Apparatus for producing a sheet-metal element, and sheet-metal element

Abstract

The invention relates to an apparatus for producing a sheet-metal element with a predeterminable sheet-metal-element form. The apparatus comprises at least one tool for forming the sheet-metal element in the sheet-metal-element shape from a metal sheet, and at least one application unit for applying a bonding layer to at least one surface of the metal sheet and / or to at least one surface of the sheet-metal element, the bonding layer comprising or consisting of a bonding composition, in particular an adhesive. The at least one application unit is designed to apply the bonding layer in a predeterminable layer shape to the at least one surface of the metal sheet and / or the at least one surface of the sheet-metal element so that the at least one surface of the sheet-metal element is covered by the bonding layer to the maximum extent, the layer shape being similar to or congruent with the sheet-metal-element shape.

Description

[0001] Device for manufacturing a sheet metal element and sheet metal element

[0002] The present invention relates to a device for manufacturing a sheet metal element, a method for manufacturing a sheet metal element, and a method for manufacturing a stack of sheet metal. The invention further relates to a sheet metal element and the use of the sheet metal element for manufacturing a stack of sheet metal.

[0003] Electric motors are electromechanical converters that convert electrical power into mechanical power. Typically, electric motors consist of a stationary, magnetically actuated stator and a rotating, magnetically actuated rotor that turns a motor shaft.

[0004] Both the stator and the rotor can be constructed from stacks of laminated and firmly bonded elements. To manufacture these stacks, also known as lamination stacks, cores, or magnetic cores, individual laminations of sheet metal, also called lamination elements, are stacked on top of each other, aligned, and bonded.

[0005] Numerous methods for joining sheet metal elements and / or sheets are known from the prior art. Mechanical connections can be formed using fasteners such as rivets or screws, or by methods such as pressure joining or clinching.

[0006] Adhesive bonds are of particular importance, with two basic methods of gluing being used.

[0007] The first, industrially common variant is a full-surface coating of the sheet metal, which is usually a continuous sheet and from which the sheet metal elements for the sheet stack are formed, with adhesive and subsequent hardening and vulcanization, resulting in a full-surface bonding of the sheets.

[0008] This variant allows for a relatively simple and robust design of the production plant, but has the disadvantage that the process is expensive due to the large amount of adhesive required. In particular, even the sheet metal scrap, such as stamping waste, is coated with adhesive. Furthermore, fast-curing adhesives cannot be used.

[0009] An alternative to full-surface coating is the spot application of a particularly fast-curing adhesive. Such bonding methods are described, for example, in publications CN 114 785 060 A and CN 117 791 984 A.

[0010] While this method is characterized by low adhesive consumption, the strength of the resulting adhesive bond is weaker than with full-surface bonding. Furthermore, process-related difficulties arise, such as the nozzles used to apply the adhesive dots becoming clogged.

[0011] The present invention is therefore based on the objective of providing a device and / or a method for manufacturing sheet metal elements which at least largely avoids the aforementioned disadvantages.

[0012] The term "in particular" is used in this description and the attached claims preferably to describe optional features.

[0013] This problem is solved by a device for manufacturing a sheet metal element with a predefinable sheet metal element shape according to the independent claim in this respect.

[0014] The sheet metal element can be a sheet metal component for a stack of sheets. The stack of sheets can be an electrical steel sheet package, in particular a rotor package or a stator package.

[0015] The sheet metal element shape is, in particular, a predefinable sheet metal element shape. The sheet metal element shape can preferably be selected and / or set arbitrarily. In accordance with the invention, a shape is defined by external and / or internal contours, preferably in a principal plane of extension of an element, particularly a planar element. Contours can, for example, also define recesses and / or openings in the sheet metal element.

[0016] According to the invention, the device comprises: - at least one tool for forming the sheet metal element in the sheet metal element shape from a sheet of metal, and

[0017] - at least one application unit for applying a bonding layer to at least one surface of the sheet metal and / or to at least one surface of the sheet metal element.

[0018] Sheet metal is understood to be a flat material whose length and width are many times greater than its thickness. The length and width preferably define the principal plane of the sheet metal.

[0019] The sheet metal can be a continuous sheet. Continuous sheets can enable a continuous processing method.

[0020] In one embodiment, the sheet metal is fed to the device via a sheet metal feeding unit positioned upstream of the device in one process direction. The sheet metal feeding unit can comprise one or more rollers from which the sheet metal, in particular the continuous sheet, is unwound.

[0021] The sheet metal can be a sheet metal laminate, wherein the sheet metal laminate comprises at least two sheets which are joined together, preferably by a material bond.

[0022] When manufacturing the sheet metal element from the sheet metal, it is advantageous if at least one lamination unit is interposed between the sheet metal feeding unit and the device, in which a sheet metal laminate is produced from at least two sheets.

[0023] In a further embodiment, at least one straightening unit is arranged upstream of the device in the process direction. This at least one straightening unit is preferably located between the sheet feed unit and the device and / or between the lamination unit and the device. This has the advantage that a flat and / or stress-free sheet and / or sheet laminate is fed to the device. The sheet can, in particular, be electrical steel. Specifically, the electrical steel can consist of or comprise an iron-silicon alloy. It can be advantageous if the sheet is produced by cold rolling.

[0024] The sheet metal can have a thickness of 0.1 to 2 mm, preferably 0.3 to 0.65 mm.

[0025] The sheet metal can be coated. The at least one coating can serve to improve lubrication, corrosion protection, temperature resistance, and / or insulation resistance. The at least one layer preferably has a thickness of 1 to 4 µm.

[0026] The at least one tool is preferably designed to form the sheet metal element from the sheet metal in a predetermined shape. This can be achieved in particular by cutting and / or punching.

[0027] In one embodiment, the device comprises at least two tools, which are preferably arranged one behind the other and / or side by side with respect to a process direction. The tools can be of the same or different types. This allows for a higher throughput and / or the formation of different shapes and / or contours using different tools.

[0028] In a preferred embodiment, the at least one tool is designed to form the sheet metal element only partially from the sheet metal, so that it remains partially connected to a sheet metal element that at least partially surrounds the sheet metal element, which may in particular be the sheet metal waste or offcuts.

[0029] In particular, after punching and / or cutting, the sheet metal element is still connected to the sheet metal that at least partially surrounds the sheet metal element via at least one web.

[0030] To separate at least one web, the device can include a tool for punching out the sheet metal element. Preferably, the punching takes place after the bonding layer has been applied.

[0031] The bonding layer comprises or consists of a bonding composition. Preferably, the bonding composition is an adhesive or acts like one. In particular, the bonding layer between sheet metal elements in a stack of sheets can form a metallurgical bond between the sheet metal elements.

[0032] The compound composition can preferably be hardened by heat, pressure and / or chemical activation.

[0033] The bonding composition is preferably an adhesive based on (meth)acrylate, phenolic resin and / or epoxy resin. Furthermore, the bonding composition may include a sealant, in particular a rubber-based, resin-based and / or elastomer-based sealant.

[0034] According to the invention, the at least one application unit is configured to apply the bonding layer in a predefinable layer shape to the at least one surface of the sheet metal and / or the at least one surface of the sheet metal element, such that the at least one surface of the sheet metal element is maximally covered by the bonding layer, wherein the layer shape is similar to or congruent with the sheet metal element shape.

[0035] In one embodiment, the layer is applied to two opposing surfaces of the sheet metal and / or the sheet metal element.

[0036] Preferably, at least one surface of the sheet metal element is completely covered by the bonding layer.

[0037] Similarity, as used in the present invention, means that the layer shape and the sheet element shape are essentially the same, preferably identical, but have different dimensions. Congruence means that the layer shape and the sheet element shape are identical, i.e., they have the same shape and the same dimensions.

[0038] The size extent of the bonding layer in the main extension plane can be between 70 and 120%, preferably between 75 and 100%, particularly preferably between 85 and 99%, most preferably 90 to 95% of the size extent, in particular of the surface, of the sheet metal element in the main extension plane.

[0039] Maximum coverage means that the bonding layer and the sheet metal element are brought into as close contact as possible. In other words, preferably no or only a minimal portion of the sheet metal surface is covered by the bonding layer that is not part of the sheet metal element's surface.

[0040] Preferably the thickness of the applied compound layer is between 1 and 9 pm, more preferably between 4 and 8 pm, and particularly preferably between 5 and 7 pm.

[0041] The thickness of the bonding layer is preferably an average thickness perpendicular to the main extension plane of the sheet and / or sheet element after coating.

[0042] This has the advantage that the bonding agent, especially the adhesive, is applied with the highest possible contour accuracy. In this way, the amount of bonding agent can be reduced compared to completely coating the sheet metal, while still achieving at least near-complete coverage of the sheet metal element. In particular, little to no adhesive-coated sheet metal waste, especially stamping waste, is generated.

[0043] In a preferred embodiment, the device comprises a control unit for controlling the device. In particular, the control unit is configured to control the at least one application unit and / or the at least one tool, so that the bonding layer is applied in the predefinable layer shape to the at least one surface of the sheet metal and / or the at least one surface of the sheet metal element in such a way that the at least one surface of the sheet metal element is maximally, preferably completely, covered by the bonding layer and / or no or only a small amount of adhesive-coated sheet metal waste, in particular stamping waste, is generated.

[0044] The control unit can be caused, in particular by a computer program, to control the device, especially the application unit and / or the tool. Such a computer program comprises commands which, when executed by a computer (which may be the control device), cause the computer to control the device and / or to carry out a procedure described herein.

[0045] In another embodiment, the at least one tool is positioned upstream of the at least one application unit. "Upstream" means that the at least one tool is arranged in the process direction before the at least one application unit. This means, in particular, that the forming of the sheet metal element in the sheet metal element shape takes place from the sheet metal before the application of the bonding layer. This arrangement has the advantage that fast-drying bonding compounds can also be used, since stacking at least two sheet metal elements into a sheet stack can take place immediately afterward.

[0046] Complete removal, in particular the punching out, of the sheet metal element from the sheet metal can take place especially between the application of the bonding layer and the stacking.

[0047] Preferably, the size expansion of the bonding layer is equal to or smaller than the size expansion of the sheet metal element, so that only the surface of the sheet metal element and / or a part of the surface of the sheet metal element is coated.

[0048] Alternatively, at least one application unit is positioned upstream of at least one tool. In this embodiment, the bonding layer is applied before the sheet metal element is formed from the sheet metal in the sheet metal element mold. In this embodiment, the surface of the sheet metal is coated. This can have the advantage that existing devices can be upgraded with only minor modifications.

[0049] Preferably, in this embodiment as well, the dimensions of the bonding layer are equal to or less than those of the sheet metal element, so that only that surface area of ​​the sheet metal which forms the surface of the sheet metal element after its formation is coated. Surfaces of sections of the sheet metal that are present as sheet metal waste, in particular stamping waste, after the formation of the sheet metal element remain uncoated. It can be advantageous if the at least one tool is a stamping tool. The formation of the sheet metal element, in particular by cutting the sheet metal and / or separating it from the sheet metal, is carried out especially by stamping.

[0050] Additionally or alternatively, the sheet metal element can be formed by electromagnetic forming. For this purpose, material weakening is preferably introduced into the sheet metal, for example by shearing and / or wedge cutting and / or embossing. Subsequently and / or during this process, the sheet metal is preferably cut by generating an electromagnetic pulse, for example by a pulse generator.

[0051] Additionally or alternatively, the sheet metal element can be formed by laser cutting and / or laser punching.

[0052] In a further embodiment, the at least one application unit comprises at least one application roller, wherein a surface of the application roller has at least one negative shape of the layer shape and / or the sheet metal element shape. The surface is preferably a lateral surface of the application roller. Due to the negative shape, it is possible to apply the compound composition to the surface of the sheet metal and / or the surface of the sheet metal element with contour accuracy.

[0053] Preferably, the application roller is in direct contact with the sheet metal in a transfer area, whereby the compound composition located in the negative mold is transferred as a bonding layer onto the surface of the sheet metal and / or the sheet metal element.

[0054] The application roller can be made of rubber and / or plastic. The application roller preferably has a non-stick coating.

[0055] The application form can have a variety of negative shapes on its surface, particularly on the outer surface. This has the advantage that high throughput is possible, especially in continuous processes with endless sheets. Furthermore, existing systems can be easily retrofitted. Additionally or alternatively, the at least one application unit can comprise a film and a transfer area, wherein the compound layer is applied to the film, and wherein the at least one application unit is configured to transfer the compound layer in the transfer area from the film to the surface of the sheet and / or the surface of the sheet element.

[0056] Preferably, the bonding layer is applied to the film in layer form. In this way, the bonding composition is already pre-assembled and only needs to be transferred to the surface of the sheet metal and / or the surface of the sheet metal element in the transfer area.

[0057] The transfer can be carried out, for example, using an application roller, which transfers the bonding layer applied to the film to the surface of the sheet metal and / or the surface of the sheet metal element in the transfer area.

[0058] It can be advantageous for the application roller to have at least one positive shape on a surface, particularly a cylindrical surface, in the form of the layer shape and / or the sheet metal element shape. The cylindrical surface can, in particular, have a plurality of such positive shapes. Due to the at least one raised positive shape, contact between the film and the surface of the sheet metal and / or the surface of the sheet metal element in the form of the positive shape can be ensured in the transfer area. This has the advantage that the bonding layer is transferred with particular precision according to the layer shape.

[0059] The application roller can be made of rubber and / or plastic. The application roller preferably has a non-stick coating. The non-stick coating can, in particular, simplify the transfer of the compound to the surface of the sheet metal.

[0060] The problem is also solved by a method for manufacturing a sheet metal element with a predefinable sheet metal element shape according to the independent claim in this respect. The sheet metal element can be any sheet metal element described herein. In particular, the sheet metal element is a sheet metal element for a stack of sheets. The stack of sheets can be an electrical steel stack, in particular a rotor stack or a stator stack.

[0061] The sheet metal element shape is, in particular, a predefinable sheet metal element shape. The sheet metal element shape can preferably be selected and / or set as desired.

[0062] The method comprises at least the following steps: i) forming the sheet metal element in the sheet metal element shape from a sheet; ii) applying a bonding layer to at least one surface of the sheet and / or to at least one surface of the sheet metal element.

[0063] The bonding layer may comprise or consist of any bonding composition described herein, in particular an adhesive.

[0064] According to the invention, the bonding layer has a predefinable layer shape similar to or congruent with the sheet metal element shape and is applied in such a way that it maximally covers at least one surface of the sheet metal element.

[0065] Preferably, the bonding layer completely covers the surface of the sheet metal element.

[0066] Preferably, the method is carried out using a device described herein.

[0067] The process can be controlled by a control unit as described herein.

[0068] In a preferred embodiment, the process is a continuous process and / or suitable for the serial production of sheet metal components. A large number of sheet metal components can preferably be produced from the sheet metal.

[0069] The process is preferably part of a flow production system, in which, in particular, a spatially progressive, temporally defined, and uninterrupted sequence of work steps is realized. The sequence of work steps can, in particular, determine the process direction. In the process, step i) can be carried out before step ii) or vice versa.

[0070] The sheet metal may have a width of between 50 mm and 500 mm, preferably 120 mm to 350 mm, and particularly preferably between 150 mm and 300 mm.

[0071] Preferably, the sheet metal is a continuous sheet. The width of the sheet can define the maximum dimensions of the sheet metal element in at least one spatial direction. Furthermore, the width of the sheet can allow two or more sheet metal elements to be formed side by side in a section of the sheet metal in the process direction.

[0072] The formation of the sheet metal element in the sheet metal element shape from the sheet metal can be carried out in any way described herein.

[0073] In particular, step i) can include punching out the sheet metal element from the sheet metal. Preferably, at least one punching tool is used for this purpose.

[0074] It may be possible to preheat the sheet metal, at least in certain areas, before and / or during punching, particularly locally. For example, local preheating can take place in an area where a punch line is formed during the punching process. Preheating within a range of ±5 mm, preferably ±2 mm, around the future punch line is conceivable. Preheating is preferably carried out using a laser. This heating can promote the formation of sheet metal elements with optimized form quality.

[0075] In a preferred embodiment, the punching is a partial punching of the sheet metal element. In particular, the sheet metal element can remain connected to the sheet metal via at least one web.

[0076] The complete removal of the sheet metal element can be achieved using at least one additional tool, in particular a die-cutting tool. Removal preferably takes place after the application of the bonding layer. This has the advantage that the position of the sheet metal elements is clearly defined and enables particularly precise application of the bonding layer.

[0077] In one embodiment, the application of the bonding layer can be carried out using an application roller, wherein the application roller has a surface with at least one negative shape of the layer shape and / or the sheet element shape. The surface of the application roller is, in particular, a cylindrical surface.

[0078] The application roller can be any application roller described herein.

[0079] Preferably, the sheet metal and / or the sheet metal element is guided past the rotating application roller in such a way that the application roller is in direct contact with at least one surface of the sheet metal and / or the at least one surface of the sheet metal element in a transfer area.

[0080] In the transfer area, the compound composition can be applied to the surface of the sheet metal and / or sheet metal element as a bonding layer in layer form and / or sheet metal element form. The at least one negative mold on the application roller can be oriented in such a way that the transferred bonding layer covers the surface of the sheet metal element to a maximum extent, preferably completely, and / or is positioned on the surface of the sheet metal in such a way that a subsequent development step results in maximum, preferably complete, coverage of the surface of the sheet metal element.

[0081] Alternatively or additionally, the bonding layer can also be applied using a film. In this case, the bonding layer is applied to the film and is transferred from the film to the surface of the sheet metal and / or the surface of the sheet metal element within a transfer area.

[0082] The transfer can be carried out, for example, using an application roller, which brings the film into contact with the surface of the sheet metal and / or the surface of the sheet metal element in the transfer area, so that the compound composition located on the film is transferred. In a preferred embodiment, the compound composition is applied to the film in a layered form, which can be congruent with the shape of the sheet metal element.

[0083] The invention further relates to a method for producing a stack of sheet metal according to the independent claim in this respect.

[0084] The stack of laminations can be an electrical steel lamination stack, in particular a rotor stack or a stator stack.

[0085] The process comprises the following steps: i) manufacturing at least two sheet metal elements; ii) bringing the at least two sheet metal elements together so that a connection is formed between the at least two sheet metal elements.

[0086] The at least two sheet metal elements can be manufactured according to a method described herein. The use of such sheet metal elements can have the advantage that the reduced amount of adhesive lowers the process costs. Furthermore, sheet metal scraps can be recycled more easily, as they are coated with only a small amount of adhesive, if at all.

[0087] The connection is preferably a material-bonded connection, in particular an adhesive bond. The connection can be formed, in particular, by a bonding layer of at least one of the at least two sheet metal elements.

[0088] It can be advantageous if the at least two sheet metal elements are aligned before forming the connection, in particular the adhesive connection.

[0089] In particular, these can be aligned in overlapping positions and / or concentrically aligned with each other.

[0090] It can be advantageous if the at least two sheet metal elements are manufactured individually or simultaneously and / or cut out of the sheet metal and then stacked on top of each other before being bonded together. Stacking can be carried out using a stacking unit. A stacking direction is preferably perpendicular to a main plane of extension of the sheet metal.

[0091] It can be advantageous to align the at least two sheet metal elements relative to each other during and / or after stacking. Internal and / or external contour features of the at least two sheet metal elements, such as recesses, notches, and / or openings, can simplify the alignment.

[0092] In a further advantageous embodiment, the formation of the connection, in particular the adhesive connection, is achieved by heating at least one bonding layer and / or pressing the at least two sheet metal elements together and / or chemically activating the bonding composition.

[0093] Heating can be done using a heating device, in particular an IR heating device.

[0094] It can be advantageous if the sheet metal elements are pressed together along the stacking direction, particularly across their entire surface. This is preferably carried out within the pressing tool. Preferably, the pressing tool can be combined with the stacking unit, and in particular, integrated into it.

[0095] In chemical activation, the compound composition is preferably brought into contact with a reaction initiator, and / or a reaction initiator is added at a time before and / or during the stacking process.

[0096] A reaction initiator is, for example, a crosslinking agent and / or a radical initiator. The reaction initiator can be selected particularly depending on the compound composition. Examples of radical initiators that can be used include azoisobutyronitrile (AIBN), dibenzoyl peroxide (DPBO), inorganic peroxides such as peroxodisulfates, bis(2-ethylhexyl)peroxydicarbonate, and / or methyl ethyl ketone peroxide.

[0097] The resulting stack of sheet metal, in particular the rotor or stator assembly, can undergo further processing steps. These preferably include post-processing steps such as surface treatment and / or cleaning, quality control, and / or joining with other components of an electric motor, such as a housing.

[0098] The sheet metal waste remaining after the sheet metal elements have been cut out, in particular stamping waste, can be collected, especially in a container. The sheet metal waste can be free of the bonding compound of the bonding layer.

[0099] The invention also relates to a sheet metal element with a predefinable sheet metal element shape according to the independent claim in this respect.

[0100] The sheet metal element can, in particular, be a sheet metal element for a stack of sheet metal. The stack of sheet metal can be an electrical steel stack, in particular a rotor pack or a stator pack.

[0101] The sheet metal element has a bonding layer with a predefinable layer shape on at least one surface, wherein the surface is partially covered by the bonding layer and wherein the layer shape is at least similar to the sheet metal element shape.

[0102] The bonding layer may comprise or consist of a bonding composition, in particular an adhesive. The bonding composition may be any composition described herein.

[0103] In a preferred embodiment, the layer shape is nearly congruent with the shape of the sheet metal element. This means that the bonding layer has at least substantially the same, preferably the same, shape as the sheet metal element, but with a smaller surface area. In particular, at least one surface of the sheet metal element is not completely covered by the bonding layer.

[0104] Preferably, at least 70%, preferably at least 85%, and particularly preferably between 90% and 99% of at least one surface of the sheet metal element is covered by the bonding layer. In one embodiment, the sheet metal element has a bonding layer on each of two opposing surfaces.

[0105] The sheet metal element can be manufactured in particular using a device described herein.

[0106] The sheet metal element is preferably obtainable by a method described herein.

[0107] The invention also relates to the use of a sheet metal element for the production of a stack of sheet metal.

[0108] The sheet metal element can be any sheet metal element described herein.

[0109] The stack of sheet metal can in particular be an electrical steel stack, especially a rotor pack or a stator pack.

[0110] The production of the sheet metal stack is preferably carried out according to a method and / or using a device described herein.

[0111] Further preferred features and / or advantages of the invention are the subject of the following description and the graphic representation of exemplary embodiments.

[0112] The drawings show:

[0113] Fig. 1: a schematic representation of a plant for the production of a

[0114] a stack of sheet metal comprising a device for producing a sheet metal element from a sheet according to an embodiment of the invention;

[0115] Fig. 2: a schematic representation of a plant for the production of a

[0116] Sheet stack comprising a device for producing a sheet element from a sheet laminate according to an embodiment of the invention; Fig. 3: a schematic representation of an application device according to an embodiment of the invention;

[0117] Fig. 4: a schematic representation of an application device according to a further embodiment of the invention;

[0118] Fig. 5: a schematic top view of a sheet metal part with a

[0119] junction layer; and

[0120] Fig. 6: a schematic top view of a sheet metal element according to a

[0121] embodiment of the invention.

[0122] Identical or functionally equivalent elements are provided with the same reference symbols in all figures.

[0123] Fig. 1 schematically shows a system 1 comprising a device 30 for manufacturing a sheet metal element 50. System 1 enables the mass production of sheet metal elements 50.

[0124] The sheet metal elements 50 are preferably electrical steel elements.

[0125] The sheet metal elements 50 can be stacked to form sheet metal stacks 55, which are preferably rotor packages 56 and / or stator packages 57.

[0126] The system 1 comprises a sheet feeding unit 10 for providing at least one sheet 11. The sheet 11 is preferably a sheet 11 comprising or formed from metallic materials. Preferably, the sheet 11 is electrical steel. For example, the sheet 11 is made of at least one iron-silicon alloy and / or processed into a flat material by cold rolling.

[0127] It can be advantageous if the sheet 11 has a pre-coating. The pre-coating is particularly electrically insulating. Preferably, the pre-coating comprises one or more of the following materials or is formed from one or more of the following materials: polyvinyl butyral, polyamide, polyester, modified polyamide, and / or epoxy. The pre-coating serves in particular to promote adhesion between a bonding layer 51 and the sheet 11.

[0128] For series production, it can be advantageous if the sheet metal 11 can be supplied wound into a roll 12. For example, the sheet metal 11 can be supplied as coil material.

[0129] The width of the roll 114 and / or coils is preferably in the range of approximately 50 mm to approximately 500 mm. The width is defined in particular perpendicular to a winding direction.

[0130] The sheet metal 11, which can in particular be a continuous sheet, can be fed to the device 30 for the production of sheet metal elements 50.

[0131] The device 30 comprises, in particular, at least one tool 31 which can separate and / or cut out sheet metal elements 50 from the sheet metal 11. Preferably, the at least one tool 31 is a punching tool 32.

[0132] The at least one tool 31 can be configured to only partially separate and / or cut out the sheet metal elements 50 from the sheet metal 11. In particular, the sheet metal elements 50 can remain connected to the sheet metal 11 via at least one web. Complete separation and / or cutting out can be carried out by at least one further tool (not shown), in particular a tool for punching out. Preferably, the at least one further tool is arranged after at least one application unit 40 and / or immediately before at least one stacking unit 33.

[0133] The punching tool 32 preferably comprises two tool halves, each equipped with one or more cutting elements (not shown). By pressing the two tool halves of the punching tool 32 together, the sheet metal element 50 is preferably separated and / or cut out of the sheet metal 11 in a predefinable sheet metal element shape using the cutting elements. To minimize edge curl, it can be advantageous to preheat the sheet metal 11, particularly before punching. For example, an area of ​​the sheet metal laminate 11 in which one or more cutting elements of the punching tool 32 cut is preheated. This area is, for example, a cutting edge area. Preheating is preferably carried out using a laser.

[0134] It can be provided that the stamping process completely cuts the sheet metal 11, or that the stamping tool 32 first weakens the material and then, subsequently and / or during this process, completely cuts the sheet metal 11 by an electromagnetic pulse. The electromagnetic pulse is generated, for example, by an electromagnetic pulse generator (not shown).

[0135] The device 30 further comprises at least one application unit 40 for applying a bonding layer 51 to at least one surface 15 of the sheet metal 11 and / or a surface 59 of the sheet metal element 50.

[0136] The at least one application unit 40 can be positioned upstream and / or downstream of the at least one tool 31 in one process direction.

[0137] The at least one application unit 40 is particularly designed to apply the compound layer 51 in a predefinable layer shape to the at least one surface 15 of the sheet 11 and / or the at least one surface 59 of the sheet element 50, such that the at least one surface 59 of the sheet element 50 is maximally covered by the compound layer 51, wherein the layer shape is similar or congruent to the sheet element shape.

[0138] Preferably, at least one surface 59 of the sheet metal element 50 is completely covered by the bonding layer 51.

[0139] The bonding layer 51 comprises or consists of a bonding composition, in particular an adhesive. The bonding composition is preferably an adhesive based on (meth)acrylate, phenolic resin, and / or epoxy resin. The device 30 may include a control unit (not shown). In particular, the control unit may be configured to control the at least one application unit 40 and / or the at least one tool 31 in such a way that the bonding layer 51 is applied in the predefinable layer shape to the at least one surface 15 of the sheet 11 and / or the at least one surface 59 of the sheet element 50, such that the at least one surface 59 of the sheet element 50 is maximally, and preferably completely, covered by the bonding layer 51.

[0140] The sheet metal elements 50, cut from the sheet metal 11 and coated with the bonding layer 51, can be stacked to form sheet metal stacks 55. For this purpose, the device 30 can in particular comprise at least one stacking unit 33 in which at least two sheet metal elements 50 can be stacked.

[0141] In particular, between 50 and 1500, preferably between 500 and 900, sheet metal elements 50 can be stacked to form a sheet metal stack 55.

[0142] Preferably, the sheet metal elements 50 are aligned in a straight line when stacked. In particular, they can be aligned in overlapping positions and / or concentric with each other.

[0143] After stacking the at least two sheet metal elements 50, the sheet metal elements 50 are preferably joined together by a material bond.

[0144] The material-bonded connection can be formed, in particular, via at least one bonding layer 51, preferably via all bonding layers 51 of the at least two sheet metal elements 50 of the sheet metal stack 55. For this purpose, the bonding composition, in particular the adhesive, can be activated. Activation is preferably carried out by heating at least one bonding layer 51 and / or pressing the at least two sheet metal elements 50 together and / or chemically activating a bonding composition.

[0145] The heating of at least one bonding layer 51, preferably all bonding layers 51, can take place before, during and / or after stacking the at least two sheet metal elements 50. The heating is effected in particular by means of at least one heating device 22, which can be an IR heating device 23.

[0146] Preferably, the compound layers are heated to a temperature between 50 and 250°C, preferably between 120 and 190°C.

[0147] Pressing and / or compressing the at least two sheet metal elements together

[0148] The joining of the sheet metal elements 50 can be carried out using at least one pressing tool 34. The pressing together and / or compression preferably takes place substantially perpendicular to a main extension plane of the sheet metal elements 50. Preferably, the at least one pressing tool 34 is combined with the stacking unit 33, in particular integrated into it.

[0149] In the chemical activation of the compound composition, it is preferably brought into contact with a reaction initiator described herein, and / or a reaction initiator is added at a time before and / or during stacking.

[0150] The resulting stack of laminations 55 can be a rotor stack 56 or a stator stack 57. Preferably, the device 30 can be used to produce rotor stacks 56 and stator stacks 57. In this way, the lamination waste 58 can be reduced.

[0151] For this purpose, the device 30 preferably comprises at least two tools 31 and / or at least two application units 40. The device 30 may also comprise further tools 31 and / or application units 40, which are preferably arranged side by side and / or one behind the other in the process direction.

[0152] The sheet metal waste 58 is preferably not or only slightly related to the connection view

[0153] 51 coated.

[0154] Fig. 2 shows a schematic representation of a plant 1 for the production of a stack of sheet metal 55 comprising a device 30 for the production of a sheet metal element 50 from a sheet metal laminate 14.

[0155] To produce a sheet metal element 50 from a sheet metal laminate 14, the sheet metal feeding unit 10 preferably comprises several rollers 12. In this case, three sheets 11 are each provided on both sides with a laminating layer 13, which comprises or consists of a laminating composition. The laminating composition can be an adhesive and / or act like an adhesive. In particular, the sheets 11 can be bonded together by means of the laminating composition.

[0156] The lamination composition may, in particular, include or consist of an epoxy resin material and / or a phenolic resin material.

[0157] The joining of the sheets 11 can take place, in particular, in a lamination unit 20. Preferably, the sheets 11 are brought together and / or arranged one above the other before the formation of the, preferably material-bonded, connection.

[0158] The lamination unit 20 can in particular comprise at least one reaction chamber 21 in which the lamination layers 13 are activated, preferably thermally.

[0159] Thermal activation can be achieved, for example, using a heating device 22. Preferably, the heating device 22 is an IR heating device 23. Activation is preferably carried out at a temperature between 50 and 250°C, particularly preferably between 120 and 190°C.

[0160] To form the connection, it may be advantageous to press and / or squeeze the sheets 11 together using rollers.

[0161] After the sheets 11 have been joined, preferably by a material bond, to form a sheet laminate 14, the sheet laminate 14 is preferably passed through a cooling device 24. The cooling device 24 can be designed as an active cooling channel, which can serve to cool the sheet laminate 14 to room temperature (approx. 20°C).

[0162] The sheet laminate 14 can be temporarily stored in a tape storage unit before processing in the device 30. This tape storage unit is preferably arranged between the laminating unit 20 and a device 30 for manufacturing sheet metal elements 50. Preferably, the device 30 corresponds to the device 30 shown in Fig. 1.

[0163] Fig. 3 shows a schematic representation of an embodiment of an application device 40 for a device 30.

[0164] The application unit 40 can have at least one application roller 41 and at least one pressure roller 42. These can be arranged apart from each other, creating a gap.

[0165] A foil 43 and a sheet 11 and / or at least one sheet element 50, preferably a plurality of sheet elements 50 arranged one behind the other and / or next to each other, are preferably guided through the gap formed by the at least one application roller 41 and the at least one pressure roller 42. The sheet 11 can be a sheet laminate 14.

[0166] The directions of movement of the foil 43 and the sheet 11 and / or the at least one sheet element 50 are indicated by the corresponding arrows.

[0167] At least one bonding layer 51 can be applied to a surface of the foil 43. The surface is in particular facing a surface 15 of the sheet 11 and / or a surface 59 of the at least one sheet element 50.

[0168] Preferably, the compound layer 51 is applied to the film 43 in a predefinable layer form and / or a predefinable sheet element form. In particular, a plurality of compound layers 51 in layer form and / or sheet element form can be applied to the film one after the other and / or next to each other along the film.

[0169] The gap preferably forms a transfer area 44 in which the bonding layer 51 is transferred from the film 43 to the surface 15 of the sheet 11 and / or the surface 59 of the at least one sheet element 50. In particular, the film 43 and the sheet 11 and / or the at least one sheet element 59 are pressed together in the transfer area 44, so that the bonding layer 51 is printed onto the surface 15 and / or the surface 59. The contact pressure between the film 43 and the sheet 11 and / or the at least one sheet element 50 can be controlled and / or adjusted, in particular, via the pressure roller 42.

[0170] If the application unit 40 is positioned upstream of a tool 31 in the process direction, the coating of the surface 15 of the sheet 11 is carried out in such a way that, in a subsequent formation of at least one sheet element 50 using a tool 31 (not shown), a surface 59 of the formed sheet element 50 is covered to a maximum extent, preferably completely, by the bonding layer 51.

[0171] If the application unit 40 is located downstream of the tool 31 in the process direction, the coating of the surface 59 of the sheet metal element 11 is carried out in such a way that the surface 59 of the sheet metal element 50 is covered to a maximum extent, preferably completely, by the bonding layer 51.

[0172] Fig. 4 shows another embodiment of an application device 40 for a device 30.

[0173] The application unit 40 can have at least one application roller 41 and at least one pressure roller 42. These can be arranged apart from each other, creating a gap.

[0174] The application roller 41 can have at least one negative shape 45 of a predefinable layer shape and / or a predefinable sheet element shape on a surface, in particular on a cylindrical surface.

[0175] The surface of the application roller 41, in particular the at least one negative form 45, can be coated and / or covered and / or filled with a compound composition from a reservoir not shown.

[0176] Excess compound on the application roller 41 is preferably removed by a wiper element 46. The wiper can be carried out in such a way that only the at least one negative mold is coated and / or covered and / or filled with the adhesive composition. The sheet 11 and / or at least one sheet element 50, preferably a plurality of sheet elements 50 arranged one behind the other and / or side by side, are preferably guided through the gap formed by the at least one application roller 41 and the at least one pressure roller 42. The sheet 11 can be a sheet laminate 14.

[0177] The direction of movement of the sheet metal 11 and / or of at least one sheet metal element 50 is indicated by an arrow.

[0178] The gap preferably forms a transfer area 44 in which the compound composition, in particular an adhesive, is transferred as a bonding layer 51 from the negative shape of the application roller to the surface 15 of the sheet 11 and / or the surface 59 of the at least one sheet element 50.

[0179] In particular, the application roller 41 and the sheet metal 11 and / or the at least one sheet metal element 59 are pressed together in the transmission area 44, so that the bonding layer 51 is formed on the surface 15 and / or the surface 59. The contact pressure between the application roller 41 and the sheet metal 11 and / or the at least one sheet metal element 50 can be controlled and / or monitored and / or adjusted, in particular, via the pressure roller 42.

[0180] If the application unit 40 is positioned upstream of a tool 31, the coating of the surface 15 of the sheet metal 11 is carried out in such a way that, in a subsequent formation of at least one sheet metal element 50 using a tool 31 (not shown), a surface 59 of the formed sheet metal element 50 is maximally, preferably completely, covered by the bonding layer 51.

[0181] If the application unit 40 is downstream of the tool 31, the coating of the surface 59 of the sheet metal element 11 is carried out in particular in such a way that the surface 59 of the sheet metal element 50 is covered to a maximum extent, preferably completely, by the bonding layer 51.

[0182] Fig. 5 shows a schematic top view of a sheet 11, in particular a section of a sheet 11, with a bonding layer 51. The sheet 11 can be a sheet laminate 14. The sheet can in particular be a continuous sheet.

[0183] A compound layer 51 is preferably applied to a surface 15 of the sheet 11. The compound layer 51 can be applied to the surface 15 using an application unit 40 (not shown) described herein.

[0184] The sheet 11 can be coated on both sides with the bonding layer 51.

[0185] The compound layer 51 can have a predefinable layer shape such as the layer shape shown here.

[0186] The layer shape can be similar to, preferably congruent with, the shape of a sheet metal element 50. The similarity of the layer shape and the sheet metal element shape is illustrated, for example, by the schematic top view of a sheet metal element 50 in Fig. 6.

[0187] The sheet metal element 50 can be separated and / or cut out of the sheet metal 11, in particular by punching.

[0188] The sheet metal element 50 preferably has contour features such as recesses 53 and / or openings 54. The sheet metal element 50, in particular its outer and / or inner contours, can be defined by punch lines 52. The recesses 53, especially on an outer punch line 52, and / or openings 54 can simplify the stacking and / or alignment of at least two sheet metal elements 50.

[0189] The compound layer 51 can have similar, preferably the same, outer and / or inner contours as shown.

[0190] The compound layer 51 is applied to the surface 59 of the sheet metal element 50 in such a way that at least 70%, preferably 85%, and particularly preferably between 90% and 99% of the surface 59 of the sheet metal element 50 is covered by the compound layer 51. It can be advantageous to apply the compound layer 51 in such a way that the surface 59 of the sheet metal element 50 is maximally, and preferably completely, covered by the compound layer 51. Conversely, it is advantageous if sheet metal waste 58, in particular stamping waste, is not covered by the compound layer 51 or is covered only minimally.

[0191] Reference symbol list

[0192] Sheet metal feeding unit, sheet metal roll, laminating layer, sheet metal laminate, surface, laminating unit, reaction chamber, heating unit, IR heating unit, cooling unit, fixture, tool, punching tool, stacking unit, press tool, application unit, application roller, pressure roller, film

[0193] Transmission area Negative form Stripper element Sheet metal element Connecting layer Punch line Recess Opening Sheet metal stack Rotor package Stator package 58 Sheet metal waste

[0194] 59 surface

Claims

Patent claims 1. Device (30) for producing a sheet metal element (50) with a predefinable sheet metal element shape, in particular a sheet metal element (50) for a stack of sheets (55), which may be, for example, an electrical steel stack, the device (30) comprising: at least one tool (31) for forming the sheet metal element (50) in the sheet metal element shape from a sheet (11), and at least one application unit (40) for applying a bonding layer (51) to at least one surface (15) of the sheet (11) and / or to at least one surface (59) of the sheet metal element (50), wherein the bonding layer (51) comprises or consists of a bonding composition, in particular an adhesive, characterized in that the at least one application unit (40) is configured to apply the bonding layer (51) in a predefinable layer shape to the at least one surface (15) of the sheet (11) and / or the at least one surface (59) of the sheet metal element (50).such that at least one surface (59) of the sheet metal element (50) is maximally, preferably completely, covered by the bonding layer (51), wherein the layer shape is similar to or congruent with the sheet metal element shape.

2. Device (30) according to claim 1 , characterized in that the at least one tool (31) is positioned upstream of the at least one application unit (40).

3. Device (30) according to claim 1, characterized in that the at least one application unit (40) is positioned upstream of the at least one tool (31).

4. Device (30) according to one of claims 1 to 3, characterized in that the at least one tool (31) is a stamping tool (32).

5. Device (30) according to one of the preceding claims, characterized in that the at least one application unit (40) includes at least one application roller (41) comprises a surface of the application roller (41) having at least one negative shape (45) of the layer shape and / or the sheet element shape.

6. Device (30) according to one of the preceding claims, characterized in that the at least one application unit (40) comprises a film (43) and a transfer area (44), wherein the bonding layer (51), preferably in layer form, is applied to the film (43), and wherein the at least one application unit (40) is configured to transfer the bonding layer (51) in the transfer area (44) from the film (43) to the surface (15) of the sheet (11) and / or the surface (59) of the sheet element (50).

7. Method for producing a sheet metal element (50) with a predefinable sheet metal element shape, in particular a sheet metal element (50) for a stack of sheets (55), which may be, for example, an electrical steel stack, wherein the method comprises the following steps: i) forming the sheet metal element (50) in the sheet metal element shape from a sheet (11); ii) applying a compound layer (51) to at least one surface (15) of the sheet (11) and / or to at least one surface (59) of the sheet metal element (50), wherein the compound layer (51) comprises or consists of a compound composition, in particular an adhesive, wherein the compound layer (51) has a predefinable layer shape similar to or congruent with the sheet metal element shape, and wherein the compound layer (51) is applied in such a way that it maximally, preferably completely, covers the at least one surface (59) of the sheet metal element (50).

8. Method according to claim 7, characterized in that step i) comprises punching out the sheet metal element (50) from the sheet metal (11).

9. Method according to claim 7 or 8, characterized in that the application of the compound layer (51) is carried out using an application roller (41), wherein the The application roller (41) has a surface with at least one negative shape (45) of the layer shape and / or the sheet element shape, and / or is carried out using a film (43), wherein the bonding layer (51) to be applied, preferably in the layer shape, is applied to the film (43) and is transferred in a transfer area (44) from the film (43) to the surface (15) of the sheet (11) and / or the surface (59) of the sheet element (50).

10. Method for producing a stack of sheet metal (55), in particular a stack of electrical steel, wherein the method comprises the following steps: i) producing at least two sheet metal elements (50) according to the method of any one of claims 7 to 9; ii) bringing together the at least two sheet metal elements (50) such that a connection, in particular an adhesive connection, is formed between the at least two sheet metal elements (50).

11. Method according to claim 10, characterized in that the at least two sheet metal elements (50) are aligned in alignment before forming the connection, in particular the adhesive connection.

12. Method according to claim 10 or 11, characterized in that the formation of the connection, in particular the adhesive connection, is carried out by heating at least one bonding layer (51) and / or pressing the at least two sheet metal elements (50) together and / or chemically activating a bonding composition.

13. Sheet metal element (50) with a predefinable sheet metal element shape, in particular a sheet metal element (50) for a sheet metal stack (55), which may be, for example, an electrical steel stack, wherein the sheet metal element (50) has a bonding layer (51) with a predefinable layer shape on at least one surface (59), wherein the surface (59) is partially covered by the bonding layer (51), wherein the bonding layer (51) comprises or consists of a bonding composition, in particular an adhesive, and wherein the layer shape is at least similar, preferably almost congruent, to the sheet element shape.

14. Sheet metal element (50) according to claim 13, characterized in that at least 70%, preferably 85%, particularly preferably between 90 and 99% of the at least one surface (59) of the sheet metal element (50) is covered by the bonding layer (51).

15. Use of a sheet metal element (50) according to claim 13 or 14 for the production of a sheet metal stack (55), which may be, for example, an electrical steel stack.

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