Method for manufacturing axial flux core

Abstract

A method for manufacturing an axial flux core. In this method, steel sheets are wound to form a steel coil. The steel coil comprises several layers of steel sheets stacked together along its radial direction. The surfaces of the steel sheets are covered with a self-adhesive coating. Winding the steel sheets involves applying pressure to these layers of steel sheets using the winding tension of the steel sheets. The steel coil is heated to activate the self-adhesive coating, thereby bonding any two adjacent layers of the steel coil together. A cutting operation is performed to cut the steel coil radially, thereby cutting the steel coil into several axial flux cores.

Claims

1. A method for manufacturing an axial flux core, comprising: winding a steel sheet to form a steel coil, wherein the steel coil comprises a plurality of overlapping layers of the steel sheet along a radial direction of the steel coil, and one surface of the steel sheet is covered with a self-adhesive coating film, the winding of the steel sheet comprising applying a pressure treatment to the layers using a winding tension of the steel sheet; after winding the steel sheet to form the steel coil, performing a heat treatment on the steel coil to activate the self-adhesive coating film, thereby adhering any two adjacent layers of the steel coil; and after performing the heat treatment on the steel coil, performing a cutting operation on the steel coil to cut the steel coil along the radial direction of the steel coil, thereby cutting the steel coil into a plurality of axial flux cores.

2. A method for manufacturing an axial flux core as described in claim 1, wherein the steel sheet is an electromagnetic steel sheet or an amorphous alloy steel sheet.

3. A method for manufacturing an axial flux core as described in claim 1, wherein the self-adhesive coating is an organic polymer.

4. A method for manufacturing an axial flux core as claimed in claim 1, wherein the pressurization process comprises applying a pressure to the layers, the pressure being 0.1 MPa to 10 MPa.

5. The method for manufacturing an axial flux core as described in claim 4, wherein the winding of the steel sheet further includes a welding process at one end of the steel coil to fix the structure of the steel coil.

6. A method for manufacturing an axial flux core as described in claim 5, wherein the welding process includes using a resistance welding method, a laser welding method, or an arc welding method.

7. A method for manufacturing an axial flux core as described in claim 1, wherein the heat treatment includes using a baking method.

8. A method for manufacturing an axial flux core as described in claim 1, wherein the heating process includes using an induction heating method.

9. A method for manufacturing an axial flux core as claimed in claim 1, wherein the heat treatment comprises controlling a heating temperature between 150°C and 250°C.

10. The method for manufacturing an axial flux core as described in claim 9 further includes cooling the steel coil to below 70°C before performing the cutting operation.

11. A method for manufacturing an axial flux core as described in claim 1, wherein the cutting operation comprises using a one-wire electrical discharge machining technique.

12. A method for manufacturing an axial flux core as described in claim 1, wherein each of the axial flux cores has a teardrop-shaped fan-shaped structure.

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