42 will be at least similar to the outer diameter of the stator stack and rotor stack being manufactured. The material length will be significantly longer than the width, allowing the strip-shaped material to be continuously fed to both the upper layer handling device 28 and the lower layer handling device 40. In order to further increase production capacity, a coil sheet welding machine can be included to butt weld 44 the end portions of the coil material together to the starting portion of the replacement coil. In one aspect, the butt welding position can be located between the unwinder 32 and the straightener 46. The butt welding process can produce annular strips of coiled material provided to both the upper device 28 and the lower device 40 of the multi-layer lamination device 22, thereby increasing production and reducing processing requirements. The upper electrical coiled sheet material 30 and the lower electrical coiled sheet material 42 are each fed into a separate straightener 46 to flatten the material (due to being wound around the coil) so that the final laminate layers can be placed parallel to each other and close to each other when joined. The straightener 46 and the single-layer roller feeder 36 for each layer can be positioned and operated at a feed rate that allows a strip loop 50 of loose material to hang freely between the straightener 46 and the single-layer roller feeder 36. Each individual electrical coiled sheet material 30 and 42 can pass through the single-layer roller feeder 36 to continue moving the material toward the first adhesive application station 60. So far in the process, the upper electrical coiled sheet material 30 and the lower electrical coiled sheet material 42 have been processed by the processing devices 28 and 40 in similar parallel processing steps. The above-mentioned straightener 46 may also be optional, depending on the needs and performance of the process.

[0049] Continue to refer to Figure 1, when each electrical coil material 30 and 42 enters the first adhesive application station 60, adhesive 62 is applied to the upper surface 64 of the lower electrical coil material 42 by applicator 66. Adhesive 62 is applied to the upper surface because it is easier to deposit the adhesive in the direction of gravity due to the stickiness of the adhesive. Optionally, at this location, an activator 68 can be applied to the lower surface 70 of the upper electrical coil material 30 via applicator 72 to improve the bonding performance of adhesive 62. Surface adhesive 62 and activator 68 can also be applied to surfaces opposite to those described in this example. Before the optional activator 68, adhesive 62, and the surface 70 of the electrical coil material 30 and the surface 64 of the electrical coil material 42 are brought together at the multi-layer roll feeder 74, the predetermined distance "X" between the adhesive applicator 66 and the multi-layer roll feeder 74 will allow sufficient time for any chemical reaction required in preparation for bonding to occur. If the optional activator 68 requires additional time to prepare the surface and evaporate from the lower surface 70 of the upper electrical coiled sheet material 30, the activator applicator 72 can be positioned earlier in the process, such as before the single layer roller feeder 36, as shown at 72A. After applying the adhesive 62 and the optional activator 68, the multi-layer roller feeder 74 compacts each electrical coiled sheet material 30 and 42 together to produce the multi-layer material sheet 26. The volume of adhesive dispensed is selected to achieve proper bonding between the layers without causing excessive adhesive to bleed between the layers, as this would be detrimental to further pressing operations. At this stage, curing begins and the material is received by the stack forming device 24 as a single piece of assembled multi-layer material sheet 26, which provides a substrate for forming rotor laminations and stator laminations, wherein there is exposed coated electrical steel on the top surface 76 and the bottom surface 78 of the multi-layer material sheet 26.

[0050] The adhesive applicator 66 may be X / Y adjustable relative to the layers to ensure that the adhesive is applied within the intended final location where the lamination stamping occurs. For example, in adhesive application where the location of the desired adhesive can be controlled, the goal is to apply the adhesive to the functional areas of the resulting rotor and stator plates rather than across the entire surface. Thus, the X / Y adjustment may be used to control the precise area where the adhesive is applied. Figures 3 to 8 Some example options for controlled adhesive application location can be seen in . For example, Figure 8 An example of precise control of bonding points avoiding areas of windings or magnets is illustrated.

[0051] The multilayer roller feeder 74 is illustrated as having a pair of opposing rollers that feed and combine two layers of material after applying adhesive between them. However, it will be understood that the illustration is schematic and that the illustration may also be applicable to a multilayer roller feeder unit comprising a separate feeder and a separate 2-in-1 combiner. In this regard, one or more feeders in the multilayer roller feeder 74 may convey layers forward in the process, wherein the 2-in-1 combiner applies force to place the layers together. Although the primary function of the 2-in-1 combiner is to apply force, the rolling action will also provide the ability to advance layers at the same speed in combination with other feeding mechanisms. The feeding mechanism of the multilayer roller feeder 74 may be located before or after the 2-in-1 combiner mechanism.

[0052] In order to precisely control the position of the coil material, especially the lower electrical coil sheet material 42 to which the adhesive is applied at the adhesive applicator 66, the lower electrical coil sheet material 42 is kept tensioned during the process. This tensioning and controlled positioning of the lower electrical coil sheet material 42 ensures that the position of the applied adhesive 62 is correct relative to the actual position of the rotor lamination plates 92 and stator lamination plates 94 stamped out of the material. In order to achieve this tensioning and precise positioning, the feeder mechanism within the multi-layer roller feeder 74 acts as a master controller, and other feeders and / or pullers including the bottom single roller feeder 36, the 2-in-1 combination of the multi-layer roller feeder 74, and the coil puller 38 follow this master controller. This arrangement ensures the tension of the lower electrical roll sheet material 42 and the synchronous advancement of the material throughout the process, which limits the upward curling / downward curling of the material. Due to the difference in rolling force between the upper electrical roll sheet material 30 and the lower electrical roll sheet material 42, the upward curling / downward curling of the material may cause the electrical roll sheet materials 30, 42 to separate from each other or the electrical roll sheet materials 30, 42 to slide relative to each other.

[0053] Move to Figure 1 , the multi-layer material sheet 26 is received by a lamination forming device 24 positioned in line with the multi-layer forming device 22. The function of the lamination forming device 24 is to process the multi-layer material sheet 26 into a combined stack of a final rotor lamination assembly 80 and a final stator lamination assembly 82. The lamination forming device 24 includes a second application station 84, a punching tool 86 positioned in a punch press, and two separate stacking machines 88 for finally forming the rotor lamination assembly 80 and the stator lamination assembly 82. The punching tool 86 will gradually form features in the multi-layer material sheet 26 through punching by vertically moving the punch 90 into a die (not shown), thereby producing an operation of punching out a separate rotor lamination plate 92 from a central portion of the multi-layer material sheet 26, and then subsequently punching features, and then punching out a separate stator lamination plate 94 from the remaining multi-layer material sheet 26 around the radially outer portion of the removed rotor portion.

[0054] Figure 1 A simplified arrangement of a single stamping station for forming rotor and stator plates is shown, but it should be understood that the stamping tool 86 may include multiple stamping stations that each form various specific features, such as magnet pockets or winding slots, in individual rotor and stator laminations 92, 94 as the multi-layer material sheet 26 is indexed through the stamping tool 86.

[0055] Continue to refer to Figure 1 , details of the second application station 84 will be provided. The second application station 84 is positioned in the production line before any stamping operation. The positioning may include physically positioning the second application station 84 before the stamping tool 86 or incorporating the station 84 into the stamping tool 86. In this aspect, the multilayer material sheet 26 receives a second treatment of an adhesive 62A and an optional activator 68A from the second application station 84. The adhesive 62A and (optional) activator 68A are of the same type and chemical composition that may be used previously in the process. The adhesive 62A and (optional) activator 68A are applied to prepare for forming a combined stack of rotor lamination assembly 80 and stator lamination assembly 82 by rotor lamination plates 92 and stator lamination plates 94. The rotor lamination assembly 80 is made of dozens of individually stamped annular rotor lamination plates 92, wherein the adhesive 62A is located between each layer of the rotor lamination plates 92. When the rotor lamination plate 92 is placed in the stacking machine 88, the force from the punching tool 86 is used to apply pressure to the stacking piece when the stacking piece is built from the bottom up in the stacking machine 88, thereby combining each rotor lamination plate 92 together. Once the target height of the rotor lamination assembly 80 is achieved, the stacking piece is removed from the stacking machine 88, and the process of building a new rotor lamination assembly 80 can be started again. The stator lamination assembly 82 is assembled in the same manner. Producing and utilizing a multi-layer material sheet 26 reduces the number of stamping operations for producing a lamination assembly of a given height because multiple layers are processed via each stroke of the press instead of using a single layer of material. In one aspect, heat (e.g., 110 degrees Celsius) can be used in the stacking machine 88 to form the stacking assembly. In addition, heat is usually not applied before this stage.

[0056] In this Figure 1In an embodiment, before the stamping operation of the rotor lamination plate 92 or the stator lamination plate 94, the second adhesive applicator 96 applies the adhesive 62A to the top surface 76 of the multilayer material sheet 26. If the optional activator 68A is used, the optional activator 68A is applied to the bottom surface 78 of the multilayer material sheet 26 via the second activator applicator 98. The application of the adhesive 62A and the activator 68A can be performed in a similar manner as described for the first adhesive application station 60. Depending on the press configuration and environment for positioning the second adhesive application station 84, the surfaces to which the adhesive 62A and the activator 68A are applied can be reversed. For example, the adhesive 62A can be applied to the bottom surface 78 of the multilayer material sheet 26 instead, especially in the case where the multilayer material sheet 26 is displaced in the vertical direction when the multilayer material sheet 26 enters the punch during the pressing operation, because this can promote the adhesive 62A to be more easily displaced in a contact method because the applicator 96 can remain stationary when the multilayer material sheet 26 contacts the applicator. On the other hand, if the multilayer material sheet 26 is not vertically displaced as it travels toward the punch press, it can facilitate applying the adhesive 62A to the surface from above via spray or droplets in an easier manner. There will also be situations where the adhesive 62A or (optional) activator 68A will intentionally not be applied to the multilayer surface 26, particularly when the stamped laminations from the multilayer material sheet 26 are the starting bottom pieces of the rotor lamination assembly 80 and / or the stator lamination assembly 82 or are the last top pieces of the rotor lamination assembly 80 and / or the stator lamination assembly 82.

[0057] The stack forming apparatus 24 described above (and the improved stack forming apparatus 24' described below) is preferably isolated from the structure of the roller feeders 36 and 74, and also from the structure of the coil puller 38. This isolation improves the accuracy of stack forming by reducing vibrations from the press that might otherwise propagate to the feeder / puller.

[0058] In addition to the controlled feeding and vibration isolation described above to improve accuracy, the upper electrical coil material 30 and the lower electrical coil material 42 can be mechanically interlocked with each other before punching / stamping / blanking. The mechanical interlocking connection can be provided via a punch, such as an additional punch 90, disposed before the punch 90 that produces the rotor lamination plate 80. The additional punch 90 can be disposed within the lamination forming device 24, 24', or outside the lamination forming device 24, 24' after the multi-layer roller feeder 74. The mechanical interlocking connection 120a can be provided in the scrap portion 120 or 122 that does not become part of the final rotor or stator (see Figure 3 The mechanical connection further maintains the position of the electrical coiled sheet materials 30, 42 relative to each other.

[0059] Figure 2 An overview of an alternative embodiment of a multilayer lamination device 20 is provided, which again includes a multilayer forming device 22, followed directly by an improved lamination forming device 24'. In this alternative embodiment, the functions and features of the multilayer lamination device 20 as previously described remain unchanged, including that the activator is optional. The lamination forming device 24' is modified to position the second application station 84' immediately before the blanking operation of the rotor lamination plate 92, and to add a third application station 100 immediately before the blanking operation of the stator lamination plate 94. The application stations each include an adhesive applicator and an optional activator applicator. A stamping operation occurs before applying the adhesive to form various features in the rotor lamination plate 92 and the stator lamination plate 94. The second application station 84' is different from the second application station 84 of the first embodiment because the second application station 84' applies the adhesive 62A and the optional activator primarily to the area on the multilayer material sheet 26 that becomes the rotor lamination plate 92, rather than to both the rotor area and the stator area. The third application station 100 applies the adhesive 62B and the optional activator 68B to the remaining material of the multilayer material sheet 26 , or specifically to the annular material portion from which the stator lamination plates 94 were punched out, or to both areas.

[0060] Preferably, adhesives 62A and 62B are applied in a manner that will result in minimal contact with the punch 90 during the blanking process to reduce contamination. As described in the original embodiment, the adhesive in the second application station 84' and the third application station 100 can apply the adhesive and optional activator to the top surface 76 or the bottom surface 78 of the multilayer material sheet 26 in the second application station 84. In a similar manner, it is recommended that the adhesive 62B and the activator 68B have the same type and chemical composition as 62A and 68A. Due to the arrangement of the alternating layers of the binder and the laminate, the surface on which the second application station 84' applies the adhesive 62A will be the same as the surface on which the third application station 100 applies the adhesive 62B. The positioning of the second adhesive application station 84' before the rotor blanking and the positioning of the third adhesive application station 100 before the stator laminate 94 blanking provides the benefit of reducing the risk of glue contamination to the tool because the adhesive is applied immediately before the blanking operation. If adhesive 62A and 62B are applied by an applicator prior to the multiple pressing operations used to form magnet pockets and stator wire winding slots in rotor lamination plates 92 and stator lamination plates 94, punch 90 may be contaminated with adhesive. Separating second application station 84' from third application station 100 may also provide flexibility in the optional application of activator 68, potentially staggering the time from activator application to adhesive application within the process, thereby improving the curing time at room temperature. Other features previously described in second application station 84 may also be applied to third application station 100.

[0061] In one aspect, the system preferably does not include applying an activating agent at station 60, 84, 84' or 100 via applicator 72, 72A, 68A, 68B. Figure 1 and Figure 2 Each includes illustrations of these applicators and applied activator where application of an activator is desired, but it will be understood that the illustrations provided are not limiting and that such application is not required. Preferably, only adhesive is applied at stations 60, 84, 84' and 100.

[0062] Figures 3 to 8 Each of the figures depicts a short length of coiled material covered by the rotor lamination plate 92 around the contour of the stator lamination plate 94, and also shows various patterns in which adhesive 62 can be applied to the coiled material. These adhesive patterns can be applied at the first adhesive application station 60 to form the multilayer material sheet 26, or at the second application station 84 and the third application station 100 to form the lamination assembly 80 and 82. As an example, the drawings will each show how different patterns of adhesive 62 are applied to the upper surface 64 of the lower electrical coiled sheet material 42 at the first adhesive application station 60. It should be understood that these figures can also describe the situation where the pattern of the optional activator 68 will also be applied in a similar arrangement or the adhesive 62 can be applied at the application station 84, 84 'and 100 at a later stage in the process. Each figure will represent a short length 110 of a longer strip of the lower electrical coiled sheet material 42. The width 112 of the material can be selected to be slightly wider than the outer diameter 114 of the stator lamination plate 94 to utilize as much material as possible. The annular stator lamination plate 94 includes a stator outer diameter 114 and a stator inner diameter 116. The stator inner diameter 116 is slightly larger than the rotor outer diameter 117 of the rotor lamination plate 92. The rotor lamination plate 92 will also include a rotor inner diameter 118, which when formed will produce a circular scrap portion 120 removed from the center of the rotor lamination plate 92. After forming the stator laminations 94 and rotor laminations 92, the remaining portion of the excess coil material 122 with multiple circular cutouts produced by the stamping operation will leave the lamination forming device 24 through the action of the coil puller 38. The design of the rotor lamination plate 92 and the stator lamination plate 94 should not be considered a limiting design or arrangement, but only an example to further explain the various patterns of the applied adhesive. Features such as magnet pockets and stator wire winding slots can vary depending on the application, and the description of such an example design herein should not be limiting.

[0063] Figure 3110 and across the width 112. Advantages of this technique include, but are not limited to, that the highest strength and punching locations of the stator laminations 94 and rotor laminations 92 do not have to be so tightly controlled because there is no positional relationship of the adhesive 62 because it covers the entire surface of the material from which the stator laminations 94 and rotor laminations 92 are punched out. The complete coverage arrangement also improves isolation between layers because it is guaranteed that there is adhesive on the entire face of the rotor laminations 92 and stator laminations 94. Because the adhesive 62 is applied to the scrap portions 120 and 122, an excess of adhesive is used. One disadvantage is that because the adhesive 62 is applied over the entire surface, the punch 90 may be contaminated by the adhesive 62 because it will cut into an area that is already covered by the adhesive.

[0064] Figure 4 Represents something like Figure 3 The adhesive 62 of the coil material is applied to the entire surface of the coil material, except that no adhesive is applied within the circular waste portion 120. The adhesive 62 has been applied to almost the entire extent of the coil material, covering the surface along the length 110 and across the width 112, except for the portion inside the rotor inner diameter 118 that will become the waste portion 120. Because the circular waste portion 120 is not included in the final lamination assembly, the absence of adhesive 62 has no effect on functionality. Advantages of this technique include, but are not limited to, maintaining the highest strength because the layers are fully bonded within the lamination; however, some alignment is required to ensure that the rotor lamination plate 92 is punched from the area where the adhesive 62 has been applied. Since the adhesive covers the entire face of the rotor lamination plate 92 and the stator lamination plate 94, the isolation between the layers is still guaranteed. Because the adhesive 62 is not applied to the waste portion 120, some adhesive material is saved, but the adhesive 62 is still applied to the outer waste portion 122. The punch 90 may still be contaminated when punching through the adhesive in the area outside the rotor inner diameter 118.

[0065] Figure 562 is applied completely from the rotor inner diameter 118 to the stator outer diameter 114. Because the area where the adhesive 62 is not applied is not included in the final lamination assembly, there is no negative impact on the function of the final product. The advantages of this technology include but are not limited to maintaining the highest strength because the layers are fully bonded within the lamination, but alignment is required to ensure that the rotor lamination plates 92 and the stator lamination plates 94 are stamped from the area where the adhesive 62 has been applied. Isolation between the layers is still guaranteed because the adhesive covers the entire face of the rotor lamination plates 92 and the stator lamination plates 94. Because the adhesive 62 is not applied to the waste portion 120 or 122, the applied adhesive material is completely used in the final rotor lamination assembly 80 and the stator lamination assembly 82. The punch 90 is less likely to be contaminated when punching because the punch 90 will generally only traverse the adhesive when forming the stator outer diameter 114 and the rotor outer diameter 117 and other internal features of the rotor and stator laminations. Figure 2 In the case where a third adhesive application station 100 is used in the process, adhesive 62A will be applied to the rotor lamination plate 92 area at adhesive application station 84' before blanking plate 92, and adhesive 62B will be applied to the stator lamination plate 94 area at third station 100 before blanking plate 94. Separating the application of adhesives 62A and 62B can further minimize contamination of punch 90.

[0066] Figure 6The rings formed using adhesive are illustrated to provide a bonding area around 360 degrees of a given width 130 on the faces of the rotor lamination plates 92 and the stator lamination plates 94. In the example provided, a single ring formed by adhesive 62 is applied to each of the areas aligned with the final position of the rotor or stator. The rotor adhesive ring 132 is applied to the area to be aligned with the rotor lamination plates 92, and the second stator adhesive ring 134 is applied to the area aligned with the stator lamination plates 94. The rings 132 and 134 are concentrically positioned relative to each other and are centrally positioned relative to the diameter that is stamped later in the process to form the rotor lamination plates 92 and the stator lamination plates 94. Although two rings are shown in this example, additional rings can be included, wherein the width 130 is adjusted to allow more rings formed by adhesive 62 to fit between the rotor inner diameter 118 and the stator outer diameter 114. It is proposed that the stator adhesive ring 134 is positioned toward the stator outer diameter 114 because this location has full face contact because the stator slots 136 that cause interruptions in the face of the laminations are located inside the stator adhesive ring 134 so as not to contaminate the punch 90. The rotor adhesive ring 132 can be centrally positioned between the rotor inner diameter 118 and the rotor outer diameter 117. Relatively precise alignment can be used to ensure that the rotor adhesive ring 132 and the stator adhesive ring 134 are correctly positioned and aligned with the rotor lamination plates 92 and stator lamination plates 94 that are stamped out later in the process. This annular arrangement of adhesive reduces waste when compared to previous full face adhesive arrangements. Because there are areas on the face of the laminations without adhesive, there may be the possibility of metal connection and reduced isolation, especially on the cut edges of the diameters and other features stamped into the laminations. Alternatively, pairs of rings formed of adhesive may be positioned at the stator outer diameter 114, the stator inner diameter 116, and the rotor inner diameter 118 to improve electrical insulation at these cut edges. Where a third adhesive application station 100 is used in the process, the stator adhesive ring 134 may be applied at the third station 100, while the rotor adhesive ring 132 may be applied at the adhesive application station 84' prior to stamping out the rotor lamination plates 92. It is proposed that both the stator adhesive ring 134 and the rotor adhesive ring 132 are applied together at the first adhesive application station 60 used to form the multilayer material sheet 26, or in the first embodiment, at a single second adhesive application station 84.

[0067] Figure 7140. The application of adhesive 62 to the surface of the lower electrical coil material 42 in a grid pattern of dots 140 is shown. These dots 140 of adhesive can be applied to the surface of the lower electrical coil material 42 in a uniform manner, regardless of the location where the rotor lamination plate 92 and the stator lamination plate 94 will be stamped. An arrangement of four dots 140 with a given dot outer diameter 142 is shown as being placed across the width 112 of the coil material, but the arrangement, the number of dots, and the outer diameter 142 of the dots can be changed to increase or decrease the number of dots 140 in a given area or the percentage of the surface covered by the dots 140. The advantage of this arrangement is that the application of the dots 140 can be applied by a variety of contact methods and non-contact methods. These methods are generally very fast and have a high level of controllability related to the location and amount of adhesive 62 applied. Because a grid arrangement is utilized that is independent of the final rotor lamination plate 92 and stator lamination plate 94 formed by the material strip, alignment is less important. As previously described in other adhesive application methods, edge isolation and contamination of the punch 90 due to adhesive not being integrally present between the faces of the laminations can be disadvantages. It is also possible to use some adhesive 62 that is applied to surfaces that become waste because they are not within the scope of the final lamination area.

[0068] Figure 8 150 is represented as another optimized application of adhesive 62 as it applies dots 150 to specific locations within the final rotor lamination plate area 92 and stator lamination plate area 94. The illustration also represents the process that requires relatively precise control over the location and amount of adhesive 62 applied to the surface of the coiled material. The dots 150 can be applied only to useful areas. For example, in the area of ​​material that will become the stator lamination plate 94, the dots 150 can be located between the stator outer diameter 114, but radially outside the extent of the stator slots 136. Similarly, in the area that will become the rotor lamination plate 92, the dots 150 can be positioned in a manner that avoids areas formed for magnet pockets 154. The number of points 150 and the amount of adhesive 62 applied can be based on the functional and structural requirements of the final lamination stack. As Figure 7 The complete arrangement of dots 150 shown in FIG. 1 can be applied at the first adhesive application station 60 to bond the layers together, thereby producing the multilayer material sheet 26. At the second application station 84, all of the dots 150 can be applied to the rotor laminations 92 and stator laminations 94 prior to the stamping operation. Figure 2In the case of using the second adhesive application station 84' and the third adhesive application station 100 in the process, the dots 150 applied to the area of ​​the stator lamination plate 94 can be applied at the third station 100 before punching, and the area of ​​the rotor lamination plate 92 can have the dots 150 applied at the second adhesive application station 84' before punching out the rotor lamination plate 92. Compared with other methods proposed, edge isolation caused by the adhesive not being present in its entirety between the faces of the laminations may be more of a concern, but applying the dots 150 at such specific locations in any adhesive application station results in reduced contamination issues for the punch 90 and optimizes the use of adhesive material.

[0069] It is suggested that the adhesive pattern described previously need not be utilized uniformly at all adhesive application stations within a process. Figure 5 The optimized full surface bonding shown in FIG. 2 can be used to produce a bond of a multi-layer material sheet 26, while Figure 8 Optimized point bonding may be used to create bonds between the blanked panels of the multi-layer material sheet 26 when forming the rotor lamination assembly 80 and the stator lamination assembly 82. Other combinations of adhesive patterns may also be used.

[0070] For the purpose of illustration and description, the foregoing description of the embodiments has been provided. The foregoing description is not intended to be exhaustive or to limit the present disclosure. Each element or feature of a particular embodiment is generally not limited to the particular embodiment, but is interchangeable and can be used for a selected embodiment where applicable, even if not specifically shown or described. Each element or feature of a particular embodiment may also be varied in a variety of ways. These variations should not be considered as departing from the present disclosure, and all of these modifications are intended to be included within the scope of the present disclosure.

[0071] Reference numerals

[0072] 20 multi-layer stacking device

[0073] 22Multi-layer forming device

[0074] 24, 24' lamination forming device

[0075] 26 Multilayer material sheets

[0076] 28 Upper processing device

[0077] 30 Upper electrical coil material

[0078] 32 Uncoiler

[0079] 34 rolls

[0080] 36 single layer roller feeder

[0081] 38 Coil puller

[0082] 40 Lower layer processing device

[0083] 42 Lower electrical coil material

[0084] 44 Butt welding

[0085] 46 Straightening Machine

[0086] 50 belt loops

[0087] 60 First adhesive application station

[0088] 62, 62A, 62B adhesive

[0089] 64 upper surface

[0090] 66 Applicator

[0091] 68, 68A, 68B activator

[0092] 70 lower surface

[0093] 72, 72A applicator

[0094] 74 multi-layer roller feeder

[0095] 76 Top surface of the multilayer material sheet

[0096] 78 Bottom surface of multilayer material sheet

[0097] 80 rotor lamination assembly

[0098] 82 stator lamination assembly

[0099] 84, 84' Second application station

[0100] 86 stamping tools

[0101] 88 stacking machine

[0102] 90 punch

[0103] 92 rotor lamination plates

[0104] 94 stator laminated plate

[0105] 96 second adhesive applicator

[0106] 98 Second Activator Applicator

[0107] 100 Third Application Station

[0108] 110 Length

[0109] 112, 130 width

[0110] 114 stator outer diameter

[0111] 116 stator inner diameter

[0112] 117 rotor outer diameter

[0113] 118 Rotor inner diameter

[0114] 120, 122 waste parts

[0115] 120a Mechanical interlocking connection

[0116] 122 Coil Material

[0117] 132 Rotor Adhesive Ring

[0118] 134 stator adhesive ring

[0119] 136 stator slots

[0120] 140, 150 points

[0121] 142 points outer diameter

[0122] 154 Magnet cavity

Claims

1. A method for producing a lamination stack assembly for an electrical component, the method comprising: Providing an upper electrical coil material (30) and a lower electrical coil material (42); applying a first adhesive (62) between the upper electrical coil material (30) and the lower electrical coil material (42); combining the upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42) together and producing a combined multi-layer material sheet (26), wherein the upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42) are bonded together by the adhesive (62); applying a second adhesive (62A) to the multilayer material sheet (26) to produce a final laminate stack; stamping (86) a plurality of laminated plates from the multi-layer material sheet (26) arrangement; vertically arranging the plurality of laminate plates into at least one stack; The rotor lamination plates (92) and the stator lamination plates (94) are pressed together and a final combined stack of the rotor lamination assembly (80) and the stator lamination assembly (82) is constructed, wherein the stack of the rotor lamination assembly (80) and the stator lamination assembly (84) are bonded by the second adhesive (62A) disposed between vertically adjacent lamination plates in the rotor lamination plates (92) and the stator lamination plates (94) in the stack.

2. The method according to claim 1, wherein: The first adhesive (62) is applied to an upper surface (64) of the lower electrical bead material (42).

3. The method according to claim 1, wherein: After applying the first adhesive (62), the upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42) are combined and bonded in a multi-layer roll feeder (74).

4. The method according to claim 3, wherein: The multi-layer roller feeder (74) includes a single-layer roller feeder (36) and a 2-in-1 combiner, wherein the 2-in-1 combiner presses the layers together.

5. The method according to claim 1, wherein: The second adhesive (62A) is applied prior to stamping each of the plurality of laminated sheets.

6. The method according to claim 5, wherein: The second adhesive (62A) is applied via an adhesive applicator (66) disposed within the lamination forming apparatus (24, 24').

7. The method according to claim 1, wherein: For each laminate of the plurality of laminates, the second adhesive (62A) is applied in a common area with the first adhesive (62).

8. The method according to claim 1, wherein: The plurality of lamination plates include a plurality of rotor lamination plates (92) and a plurality of stator lamination plates (94), wherein the at least one stack includes a rotor lamination assembly (80) and a stator lamination assembly (82).

9. The method according to claim 8, wherein: The stator laminations (94) and the rotor laminations (92) are stamped from a common length and width of the multi-layer material sheet (26), wherein the rotor laminations (92) are stamped from material radially disposed within the material for the stator laminations (94).

10. The method according to claim 9, wherein: The rotor lamination stack (92) is stamped before the stator lamination stack (94).

11. The method according to claim 10, wherein: A third adhesive (62B) is applied to the multilayer material sheet (26) after stamping the rotor laminations (92) and before stamping the stator laminations (94).

12. The method according to claim 11, wherein: The third adhesive (62B) is applied to a region corresponding to the stator lamination plate (94), and the second adhesive (62A) is applied to a region corresponding to the rotor lamination plate (92).

13. The method according to claim 1, wherein: The first adhesive (62) and the second adhesive (62A) are selectively applied to areas of the multilayer material sheet (26) such that areas contacted by the punch do not include adhesive.

14. The method according to claim 12, wherein: The first adhesive (62) and the second adhesive (62A) are provided in the form of dots (140, 150) within the contour of the lamination plates and outside the area of ​​the stator windings and rotor magnet pockets (154).

15. The method according to claim 1, wherein: An adhesive activator (68, 68A, 68B) is applied to an area of ​​the upper electrical winding sheet material (30) or the lower electrical winding sheet material (42) or to an area of ​​the multilayer material sheet (26) corresponding to at least the first adhesive (62), wherein the applied adhesive activator (68, 68A, 68B) is configured to contact the corresponding adhesive (62, 62A, 62B) prior to bonding.

16. The method of claim 1, further comprising providing the multilayer material sheet (26) to a stack forming device (24, 24') comprising a punch press, wherein: The upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42) are joined together immediately prior to the stamping step in an area in line with and adjacent to the stamping press.

17. The method according to claim 1, wherein: As the multilayer material sheet (26) is fed through the punch press and the first adhesive (62) and the second adhesive (62A) are applied, the lower electrical roll sheet material (42) is maintained in tension to control the position of the lower electrical roll sheet material (42) and limit relative movement between the upper electrical roll sheet material (30) and the lower electrical roll sheet material (42).

18. The method according to claim 2, wherein: The second adhesive (62A) is applied to the top surface (76) of the multilayer material sheet.

19. The method of claim 1 further comprising applying heat to the lamination stack while constructing the final bonded lamination stack.

20. The method of claim 1, further comprising mechanically interlocking the upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42) in the multi-layer material stack prior to stamping the laminate.

21. A system for performing the method according to any one of the preceding claims, the system comprising: a multi-layer roll feeder (74) receiving an upper layer and a lower layer formed of sheet material, wherein the multi-layer roll feeder (74) feeds the upper electrical roll sheet material (30) and the lower electrical roll sheet material (42) and combines the upper electrical roll sheet material (30) and the lower electrical roll sheet material (42) into a bonded multi-layer material sheet (26), wherein the first adhesive (62) is disposed between the upper electrical roll sheet material (30) and the lower electrical roll sheet material (42); a first adhesive applicator (72) disposed before the multi-layer roll feeder (74), the first adhesive applicator (72) applying the first adhesive (62) to one of the upper electrical coiled sheet material (30) and the lower electrical coiled sheet material (42); at least one stamping punch (90) for performing stamping of the plurality of laminated plates, wherein the stamping punch is disposed after the multi-layer roller feeder (74); a second adhesive applicator (72A) disposed after the multi-layer roll feeder (74) and before the at least one stamping punch (90), wherein the second adhesive applicator (72A) applies the second adhesive (62A) to the multi-layer material sheet (26); At least one stacker (88) receives the plurality of laminate plates, wherein the at least one stacker (88) combines the plurality of laminate sheets (26) into a final combined laminate stack.

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