Method for Producing Plate Packs

Abstract

Plate packs are produced from a sheet-like starting product (1), which is cut to form plates, which are stacked to form a plate pack. The plates within the plate stack are joined to one another by a bonding agent. The bonding agent used is a cyanoacrylate adhesive with a high temperature stability rating. It is applied to a wetting layer (14) for the adhesive. The wetting layer (14) is formulated to a pH in a region >7. The cyanoacrylate adhesive with a high temperature stability rating is able to spread on the wetting layer (14) such that effective wetting takes place, thus achieving quick and secure joining of the plates to one another.

Claims

1.-16. (canceled)

17. A method for producing lamination packs, the method comprising: punching laminations from a flat starting product; stacking the laminations to a lamination stack; connecting the laminations in the lamination stack to each other by a high temperature-resistant cyanoacrylate adhesive applied to a wetting layer provided on the laminations and adjusted to a pH value in a range >7.

18. The method according to claim 17, further comprising preparing the wetting layer from dipropylene glycol, distilled and/or demineralized and/or deionized water, and, as needed, at least one additive.

19. The method according to claim 18, further comprising selecting the at least one additive from the group consisting of diamond; polyglycol oil; corrosion protection additives; and alkaline additives; and combinations thereof.

20. The method according to claim 18, further comprising preparing the wetting layer to contain between approximately 30% to approximately 75% by weight distilled and/or demineralized and/or deionized water and approximately 25% to approximately 70% by weight dipropylene glycol.

21. The method according to claim 18, further comprising selecting a proportion of the at least one additive to be between 0% and approximately 20% by weight.

22. The method according to claim 17, further comprising spraying the wetting layer onto the starting product.

23. The method according to claim 17, further comprising brushing the wetting layer onto the starting product.

24. The method according to claim 17, further comprising applying the wetting layer by polishing onto the starting product.

25. The method according to claim 17, further comprising applying the wetting layer onto an entire surface of the starting product.

26. The method according to claim 17, further comprising applying the wetting layer onto a first face of the starting product and a second face of the starting product.

27. The method according to claim 17, further comprising applying the wetting layer in an advancing direction of the starting product upstream of a punching device onto the starting product.

28. The method according to claim 17, further comprising applying the wetting layer by at least one application unit, provided at a punching tool, onto the starting product.

29. The method according to claim 17, further comprising providing an application unit for the high temperature-resistant cyanoacrylate adhesive at a punching tool.

30. The method according to claim 17, further comprising applying the high temperature-resistant cyanoacrylate adhesive and the wetting layer onto the starting product immediately prior to punching.

31. The method according to claim 17, further comprising applying the high temperature-resistant cyanoacrylate adhesive and the wetting layer onto the laminations immediately after punching.

32. The method according to claim 17, further comprising providing the starting product as a strip-shaped starting product and applying the wetting layer onto the strip-shaped starting product, in an advancing direction of the strip-shaped starting product (1), after coating the strip-shaped starting product and prior to winding the strip-shaped starting product onto a coiler.

33. The method according to claim 17, further comprising providing the starting product as a strip-shaped starting product and applying the wetting layer onto the strip-shaped starting product, in an advancing direction of the starting product, prior to splitting the strip-shaped starting product.

Description

[0028] The invention will be explained in more detail with the aid of some embodiments illustrated in the drawings. It is shown in:

[0029] FIGS. 1 to 3 in schematic illustration, respectively, different facilities for performing the method according to the invention;

[0030] FIG. 4 in schematic and enlarged illustration a section of a lamination pack which is lying in a braking unit of a punching device;

[0031] FIG. 5 a section of a punching device in the region of the braking unit;

[0032] FIG. 6 in greatly enlarged illustration, in section as well as in plan view, an electric strip or an electric sheet which is provided on both faces with a wetting layer;

[0033] FIG. 7 and FIG. 8 in an illustration corresponding to FIG. 6 a second embodiment of an electric sheet or electric strip;

[0034] FIG. 9 in schematic illustration the electric sheet or electric strip according to FIGS. 7 and 8 in a punching tool whose tool top part is in a starting position;

[0035] FIG. 10 in an illustration corresponding to FIG. 9 the tool top part in its end position wherein a part of the contact area between the wetting layer and a tool bottom part is illustrated greatly enlarged;

[0036] FIG. 11 in schematic illustration a device for applying a coating and a wetting layer onto an electric strip;

[0037] FIG. 12 in an illustration corresponding to FIG. 11 a second embodiment for applying a wetting layer onto an electric strip.

[0038] FIG. 1 shows in schematic illustration a device with which laminations 2 are cut from an electric strip 1 or an electric sheet in a known manner (FIG. 5). In an exemplary fashion, FIG. 5 shows a punch 3 of a punching device 11 with which the laminations 2 are punched from the electric strip 1. They are stacked to a lamination pack 5 in a chamber 4 of the punching device 11. The chamber 4 extends through a bottom die 6 of the punching device 11. As is known, a braking unit 7 is located in the chamber 4 which is of an annular configuration and exerts on the laminations 2 or the lamination pack 5 a radial braking force 8 in the known manner. This braking force is so high that the punch 3 can push the respectively punched lamination 2 with sufficient pressure onto the lamination pack 5 located in the chamber 4 so that the laminations 2 lying on top of each other can be fixedly connected to each other in a way to still be described. In FIG. 5, it is shown in an exemplary fashion that, between neighboring laminations 2 within the lamination pack 5, adhesive dots 9 are located by means of which the laminations 2 lying on top of each other are fixedly connected to each other.

[0039] In addition to the adhesive connection, the laminations 2 lying on top of each other can also be connected with form fit to each other, for example, by means of raised portions pushed out of the lamination or partially punched-out tongues which engage corresponding recesses or cutouts of the neighboring lamination, respectively.

[0040] The lamination pack 5 is employed for producing rotors and/or stators of electric motors as well as of generators also.

[0041] As can be seen in FIG. 1, the electric strip 1 is coiled on a coiler 10 that is rotatable about its axis. The electric strip 1 which is decoiled from the coiler 10 is guided through a straightening apparatus (not illustrated) by means of which the electric strip 1 is straightened for the subsequent punching process. Downstream of the straightening apparatus, the electric strip reaches the punching device 11 in which the laminations 2 are punched in the described way from the electric strip 1.

[0042] Also, two or more electric strips 1 can be guided adjacent to each other into the punching device 11 so that the laminations 2 can be punched simultaneously from the individual electric strips 1. Furthermore, it is possible to punch the laminations 2 in the electric strip 1 not only in one track but, for example, also in two tracks.

[0043] The punching device 11 is provided with one or a plurality of corresponding punching tools in the form of the punches 3. The laminations 2 which are punched by them reach in the described way the chamber 4 into which the laminations 2 are pushed by the punch 3 immediately after punching. The chamber 4 forms the receptacle for the lamination pack 5. The braking unit 7 ensures that the laminations 2 are contacting with their edge with friction the inner wall of the chamber 4 so that they cannot fall out of the chamber 4. For each punching stroke, the respectively punched lamination 2 is pushed downwardly onto the laminations which are already located within the chamber 4. A support plunger (not illustrated) is projecting into the chamber 4 and the laminations 2 are stacked on it to the lamination pack 5. With each punching stroke, the support plunger is moved step-by-step in downward direction so that the respectively punched lamination 2 can be moved so far downwardly into the chamber 4 that the subsequent lamination 2 to be punched can be reliably pushed into the chamber 4.

[0044] In case of a plurality of electric strips 1 guided simultaneously through the punching device 11, it is advantageous when each electric strip 1 has correlated therewith one chamber 4 so that in the punching device 11 a plurality of lamination packs can be stacked adjacent to each other at the same time. However, there is also the possibility to provide in the punching device 11 only one chamber 4 into which the laminations 2 which are punched from different electric strips 1 are transported by means of a transport device, for example, a rotary unit, into the area above the chamber 4 and then are pushed into the chamber 4. Such a transport device is in particular advantageous when the laminations 2 are punched in adjacently positioned tracks from an electric strip 1. Then, the adjacently positioned laminations 2 can be transported with such a transport unit into the only chamber 4.

[0045] Within the lamination pack 5, the laminations 2 lying on top of each other are fixedly connected by a bonding agent. In the exemplary embodiment according to FIG. 1, the bonding agent is applied by means of an application unit 12 onto the electric strip 1 in a known manner, still prior to punching the laminations 2. The bonding agent can be applied in different ways onto the electric strip 1, for example, contactless by spraying but also by application by means of a drum, a roller and the like. In this context, the bonding agent can be applied areally but also only in dots or strip-like onto the electric strip 1. Depending on the size of the lamination 2, a different quantity of bonding agent is required in order to connect the laminations 2 fixedly to each other within the lamination pack 5. Preferably, the bonding agent is applied in dots onto the electric strip 1.

[0046] As a bonding agent, high temperature-resistant cyanoacrylate adhesives are employed. Ethyl or allyl cyanoacrylates are conceivable as such adhesives. They are solvent-free, cold-curing 1-component adhesives which quickly polymerize and cure within a short period of time. These cyanoacrylate adhesives have a high temperature resistance which reaches at least 130? C., preferably up to approximately 150? C. and higher.

[0047] Allyl cyanoacrylate can be exposed to even higher temperatures at minimal loads for short periods of time. After approximately two hours, the adhesive connection reaches a temperature resistance up to 250? C. Ethyl cyanoacrylates can also be used for short periods of time at higher temperatures when the loads are minimal.

[0048] The electric strip but also electric sheets used for producing the laminations 2 are provided with a coating 13 (FIG. 6) which forms an electrical insulation layer and is present at both faces of the electric strip 1. The electric insulation layers 13 have only a very minimal thickness which is within the ?m range. The insulation layers 13 are comprised preferably of purely organic or purely inorganic materials. However, hybrid coatings can be used also which are comprised of organic and inorganic proportions. Such insulation layers for electric strips 1 or electric sheets are known and are therefore not explained in detail. For forming these insulation layers 13, varnishes are applied onto the electric strip 1, which may exhibit different properties that have a positive effect on the cutting methods as well as the pack assembly or stacking of the laminations 2.

[0049] In order for the cyanoacrylate adhesive to ensure a reliable connection of laminations 2 lying on top of each other in the lamination pack 5, a wetting layer 14 is applied onto the insulation layer 13. It is configured such that a good wetting action is achieved with the cyanoacrylate adhesive, the pH value at the surface is >7, and the OH.sup.? proportion in the water is predominant. Due to the good wettability of the wetting layer 14, the adhesive drops do not form individual drops but spread areally on the wetting layer 14. In this way, it is ensured that the laminations 2 within the lamination pack 5 are connected reliably and fixedly to each other.

[0050] The wetting layer 14 in the embodiment according to FIG. 1 is applied in the region between the coiler 10 and the punching device 11 on both faces of the electric strip 1 by means of an appropriate application unit 15. The application can be realized by spraying, by brushing, or by polishing with the corresponding medium.

[0051] For producing the wetting layer 14, a lubricant is employed that contains dipropylene glycol as well as distilled and/or demineralized and/or deionized water. A preferred composition of the lubricant is: [0052] 30 to 75% by weight distilled and/or demineralized and/or deionized water 25 to 70% by weight dipropylene glycol.

[0053] Depending on the application situation, the lubricant can contain additionally polyglycol oil whose proportion can amount to between 0 and 20% by weight. When polyglycol oil is contained in the lubricant, the proportion of dipropylene glycol and/or of distilled and/or demineralized and/or deionized water can be reduced correspondingly.

[0054] As polyglycol oils, in particular polyethylene glycols (PEG), polyalkylene glycols (PAG), and polypropylene glycols (PPG) are conceivable. The pH value of the polyglycol values is within the alkaline range, i.e., above 7. Since the pH value of the wetting layer 14 is in the alkaline range, not only proper bonding of neighboring laminations 2 can be achieved in connection with the good wettability but also a very short curing time. In this way, high numbers of units can be achieved in the production of the laminations 2 or the lamination packs 5. Due to the use of the wetting layer 14, curing times of approximately one second can be achieved.

[0055] The additional lubricant has moreover further advantageous properties. For example, it can be used for increasing the tool service life in the punching process. Moreover, the lubricant serves for cooling the punching process.

[0056] In combination, the use of the described lubricant thus results in an effective wear reduction of the punching tools and in an improvement of the energy efficiency in the punching process due to the cooling action.

[0057] The described lubricant is water-soluble so that it is easy to handle. The wetting layer 14 also acts to inhibit corrosion protection. The electric strip 1 or also the electric sheet exhibits no corrosion even after weeks.

[0058] The described lubricant has moreover an excellent viscosity index. The viscosity of the lubricant decreases only minimally with increasing temperature so that it ensures constant properties even at higher temperatures.

[0059] In the described way, the lubricant contains deionized or also demineralized water. Also, a completely desalted water can be employed. Demineralized water can be obtained in a simple way from normal tap water by means of ion exchangers.

[0060] When completely desalted water is employed as an additive to polyglycol oil, the degree of purity is measured by measuring the conductivity. The conductivity measuring devices required for this are known. The lower the conductivity, measured in S/cm or ?S/cm, the fewer contaminants are contained in the water.

[0061] In order to achieve an optimal corrosion protection as well as excellent lubrication properties, the electric strip 1 is advantageously covered across its entire top and bottom faces by wetting layers 14. Due to the areal application, the punching tool of the punching device 11 is lubricated and cooled by means of the wetting layer 14. During the punching process, the wetting layer 14 is distributed by the corresponding punching tool across the cut surface in the electric strip 1 or in the electric sheet so that the cut surface is protected against corrosion.

[0062] FIGS. 7 and 8 show in a schematic illustration wetting layers 14 which comprise abrasive and fillers or solid bodies 16, for example, diamond grains. The fillers 16 are provided in distribution in the wetting layer 14. In addition to the described advantages of the wetting layer 14, an optimization, i.e., a reduction of the surface roughness of the laminations 2, is obtained by addition of the fillers 16. This optimization or reduction is the result of the punching process, as will be explained in more detail with the aid of FIGS. 9 to 10. In the embodiment according to FIG. 7, the fillers 16 project slightly past the wetting layer 14 while in the embodiment according to FIG. 8 they are embedded completely in the wetting layer 14.

[0063] FIG. 9 shows schematically a guide plate of a tool top part as well as a tool bottom part 18 of the punching device 11. Both tool parts 17, 18 each have a flat pressure side 19, 20.

[0064] The electric strip 1 or also the electric sheet with the wetting layers 14 applied to both its faces and the fillers 16 contained therein is resting on the pressure side 20 of the tool bottom part 18. The tool top part 17 is spaced from the electric strip 1. It is moved in the direction of arrow 21 (punching direction) downwardly in the direction toward the tool bottom part 18. The fillers 16 in the wetting layer 14 secure during the punching process the electric strip 1. As can be seen in FIG. 10 in greatly enlarged illustration for the tool bottom part 18, this is caused in that the fillers 16 which project partially past the top side of the wetting layer 14 get hooked in the pressure side 20 of the tool bottom part 18 as a result of the roughness of the pressure side 20. In the same way, also the fillers 16 get hooked in the roughness peaks of the pressure side 19 of the tool top part 17.

[0065] The described guide plate of the tool top part 17 can be provided in the punching tool itself. In principle, there is also the possibility of providing the guide plate separate from the punching tool in the punching device 11.

[0066] In the process according to FIG. 1, by means of the application unit 15 the wetting layer 14 is applied onto both faces of the electric strip prior to adhesive application. The additional lubricant polyglycol oil of the wetting layer 14 ensures that the good lubrication properties are effective in all punching operations. By means of the wetting layers 14 on both faces of the electric strip 1, a reproducible and reliable reaction of the cyanoacrylate adhesive as a result of the alkaline wetting layer 14 is also ensured. The cut surfaces which are produced during the punching process at the electric strip 1 are covered by the wetting agent in the described way so that these cut surfaces are protected against corrosion.

[0067] While in the embodiment according to FIG. 1 the application unit 12 for the adhesive is provided at the punching tool, the application unit 15 for the wetting layer 14 is also provided, together with the application unit 12 for the adhesive, at the punching tool in the embodiment according to FIG. 2. By means of the application unit 15, the wetting layer 14 is applied onto both faces of the electric strip 1 that is decoiled from the coiler 10. The application of the material of the wetting layers 14 is realized prior to the adhesive application. In this way, it is ensured that the cyanoacrylate adhesive can react reliably.

[0068] FIG. 3 shows schematically a further embodiment in which the application of the wetting medium and of the adhesive is carried out within the braking unit 7 of the punching device 11. In this case, onto the punched laminations 2 first the wetting layer 14 is applied and subsequently the adhesive is applied. The wetting layers 14 provide a high corrosion protection, also of the cut surfaces that are produced at the lamination by punching. On the wetting layers 14, the cyanoacrylate adhesive can react reproducibly and reliably. In FIG. 3, the application units 12 and 15 for the adhesive and the wetting layer material are again only schematically illustrated. The electric strip 1 is decoiled from the coiler 10.

[0069] FIG. 4 shows in schematic illustration the lamination pack 5 which is located within the braking unit 7. In the braking unit 7, at least one cooling circuit 22 is accommodated by means of which a cooling medium 23 is conveyed in order to cool the lamination pack 5. The cooling medium is located in a tank 24. Since the lamination pack 5 is formed in the braking unit 7 in the described way, there is sufficient time available in order to cool the laminations 2 or the lamination pack 5 and also to activate the cyanoacrylate adhesive. When the lamination pack 5 is removed from the braking unit 7, the laminations 2 are fixedly and reliably connected to each other.

[0070] FIG. 11 shows in schematic illustration a device with which the wetting layer 14 can be applied to the electric strip 1. The electric strip 1 is supplied coiled onto a coiler 10. The electric strip 1 is guided through a schematically illustrated straightening apparatus 25 with which the electric strip is straightened in the known manner. The electric strip 1 reaches subsequently a coating device 26 in which the coating 13 (FIG. 6) is applied onto the electric strip 1 on both faces. In advancing direction of the electric strip 1 downstream of the coating device 26, at least one application unit 15 is provided with which the wetting layer 14 is applied onto the coating 13 in the described way. The application unit 15 is provided such that it applies the wetting layer 14 to both faces of the electric strip 1. Subsequently, the electric strip 1 with the coating 13 and the wetting layer 14 is wound onto the coiler 10. It is then moved to the punching device 11 with which the laminations 2 are punched and stacked to the lamination pack 5 in the described way.

[0071] FIG. 12 shows schematically a device in which the electric strip 1 is decoiled from the drum 10 and guided through a splitting device 27. The electric strip 1, in contrast to the embodiment according to FIG. 11, is already provided with the coating 13. The electric strip 1 in advancing direction upstream of the splitting device 27 is provided by means of an application unit 15 with the wetting layer 14. In the splitting device 27, the electric strip 1 is split across its length in the known manner. The thus produced electric strips are coated on both faces, provided with the wetting layer 14 and are wound onto the coiler 10, respectively. The coiler 10 is then moved to the punching device 11, with which the laminations 2 are punched and the lamination packs 5 are produced in the described way.