Embodiments are directed to a method of forming a magnetic stack arrangement of a laminated magnetic inductor having a high frequency peak quality factor (Q). A first magnetic stack is formed having one or more magnetic layers alternating with one or more insulating layers in a first inner region of a laminated magnetic inductor. A second magnetic stack is formed opposite a surface of the first magnetic stack in an outer region of the laminated magnetic inductor. A third magnetic stack is formed opposite a surface of the second magnetic stack in a second inner region of the laminated magnetic inductor. The insulating layers are formed such that a thickness of an insulating layer in the second magnetic stack is greater than a thickness of an insulating layer in the first magnetic stack.

In a method for manufacturing lamination stacks of controlled height in a tool, starting material is provided as continuous strip delivered from a coil or as an individual sheet. Laminations are punched from the starting material in several punching steps to a required contour of the laminations. A heat-curing adhesive is applied onto the laminations prior to performing a last punching step. The laminations are combined to a lamination stack. The laminations of the lamination stack are partially or completely heated in a lamination storage. The adhesive is liquefied by heating the lamination stack to build up adhesion and then solidified. Curing the adhesive at the liquefying temperature or solidifying the adhesive in the tool by cooling and subsequently heating the adhesive to a temperature below the liquefying temperature is possible so that the adhesive does not melt but undergoes further curing resulting in higher temperature stability.

In a method for manufacturing lamination stacks of controlled height in a tool, starting material is provided as continuous strip delivered from a coil or as an individual sheet. Laminations are punched from the starting material in several punching steps to a required contour of the laminations. A heat-curing adhesive is applied onto the laminations prior to performing a last punching step. The laminations are combined to a lamination stack. The laminations of the lamination stack are partially or completely heated in a lamination storage. The adhesive is liquefied by heating the lamination stack to build up adhesion and then solidified. Curing the adhesive at the liquefying temperature or solidifying the adhesive in the tool by cooling and subsequently heating the adhesive to a temperature below the liquefying temperature is possible so that the adhesive does not melt but undergoes further curing resulting in higher temperature stability.

A metal laminate includes a lamination of a first metal plate and a second metal plate. The first metal plate includes a caulking that exhibits a mountain shape protruding from a back surface side and recessed on a front surface side, and the second metal plate includes an accommodating portion configured to accommodate the caulking such that the caulking is fitted to the accommodating portion. The caulking includes a recessed portion provided on an inner concave surface of the caulking and recessed toward the back surface side of the first metal plate, and an abutting portion provided on an outer convex surface of the caulking and abutted against an inner surface of the accommodating portion at a position corresponding to the recessed portion. The abutting portion expands laterally from the outer convex surface toward the inner surface of the accommodating portion.

The invention relates to a method for producing a lamination stack, e.g. a stator package or a rotor package. The method comprises the following steps: A) providing a metal sheet (1) with an adhesive coating; B) transporting the metal sheet in an in-line system comprising a cutting means (4), a separating means (6) and an activation means (5, 5a 5b); C) cutting a molded part (2) with the cutting means (4); D) activating the adhesive coating; E) separating the molded part (2); F) placing the molded part (2); G) repeating steps C) to F), wherein the adhesive coating of some molded parts (8) is provided with a treatment fluid by means of a treatment device (9) in order to allow for target breaking points for separating a molded part stack (3, 3′). In some cases a subsequent compaction can be carried out by a compaction station (7). The invention also relates to a lamination stack and an electric machine.

The invention relates to a method for producing a lamination stack, e.g. a stator package or a rotor package. The method comprises the following steps: A) providing a metal sheet (1) with an adhesive coating; B) transporting the metal sheet in an in-line system comprising a cutting means (4), a separating means (6) and an activation means (5, 5a 5b); C) cutting a molded part (2) with the cutting means (4); D) activating the adhesive coating; E) separating the molded part (2); F) placing the molded part (2); G) repeating steps C) to F), wherein the adhesive coating of some molded parts (8) is provided with a treatment fluid by means of a treatment device (9) in order to allow for target breaking points for separating a molded part stack (3, 3′). In some cases a subsequent compaction can be carried out by a compaction station (7). The invention also relates to a lamination stack and an electric machine.

This electrical steel sheet is an electrical steel sheet in which at least part of either or both surfaces of a base steel sheet is coated with an insulation coating having an adhesive ability, wherein a logarithmic decrement of the insulation coating in a temperature range of 25 to 100° C. is 0.3 or less.

A transformer core includes two stacks, each of first thickness with ≥1 flat parts, the cutting directions rectilinear and parallel or perpendicular to one another, the stacks facing across a gap, the flat parts made of an austenitic FeNi alloy 30-80% Ni and 10% alloying elements, with a sharp {100} <001> cubic texture, the cutting directions of the flat parts parallel to the rolling or transverse direction, the flat parts having magnetic losses, for a maximum induction of 1 T, <20 W/kg at 400 Hz, producing apparent magnetostriction for maximum induction values and field directions as follows: 1.2 T<5 ppm, large side of the sample parallel to rolling direction; 1.2 T<5 ppm, large side of the sample parallel to transverse direction in the rolling plane; and 1.2 T<10 ppm, length direction parallel to intermediate direction 45° to rolling and transverse directions.

A transformer core includes two stacks, each of first thickness with ≥1 flat parts, the cutting directions rectilinear and parallel or perpendicular to one another, the stacks facing across a gap, the flat parts made of an austenitic FeNi alloy 30-80% Ni and 10% alloying elements, with a sharp {100} <001> cubic texture, the cutting directions of the flat parts parallel to the rolling or transverse direction, the flat parts having magnetic losses, for a maximum induction of 1 T, <20 W/kg at 400 Hz, producing apparent magnetostriction for maximum induction values and field directions as follows: 1.2 T<5 ppm, large side of the sample parallel to rolling direction; 1.2 T<5 ppm, large side of the sample parallel to transverse direction in the rolling plane; and 1.2 T<10 ppm, length direction parallel to intermediate direction 45° to rolling and transverse directions.

Metal laminate cores can be assembled with laser pin welding through a thickness of a first laminate into a second laminate and successively laser pin welding a plurality of second laminates, ending with a third laminate to form the core stack. The laser pin welds are located within an outer perimeter of one or more of the laminates. Such laminated cores are often utilized in electrical motors, generators, transformers, lighting and other applications. The laser pin welds can be selectively provided under the control of a processor to index about the parts and/or change in intensity or even skip certain parts so as to be able to begin and end cores for some embodiments while also facilitating manual and/or automated stacking/welding embodiments and/or relative rotation of the cores.