# US 8,786,158 B2 · Continuously formed annular laminated article and method for its manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,786,158 B2 - Document ID: US8786158B2 - Status: Granted - Kind: B2 - Application number: 13/212,529 - Filed: 2011-08-18 - Published: 2012-02-23 - Granted: 2014-07-22 - Earliest claimed: 2010-08-19 - Assignees: L. H. Carbide Corporation - Applicants: Thomas R. Neuenschwander; Barry A. Lee; Trevor Hirst - Inventors: Thomas R. Neuenschwander; Barry A. Lee; Trevor Hirst - Web page: https://patentgrep.com/patent/US8786158B2 ## CPC - H02K 15/095: by laying conductors around salient poles - H02K 1/148: {Sectional cores (H02K1/141 takes precedence)} - H02K 15/022: with salient poles - Y02P 80/30: Reducing waste in manufacturing processes; Calculations of released waste quantities - Y10T 29/49009: Dynamoelectric machine - Y10T 29/49078: Laminated - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces. As the continuous strip is formed, it is wound about the rotary carousel with progressive pivoting of the body segments about the hinge portions to capture the protruding ends of the pole pieces within the recesses, with continued winding of the strip in a helical fashion around the rotary carousel continuing until a desired height is reached that is substantially equivalent to the height of the pole pieces. The strip is then cut, and the resulting annular part is welded at one or more locations to secure the components together. ## Claims ### Claim 1 A method of forming a laminated annular article having a central longitudinal axis, comprising the steps of: forming a plurality of pole pieces by forming, stacking, and interlocking a plurality of individual laminations in a first die assembly; loading the plurality of pole pieces onto a rotary carousel; forming a core portion as a continuous strip in a second die assembly separately from the pole pieces, the continuous strip including a plurality of body segments separated by gaps, the body segments connected via hinge portions; and rotating the carousel with concurrent winding of the strip around the carousel to progressively capture distal ends of the pole pieces within the gaps by pivoting the body segments about the hinge portions, with the core portion formed of a plurality of layers of the strip material and the hinge portions in successive layers aligned with one another along a direction parallel with the central longitudinal axis. ### Claim 2 (depends on 1) The method of claim 1, wherein said step of forming a continuous strip occurs concurrently with said step of rotating the carousel. ### Claim 3 (depends on 1) The method of claim 1, further comprising, after said step of rotating the carousel, the additional step of: repeating said step of rotating the carousel throughout a plurality of rotations to helically wind the strip around the carousel and progressively build helical layers of the strip around the pole pieces. ### Claim 4 (depends on 3) The method of claim 3, further comprising the additional step of vertically indexing the carousel with each rotation of the carousel. ### Claim 5 (depends on 1) The method of claim 1, wherein said step of rotating the carousel further comprises vertically indexing the carousel. ### Claim 6 (depends on 1) The method of claim 1, wherein said step of rotating the carousel further comprises capturing a convex profile of the distal ends of the pole pieces within a concave profile of the gaps. ### Claim 7 (depends on 1) The method of claim 1, further comprising, after said rotating the carousel step, the additional steps of: cutting the strip; and securing ends of the strip to the body segments. ### Claim 8 (depends on 1) The method of claim 1, further comprising, prior to said loading step, the additional step of: providing electrical windings about the pole pieces. ### Claim 9 An annular laminated article having a central longitudinal axis, comprising: an annular core portion formed of a plurality of material layers, said core portion including a plurality of body segments connected by hinge portions in said layers, said hinge portions of successive layers aligned with one another along a direction parallel with said longitudinal axis; and a plurality of pole pieces separate from said core portion, each said pole piece including an end portion captured between an adjacent pair of said body segments. ### Claim 10 (depends on 9) The annular laminated article of claim 9, wherein said end portions of said pole pieces have a convex profile, said end portions captured within concave recesses between respective adjacent pairs of said body segments. ### Claim 11 (depends on 9) The annular laminated article of claim 9, wherein said pole pieces are each formed of a plurality of material layers. ### Claim 12 (depends on 11) The annular laminated article of claim 11, wherein said pole pieces are each formed of a stack of interlocked laminations. ### Claim 13 (depends on 11) The annular laminated article of claim 11, wherein said core portion is formed of a single, helical strip. ### Claim 14 (depends on 9) The annular laminated article of claim 9, wherein said core portion is formed of a first metal or metal alloy, and said pole pieces are formed of a second metal or metal alloy different from said first metal or metal alloy. ### Claim 15 (depends on 9) The annular laminated article of claim 9, wherein said core portion and said pole pieces are each formed of a metal or metal alloy, said core portion including a grain having a first direction, and at least one of said pole pieces including a grain having a second direction different than said first direction. ### Claim 16 (depends on 9) The annular laminated article of claim 9, wherein said end portions of said pole pieces are aligned with respective said hinge portions along a plurality of respective radial directions perpendicular to said longitudinal axis. ### Claim 17 (depends on 9) The annular laminated article of claim 9, wherein recesses are defined between said adjacent pairs of said body segments, said recesses extending parallel to said central longitudinal axis of said annular laminated article, and wherein said end portions of said pole pieces are elongate and are captured within said recesses. ### Claim 18 (depends on 17) The annular laminated article of claim 17, wherein said end portions of said pole pieces are aligned with respective said hinge portions along a plurality of respective radial directions perpendicular to said longitudinal axis. ### Claim 19 (depends on 11) The annular laminated article of claim 11, wherein recesses are defied between said adjacent pairs of said body segments, said recesses extending parallel to said central longitudinal axis of said annular laminated article, and wherein said end portions of said pole pieces are elongate and are captured within said recesses. ### Claim 20 (depends on 19) The annular laminated article of claim 19, wherein said end portions of said pole pieces are aligned with respective said hinge portions along a plurality of respective radial directions perpendicular to said longitudinal axis.