US 12,081,082 B2
Laminated core and method for producing a laminated core
Frederic Bäcker, Darmstadt (DE); and Jens Diehl, Langenselbold (DE)
Assigned to VACUUMSCHMELZE GMBH & CO. KG, Hanau (DE)
Filed by Vacuumschmelze GmbH & Co. KG, Hanau (DE)
Filed on Feb. 2, 2021, as Appl. No. 17/165,894.
Claims priority of application No. 10 2020 102 638.2 (DE), filed on Feb. 3, 2020.
Prior Publication US 2021/0328484 A1, Oct. 21, 2021
Int. Cl. H02K 15/02 (2006.01); B23K 26/0622 (2014.01); B23K 26/082 (2014.01); B23K 26/21 (2014.01); B23K 26/38 (2014.01); B32B 15/01 (2006.01); B32B 37/06 (2006.01); B32B 38/00 (2006.01); C22C 30/00 (2006.01); C22C 38/02 (2006.01); C22C 38/06 (2006.01); H01F 1/147 (2006.01); H02K 1/02 (2006.01); H02K 1/16 (2006.01)
CPC H02K 15/024 (2013.01) [B23K 26/0622 (2015.10); B23K 26/082 (2015.10); B23K 26/21 (2015.10); B23K 26/38 (2013.01); B32B 15/01 (2013.01); B32B 37/06 (2013.01); B32B 38/0004 (2013.01); C22C 30/00 (2013.01); C22C 38/02 (2013.01); C22C 38/06 (2013.01); H01F 1/147 (2013.01); H02K 1/02 (2013.01); H02K 1/16 (2013.01); B32B 2307/208 (2013.01); B32B 2310/0843 (2013.01); C22C 2202/02 (2013.01); Y10T 29/49009 (2015.01)] 20 Claims
OG exemplary drawing
 
1. A method for producing a laminated core, comprising:
completely separating a plurality of lamination sheets from a strip made of a soft magnetic alloy by laser sublimation cutting, the lamination sheets each having a first main surface and a second main surface opposing the first main surface and each having a thickness d,
stacking the second main surface of a first of the lamination sheets on the first main surface of a second of the lamination sheets in a direction of stacking, wherein the direction of stacking extends perpendicular to the main surfaces of the lamination sheets,
substance-to-substance joining of the second main surface of the first lamination sheet and the first main surface of the second lamination sheets by laser welding at a plurality of points, the laser welding forming a plurality of filler-free joints between the first and the second lamination sheets and being entirely surrounded by the second main surface of the first lamination sheet and the first main surface of the second lamination sheet,
subsequently stacking the second main surface of a further lamination sheet on the first main surface of the first lamination sheet in the direction of stacking,
substance-to-substance joining of the second main surface of the further lamination sheet and the first main surface of the first lamination sheet by laser welding at a plurality of points, the laser welding forming a plurality of filler-free joints between the further lamination sheet and the first lamination sheet that are entirely surrounded by the second main surface of the further lamination sheet and the first main surface of the first lamination sheet,
wherein the soft magnetic alloy comprises:
a FeSi-based alloy with 2 to 4.5 wt % of at least one element from the group comprising Si and Al, the rest Fe and unavoidable impurities, or
a CoFe-based alloy comprising 35 to 55 wt % Co and up to 2.5 wt % V, the rest Fe and unavoidable impurities, or
a CoFe-based alloy comprising 45 wt %≤Co≤52 wt %, 45 wt %≤Fe≤52 wt %, 0.5 wt %≤V≤2.5 wt %, the rest Fe and unavoidable impurities, or
a CoFe-based alloy comprising 35 wt %≤Co≤55 wt %, 0 wt %≤Ni≤0.5 wt %, 0.5 wt %≤V≤2.5 wt %, the rest Fe and unavoidable impurities, or
a CoFe-based alloy comprising 35 wt %≤Co≤55 wt %, 0 wt %≤V≤2.5 wt %, 0 wt %≤(Ta+2Nb)≤1 wt %, 0 wt %≤Zr≤1.5 wt %, 0 wt %≤Ni≤5 wt %, 0 wt %≤C≤0.5 wt %, 0 wt %≤Cr≤1 wt %, 0 wt %≤Mn≤1 wt %, 0 wt %≤Si≤1 wt %, 0 wt %≤Al≤1 wt %, 0 wt %≤B≤0.01 wt %, the rest Fe and unavoidable impurities, or
a CoFe-based alloy comprising 5 to 25 wt % Co, 0.3 to 5.0 wt % V, the rest Fe and unavoidable impurities,
wherein the strip and the first, second and further lamination sheets each comprise an insulating layer and the lamination sheets with the insulating layer are separated from the strip by laser sublimation, and
wherein the insulating layer comprises MgO or ZrO2.