Method for producing a layered core

Abstract

[TASK] Producing a layered core formed by stacking and bonding with reduced deformation becomes possible even if the layered core has a large number of layers. [SOLUTION] A primary adhesive 86 is applied to a core layer 101 in which separating layers 100 are arranged between several blocks 13, each consisting of a predetermined number of core plates 12. The separating layers 100 are removed after the primary adhesive 86 has cured. A secondary adhesive 88 is applied to the layer surfaces between the blocks 13 and the secondary adhesive 88 is cured.

Description

TECHNICAL AREA

[0001] The present invention relates to a method for producing a layered core formed by stacking and gluing. TECHNICAL OBSTACLE

[0002] A layered core, used in a stator for a motor, is known to be formed by stacking and bonding several core plates, each consisting of a thin sheet. The layered core formed by stacking and bonding has an adhesive layer between each pair of core plates that are adjacent in the stacking direction (for example, patent document 1). STATE OF THE TECHNOLOGY PATENT DOCUMENT(S)

[0003] Patent document 1: JP6868719B1 SUMMARY OF THE INVENTIONAL TASK THAT IS SOLVED BY THE INVENTION

[0004] In the layered core formed by stacking and gluing, the adhesive layers contract as they cure, creating stresses in the core plates. These stresses cause the layered core to deform convexly in the stacking direction. Therefore, it can be observed that the greater the number of stacked core plates, the more pronounced the concave deformation of the layered core formed by stacking and gluing.

[0005] Against this background, an objective of the present invention is to enable the production of a layered core formed by stacking and gluing with reduced deformation, even if the layered core has a large number of layers. MEANS OF COMPLETING THE TASK

[0006] To achieve the above objective, the present invention, in a first aspect, provides a method for producing a layered core in which several core plates are stacked and bonded, the manufacturing method comprising: a core plate production step of producing several core plates, each having a predetermined shape, from a thin sheet; a core layer forming step of forming a core layer by stacking the core plates, such that for each of several blocks, each consisting of a predetermined number of core plates, a separating layer is inserted between adjacent core plates; a primary bonding step of applying a primary adhesive to the core layer while the core layer is held by a first holding device; a primary adhesive curing step of curing the primary adhesive while the core layer is held by the first holding device;a separating layer removal step of removing the separating layers; a secondary bonding step of applying a secondary adhesive to the layer surfaces between the blocks; and a secondary adhesive curing step of curing the secondary adhesive while the core layer is held by a second holding device.

[0007] According to this aspect, the production of a layered core formed by stacking and gluing with reduced deformation is possible even if the layered core has a large number of layers.

[0008] It should be noted that applying the primary adhesive to the thin plate layer involves forming an adhesive layer on the surface of each of the thin plates that make up the thin plate layer. Applying the secondary adhesive to the surfaces between the blocks also involves forming an adhesive layer on the surfaces between the blocks. The primary and secondary adhesives can be adhesives with an identical composition. The first and second holding devices can also be holding devices with an identical structure.

[0009] In the above aspect, the holding of the core layer by the first holding device and the second holding device can be carried out in a state in which the core layer is pressed in a stacking direction, while displacement in a direction perpendicular to the stacking direction is limited.

[0010] In accordance with this aspect, the core layer is produced with high precision. Furthermore, the layered core is produced with high precision.

[0011] In the aspect above, the primary bonding step may include a step of immersing the core layer in an adhesive bath containing the primary adhesive in a liquid state, and a step of pressure reduction within the adhesive bath.

[0012] According to this aspect, the application of the primary adhesive to the core layer is advantageously carried out.

[0013] To achieve the aforementioned objective, one aspect of the present invention further provides a method for producing a layered core in which several core plates are stacked and bonded together, the manufacturing method comprising: a thin plate stacking step of forming a thin plate layer by stacking thin plates such that for each of several blocks, each consisting of a predetermined number of the thin plates, a separating layer is inserted between adjacent thin plates; a primary bonding step of applying a primary adhesive to the thin plate layer while the thin plate layer is held by a first holding device; a primary adhesive curing step of curing the primary adhesive applied to the thin plate layer while the thin plate layer is held by the first holding device;a core body generation step of producing a core body with a predetermined shape from the thin sheet layer; a separating layer removal step of removing the separating layers; a secondary bonding step of applying a secondary adhesive to the layer surfaces between the blocks; and a secondary adhesive curing step of curing the secondary adhesive while the core body is held by a second holding device.

[0014] According to this aspect, the production of a layered core formed by stacking and gluing with reduced deformation is possible even if the layered core has a large number of layers.

[0015] It should be noted that applying the primary adhesive to the thin sheet layer involves forming an adhesive layer on the surface of each of the thin sheets that make up the thin sheet layer. Applying the secondary adhesive to the surfaces between the blocks also involves forming an adhesive layer on the surfaces between the blocks. The primary and secondary adhesives can be adhesives with an identical composition.

[0016] In the above aspect, the holding of the thin plate layer by the first holding device can be carried out in a state in which the thin plate layer is pressed in a stacking direction, while displacement in a direction perpendicular to the stacking direction is limited, and the holding of the core body by the second holding device can be carried out in a state in which the core body is pressed in the stacking direction, while displacement in the direction perpendicular to the stacking direction is limited.

[0017] In accordance with this aspect, the thin plate layer and the core body are produced with high precision. Furthermore, the layered core is produced with high precision.

[0018] In the aspect above, the primary bonding step can include a step of immersing the thin sheet layer in an adhesive bath containing the primary adhesive in liquid form, and a step of pressure reduction within the adhesive bath.

[0019] From this perspective, applying the adhesive to the thin layer of plates is advantageous.

[0020] In the aspect above, the core body production step may include an outer shape formation step using wire EDM, electron beam machining, or laser beam machining.

[0021] According to this aspect, the generation of the nuclear body is carried out advantageously.

[0022] In the above aspect, the separating layer can contain at least one of the following: fluorine, silicone, wax, oils and fats.

[0023] According to this aspect, the effect of making it difficult for the primary adhesive to adhere to the core-forming plate or the thin plate can be advantageously achieved. IMPACT OF THE INVENTION

[0024] According to the above aspect, producing a layered core formed by stacking and gluing with reduced deformation is possible even when the number of layers is large. BRIEF DESCRIPTION OF THE DRAWINGS [ Fig. 1] A perspective view of a layered core produced by a layered core manufacturing process according to a first embodiment [ Fig. 2] A perspective exploded view of a main part of a holding device for producing the layered core according to the first embodiment [ Fig. 3] A flowchart showing a manufacturing process for the layered core according to the first embodiment [ Fig. 4] A perspective view showing a step in producing a split iron core piece in the manufacturing process for the layered core according to the first embodiment [ Fig. 5] A perspective view showing an initial state of a stacking step in the manufacturing process for the layered core according to the first embodiment [ Fig. 6] A perspective view showing an initial state of a stacking step in the manufacturing process for the layered core according to the first embodiment [ Fig. 7] A perspective view showing a final state of the step of stacking split iron core pieces in the manufacturing process for the layered core according to the first embodiment [ Fig. 8] A perspective view showing a fixed state of a press plate in the manufacturing process for the layered core according to the first embodiment [ Fig. 9] A perspective view showing a pressing step in the manufacturing process for the layered core according to the first embodiment [ Fig. 10] A sectional view showing a primary bonding step in the manufacturing process for the layered core according to the first embodiment [ Fig. 11] A sectional view showing a “primary adhesive agent cleaning step” in the manufacturing process for the layered core according to the first embodiment [ Fig. 12] A perspective view showing the replacement of bolts of a first holding device in the cleaning step of the manufacturing process for the layered core according to the first embodiment [ Fig. 13] A sectional view showing a “primary adhesive agent drying step” in the manufacturing process for the layered core according to the first embodiment [ Fig. 14] A sectional view showing a separation layer removal step in the manufacturing process for the layered core according to the first embodiment [ Fig. 15] A sectional view showing a secondary bonding step in the manufacturing process for the layered core according to the first embodiment [ Fig. 16] A sectional view showing a “secondary adhesive agent cleaning step” in the manufacturing process for the layered core according to the first embodiment [ Fig. 17] A sectional view showing a “secondary adhesive agent drying step” in the manufacturing process for the layered core according to the first embodiment [ Fig. 18] A flowchart showing a manufacturing process in a manufacturing process for a layered core according to a second embodiment [ Fig. 19] A perspective view showing a stacking step for a thin layer of plates in the manufacturing process for the layered core according to the second embodiment [ Fig. 20] A perspective view showing a thin sheet-layer pressing step in the manufacturing process for the layered core according to the second embodiment [ Fig. 21] A perspective view showing a core layer production step in the manufacturing process for the layered core according to the second embodiment [ Fig. 22] A perspective view showing a core layer produced by the layered core manufacturing process according to the second embodiment MODES FOR EXECUTING THE INVENTION

[0025] In the following, embodiments of the present invention are described with reference to the drawings. (First embodiment)

[0026] Fig. Figure 1 is a perspective view of a layered core 1 produced by a layered core manufacturing process according to a first embodiment. In the present embodiment, the layered core 1 is described using the example of a stator for a motor.

[0027] As in Fig. As shown in Figure 1, the layered core 1 has a tubular shape and includes an annular yoke 2 and several teeth 3, which are designed to project inwards from the yoke 2. The several teeth 3 are arranged so that they are spaced apart from each other at a predetermined distance in the circumferential direction. Slots 4 are formed between the teeth 3 that are adjacent to each other in the circumferential direction. Each slot 4 penetrates the layered core 1 in the axial direction (in the top-bottom direction). Fig. 1) A substantially circular central hole 5 is formed in the center of the layered core 1. The central hole 5 penetrates the layered core 1 in the axial direction. A rotor for a motor (not shown in the drawings) is mounted in the central hole 5.

[0028] The layered core 1 is composed of several core plates 12, each having a circular ring shape, which are stacked and bonded together. Each core plate 12 is formed by joining a predetermined number (in the present embodiment, six) of divided iron core pieces 11, which are divided in the circumferential direction, together in the circumferential direction. Each divided iron core piece 11 corresponds to a piece obtained by dividing the annular core plate 12 into six pieces along dividing lines that extend radially through the center point and are spaced 60 degrees apart. As shown in a partial magnification in Fig. As shown in Figure 1, the divided iron core pieces 11, which lie next to each other in the stacking direction, are joined by adhesive layers 14. The adhesive layers 14 are formed by the primary adhesive 86 described later. The divided iron core pieces 11, which lie next to each other in the circumferential direction, are joined by the primary adhesive 86 described later.

[0029] The layered core 1 is formed from a combination of several, in the present embodiment three, blocks 13, which are subdivided in the stacking direction of the core plates 12.

[0030] The boundaries 11A between the split iron core pieces 11 in each block 13 are positioned such that the boundaries 11A in vertically adjacent blocks 13 are located at different positions in the circumferential direction. For example, the block 13 that is positioned above the bottommost block 13 (i.e., the second block from the bottom) has the boundaries 11A between the split iron core pieces 11 at positions that are offset in the circumferential direction by 30 degrees (i.e., by half the division angle of each split iron core piece 11).

[0031] Fig. Figure 2 shows a main part of a holding device (first holding device) 21 for producing the layered core 1 according to the first embodiment and a core layer 101 held by the holding device 21. In the present embodiment, the holding device 21 also functions as a second holding device, described later, which is used after the removal of the separating layers 100.

[0032] An upper plate 25 is provided to support the core layer 101 in the axial direction (the top-bottom direction). Fig. 2) to be clamped together with a lower plate 26. The upper plate 25 is an annular body which, in plan view, has a substantially circular ring shape. The upper plate 25 has a central opening 35 which is designed to align with a central hole 105 of the core layer 101 (which corresponds to the central hole 5 of the in Fig. The layered core 1 shown (corresponds to 1) overlaps. The central opening 35 has a diameter smaller than the central hole 105 and penetrates the upper plate 25 in the axial direction.

[0033] The upper plate 25 has a flat underside configured to contact the top surface of the core layer 101. An inner circumferential section of the upper plate 25 is provided with several inner bolt holes 41 spaced apart circumferentially at predetermined intervals. Each inner bolt hole 41 is a through hole that vertically penetrates the upper plate 25. Each inner bolt 28 is inserted into the corresponding inner bolt hole 41. The head 61 of each inner bolt 28 contacts the top surface of the upper plate 25. In the present embodiment, the number of inner bolts 28 is set to half the number of inner bolt holes 41. The inner bolts 28 are inserted into every second corresponding inner bolt hole 41.

[0034] Similarly, an outer circumferential section of the upper plate 25 is provided with several outer bolt holes 42 spaced apart from one another in the circumferential direction at a predetermined distance. Each outer bolt hole 42 is a through hole that vertically penetrates the upper plate 25. Each outer bolt 29 is inserted into the corresponding outer bolt hole 42. The number of outer bolts 29 corresponds to the number of inner bolts 28. In the present embodiment, the outer bolts 29 inserted into the respective outer bolt holes 42 are arranged in positions that radially overlap the inner bolts 28 inserted into the respective inner bolt holes 41.

[0035] Furthermore, the inner circumferential section of the upper plate 25 is provided with several inner guide holes 45, which are spaced apart from one another at a predetermined distance in the circumferential direction. Each inner guide hole 45 is arranged in a central position between the inner bolt holes 41 that adjoin it in the circumferential direction. Each inner guide hole 45 is a through hole that vertically penetrates the upper plate 25. An upper end section of each inner guide pin 30 is fitted into the corresponding inner guide hole 45. In the present embodiment, the number of inner guide pins 30 and the number of inner guide holes 45 are each twice the number of inner bolts 28 (or outer bolts 29).

[0036] Similarly, the outer circumferential section of the upper plate 25 is provided with several outer guide holes 46 spaced apart from one another at a predetermined distance in the circumferential direction. Each outer guide hole 46 is arranged in a central position between the outer bolt holes 42 that are adjacent in the circumferential direction. Each outer guide hole 46 is a through hole that vertically penetrates the upper plate 25. An upper end section of each outer guide pin 31 is fitted into the corresponding outer guide hole 46. In the present embodiment, the number of outer guide pins 31 is equal to the number of inner guide pins 30. The outer guide pins 31 are arranged in positions that radially overlap with the respective inner guide pins 30.

[0037] A radially central section of the upper plate 25 is provided with several slot-corresponding holes 49 spaced apart circumferentially at a predetermined distance. Each slot-corresponding hole 49 has substantially the same shape as each slot 4 of the layered core 1 and is positioned to overlap each slot 4 axially. The number of slot-corresponding holes 49 is equal to the number of slots 4. Each slot-corresponding hole 49 is a through-hole that vertically penetrates the upper plate 25. An upper section of each slot guide 32 is fitted into the corresponding slot-corresponding hole 49. In the present embodiment, the number of slot guides 32 is less than the number of slot-corresponding holes 49. The slot guides 32 are inserted into every second or every third corresponding slot-corresponding hole 49.

[0038] The lower plate 26 has an essentially identical configuration to the upper plate 25. More precisely, the lower plate 26 has a central opening 36, inner bolt holes 51, outer bolt holes 52, inner guide holes 55, outer guide holes 56, and slotted corresponding holes 59, each corresponding to the central opening 35, inner bolt holes 41, outer bolt holes 42, inner guide holes 45, outer guide holes 46, and slotted corresponding holes 49 of the upper plate 25. In the lower plate 26, the inner bolt holes 51 and the outer bolt holes 52 are configured as screw holes, each fitting into the threaded sections 63 and 64 provided at the tips of the shaft sections of the inner bolts 28 and the outer bolts 29. The lower plate 26 has a flat top surface configured to contact the underside of the core layer 101.

[0039] Each inner bolt 28 is inserted through the inner bolt hole 41 of the upper plate 25, and its threaded portion is secured (i.e., screwed into) the inner bolt hole 51 of the lower plate 26. At this point, the head 61 of each inner bolt 28 is locked to the top of the upper plate 25. Furthermore, the shaft section of each inner bolt 28 extends between the upper plate 25 and the lower plate 26.

[0040] Each outer bolt 29 has a similar configuration to each inner bolt 28. Each outer bolt 29 is inserted through the outer bolt hole 42 of the upper plate 25, and its threaded portion is engaged with the outer bolt hole 52 of the lower plate 26. At this point, the head 62 of each outer bolt 29 is locked to the top of the upper plate 25. Furthermore, the shaft section of each outer bolt 29 extends between the upper plate 25 and the lower plate 26.

[0041] Each inner guide pin 30 has a substantially cylindrical column shape. An upper end section and a lower end section of each inner guide pin 30 are each fitted into the inner guide hole 45 of the upper plate 25 and into the inner guide hole 55 of the lower plate 26, respectively. Thus, each inner guide pin 30 is supported by the inner guide holes 45 and 55. At this point, the intermediate section of each inner guide pin 30 extends between the upper plate 25 and the lower plate 26.

[0042] Each outer guide pin 31 has a cylindrical column shape. Each outer guide pin 31 has a larger outer diameter than each inner guide pin 30 and has the same length as each inner guide pin 30. An upper end section and a lower end section of each outer guide pin 31 are each fitted into the outer guide hole 46 of the upper plate 25 and into the outer guide hole 56 of the lower plate 26, respectively. Thus, each outer guide pin 31 is supported by the outer guide holes 46 and 56. At this point, the intermediate section of each outer guide pin 31 extends between the upper plate 25 and the lower plate 26.

[0043] The upper end section of each outer guide pin 31 is provided with a screw hole 65 extending in the axial direction. A removal tool (not shown in the drawings) is fitted into the screw hole 65 when each outer guide pin 31 is removed from the upper plate 25 and the lower plate 26.

[0044] Each slot guide 32 has a shape that, in the horizontal sectional view (i.e., in the top view), corresponds to the slot 104 of the core layer 101 (which corresponds to the slot 4 of the layered core 1). Each slot guide 32 only needs to be capable of limiting, at least in the circumferential direction of the slot 104 and thus of the split iron core piece 11 when inserted into the slot 104. More precisely, the two side faces of the slot guide 32 each contact the two side faces of the slot 104 in the circumferential direction.

[0045] The upper and lower sections of each slot guide 32 are each fitted into the slot-corresponding hole 49 of the upper plate 25 and into the slot-corresponding hole 59 of the lower plate 26, respectively, with the intermediate section of each slot guide 32 being inserted into the slot 104 of the core layer 101. At this point, the upper section of each slot guide 32 protrudes beyond the top surface of the upper plate 25 (see Fig. 7) An upper section of each slot guide 32, projecting beyond the top surface of the upper plate 25, is provided with two locking holes 68. A removal tool (not shown in the drawings) is engaged in each locking hole 68 when each slot guide 32 is removed.

[0046] Thus, the holding device 21 with the inner guide pins 30, the outer guide pins 31 and the slot guides 32 limits the displacement of the core layer 101 arranged on the lower plate 26 in the direction perpendicular to the stacking direction of the core layer 101.

[0047] It should be noted that the configuration of the holding device 21 described above can be suitably modified. For example, the upper plate 25 and the lower plate 26 need not be strictly plate-shaped, and it is only necessary that parts of them function as plates that clamp the core layer 101 in the axial direction. The upper plate 25 and the lower plate 26 can be designed as block-shaped elements. Furthermore, the sizes, shapes, and numbers of the inner guide pins 30, the outer guide pins 31, and the slot guides 32 can be modified as required.

[0048] Fig. Figure 3 is a flowchart showing a manufacturing process (ST101 to ST114) for the layered core 1 according to the first embodiment.

[0049] In the manufacturing process for the layered core 1 of the first embodiment, as described in Fig. Figure 4 shows a step for producing the split iron core pieces 11, which form the core plates 12, from a strip 10 (or coil material) by stamping (hereinafter referred to as the “production step”) (ST101). In the production step, a stamping die operation is performed on the strip 10, which consists of an electromagnetic steel sheet, using a known progressive die. This forms the multiple split iron core pieces 11 without adhering to one another (i.e., in a separate state). The plate thickness of each split iron core piece 11 is not subject to any particular limitations, but can be set relatively thin (for example, 0.05 mm).

[0050] It should be noted that the method of producing the split iron core pieces 11 is not limited to pressing, but other known methods such as wire EDM, laser beam processing, etc. can also be used.

[0051] Next, a step is performed to clean the multiple split iron core pieces 11 obtained by the production step (hereinafter referred to as the iron core cleaning step) (ST102). In the iron core cleaning step, each split iron core piece 11 is degreased and cleaned using a known solvent (e.g., acetone, thinner, organic solvent, cleaning solvent, etc.). More precisely, the split iron core pieces 11 are immersed in the solvent in the cleaning vessel and vibrated with ultrasonic waves while the cleaning vessel is evacuated. This removes substances adhering to the split iron core pieces 11 (such as press oil used in the stamping step).

[0052] It should be noted that in the iron core cleaning step, the divided iron core pieces 11 can also be cleaned by other known methods. If the adhering substances do not impair the adhesion between the divided iron core pieces 11, the iron core cleaning step can also be omitted.

[0053] Next, as in Fig. Figure 5 shows a core layer forming step in which the core plates 12, each formed by six divided iron core pieces 11, are stacked on the lower plate 26 of the holding device 21 such that a predetermined number of core plates 12 are stacked each time, a separating layer 100, shown in the drawing by cross-hatching, is provided on the core plates 12, thereby forming the core layer 101, which consists of three blocks 13 separated by the separating layers 100 (ST103). In other words, the core layer forming step is a step in which the core plates 12 are stacked such that for each of the several blocks 13, each consisting of a predetermined number of core plates 12, a separating layer 100 is provided, arranged between the adjacent core plates 12, to form the core layer 101.

[0054] More precisely, as in Fig. As shown in Figure 5, the lower end sections of the slot guides 32 are first fitted into predetermined slot-corresponding holes 59 of the lower plate 26 in the holding device 21. In this case, it is not necessary for the slot guides 32 to be fitted into all slot-corresponding holes 59. It is only necessary in the holding device 21 that at least the movement of each split iron core piece 11 in the circumferential direction is restricted by the slot guides 32. This fixes the circumferential positions of the core plates 12, which consist of the several split iron core pieces 11.

[0055] In this state, the split iron core pieces 11 are arranged on the holding device 21 from above via the slot guides 32 in the correct sequence, so that they are stacked at predetermined positions. At this point, corresponding slot guides 32 are successively inserted into some of the holes of the split iron core pieces 11 (the holes that will later form the slots 4).

[0056] It should be noted that in Fig. Figure 5 omits the illustration of the inner guide pins 30 and the outer guide pins 31 to more clearly show the arrangement of the slotted guides 32 in the holding device 21. In fact, in addition to the slotted guides 32 described above, the lower end sections of the inner guide pins 30 are fitted into the inner guide holes 55 of the lower plate 26 in the holding device 21, and the lower end sections of the outer guide pins 31 are fitted into the outer guide holes 56 of the lower plate 26.

[0057] More precisely, as in Fig. Figure 6 shows that when each split iron core piece 11 is placed on the holding device 21, the downward movement of the split iron core piece 11 is guided by the inner guide pin 30 and the corresponding outer guide pin 31. At this point, an inner circumferential surface and an outer circumferential surface of each split iron core piece 11 contact (or slide against) the inner guide pin 30 and the outer guide pin 31, respectively. This restricts the movement of each split iron core piece 11 in the radial direction.

[0058] It should be noted that in Fig. 6 only two sets of inner guide pins 30 and outer guide pins 31 for guiding the movement of the split iron core pieces 11 are shown. Furthermore, in contrast to Fig. 5, the representation of the slot guides 32 in Fig. 6 omitted to show more clearly the arrangement of the inner guide pins 30 and the outer guide pins 31 in the holding device 21.

[0059] A separating paper (release film) 70 with a circular ring shape is arranged between the underside of the core layer 101 (i.e., the split iron core piece 11 in the bottom layer) and the top surface of the lower plate 26. The separating paper 70 can be a known material coated with silicone or the like, to which an adhesive has difficulty adhering. Furthermore, the separating paper 70 has essentially the same shape as the core layer 101 when viewed from above. Although not shown in the figure, a separating paper similar to the separating paper 70 is also arranged between the top surface of the core layer 101 (i.e., the split iron core piece 11 in the topmost layer) and the underside of the upper plate 25. This facilitates the removal of the retaining device 21 from the core layer 101 (i.e., the layered core 1) in a later step (step ST114).

[0060] Each time a predetermined number of core plates 12, each formed by several divided iron core pieces 11, are stacked on the lower plate 26, a separating layer 100 is formed on the uppermost core plate 12, except for the one that was stacked last.

[0061] Each separating layer 100 is a layer for preventing (suppressing) adhesion between the core plates 12 by the primary adhesive 86 described later for bonding the stacked core plates 12. The separating layer 100 is formed by applying or spraying a material containing at least one substance from the group consisting of fluorine, silicon, wax, oils and fats, etc., onto the surface of the core plates 12. The separating layer 100 can consist of a release paper coated with silicone or the like, or of an oil-based paper bonded to the surface of the core plate 12. In other words, the separating layer 100 can be a layer containing components that inhibit or suppress the adhesion of the adhesive 86 to the surface of the core plate 12 or the adhesive action of the adhesive 86.

[0062] When the arrangement of all the split iron core pieces 11 on the holding device 21 is complete, i.e., when the core layer 101 is formed on the lower plate 26, the upper plate 25 is mounted onto the formed core layer 101. This results, as shown in Fig. Figure 7 shows the core layer 101 being brought into a state in which it is clamped between the upper plate 25 and the lower plate 26 (hereinafter referred to as the “temporarily held state”).

[0063] It should be noted that the number of core plates 12 forming each block 13 can be determined by counting the number of core plates 12 or by determining the number of core plates 12 that yield a predetermined weight. Each core plate 12 can consist of a single continuous plate element with a circular ring shape instead of several divided iron core pieces 11.

[0064] Next, as in Fig. As shown in Figure 8, a pressure plate 75 is placed on the upper plate 25 to cover the parts of the slot guide 32 that protrude from the slot-corresponding holes 49 of the upper plate 25. The pressure plate 75 forms part of the holding device 21.

[0065] The pressure plate 75 has a substantially circular ring shape and is arranged between the multiple inner guide pins 30 and the multiple outer guide pins 31, which are arranged circumferentially on the upper plate 25. The pressure plate 75 is provided with multiple slot guide receiving openings 76 in which the upper end sections of the respective slot guides 32 are received. Each slot guide receiving opening 76 has a size and shape that can receive at least the upper end section of each slot guide 32 and is arranged in a position that overlaps each slot 104 of the core layer 101 in the axial direction.

[0066] Next, as in Fig. Figure 9 shows the core layer 101 being supported by the holding device 21, with the core layer 101 being pressed in the stacking direction (axial direction) by several press bars 80 (ST104).

[0067] More precisely, the core layer 101, temporarily held by the holding device 21, is positioned on an assembly table 79 in a press device 78 and pressed in this state by the multiple press rods 80. The multiple press rods 80 are arranged at equal intervals in the circumferential direction. At this point, each press rod 80 is driven downwards (i.e., towards the assembly table 79) with a predetermined force, its lower end contacting a flat top surface of the pressure plate 75. This presses the core layer 101 in the stacking direction while it is clamped between the upper plate 25 and the lower plate 26, thus adjusting the thickness of the entire core layer 101 and the gaps between the axially adjacent core plates 12.

[0068] In the state where the core layer 101 is pressed by the pressing device 78, the inner bolts 28 and the outer bolts 29, which are temporarily inserted into the inner bolt holes 41, 51 and the outer bolt holes 42, 52, are tightened. This ensures that, in the state where the thickness of the entire core layer 101 and the gaps between the core plates 12 are correctly adjusted, the upper plate 25 and the lower plate 26 are firmly fixed over a predetermined distance.

[0069] The printing plate 75 is then removed, and all slot guides 32 are also removed. At this point, the slot guides 32 are pulled upwards out of the upper plate 25. This completes the manufacturing process of the core layer 101, and the core layer 101 is brought into the state in which it is held by the holding device 21. Thus, the holding device 21 holds the core layer 101 in the state in which it is pressed in the stacking direction, while displacement in the direction perpendicular to the stacking direction is restricted.

[0070] Next, a primary bonding step is performed by applying the adhesive 86 (primary adhesive) to the core layer 101 held by the holding device 21 (ST105).

[0071] In the primary gluing step, as described in Fig. As shown in Figure 10, the core layer 101, held by the holding device 21, is immersed in an adhesive bath (adhesive container) 85 filled with the adhesive 86 in a liquid state, specifically in the adhesive bath 85 containing an adhesive 88. In this state, the adhesive bath 85 is placed in a vacuum device 87, and the interior of the vacuum device 87 is brought into a vacuum (negative pressure) state by a vacuum pump (not shown in the drawing). This impregnates (coats) the core layer 101, which is held by the holding device 21 such that its displacement in the direction perpendicular to the stacking direction of the core-forming plate 12 is restricted, with the adhesive 86. In other words, in the core layer 101, the adhesive 86 penetrates the boundaries between the circumferentially adjacent split iron core pieces 11 and the boundaries (i.e.,tiny gaps) between the split iron core pieces 11 adjacent in the top-bottom direction (stacking direction) and the adhesive 86 adheres to the layer surfaces of the core layer 101. A known thermosetting adhesive such as an epoxy-based adhesive can be used as the adhesive 86.

[0072] Next, a cleaning step is performed to clean the core layer 101 in order to remove excess adhesive 86 from the core layer 101 (ST106). The excess adhesive 86 to be removed in the cleaning step may include the adhesive adhering to the outer circumferential surface of the core layer 101.

[0073] In the cleaning step, as in Fig. Figure 11 shows the core layer 101, held by the holding device 21, being immersed in a liquid cleaning agent 92 contained in a cleaning container 91 (cleaning agent bath). This immersion of the core layer 101 in the cleaning agent 92 can be performed several times for a predetermined immersion time each time, while the extent to which the adhesive has been removed is checked. At this point, a suitable immersion time and number of immersion cycles are determined so that the adhesive 86 that has penetrated the core layer 101 is not excessively removed. For example, acetone, thinner, organic solvent, cleaning solvent, or the like can be used as a cleaning agent.

[0074] Furthermore, in the cleaning step, the core layer 101 is removed from the cleaning container 91 after immersion in the cleaning agent 92, and the inner bolts 28 and the outer bolts 29 are removed (replaced by additional bolts 128, 129). More precisely, as in Fig. As shown in Figure 12, in the layering step described above, the same number of additional bolts 128 as the inner bolts 28 are inserted into or attached to the remaining inner bolt holes 41, 51 where the inner bolts 28 are not inserted into or attached to. Similarly, the same number of additional bolts 129 as the outer bolts 29 are inserted into or attached to the remaining outer bolt holes 42, 52 where the outer bolts 29 are not inserted into or attached to. This ensures that the additional bolts 128, 129 are inserted into or attached to the inner bolt holes 41, 51 and the outer bolt holes 42, 52 after cleaning and are therefore not affected by the adhesive 86. Furthermore, the curing of the adhesive 86 prevents the inner bolts 28 and the outer bolts 29 from adhering firmly to the upper plate 25 and the lower plate 26 of the holding device 21.

[0075] In this case, to maintain the stability of the core layer 101, the inner bolts 28 and the outer bolts 29 that were installed are removed after all the additional bolts 128 and 129 have been installed. To prevent the additional bolts 128 and 129 from being overtightened, the tightening torque is adjusted accordingly.

[0076] Next, a primary adhesive curing step is performed to cure the adhesive 86 that has penetrated the core layer 101 (ST107).

[0077] In the primary adhesive curing step, as described in Fig. Figure 13 shows the core layer 101, which is held by the holding device 21, being heated in the furnace chamber of the heating furnace 95. At this point, the bottom wall 96 of the furnace chamber, on which the core layer 101 is arranged, is provided with a hot air outlet 96A to release hot air for heating. At this point, the core layer 101 is arranged in the furnace chamber such that the central opening 36 of the lower plate 26 of the holding device 21, which holds it, overlaps the hot air outlet 96A.

[0078] This causes the hot air discharged from the hot air outlet 96A to be directed from the central opening 36 of the lower plate 26 into the holding device 21 and then flows upwards through the central hole 105 of the core layer 101 and the central opening 35 of the upper plate 25. The hot air then flows around the outer circumferential surface of the core layer 101 and is discharged to the outside through outlet openings 97A, which are provided in a lower section of a side wall 97 of the furnace chamber. With such a configuration, the heating furnace 95 can heat the entire core layer 101 uniformly with the hot air discharged from the hot air outlet 96A. For example, a known electric furnace can be used as the heating furnace 95.

[0079] After the primary adhesive curing step, the core layer 101 is cooled until its temperature returns to near room temperature. Once the cooling of the core layer 101 is complete, the inner bolts 28, the outer bolts 29, and the top plate 25 of the holding device 21 are removed. This releases the pressure on the core layer 101 (ST108).

[0080] Next, as in Fig. Figure 14 shows a separation layer removal step in which the core layer 101, in which gaps were created between adjacent blocks 13 after pressing, is immersed in a cleaning fluid 112 contained in a cleaning container 111 to remove the separation layers 100 (ST109). The cleaning fluid 112 is selected to remove the separation layers 100 without affecting the adhesive 86. The removal of the separation layers 100 can be carried out by wiping them with a cloth impregnated with a cleaning agent, a cleaning brush, or the like, instead of immersing the core laminate 101 in the cleaning fluid 112.

[0081] Next, another pressing step is performed in which the holding device 21 is reattached to the core layer 101 to press the core layer 101 again (ST110). The repressing step is performed in the same way as the pressing of the core layer 101 in ST104 described above. The holding device (second holding device) 21 used in and after the repressing can be the same as the one in ST104. Fig. 2 shown holding device (first holding device) 21 be or differ from it.

[0082] Next, a secondary bonding step is performed by applying the adhesive (secondary adhesive) 88 to the core layer 101 held by the holding device 21 (ST111).

[0083] In the secondary gluing step, as described in Fig. As shown in Figure 15, the core layer 101, held by the holding device 21 (i.e., in a state where displacement in the direction perpendicular to the stacking direction is restricted), is immersed in the adhesive bath 85, which contains the liquid adhesive (secondary adhesive) 88. In this state, the adhesive bath 85 is placed in the vacuum device 87, and the interior of the vacuum device 87 is brought into a vacuum (negative pressure) state by a vacuum pump (not shown in the drawing). This impregnates the core layer 101, held by the holding device 21 such that displacement in the direction perpendicular to the stacking direction of the core plates 12 is limited, with the adhesive 88. In other words, in the core layer 101, the adhesive 88 penetrates the minute gaps between the adjacent blocks 13 from which the separating layers 100 have been removed.Through this penetration of the adhesive 88, the adhesive 88 adheres to the layer surfaces of the core plates 12, which are located opposite each other between the adjacent blocks 13. A thermosetting adhesive identical to the adhesive 86 can be used as the adhesive 88.

[0084] Next, as in Fig. 16 shows that the core layer 101 held by the holding device 21 is cleaned by a cleaning step corresponding to the cleaning step in ST106 using the cleaning container 91 (ST112).

[0085] Next, a secondary adhesive curing step is performed in which the adhesive 88, which has penetrated between the blocks 13 of the core layer 101, is cured while the core layer 101 is held by the holding device 21 (ST113). Similar to the primary adhesive curing step, the secondary adhesive curing step is carried out by heating using the Fig. 17 of the heating furnaces shown 95 carried out.

[0086] It should be noted that the primary adhesive 86 and the secondary adhesive 88 can be the same or different. The primary adhesive 86 and the secondary adhesive 88 are not limited to heat-curing adhesives and can be room-temperature curing adhesives such as instant adhesives, as long as they provide the required bond strength for the layered core 1.

[0087] After completion of the secondary adhesive curing step, a fixture removal step is performed to remove the fixture from the core layer 101 (ST114). This completes the layered core 1, in which a predetermined number of core plates 12 are stacked and adhesively bonded.

[0088] In the above-described method for producing the layered core 1, the stacking and gluing are carried out individually for each of the divided multiple blocks 13, and the multiple blocks 13 for which the stacking and gluing are completed are joined to form the layered core 1. In other words, the layered core 1 is constituted by a stack of the multiple blocks 13, each consisting of multiple core plates 12 and separated from one another by the separating layers 100.

[0089] In this layered core 1, due to the shrinkage of the adhesive layers 14 (see Fig. 1) During curing, the layered core 1 deforms into a concave shape in the stacking direction between the core plates 12, specifically for each block 13, which consists of fewer stacked core plates 12 than the total number of stacked core plates 12 in the entire core. Therefore, in the layered core 1 formed by stacking multiple blocks 13, the deformation into a concave shape in the stacking direction is smaller than in the case where the entire layered core 1 is formed at once by stacking and bonding.

[0090] Thus, according to the above described method for producing the layered core 1, the layered core 1 can be produced easily and reliably with low deformation, even if the layered core 1 consists of a large number of stacked core plates 12. (Second embodiment)

[0091] Next, a second embodiment will be described with reference to the Fig. described in sections 18 to 22. It should be noted that the second embodiment is identical to the first embodiment described above, except for the points specifically mentioned below. Furthermore, the following are described in the Fig. 19 to 22 the parts which are in Fig. 1 correspond, with the same reference symbols as in Fig. 1 is designated, and its description is omitted.

[0092] Fig. Figure 18 is a flowchart showing a manufacturing process (ST201 to ST212) of a layered core 1 according to the second embodiment.

[0093] In the manufacturing process for the layered core 1 of the second embodiment, as described in Fig. Figure 19 shows a thin plate stacking step in which a predetermined number of rectangular thin plates 151, each formed from an electromagnetic steel sheet or the like, are stacked on a first holding device 141, i.e. for each block 152 a separating layer 153 is arranged between adjacent thin plates 151 to form a thin plate layer 155 (ST201).

[0094] As in Fig. As shown in Figure 19, the first holding device 141 has an upper plate 142, a lower plate 143, several fastening bolts 146 and several guide pins 147.

[0095] The upper plate 142 has a flat, rectangular underside that contacts the top surface of the thin plate layer 155. Each corner section of the upper plate 142 is provided with a bolt hole 144 into which the fastening bolt 146 is inserted. An intermediate section on each side of the upper plate 142 is provided with a guide hole 148 into which the guide pin 147 is fitted. The bolt holes 144 and the guide holes 148 are each through holes that penetrate vertically through the upper plate 142.

[0096] The lower plate 143 has a flat, rectangular top surface designed to contact the underside of the thin plate layer 155. Each corner section of the lower plate 143 is provided with a screw hole 145 into which the fastening bolt 146 is screwed. A guide pin 147 is inserted vertically in an intermediate section on each side of the lower plate 143. Each guide pin 147 contacts the corresponding outer surface of the rectangular thin plates 151 arranged on the lower plate 143 and limits the displacement of the thin plates 151 on the lower plate 143 in a direction perpendicular to the stacking direction of the thin plates 151. This limitation ensures that the multiple thin plates 151 are stacked in an aligned manner on the lower plate 143.

[0097] Each time a predetermined number of the thin plates 151 are stacked on the lower plate 143, a separating layer 153 is formed on the uppermost thin plate 151, except for the one that was stacked last.

[0098] Similar to the separating layers 100 of the first embodiment, each separating layer 153 is a layer for preventing (suppressing) adhesion between the thin plates 151 by the adhesive (primary adhesive) 86 described below and for bonding the stacked thin plates 151. The separating layer 153 is formed by applying or spraying a material containing at least one component from the group consisting of fluorine, silicon, wax, oils, and fats, etc., onto the surface of the thin plate 151. The separating layer 153 can consist of a separating paper coated with silicon or the like, or of oiled paper applied to the surface of the core plates 12. In other words, the separating layer 153 can be a layer containing components that inhibit or suppress the adhesion of the adhesive 86 to the surface of the thin plate 151 or the adhesive action of the adhesive 86.

[0099] This creates several blocks 152 in which the layered thin plates 151 are subdivided by the separating layers 153.

[0100] As in Fig. As shown in Figure 20, each guide pin 147 is fitted into the corresponding guide hole 148, and each fastening bolt 146 is passed through the corresponding bolt hole 144 and engages in the threaded connection with the corresponding screw hole 145, thereby clamping the thin sheet 155 between the upper plate 142 and the lower plate 143. This holds the thin sheet 155 in place by the first holding device 141 and restricts displacement in the direction perpendicular to the stacking direction of the thin sheets 151.

[0101] Next, a pressing step is performed in which the thin sheet layer 155, held by the first holding device 141, is pressed in the stacking direction (ST202) by a press bar 150. As the press bar 150 drives the upper sheet 142 towards the lower sheet 143, the thin sheet layer 155 is pressed in the stacking direction in the state in which it is clamped by the upper sheet 142 and the lower sheet 143, and the thickness of the entire thin sheet layer 155 and the gaps between the thin sheets 151 that are adjacent in the axial direction are adjusted.

[0102] In this pressed state, each fastening screw 146 is tightened. This ensures that, in the state where the thickness of the entire thin plate layer 155 and the gaps between the thin plates 151 are correctly adjusted, the upper plate 142 and the lower plate 143 are firmly fixed over a predetermined distance.

[0103] Next, a primary bonding step is performed by applying the adhesive (primary adhesive) 86 to the thin sheet layer 155, which is held by the first holding device 141 (ST203).

[0104] In the primary bonding step, similar to the primary bonding step in ST105 of the first embodiment, the thin sheet layer 155, held by the first holding device 141, is immersed in the adhesive bath 85, which is filled with the adhesive 86 in a liquid state. In this state, the adhesive bath 85 is placed in the vacuum device 87, and the interior of the vacuum device 87 is brought into a vacuum state (negative pressure state) by a vacuum pump (not shown in the drawing). This impregnates (coats) the thin sheet layer 155, whose displacement in the direction perpendicular to the stacking direction of the thin sheets 151 is limited by the first holding device 141, with the adhesive 86.

[0105] Next, a cleaning step is performed to clean the thin sheet layer 155 in order to remove excess adhesive 86 from the thin sheet layer 155 (ST204). Similar to the cleaning step in ST106 of the first embodiment, the cleaning step is performed by immersing the thin sheet layer 155 in the liquid cleaning agent 92 contained in the cleaning container 91.

[0106] Next, a primary adhesive curing step is performed by curing the adhesive 86 that has penetrated the thin sheet layer 155 (ST205). Similar to the primary adhesive curing step in ST107 of the first embodiment, the primary adhesive curing step is performed by placing the thin sheet layer 155 in the oven chamber of the Fig. The heating oven shown in section 13 is heated to 95°C.

[0107] After the heat curing of the primary adhesive 86 in the thin plate layer 155 is complete, the first holding device 141 is removed from the thin plate layer 155 (ST206).

[0108] Next, as in Fig. Figure 21 shows a step for generating a core body, in which a core body 156 with a predetermined shape is produced from the thin sheet layer 155 (ST207). The core body generation step is performed by cutting the core body 156 with a predetermined shape from the thin sheet layer 155 by wire EDM using a wire electrode 160 that penetrates the thin sheet layer 155 in the stacking direction. The generation of the core body 156 in the core body generation step is not limited to wire EDM and can be performed by a process that includes an external forming step using electron beam machining, laser beam machining, or the like.

[0109] As in Fig. As shown in Figure 22, the core body 156 cut from the thin plate layer 155 forms a layer in which several blocks 13, each consisting of several core plates 12 bonded together, are separated from one another by the separating layers 153. This core body 156 differs from the first embodiment in that the core plates 12, which are not divided and have a continuous circular ring shape, are stacked and bonded together, but is essentially identical to the first embodiment in that it is formed by a stack of the several blocks 13, each consisting of several core plates 12, which are separated from one another by the separating layers 153.

[0110] Next, a separation layer removal step is performed to remove the separation layers 153 of the core body 156 (ST208). Similar to the separation layer removal step in ST109 of the first embodiment, the separation layer removal step can be performed by immersing the core body 156 in the cleaning fluid 112 contained in the Fig. The cleaning container 111 shown in Figure 14 contains the cleaning fluid. In this case as well, a cleaning fluid 112 is selected that can remove the separating layers 153 without affecting the adhesive 86. The removal of the separating layers 153 can be carried out by wiping them with a cloth soaked in a cleaning agent, a cleaning brush, or the like, instead of immersing the core body 156 in the cleaning fluid 112.

[0111] Next, similar to ST110 and ST111 of the first embodiment, the core body 156 is mounted on a holding device (second holding device) 21, which corresponds to the holding device 21 of the first embodiment, in order to press the core body 156, and the core body 156 held by the holding device 21 is placed in the adhesive bath 85 filled with a liquid adhesive (secondary adhesive) 88 (see Fig. 15) immersed (ST209). In this state, the adhesive bath 85 is inserted into the vacuum device 87 and the interior of the vacuum device 87 is brought into a vacuum state (negative pressure state) by a vacuum pump not shown in the drawing (see Fig. 15).

[0112] This impregnates the core layer body 156 with the adhesive 88, and the adhesive (secondary adhesive) 88 is applied to the layer surfaces between the adjacent blocks 13. In other words, the adhesive 88 penetrates the tiny gaps between the adjacent blocks 13 in the core body 156, from which the separating layers 153 have been removed, and the adhesive 88 adheres to the layer surfaces of the core plates 12 that face each other between the adjacent blocks 13. A thermosetting adhesive identical to adhesive 86 can be used as the adhesive 88.

[0113] Subsequently, the core body 156, held by the holding device 21, is cleaned by a cleaning step that corresponds to the cleaning step in ST106, in which the cleaning container 91 is used (ST210).

[0114] Next, a secondary adhesive curing step is performed to cure the adhesive 88 that has penetrated between the blocks 13 of the core body 156 (ST211). Similar to the primary adhesive curing step, the secondary adhesive curing step is performed by heating using the heating oven 95, as shown in Fig. 17 shown.

[0115] It should be noted that in the second embodiment, the primary adhesive 86 and the secondary adhesive 88 can be the same or different, as in the first embodiment. The primary adhesive 86 and the secondary adhesive 88 are not limited to heat-curing adhesives and can be room-temperature curing adhesives such as cyanoacrylate adhesives, as long as they provide the required bond strength for the layered core 1.

[0116] After completion of the secondary adhesive curing step, a fixture removal step is performed to remove the fixture from the core body 156 (ST212). This completes the layered core 1, in which a predetermined number of core plates 12 are stacked and adhesively bonded.

[0117] In the above-described method for producing the layered core 1, the stacking and gluing are carried out individually for each of the divided multiple blocks 13, and the multiple blocks 13 for which the stacking and gluing are completed are joined to form the layered core 1. In other words, the layered core 1 is formed by a stack of the multiple blocks 13, each consisting of multiple core plates 12 and separated from one another by the separating layers 100.

[0118] In this layered core 1, due to the shrinkage of the adhesive layers 14 (see Fig. 1) During curing, the layered core 1 deforms into a concave shape in the stacking direction between the core plates 12, and this deformation occurs individually for each block 13, which consists of a smaller number of stacked core plates 12 than the total number of stacked core plates 12 in the entire core. Therefore, in the layered core 1 formed by stacking multiple blocks 13, the deformation into a concave shape in the stacking direction is smaller than in the case where the entire layered core 1 is formed by stacking and bonding all at once.

[0119] Thus, with the manufacturing process for the layered core 1 according to the second embodiment, the layered core 1 can be produced easily and reliably with low deformation, even if the layered core 1 consists of a large number of stacked core plates 12.

[0120] In the second embodiment, each core plate 12 can also consist of several split iron core pieces 11, as in the first embodiment. In this case, several split iron core pieces 11 are produced in ST207.

[0121] The present invention has been described with reference to specific embodiments; however, these embodiments are merely examples and the present invention is not limited to these embodiments.

[0122] For example, the application of the adhesive 86, 88 to the core plates 12 and the thin plates 151 can be carried out by spreading or spraying the adhesive 86, 88 onto the core plates 12 and the thin plate 151, instead of the method in which the core layer 101 and the thin plate layer 155 are immersed in the adhesive 86, 88 contained in the adhesive bath 85 under a vacuum.

[0123] The arrangement of the split iron core pieces 11 in the first embodiment can differ from the arrangement in which the boundaries 11A are offset, and can be an arrangement in which the boundaries 11A run in a straight line in the stacking direction throughout the entire region. The present invention can also be used in a split iron core consisting of split iron core pieces 11 that are stacked and adhesively joined without being arranged in a ring shape.

[0124] The layered core 1 according to the present invention is not only used in a motor, but can also be used in rotating electrical machines such as an electric generator which has a similar configuration to this one.

[0125] It should be noted that not all components of the manufacturing process for the layered core and the holding device for manufacturing the layered core according to the present invention, shown in the above embodiments, are necessarily indispensable, and that they can be selectively chosen accordingly, as long as they do not deviate from the scope of the present invention. REFERENCE MARK LIST 1 layered core 2 yoke 3 teeth 4 slots 5 center holes 10 strips 11 divided iron core piece 11A border 12 core plate Block 13 14 adhesive layer 21 Holding device (first holding device, second holding device) 25 top plate 26 lower plate 28 inner bolt 29 outer bolt 30 inner guiding pen 31 outer guide pin 32 slot guide 35 Center opening 36 Center opening 41 inner bolt hole 42 outer bolt hole 45 inner guide hole 46 outer guide hole 49 slot-corresponding hole 51 inner bolt hole 52 outer bolt hole 55 inner guide hole 56 outer guide hole 59 slot-corresponding hole 61 heads 62 heads 63 Threaded part 64 threaded part 65 screw holes 68 locking holes 70 sheets of separating paper 75 Printing plate 76 Slotted guide mounting hole 78 Pressing device 79 Assembly table 80 Press rod 85 Adhesive bath 86 adhesives (primary adhesives) 87 Vacuum device 88 Adhesives (Secondary Adhesives) 91 cleaning containers 92 cleaning products 95 Heating stove 96 Floor wall 96A Hot air outlet 97 side wall 97A Outlet opening 100 separating layer 101 Core layer 104 slots 105 center hole 111 Cleaning containers 112 Cleaning fluid 128 bolts 129 bolts 141 first holding device 142 upper plate 143 lower plate 144 bolt holes 145 screw hole 146 fastening bolts 147 Guide pin 148 Guide hole 150 press rod 151 thin plate 152 Block 153 Separation layer 155 thin plate layer 156 nuclear bodies 160 wire electrode QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 6868719B1

[0003]

Claims

[1] Method for producing a layered core in which several core plates are stacked and bonded together, the manufacturing process comprising: a core plate manufacturing step of producing several core plates, each with a predetermined shape, from a thin plate; a core layer forming step of forming a core layer by stacking the core plates, such that for each of several blocks, each consisting of a predetermined number of core plates, a separating layer is inserted between adjacent core plates; a primary bonding step of applying a primary adhesive to the core layer while the core layer is held by a first holding device; a primary adhesive curing step of curing the primary adhesive that has been applied to the core layer while the core layer is held by the first holding device; a separation layer removal step of removing the separation layers; a secondary bonding step of applying a secondary adhesive to the layer surfaces between the blocks; and a secondary adhesive curing step of curing the secondary adhesive while the core layer is held by a second holding device. [2] Method for producing the layered core according to claim 1, wherein the holding of the core layer by the first holding device and the second holding device is carried out in a state in which the core layer is pressed in a stacking direction, while displacement in a direction perpendicular to the stacking direction is limited. [3] Method for producing the layered core according to claim 1 or 2, wherein the primary bonding step includes a step of immersing the core layer in an adhesive bath containing a liquid adhesive and a step of reducing the pressure within the adhesive bath. [4] Method for producing a layered core in which several core plates are stacked and bonded together, the manufacturing process comprising: a thin plate stacking step of forming a thin plate layer by stacking thin plates such that for each of several blocks, each consisting of a predetermined number of thin plates, a separating layer is inserted between adjacent thin plates; a primary bonding step of applying a primary adhesive to the thin sheet layer while the thin sheet layer is held by a first holding device; a primary adhesive curing step of curing the primary adhesive that has been applied to the thin sheet layer while the thin sheet layer is held by the first holding device; a nuclear body generation step of generating a nuclear body with a predetermined shape from the thin plate layer; a separation layer removal step of removing the separation layers; a secondary bonding step of applying a secondary adhesive to the layer surfaces between the blocks; and a secondary adhesive curing step of curing the secondary adhesive while the core body is held by a second holding device. [5] Method for producing the layered core according to claim 4, wherein the holding of the thin plate layer by the first holding device is carried out in a state in which the thin plate layer is pressed in a stacking direction, while displacement in a direction perpendicular to the stacking direction is limited, and the holding of the core body by the second holding device is carried out in a state in which the core body is pressed in the stacking direction, while displacement in the direction perpendicular to the stacking direction is limited. [6] Method for producing the layered core according to claim 4 or 5, wherein the primary bonding step includes a step of immersing the thin sheet layer in an adhesive bath containing the primary adhesive in liquid form and a step of reducing the pressure within the adhesive bath. [7] Method for producing the layered core according to claim 4 or 5, wherein the core body production step includes an outer shape formation step in which wire EDM, electron beam processing or laser beam processing is used. [8] Method for producing the layered core according to claim 1 or 4, wherein the separating layer contains at least one of the group consisting of fluorine, silicone, wax and oils and fats.

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