Stator Lamination Made of Steel Foil
AssigneeBorgWarner Inc.
InventorsDavid Fulton, Kirk Neet
Life of this patent
Estimating the term…
Abstract
A stator core incorporates thin laminations and and/or higher silicon material in order to further reduce eddy current losses. The stator core may be made from super thin Ductile High Silicon Steel (DHSS). The DHSS is provided as a foil that may be less than fifty microns thick, such as ten microns to forty microns thick. The foil may also be made in ribbons which are twenty-five to fifty mm wide.
Claims20
A core for an electric machine, the core defining an outer diameter and a plurality of inwardly extending teeth with slots formed between the teeth, the core comprising:
- a lamination stack comprising a plurality of lamination sheets, each lamination sheet of the plurality of lamination sheets comprising a substack of a plurality of foil sheets bonded together to form the lamination sheet, each foil sheet of the plurality of foil sheets in each substack having a thickness of less than fifty microns, wherein each lamination sheet is separated from an adjacent lamination sheet by an insulation layer.
A method of making a core for an electric machine comprising:
- forming a plurality of lamination sheets, wherein each of the plurality of lamination sheets is formed by:
- stacking a plurality of foil ribbons, each of the plurality of foil ribbons having a thickness of less than fifty microns;
- bonding the plurality of foil ribbons together to form a lamination sheet for the core that is greater than seventy-five microns;
- applying insulation to the lamination sheet;
- and
- forming the lamination sheet into a shape associated with the core;
- and
- stacking the plurality of formed lamination sheets to form at least a portion of the core for the electric machine.
Dependencies are inferred from the claim text.