Segmented Laminated Core Assembly for Preserving Magnetic Properties

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Solution Overview

Problem

Existing methods for producing laminated cores, particularly those using different materials, result in significant deterioration of soft magnetic properties due to internal stresses and structural changes from welding and adhesive bonding, making assembly complex and unreliable.

Innovation Solution

A laminated core production method involving two distinct connection types: a first connection type within segments, such as welding, and a second connection type between segments, such as adhesive bonding, to minimize material stress and maintain magnetic properties, using materials like FeSi and CoFe alloys.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If welding is used to join lamination sheets to form a laminated core, then assembly is simplified and structural strength is improved, but soft magnetic properties deteriorate due to internal stresses and structural changes

Engineering Contradiction:

Improveassembly simplicityVSAvoidmagnetic properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The laminated core is divided into multiple segments, each comprising several lamination sheets stacked and joined together. This segmentation allows welding to be applied locally within segments rather than across the entire core, reducing the overall impact on magnetic properties while maintaining assembly simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different connection methods are applied to different parts of the structure: welding is used within segments where structural strength is needed, while adhesive bonding is used between segments where magnetic property preservation is prioritized. This local differentiation resolves the contradiction between assembly simplicity and magnetic property retention.

Inventive Principle:

Principle #3Local quality

2Reliability

If adhesive bonding is used to join lamination sheets, then soft magnetic properties are better preserved compared to welding, but assembly complexity increases and reliability decreases

Engineering Contradiction:

Improvemagnetic propertiesVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The core structure is segmented into multiple units that can be pre-assembled using welding (simplifying that portion of the process), then quickly bonded together using adhesive. This segmentation reduces the overall assembly complexity compared to bonding all sheets individually while preserving magnetic properties through minimal adhesive contact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines two connection methods (welding and adhesive bonding) into a hybrid approach: welding provides strong structural integrity within segments, while adhesive bonding efficiently joins segments together with minimal impact on magnetic properties. This merging resolves the contradiction between assembly ease and magnetic property preservation.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If thin lamination sheets are stacked and joined individually, then magnetic properties are maintained, but manufacturing effort and time increase significantly

Engineering Contradiction:

Improvemagnetic propertiesVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Multiple thin lamination sheets are grouped into segments of manageable size (e.g., 5-20 sheets per segment). These segments can be pre-assembled using efficient welding processes, then quickly bonded together. This segmentation dramatically reduces manufacturing effort compared to individual sheet assembly while maintaining magnetic properties through minimal adhesive usage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Segments are pre-assembled and prepared before final assembly of the complete laminated core. This preliminary action allows for optimized welding processes within segments and simplifies the final assembly step, significantly improving manufacturing efficiency while preserving magnetic properties through the adhesive bonding approach.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method allows for easier handling and assembly of thin lamination sheets, reducing material impairment and maintaining magnetic properties, resulting in improved performance and simplified production of laminated cores.

Implementation Method 1

a first connection type within segments, such as welding

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

a second connection type between segments, such as adhesive bonding

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 3

these easy-to-handle segments are annealed to adjust and set the magnetic properties of the basic material

Methodology Applied

Scientific EffectAnnealing: Annealing

Data Source

PatentUS12407199B2Laminated core with segments and lamination welded together, laminations made from FeSi alloy and CoFe alloy

Publication Date: 2025.09.02 VACUUMSCHMELZE GMBH & CO KG

AI summary

A laminated core comprising a plurality of segments is provided. The segments each comprise a plurality of soft magnetic lamination sheets that are stacked one on top of another in a direction of stacking and attached to one another by means of a first connection type to form a segment. The segments are attached by means of a second connection type to form a laminated core, the first and second connection types being different.