Laminated core with welding mark, rotary electric machine having the same, and method for manufacturing laminated core with welding mark

Patent metadata

Field	Value
Publication number	US-11575284-B2
Application number	US-202016809139-A
Country	US
Kind code	B2
Filing date	Mar 4, 2020
Priority date	Apr 8, 2019
Publication date	Feb 7, 2023
Grant date	Feb 7, 2023

Abstract

A laminated core has a plurality of steel plates that are laminated in a thickness direction. The laminated core has a line shaped welding mark connecting a plurality of steel plates. The welding mark extends over the plurality of steel plates at the end face where the plurality of steel plates are exposed. The welding mark has a welding depth which fluctuates with a wavelength that is longer than the thickness of the steel sheet. The welding mark has a continuous portion in which the welding depth extends over a plurality of steel plates without fluctuation. Furthermore, the welding mark has a fluctuation portion in which the welding depth periodically fluctuates over a plurality of steel plates. The depth in the continuous portion is substantially equal to the depth in the fluctuation portion.

First claim

What is claimed is:

1. A laminated core comprising:
a plurality of steel plates laminated in a thickness direction; and
a line-shaped welding mark connecting the plurality of steel plates, the line-shaped welding mark extending over the plurality of steel plates at an end surface of the plurality of steel plates where the plurality of steel plates are exposed, and the line-shaped welding mark including a welding depth in a depth direction perpendicular to the thickness direction that fluctuates along a length direction of the line-shaped welding mark so that a line of intersection between the line-shaped welding mark and the plurality of steel plates is wavy and has a wavelength along the length direction that is longer than a thickness of one of the plurality of steel plates, wherein:
a width of the line-shaped welding mark is greater than the thickness of one of the plurality of steel plates at the end surface;
the line-shaped welding mark with respect to the depth direction includes a continuous portion extending without fluctuation in depth over the plurality of steel plates and a fluctuating portion whose depth fluctuates periodically over the plurality of steel plates; and
a depth of the continuous portion and a maximum depth of the fluctuating portion are substantially equal.

2. The laminated core claimed in claim 1 , wherein
the width of the line-shaped welding mark at the end surface of the plurality of steel plates fluctuates, and
a one-sided fluctuation width of the line-shaped welding mark is smaller than the thickness of one of the plurality of steel plates.

3. The laminated core claimed in claim 1 , wherein
the line-shaped welding mark is inclined with respect to the thickness direction.

4. The laminated core claimed in claim 1 , comprising
a plurality of welding marks, one of which is the line-shaped welding mark.

5. The laminated core claimed in claim 4 , wherein
the plurality of welding marks are arranged at equal intervals.

6. A rotary electric machine comprising:
a rotor core or a stator core, which is a laminated core comprising:
a plurality of steel plates laminated in a thickness direction; and
a line-shaped welding mark connecting the plurality of steel plates, the line-shaped welding mark extending over the plurality of steel plates at an end surface of the plurality of steel plates where the plurality of steel plates are exposed, and the line-shaped welding mark including a welding depth in a depth direction perpendicular to the thickness direction that fluctuates along a length direction of the line-shaped welding mark so that a line of intersection between the line-shaped welding mark and the plurality of steel plates is wavy and has a wavelength along the length direction that is longer than a thickness of one of the plurality of steel plates, wherein:

a width of the line-shaped welding mark is greater than the thickness of one of the plurality of steel plates at the end surface;
the line-shaped welding mark with respect to the depth direction includes a continuous portion extending without fluctuation in depth over the plurality of steel plates and a fluctuating portion whose depth fluctuates periodically over the plurality of steel plates;
a depth of the continuous portion and a maximum depth of the fluctuating portion are substantially equal; and
the welding depth of the line-shaped welding mark fluctuates along an axial direction of the rotor core or the stator core.

7. The laminated core claimed in claim 1 , wherein
the laminated core is one of a plurality of laminated cores arranged in a laminated manner.

8. A method for manufacturing a laminated core, the method comprising:
laminating a plurality of steel plates in a thickness direction;
generating pulses of welding energy by a welding device;
welding by applying the welding energy to a welding position of an end surface where the plurality of steel plates are exposed, thereby forming a line-shaped welding mark having a welding depth in a depth direction perpendicular to the thickness direction according to the welding energy; and
moving the welding position across the plurality of steel plates on the end surface, wherein
the welding and the moving form the line-shaped welding mark by a plurality of the pulses on the end surface, the line-shaped welding mark connecting the plurality of steel plates, the line-shaped welding mark extending over the plurality of steel plates at the end surface, and the line-shaped welding mark including the welding depth that fluctuates along a length direction of the line-shaped welding mark so that a line of intersection between the line-shaped welding mark and the plurality of steel plates is wavy and has a wavelength along the length direction that is longer than a thickness of one of the plurality of steel plates, and
the welding and the moving form the line-shaped welding mark so that
a width of the formed line-shaped welding mark is greater than the thickness of one of the plurality of steel plates at the end surface;
the formed line-shaped welding mark with respect to the depth direction includes a continuous portion extending without fluctuation in depth over the plurality of steel plates and a fluctuating portion whose depth fluctuates periodically over the plurality of steel plates; and
a depth of the continuous portion and a maximum depth of the fluctuating portion are substantially equal.

Assignees

• Denso Corp

Inventors

• Eto Jun
• Yamauchi Kazuki

Classifications

• H02K15/021 Primary

  Magnetic cores · CPC title

• H02K15/03

  having permanent magnets · CPC title

• H02K15/02

  of stator or rotor bodies · CPC title

• H02K1/276

  Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] · CPC title

• B23K26/0622

  by shaping pulses · CPC title