# US 11,309,776 B2 · Manufacturing method of core for rotary electric machine > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,309,776 B2 - Document ID: US11309776B2 - Status: Granted - Kind: B2 - Application number: 16/637,404 - Filed: 2018-09-28 - Published: 2020-06-11 - Granted: 2022-04-19 - Earliest claimed: 2017-09-29 - Assignees: Aisin Corporation - Applicants: Aisin Corporation - Inventors: Masayuki Maki; Tetsuya Matsubara - Web page: https://patentgrep.com/patent/US11309776B2 ## CPC - B21D 28/22: Notching the peripheries of circular blanks, e.g. laminations for dynamo-electric machines - H02K 15/03: having permanent magnets - B21D 28/26: in sheets or flat parts - H02K 1/16: Stator cores with slots for windings - H02K 1/165: {Shape, form or location of the slots} - H02K 1/276: Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] - H02K 1/2766: {having a flux concentration effect} - H02K 15/021: Magnetic cores - H02K 15/12: Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) ## Abstract A manufacturing method of a core for a rotary electric machine includes: a step of forming a stator side release hole in at least a first portion of a portion of an electric steel plate in which a slot portion is formed; a step of forming a rotor side hole portion in at least a part of a portion of the electric steel plate in which a hole portion is formed; a step of forming a flattened portion; and a step of forming a rotor plate member and a stator plate member by blanking the electric steel plate. ## Claims ### Claim 1 A manufacturing method of a core for a rotary electric machine, said core includes a rotor core and a stator core, the method comprising the steps of: forming the rotor core by stacking a plurality of rotor plate members each having a hole portion, and forming the stator core by stacking a plurality of stator plate members each having a slot portion; forming a stator side release hole in at least a first portion of a portion of an electric steel plate in which the slot portion is formed; forming a rotor side hole portion in at least a part of a portion of the electric steel plate in which the hole portion is formed; forming a flattened portion between the stator side release hole and the rotor side hole portion, by decreasing a thickness of a portion of the electric steel plate that becomes a part of an outer periphery of the rotor core in a radial direction, after the forming the stator side release hole and the forming the rotor side hole portion; and forming the rotor plate member and the stator plate member by blanking the electric steel plate, after the forming the flattened portion. ### Claim 2 (depends on 1) The manufacturing method of a core for a rotary electric machine according to claim 1, wherein the forming the stator side release hole comprises integrally blanking the first portion and a connecting portion between a portion in which the flattened portion is formed and a portion in which the slot portion is formed. ### Claim 3 (depends on 2) The manufacturing method of a core for a rotary electric machine according to claim 2, wherein the forming the stator side release hole comprises integrally blanking the connecting portion and the first portion so that the connecting portion and the first portion have at least one shape of a U shape, an L shape, or an I shape when viewed in plan. ### Claim 4 (depends on 3) The manufacturing method of a core for a rotary electric machine according to claim 3, wherein the forming the stator side release hole comprises integrally blanking the connecting portion and the first portion while a width of the first portion in a circumferential direction is larger than a width of the connecting portion in the radial direction. ### Claim 5 (depends on 4) The manufacturing method of a core for a rotary electric machine according to claim 4, wherein the forming the stator side release hole comprises forming the stator side release hole so that the width of the connecting portion in the radial direction is equal to or more than 0.4 mm and equal to or less than 0.8 mm. ### Claim 6 (depends on 3) The manufacturing method of a core for a rotary electric machine according to claim 3, wherein the forming the stator side release hole comprises forming the stator side release hole so that the width of the connecting portion in the radial direction is equal to or more than 0.4 mm and equal to or less than 0.8 mm. ### Claim 7 (depends on 3) The manufacturing method of a core for a rotary electric machine according to claim 3, wherein the manufacturing method further comprises blanking a second portion after the forming the stator side release hole and before the forming the rotor plate member, the second portion including the stator side release hole and being at least a part of a portion of the electric steel plate in which the slot portion is formed. ### Claim 8 (depends on 7) The manufacturing method of a core for a rotary electric machine according to claim 7, wherein the blanking the second portion comprises integrally blanking the second portion that is at least a part of a portion in which a plurality of the slot portions are formed. ### Claim 9 (depends on 2) The manufacturing method of a core for a rotary electric machine according to claim 2, wherein the forming the stator side release hole comprises forming the stator side release hole so that the width of the connecting portion in the radial direction is equal to or more than 0.4 mm and equal to or less than 0.8 mm. ### Claim 10 (depends on 9) The manufacturing method of a core for a rotary electric machine according to claim 9, wherein the forming the stator side release hole comprises forming the stator side release hole so that the width of the connecting portion in the radial direction is equal to or more than 0.4 mm and equal to or less than 0.7 mm. ### Claim 11 (depends on 2) The manufacturing method of a core for a rotary electric machine according to claim 2, wherein the manufacturing method further comprises blanking a second portion after the forming the stator side release hole and before the forming the rotor plate member, the second portion including the stator side release hole and being at least a part of a portion of the electric steel plate in which the slot portion is formed. ### Claim 12 (depends on 11) The manufacturing method of a core for a rotary electric machine according to claim 11, wherein the blanking the second portion comprises integrally blanking the second portion that is at least a part of a portion in which a plurality of the slot portions are formed. ### Claim 13 (depends on 1) The manufacturing method of a core for a rotary electric machine according to claim 1, wherein the forming the stator side release hole comprises forming the stator side release hole in the first portion having a width in the circumferential direction that is smaller than the width of the slot portion in the circumferential direction. ### Claim 14 (depends on 1) The manufacturing method of a core for a rotary electric machine according to claim 1, wherein the manufacturing method further comprises blanking a second portion after the forming the stator side release hole and before the forming the rotor plate member, the second portion including the stator side release hole and being at least a part of a portion of the electric steel plate in which the slot portion is formed. ### Claim 15 (depends on 14) The manufacturing method of a core for a rotary electric machine according to claim 14, wherein the blanking the second portion comprises integrally blanking the second portion that is at least a part of a portion in which a plurality of the slot portions are formed. ### Claim 16 (depends on 15) The manufacturing method of a core for a rotary electric machine according to claim 15, wherein the forming the rotor plate member and the stator plate member comprises blanking the stator plate member from the electric steel plate after blanking the rotor plate member from the electric steel plate by cutting off a portion, which is different from the stator side release hole and the second portion, of the electric steel plate which becomes the outer periphery of the rotor core, after the blanking the second portion. ### Claim 17 (depends on 16) The manufacturing method of a core for a rotary electric machine according to claim 16, wherein the forming the rotor plate member and the stator plate member comprises blanking the stator plate member from the electric steel plate after forming the slot portion by integrally blanking the slot portions and a portion from which the portion that becomes the outer periphery of the rotor core is cut off, after the blanking the rotor plate member from the electric steel plate. ### Claim 18 (depends on 14) The manufacturing method of a core for a rotary electric machine according to claim 14, wherein the forming the rotor plate member and the stator plate member comprises blanking the stator plate member from the electric steel plate after blanking the rotor plate member from the electric steel plate by cutting off a portion, which is different from the stator side release hole and the second portion, of the electric steel plate which becomes the outer periphery of the rotor core, after the blanking the second portion. ### Claim 19 (depends on 18) The manufacturing method of a core for a rotary electric machine according to claim 18, wherein the forming the rotor plate member and the stator plate member comprises blanking the stator plate member from the electric steel plate after forming the slot portion by integrally blanking the slot portions and a portion from which the portion that becomes the outer periphery of the rotor core is cut off, after the blanking the rotor plate member from the electric steel plate. ### Claim 20 (depends on 1) The manufacturing method of a core for a rotary electric machine according to claim 1, wherein the forming the rotor side hole portion is a step of forming a rotor side release hole portion in a part of a portion of the electric steel plate in which the hole portion is formed.