In-line bonding process of laminated core

Abstract

A machine assembly configured to process a roll of metal sheet to form a laminated core is provided. The assembly includes an uncoiler configured to uncoil the roll of metal sheet. An adhesive applicator is arranged downstream of the uncoiler and configured to apply adhesive to the metal sheet. A first curing device is arranged downstream of the adhesive applicator and configured to partially cure the adhesive. A punch press is arranged downstream of the first curing device and configured to blank and punch the metal sheet to form a punched metal piece. A stacking device is configured to form a stack of the punched metal pieces. A second curing device is configured to fully cure the adhesive between each punched metal piece in the stack to form the laminated core.

Description

[0001] Related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 558,232, filed February 27, 2024, which is incorporated herein by reference. Technical Field

[0003] Generally, the present invention relates to a machine assembly for applying adhesive to metal sheets, and more particularly to an online bonding process using the machine assembly to produce laminated cores. Background Technology

[0004] An electric motor converts electrical energy into mechanical energy to rotate a rotor around a stator. In some cases, when electrical energy is applied to the electric motor, a magnetic force is created, causing the rotor to rotate around the stator. Each of the rotor and stator in an electric motor can include a laminated core instead of a single solid metal piece to reduce eddy current losses and thus improve the motor's efficiency. A laminated core consists of a stack of thin, stamped metal sheets bonded together. Factors such as the metal sheets of each laminated core, the bonding technique, and the overall shape can all affect the overall cost and performance of the electric motor. Summary of the Invention

[0005] According to one embodiment of the present invention, a machine assembly is provided. The assembly includes: an uncoiler configured to unwind a roll of metal sheet; and a straightener configured to receive and straighten the metal sheet after unwinding. The assembly further includes an adhesive application device disposed downstream of the straightener and configured to apply adhesive to one side of the metal sheet. A first curing device disposed downstream of the adhesive application device and configured to partially cure the adhesive. A stamp and punch machine disposed downstream of the first curing device and configured to stamp and punch the metal sheet to form stamped metal parts. A stacking device is configured to form a stack of the stamped metal parts. A second curing device is configured to fully cure the adhesive between each stamped metal part in the stack to form a laminated core.

[0006] According to another embodiment of the present invention, a method for forming a stack of stamped metal parts is provided. The method includes: obtaining a roll of metal sheet; loading the roll of metal sheet onto an uncoiler; unwinding the roll of metal sheet using the uncoiler; aligning and straightening the metal sheet after unwinding; applying an adhesive to one side of the metal sheet; partially curing the adhesive in a first curing apparatus; punching and stamping the metal sheet to form a stamped metal part coated with the adhesive; stacking the stamped metal parts; and fully curing the adhesive to bond the stamped metal parts together.

[0007] According to another embodiment of the present invention, a laminated core is provided. The laminated core includes a first metal layer, a second metal layer, and a third metal layer. Furthermore, a first adhesive layer is disposed between the first metal layer and the second metal layer, and a second adhesive layer is disposed between the second metal layer and the third metal layer. The laminated core is manufactured by a process comprising the following steps: obtaining a roll of metal sheet; loading the roll of metal sheet onto an uncoiler; unwinding the roll of metal sheet using the uncoiler; aligning and straightening the metal sheet after unwinding; applying an adhesive to one side of the metal sheet; partially curing the adhesive in a first curing apparatus; punching and stamping the metal sheet to form the first metal layer, the second metal layer, and the third metal layer, wherein the adhesive forms the first adhesive layer on the first metal layer and the second adhesive layer on the second metal layer; stacking the first metal layer, the second metal layer, and the third metal layer; and fully curing the first adhesive layer and the second adhesive layer to bond the first metal layer, the second metal layer, and the third metal layer to each other, thereby forming the laminated core.

[0008] These and other objects of the invention will become apparent from the accompanying drawings, detailed descriptions, and appended claims. Attached Figure Description

[0009] Figure 1 Schematic diagrams of some embodiments of a machine assembly are shown, the machine assembly being configured to unwind a roll of metal sheet, apply an adhesive to the metal sheet, partially cure the adhesive, and stamp a metal part from the metal sheet.

[0010] Figure 2 It shows Figure 1 Block diagrams of some embodiments of the machine components.

[0011] Figure 3 Flowcharts illustrating some embodiments of a method for applying adhesive to a metal sheet while it is being continuously unwound are shown.

[0012] Figure 4A Schematic diagrams of some other embodiments of the machine assembly disclosed herein are shown, the machine assembly also including loop control located between the first curing device and the stamping press.

[0013] Figure 4B Schematic diagrams of some other embodiments of the machine assembly disclosed herein are shown, the machine assembly including a cooling component located between a first curing device and a stamping press.

[0014] Figure 5 A perspective view of some embodiments of the adhesive application device is shown.

[0015] Figure 6 Perspective views of some embodiments of the adhesive application device and the first curing device are shown.

[0016] Figure 7 , Figure 8 , Figure 9 and Figure 10 Various views of some embodiments of a first curing apparatus including an induction coil are shown.

[0017] Figure 11 and Figure 12 Various views of some embodiments of a first curing apparatus arranged at an angle relative to a metal sheet are shown.

[0018] Figure 13 Some embodiments are shown that use two first curing devices to partially cure the adhesive on the metal sheet.

[0019] Figure 14 Some embodiments of a laminated core including an adhesive layer disposed between stamped metal parts are shown.

[0020] Figure 15 Some other embodiments of a laminated core are shown, including an adhesive layer disposed between interlocking stamped metal parts.

[0021] Figure 16 Other embodiments of a laminated core including an adhesive layer disposed between stamped metal parts having through holes are also shown. Detailed Implementation

[0022] Embodiments of this application relate to a method and components for coating a metal sheet with an adhesive immediately after it is unwound, within the same production line. The adhesive can then be partially cured before the adhesive-coated metal sheet is stamped and die-cut to form stamped metal parts. The stamped metal parts can be stacked and undergo a final curing process to form a laminated core comprising several sheets of stamped metal parts bonded together by the adhesive. To unwound the metal sheet, a roll of metal sheet is loaded onto an uncoiler. The roll of metal sheet does not contain any adhesive before being loaded onto the uncoiler. Over time, incompletely cured adhesive may decompose. Therefore, due to the absence of any adhesive, the roll of metal sheet has a longer shelf life, thus reducing waste. With the longer shelf life, laminated core manufacturers can purchase adhesive-free rolls of metal sheet in bulk and / or maintain a large inventory of different types of metal sheet materials. Therefore, laminated core manufacturers can customize which adhesive and metal materials are used when producing laminated cores, thereby increasing the number of design options available to laminated core customers.

[0023] Referring to the accompanying drawings, the same reference numerals denote the same or corresponding parts in several views. However, the inclusion of the same elements in different views does not imply that a given embodiment necessarily includes these elements, nor does it mean that all embodiments of the invention include these elements. The examples and drawings are merely illustrative and are not intended to limit the scope and spirit of this application, which are defined by the claims.

[0024] Turn now Figure 1 and Figure 2 An exemplary mechanical production line for processing 114 rolls 112 of metal sheets is shown. Figure 1 A schematic diagram of the machine is shown. Figure 2 It shows the relationship with Figure 1 The corresponding block diagram for the Chinese machinery.

[0025] The exemplary production line includes an uncoiler 102, a straightener 104 disposed downstream of the uncoiler 102, an adhesive application device 106 disposed downstream of the straightener 104, a first curing device 108 disposed downstream of the adhesive application device 106, and a stamping press 110 disposed downstream of the first curing device 108. The uncoiler 102 is configured to receive and unwind a roll 112 of metal sheet 114, such that the metal sheet 114 can be fed into each component of the exemplary production line for processing. The metal sheet 114 is unwound and fed into each component generally along a feed direction 119. The production line may include one or more feeding devices configured to continuously guide the metal sheet 114 between the uncoiler 102 and the stamping press 110 at a predetermined speed. In some embodiments, the predetermined speed is in the range of, for example, from about 10 m / min to about 75 m / min. The one or more feeding devices may be a conveyor belt, a single-sided roller, a double-sided roller, or some other suitable structure configured to push and / or pull the metal sheet 114 between the various parts of the production line.

[0026] In some embodiments, the metal sheet 114 may comprise steel or certain other metals in sheet form suitable for a laminated core. When loaded onto the uncoiler 102, the roll 112 of the metal sheet 114 contains no adhesive. Because there is no adhesive on the roll 112, its shelf life can be extended, and more customized adhesive can be applied to the metal sheet 114 during the in-line process between uncoiling and stamping. In other words, the roll 112 can be stored in a warehouse for an extended period before being loaded onto the uncoiler 102. For example, the roll 112 can be stored in a warehouse for more than six months. The roll 112 can also be stored in the same warehouse as the uncoiler 102 and other components of the production line. Furthermore, because the metal sheet 114 is not pre-coated with adhesive before being loaded onto the uncoiler 102, the roll 112 of the metal sheet 114 can be purchased from various metal manufacturers. In some embodiments, the metal sheet 114 roll 112 may include an insulating layer on one or both sides of the metal sheet 114 before the roll 112 is loaded onto the uncoiler 102. Non-limiting examples of the insulating layer include a C5 or C5A type coating.

[0027] Adhesive application device 106 is configured to apply adhesive 118 to one or both sides of metal sheet 114. In some embodiments, for simplicity and cost savings, adhesive 118 is applied only to one side of metal sheet 114. Alternatively, adhesive 118 may completely or substantially cover one or both sides of metal sheet 114. After coating metal sheet 114 with adhesive 118, metal sheet 114 is fed into first curing device 108 to dry and / or partially cure adhesive 118. First curing device 108 may include various curing system methods, such as hot box, induction, hot air tunnel, and infrared systems. In some embodiments, adhesive 118 may be cured to a state commonly referred to as “stage B” curing, which is partial curing (i.e., partial crosslinking) of adhesive 118. In some other embodiments, adhesive 118 may be heated to remove moisture from adhesive 118, but not sufficiently to initiate any crosslinking of adhesive 118. By removing only the moisture from the adhesive 118 without curing the adhesive coating, a thinner layer of adhesive 118 can be applied to the metal sheet 114, saving material costs and using less heat and time at this stage to reduce energy consumption and manufacturing costs. Examples of adhesive 118 include adhesives that can be controlled to cure to stage B and then to stage C, and the adhesive is configured to adhere adjacent metals to each other when curing in stage C, but may also provide electrical insulation between the metals. Other examples of adhesive 118 include adhesives that cure upon contact with an activator or under pressure.

[0028] After the adhesive 118 has dried and / or partially cured, a metal sheet 114 with a partially cured adhesive coating 120 is fed into a stamping press 110 to form a stamped metal part 122 comprising the partially cured adhesive coating 120 disposed on the metal sheet 114. Because the adhesive coating 120 is partially cured, the stamping press 110 and any other associated feed devices or machine parts downstream of the first curing unit 108 remain substantially clean, free of adhesive residue. After passing through the stamping press 110, multiple stamped metal parts 122 are aligned and stacked on top of each other using a stacking device 116. The stacked stamped metal parts 122 can then enter a second curing unit 117. Under various temperature, time, and pressure conditions in the second curing unit 117, the partially cured adhesive coating 120 on each stamped metal part 122 can be fully cured (sometimes referred to as “C-stage” curing) and bonded to the surfaces of adjacent stamped metal parts 122 to produce a reliable laminated core 124. The laminate core 124 includes a fully cured adhesive layer 126 disposed between stamped metal parts 122.

[0029] Turn again Figure 3 A flowchart illustrating an exemplary method for forming laminated cores using this mechanical production line is shown. Figure 3The method can correspond to Figure 1 and Figure 2 The various steps shown are illustrated. It should be understood that other steps may also be incorporated. Figure 3 In the flowchart, there are steps such as cleaning, cutting, alignment and cooling.

[0030] In step 302, a roll of metal sheet is obtained, which does not yet have any adhesive layer. In step 304, the roll of metal sheet is loaded onto an uncoiler. In step 306, the roll of metal sheet is unwound by the uncoiler. In step 308, the metal sheet is aligned and straightened after unwinding. In step 310, adhesive is applied to at least one side of the metal sheet. In step 312, the metal sheet is fed into a first curing apparatus to partially cure the adhesive. In step 314, the metal sheet is punched and stamped to form stamped metal parts. In step 316, the stamped metal parts are stacked on top of each other. In step 318, heat and / or pressure are applied to the stacked stamped metal parts to fully cure the adhesive and form a laminated core.

[0031] Turn again Figure 4A , showed Figure 1 An exemplary production line, but with additional components. In some embodiments, more components are used in the exemplary production line. Furthermore, it should be understood that... Figure 1 , Figure 4A and Figure 4B Only schematic diagrams of the components in the production line are shown, and for simplicity, various details such as electrical and mechanical connections to the components are omitted.

[0032] In some embodiments, the cleaning system 402 is coupled to or integrated with the adhesive application device 106. If the adhesive application device 106 becomes clogged or a different adhesive is required, the cleaning system 402 is configured to flush out the old adhesive 118 from the adhesive application device 106. Other cleaning systems may also be used throughout the exemplary production line. For example, in some embodiments, the cleaning system may be arranged between the uncoiler 102 and the adhesive application device 106 to remove any contaminants from the sheet metal 114 before applying the adhesive 118.

[0033] In some embodiments, a loop control 404 is arranged between the first curing device 108 and the press 110. The loop control 404 is configured to maintain the metal sheet 114 exiting the first curing device 108 at a predetermined speed, because the press 110 may not be able to receive continuous feeds of the metal sheet 114 at the same predetermined speed. The loop control 404 may be an S-shaped loop, a U-shaped loop, or some other suitable embodiment.

[0034] In some embodiments, the production line may include a slitting machine configured to cut the metal sheet 114 to the desired width after uncoiling. Therefore, in some embodiments, the slitting machine may be arranged prior to the uncoiling machine and / or the adhesive application device 106. Those skilled in the art may also implement several other components conventionally used for metal sheet processing throughout the exemplary production line to meet other requirements.

[0035] Turn again Figure 4B In some embodiments, the production line includes a cooling component 406 disposed downstream of the first curing unit 108 to cool the metal sheet 114 after partial curing. In some embodiments, the cooling component 406 is disposed between the first curing unit 108 and the press 110. While partial curing at the first curing unit 108 can reduce adhesive adhesion at the press 110, the metal sheet 114 may leave the first curing unit 108 at undesirable high temperatures for stamping and blanking processes at the press 110, resulting in uneven stamped metal parts 122. Therefore, the cooling component 406 can reduce the temperature of the metal sheet 114 immediately after the first curing unit 108 and before entering the press 110.

[0036] like Figure 4B As shown, the cooling component 406 includes a series of cooling rollers that at least contact the side of the metal sheet 114 opposite to the surface where the partially cured adhesive coating 120 is disposed. In some embodiments, the partially cured adhesive coating 120 contacts at least one of the rollers. For example, in Figure 4B In this configuration, the first and third cooling rollers contact the side of the metal sheet 114 opposite to the surface where the partially cured adhesive coating 120 is disposed, while the second cooling roller contacts the partially cured adhesive coating 120. When the cooling component 406 is a series of cooling rollers, the cooling component 406 may also provide loop control. In other embodiments, it should be understood that the cooling component 406 may be a fan, a cold box, or other suitable cooling machine configured to reduce the temperature of the metal sheet 114 as needed. It should be understood that, in addition to the cooling component 110, loop control (e.g., ...) may also be used. Figure 4A 404).

[0037] The need for cooling component 110, the type of cooling component 110, and / or the amount of cooling provided by cooling component 110 can depend on factors such as the type of adhesive, the thickness of the adhesive, the width and thickness of the metal sheet 114, the stamping design, the operating parameters of the stamping machine 110, the distance between the first curing unit 108 and the stamping machine 110, the parameters of the final complete curing process at the second curing unit 117, and / or the partial curing temperature used at the first curing unit 108. For example, in some applications, a higher partial curing temperature at the first curing unit 108 helps eliminate adhesive extrusion during the final curing process at the second curing unit 117, while in some other embodiments, a lower partial curing temperature at the first curing unit 108 helps improve the sealing performance of the laminated core finally cured at the second curing unit 117. The presence of cooling component 110 and the ability to adjust the parameters of cooling component 110 for the desired application can improve the overall performance of the finally cured laminated core.

[0038] As an example, in some embodiments, the first curing unit 108 operates at a temperature nearly 200 degrees Celsius higher than the sheet metal temperature required by the subsequent stamping press 110. In some such embodiments, the cooling unit 110 is configured to reduce the temperature of the sheet metal 114 and the partially cured adhesive coating 120 by approximately 200 degrees Celsius over a short time / distance between the first curing unit 108 and the stamping press 110. For example, in some embodiments, partial curing at the first curing unit 108 may be performed at a temperature between approximately 200 degrees Celsius and approximately 250 degrees Celsius, while the stamping press 110 should operate at a temperature below approximately 50 degrees Celsius to provide a reliable stamped metal part 122. In some such embodiments, the series of cooling rollers 110 may sufficiently cool the sheet metal 114 by 200 degrees Celsius before it enters the stamping press 110. In other embodiments, the cooling unit 110 may be shut off if a lower temperature is used at the first curing unit 108 and subsequent cooling is not necessary or less drastic.

[0039] Turn again Figure 5An enlarged view of an exemplary adhesive application device 106 is shown. In some embodiments, the adhesive application device 106 is a roller coater and includes conduits 502 to dispense and coat adhesive 118 via rollers onto the entire surface area of ​​at least one side of a metal sheet 114. The entire surface of said at least one side of the metal sheet 114 can be coated with adhesive 118 such that, upon completion of production, the laminated core 124 has a robust and uniform adhesive layer 126 between each stamped metal part 122. In some other embodiments, adhesive 118 may not be applied near the edges of the metal sheet 114. In some such embodiments, the uncoated edges of the metal sheet 114 may be scraped off during the blanking and stamping steps, such that the stamped metal part 122 is fully coated with a partially cured adhesive coating 120 on at least one side. The adhesive application device 106 can apply adhesive 118 to the metal sheet 114 at a desired thickness. The thickness of the adhesive 118 can be controlled, for example, by the application pressure between the rollers, the temperature of the adhesive 118, the metal sheet 114 and / or the rollers, and / or the viscosity of the adhesive 118. In some other embodiments, the adhesive application device 106 may be a sprayer, a curtain coater, or other suitable coating device adapted to distribute the adhesive 118 onto the metal sheet 114.

[0040] In some other embodiments, a two-part adhesive may be applied to the metal sheet 114. In some such embodiments, the adhesive application device 106 may be configured to apply a first adhesive type to one side of the metal sheet 114 and a second adhesive type to the other side of the metal sheet 114. In some such embodiments, both the first and second adhesive types may be partially cured in a first curing device 108. When the stamped metal parts 122 are stacked at the stacking device 112, the stamped metal parts 122 may be stacked such that the first adhesive type from one stamped metal part 122 contacts the second adhesive type from an adjacent stamped metal part 122. In some embodiments, one of the first or second adhesive types is a curing activator configured to cure the other adhesive type. Upon contact, pressure, and / or heating, the first and second adhesive types may be fully cured to bond each stamped metal part 122 to each other, thereby forming a laminated core 124. In some other embodiments, the same adhesive type may be applied to both sides of the metal sheet 114 by the adhesive application device 106. In the embodiments described above where one or more adhesives are applied to both sides of the metal sheet 114, the first curing device 108 is configured to partially cure the adhesives on both sides of the metal sheet 114.

[0041] Turn again Figure 6The illustration shows a perspective view of an exemplary adhesive application device 106, a first curing device 108, a first feed device 602, and a second feed device 604. In some embodiments, multiple feed devices 602, 604 are provided throughout the production line to ensure that the metal sheet 114 travels through the production line at a desired speed. Feed devices 602, 604 may include a single-sided roller system, such as... Figure 6 The first feed device 602 in the middle; may include a double-sided roller system, such as Figure 6 The second feeding device 604 may include a conveyor belt system or other systems that feed the metal sheet 114 through the production line at a desired speed. Various controllers and motors may be coupled to the feeding devices 602, 604 to control the desired speed of the metal sheet 114.

[0042] Turn again Figure 7 and Figure 8 The first curing apparatus 108 may include an induction coil heater. In some such embodiments, the induction coil heater includes a first coil housing 702a disposed on a first plate 704a and a second coil housing 702b disposed on a second plate 704b. The first plate 704a and the second plate 704b may be disposed between the first coil housing 702a and the second coil housing 702b. The first plate 704a and the second plate 704b are spaced apart by a gap 708, the height of which is equal to a first distance d1. The length between the opposing inner surfaces of the first housing coil 702a (and the second housing coil 702b) defines a second distance d2, which is the width direction through the metal sheet 114 of the first curing apparatus and is coaxial with the axis 1204. Figure 12 In some embodiments, the first distance d1 can be measured along a direction perpendicular to the feed direction 119 (the length direction of the metal sheet 114 passing through the first curing device).

[0043] The gap 708 is sized to be large enough to accommodate the metal sheet 114 as it travels through the gap 708 of the first curing device 108. Therefore, the first distance d1 is greater than the thickness of the metal sheet 114 traveling through the production line. Figure 11 As shown, the second distance d2 is greater than the width of the metal sheet 114 traveling through the production line. In some other embodiments, if, for example, more than one first curing device 108 is used (e.g., Figure 13If the second distance d2 is less than the width of the metal sheet 114, then the second distance d2 can be less than the width of the metal sheet 114. Each of the first coil housing 702a and the second coil housing 702b houses a coil 710, which is arranged within the coil housings 702a and 702b and coupled to the terminal 706 to receive power from the power source. The coil 710 is arranged such that the adhesive 118 on the metal sheet 114 can be partially cured by induction heating as the metal sheet 114 travels through the gap 708. The material, size, and configuration of the coil 710 and the power source can be adjusted to provide suitable induction heating for the adhesive 118 based on the size of the metal sheet 114, the speed at which the metal sheet 114 travels, etc. The first curing device 108 can be coupled to the production line via various support structures 712. To prevent short circuits and / or damage to the adhesive 118 and metal sheet 114 in the first curing device 108, the gap 708 is sized such that the adhesive 118 and / or metal sheet 114 can travel through the gap 708 in the first curing device 108 without contacting the first plate 704a or the second plate 704b of the first curing device 108. In some embodiments, the first plate 704a, the second plate 704b, the first coil housing 702a, and / or the second coil housing 702b comprise electrically insulating materials, such as plastic, to reduce the risk of short circuits in the first curing device 108 should the metal sheet 114 accidentally contact it.

[0044] Turn again Figure 9 and Figure 10 In some embodiments, when the first curing device 108 is an induction coil heater, the first plate 704a and the second plate 704b may each include a through-hole 908 extending completely through each of the first plate 704a and the second plate 704b. The through-hole 908 may be sized such that the metal sheet 114 can travel through the through-hole 908 to partially cure the adhesive 118 on the metal sheet 114 by induction heating. In this embodiment, the first curing device is oriented perpendicular to... Figure 7 and Figure 8Orientation of the first curing device 108. A first coil housing 702a may surround a through-portion 908 in a first plate 704a, and a second coil housing 702b may surround a through-portion 908 in a second plate 704b. Each through-portion 908 in the first plate 704a and the second plate 704b may have a height equal to a third distance d3 and a width equal to a fourth distance d4. The third distance d3 is greater than the thickness of the metal sheet 114, and the fourth distance d4 is greater than the width of the metal sheet 114, such that the adhesive 118 and / or the metal sheet 114 can travel through the through-portions 908 of the first curing device 108 without contacting the first plate 704a or the second plate 704b of the first curing device 108. Otherwise, the first curing device 108 may short-circuit and stop working, and / or the adhesive 118 and the metal sheet 114 may be damaged. In some other embodiments, the second coil housing 702b and the second plate 704b may be omitted from the first curing device 108.

[0045] Turn again Figure 11 and Figure 12 In some embodiments, the first curing device 108 is angled relative to the feeding direction 119 of the metal sheet 114. Figure 11 A perspective view is shown of a metal sheet 114 traveling from an adhesive application device 106 through a first curing device 108. Figure 12 A top view of the first curing device 108 is shown, which corresponds to Figure 11 The first curing device 108.

[0046] like Figure 12 As most clearly shown, the metal sheet 114 travels through the first curing device 108 along a feed direction 119, which is aligned with the length direction of the metal sheet 114. The metal sheet 114 has a width measured in a second direction 1202 perpendicular to the feed direction 119. A second distance d2 of the first curing device 108 defines the maximum heating path that the first curing device 108 can provide. The second distance d2 extends along a third direction 1204, which intersects the second direction 1202 at an angle A, such that the first curing device 108 can partially cure the length of the metal sheet 114, which is greater than the width of the metal sheet 114, thereby improving the curing efficiency of the first curing device 108. Angle A is less than ninety degrees and is equal to a value that ensures the entire area of ​​the adhesive 118 is partially cured as it travels through the first curing device 108.

[0047] Figure 11 and Figure 12The first curing device 108 is shown as an induction coil heater, wherein the metal sheet 114 travels between the first plate 704a and the second plate 704b through the gap 708 of the first curing device 108. It should be understood that this angular orientation of the first curing device 108 can also be applied to embodiments where the first curing device 108 is a hot air chamber (gas or electric heating), an infrared heater, a UV lamp, a humidity chamber, a forced air supply device, a steam heater, a radiation heater, or certain other suitable curing devices. Furthermore, it should be understood that this angular orientation of the first curing device 108 can also be applied to embodiments where the first curing device 108 has, for example, a... Figure 9 and Figure 10 The embodiment of the induction coil heater shown in the through-hole 908 allows the metal sheet 114 to travel through the through-hole 908 to partially cure the adhesive 118. For example... Figure 12 As shown, when the first curing device 108 is in an angular orientation, angle A is a non-zero angle. In some other embodiments, for example, as... Figure 6 As shown, angle A is zero because the maximum heating path is equal to the width of the metal sheet 114.

[0048] Turn again Figure 13 In some other embodiments, the maximum heating path of the first curing device 108a or 108b is less than the width of the metal sheet 114. In some such embodiments, two first curing devices 108a, 108b may be used, and they may partially overlap in the feed direction 119 to ensure that all surfaces of the adhesive 118 are partially cured after passing through the first curing devices 108a, 108b to form a partially cured adhesive coating 120.

[0049] Turn again Figure 14 The image shows a side view or cross-sectional view of some embodiments of the laminated core 124. The laminated core 124 comprises a stack of alternating layers of stamped metal parts 122 and fully cured adhesive layers 126. The fully cured adhesive layers 126 may be disposed on the top surface of each stamped metal part 122 and contact the bottom surface of each metal part 122. In some other embodiments, the fully cured adhesive layers 126 may be disposed on both sides of each metal part 122 such that adjacent fully cured adhesive layers 126 contact each other during the formation of the laminated core 124.

[0050] Turn again Figure 15The diagram shows a cross-sectional view of some embodiments of the laminated core 124 including interlocking stamped metal pieces 122. In some such embodiments, each stamped metal piece 122 of the laminated core 124 may include an interlocking region comprising a recess 122f and a protrusion 122m. The recesses and protrusions 122f, 122m are formed at a stamping press 110. For example, the stamped metal piece 122 may be stamped from a sheet of metal 114, and the protrusion 122m of the stamped metal piece 122 is pushed into a corresponding recess 112f of a previous stamped metal piece 112. Additional punching may be performed to form the laminated core 124 when a required number of stamped metal pieces 122 are stacked. The recess 122f is configured to receive and interlock with the protrusion 122m of an adjacent stamped metal piece 122. The fully cured adhesive 126 can be arranged between each stamped metal part 122, and even at the recesses and protrusions 122f, 122m, to further secure each stamped metal part 122 to each other to form a laminated core.

[0051] In some embodiments, a recess 122f is located on the top side of each stamped metal piece 122, while a protrusion 122m is located on the bottom side of each stamped metal piece 122. It should be understood that in some other embodiments, the recess 122f is located on the bottom side of each stamped metal piece 122, while the protrusion 122m is located on the top side of each stamped metal piece 122. The recess 122f may include a depression extending a fifth distance d5 from the top surface of the stamped metal piece 122. The protrusion 122m may project outwards from the bottom surface of the stamped metal piece 122 by a sixth distance d6. In some embodiments, the fifth distance d5 is less than the sixth distance d6. For example, the difference between the sixth distance d6 and the fifth distance d5 may be between about 0.0002 inches and about 0.0004 inches. In some embodiments, the bottommost stamped metal piece 122b includes an opening 1502 configured to receive the protrusion 122m covering the stamped metal piece 122. The bottom stamped metal part 122b may include an opening 1502 that extends partially or completely through the bottom stamped metal part 122b, such that the bottom surface of the laminate core 124 is substantially flat.

[0052] Turn again Figure 16 In some embodiments, one or more through holes 1602 are formed in each stamped metal piece 122 at the stamping press 110. Each through hole 1602 may extend through the thickness of the fully cured adhesive 126 and the stamped metal piece 122. When each stamped metal piece 122 is stacked to form a laminated core 124, the through holes 1602 may be aligned. It should be understood that the laminated core 124 may include, for example... Figure 16 The through hole 1602 shown and as shown Figure 15 The interlocking protrusions and recesses 122m and 122f are shown.

[0053] The systems and components described above (e.g., uncoilers, adhesive devices, first curing devices, etc.) have already described the interactions between several components and / or elements. It should be understood that such devices and components may include those elements or sub-elements specified herein, some of the specified elements or sub-elements, and / or additional elements. Furthermore, one or more elements and / or sub-elements may be combined into a single component to provide integrated functionality. The elements may also interact with one or more other elements not specifically described herein.

[0054] While the embodiments discussed herein relate to the devices, systems, and methods discussed above, these embodiments are intended to be exemplary and are not intended to limit the applicability of these embodiments to the discussions set forth herein.

[0055] The examples above are merely illustrative of several possible embodiments of various aspects of the present invention, and equivalent substitutions and / or modifications will arise in the minds of those skilled in the art upon reading and understanding this specification and the accompanying drawings. In particular, regarding the various functions performed by the aforementioned components (components, devices, systems, circuits, etc.), the terms used to describe these components (including references to "device"), unless otherwise stated, are intended to correspond to any component (e.g., hardware, software, or a combination thereof) that performs the specified function of the said component (e.g., functionally equivalent), even if it is not structurally equivalent to the disclosed structure performing that function in the embodiments shown in the present invention. Furthermore, although a particular feature of the invention may be disclosed only with respect to one of several embodiments, such a feature may be combined with one or more other features of other embodiments as needed, when it may be desirable or advantageous for any given or particular application. Additionally, if the terms "comprising," "including," "having," "having," "with," or variations thereof are used in the Detailed Description and / or the claims, these terms are intended to indicate inclusion in a manner similar to the term "comprising."

[0056] This written description uses examples to disclose the invention, including the best mode, and also enables those skilled in the art to practice the invention, including making and using any device or system and performing any incorporated methods. The patentable scope of the invention is defined by the claims, but may include other examples that would occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0057] In this specification and claims, several terms will be used with the following meanings. The singular forms “a,” “an,” and “the” include plural references unless the context clearly specifies otherwise. As used throughout this specification and claims, approximate language may be used to modify quantitative expressions that allow for variation without altering their underlying function. Thus, values ​​modified by terms such as “about” are not limited to the specified exact values. In some cases, approximate language may correspond to the precision of the instrument used to measure the value. Furthermore, unless otherwise expressly stated, the use of terms such as “first,” “second,” etc., does not indicate order or importance, but rather serves to distinguish one element from another.

[0058] As used herein, the terms “may” and “may” indicate the likelihood of something occurring in a set of circumstances; the possession of a particular attribute, characteristic, or function; and / or modifying another verb by expressing one or more of the abilities, capabilities, or possibilities associated with the verb being modified. Accordingly, the use of “may” and “may” indicates that the modified term is clearly appropriate, capable, or suitable for the indicated ability, function, or purpose, while taking into account that in some cases the modified term may sometimes not be appropriate, capable, or suitable. For example, in some cases an event or ability can be expected, while in others it will not occur—this distinction is reflected by the terms “may” and “may”.

[0059] The best mode for carrying out the invention has been described in order to illustrate the best mode known to the applicant at the time and to enable those skilled in the art to practice the invention, including making and using the apparatus or system and performing the incorporated methods. The examples given are merely illustrative and are not intended to limit the invention; the scope of the invention is measured by the scope and value of the claims. The invention has been described with reference to preferred and alternative embodiments. It is obvious that modifications and variations will occur to those skilled in the art upon reading and understanding this specification. The invention is intended to include all such modifications and variations, provided they fall within the scope of the appended claims or their equivalents. The patentable scope of the invention is defined by the claims and may include other examples that may occur to those skilled in the art. These other examples are intended to fall within the scope of the claims if they have structural elements that are indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A machine assembly for producing laminated cores, comprising: An uncoiler, configured to unwind rolls of metal sheets; An adhesive application device is disposed downstream of the uncoiler and configured to apply adhesive to at least one side of the metal sheet; A first curing device is arranged downstream of the adhesive application device and configured to partially cure the adhesive. A stamping press, which is arranged downstream of the first curing device and configured to punch and stamp the metal sheet to form a stamped metal part; A stacking device configured to form a stack of the stamped metal parts; as well as A second curing device is configured to fully cure the adhesive between each stamped metal piece in the stack to form the laminated core.

2. The machine assembly of claim 1, further comprising one or more feeding devices disposed between the uncoiler and the press, such that the metal sheet can continuously travel through the uncoiler, the adhesive application device and the first curing device.

3. The machine assembly according to claim 1 or 2, further comprising a straightener disposed between the uncoiler and the adhesive application device, wherein the straightener is configured to receive and straighten the metal sheet after uncoiling.

4. The machine assembly according to any one of claims 1 to 3, further comprising loop control arranged between the first curing device and the stamping press.

5. The machine assembly according to any one of claims 1 to 4, wherein the first curing device is an induction coil heater.

6. The machine assembly of claim 5, wherein the induction coil heater is arranged at a non-zero angle relative to the width of the metal sheet, such that the heating length is greater than the width of the metal sheet.

7. The machine assembly according to any one of claims 1 to 6, wherein the adhesive application device is a roller coater and is configured to coat only one side of the metal sheet with the adhesive.

8. The machine assembly according to any one of claims 1 to 7, further comprising a cleaning system disposed between the uncoiler and the adhesive application device.

9. The machine assembly according to any one of claims 1 to 7, further comprising a cleaning system coupled to the adhesive application device, configured to flush out the adhesive from the adhesive application device.

10. A method for producing a laminated core, the method comprising: Obtain metal sheet rolls; Load the metal sheet rolls onto the uncoiler; The uncoiler is used to unwind the metal sheet roll; After uncoiling, the metal sheet is aligned and straightened; Apply adhesive to at least one side of the metal sheet; The adhesive is partially cured in the first curing apparatus; The metal sheet is punched and stamped to form a stamped metal part coated with the adhesive; Stack the stamped metal parts; as well as The adhesive is allowed to fully cure in order to bond the stamped metal parts together to form the laminated core.

11. The method of claim 10, wherein the adhesive is applied to the metal sheet downstream of the uncoiler, and wherein the first curing device is disposed downstream of the uncoiler.

12. The method according to claim 10 or 11, wherein the first curing device is an induction coil heater.

13. The method according to any one of claims 10 to 12, further comprising cutting the metal sheet after unwinding and before applying the adhesive to one side of the metal sheet.

14. The method according to any one of claims 10 to 13, wherein the metal sheet roll is free of adhesive before being loaded onto the uncoiler.

15. The method according to any one of claims 10 to 14, wherein the adhesive is applied only to one side of the metal sheet.

16. The method according to any one of claims 10 to 15, wherein the adhesive is applied to the metal sheet using a roller coater.

17. The method according to any one of claims 10 to 16, further comprising storing the metal sheet roll in a warehouse, wherein the metal sheet roll is obtained from the warehouse, and wherein the uncoiler is arranged in the warehouse.

18. The method of claim 17, wherein the metal sheet roll is stored in the warehouse for more than six months prior to being obtained from the warehouse.

19. A laminated core, comprising: First metal layer; Second metal layer; Third metal layer; A first adhesive layer is disposed between the first metal layer and the second metal layer; as well as A second adhesive layer is disposed between the second metal layer and the third metal layer. The laminated core is manufactured by a process including the following steps: Obtain metal sheet rolls; The metal sheet roll is loaded onto the uncoiler; The uncoiler is used to unwind the metal sheet roll; After uncoiling, the metal sheet is aligned and straightened; Apply adhesive to at least one side of the metal sheet; The adhesive is partially cured in the first curing apparatus; The metal sheet is punched and stamped to form the first metal layer, the second metal layer and the third metal layer, wherein the adhesive forms the first adhesive layer on the first metal layer and the second adhesive layer on the second metal layer; Stack the first metal layer, the second metal layer, and the third metal layer; as well as The first adhesive layer and the second adhesive layer are fully cured to bond the first metal layer, the second metal layer and the third metal layer to each other, thereby forming the laminated core.

20. The laminated core of claim 19, wherein the metal sheet roll is obtained from a storage area within a warehouse, and wherein the steps of the process for forming the laminated core are performed within the warehouse.

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