Patent ID: 12224632

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

Example embodiments of apparatuses and methods for fabricating laminated cores according to the present disclosure will be described hereinafter with reference to the drawings. The example embodiments described herein are, of course, not intended to particularly limit the present invention. Elements and features having the same functions are denoted by the same reference characters, and description for the same elements and features will not be repeated or will be simplified as appropriate.

As illustrated inFIG.1, an apparatus10for fabricating a laminated core according to this example embodiment (hereinafter also referred to as a fabrication apparatus10) fabricates a laminated core8in which a plurality of iron core elements5(seeFIG.2) are laminated and bonded to each other. The fabrication apparatus10is a progressive press die. In the fabrication apparatus10, a strip metal sheet W is intermittently conveyed to a plurality of processing stages25(seeFIG.3) described later. The strip metal sheet W is, for example, a coil (strip thin steel sheet). The fabrication apparatus10includes a lower mold20, an upper mold40, a stripper plate60, an adhesive applicator70(seeFIG.5), and a controller90.

The lower mold20is fixed to a floor surface. As illustrated inFIG.3, the lower mold20includes the plurality of processing stages25. The processing stages25includes an inner shape punching stage25A, an adhesive applying stage25B, and an outer shape punching stage25C. The inner shape punching stage25A, the adhesive applying stage25B, and the outer shape punching stage25C are arranged in this order in a progressive direction D. The inner shape punching stage25A includes a first die plate22A described later, a first die23A, an inner shape punching die hole26A, and an inner shape punch45A (seeFIG.5). The outer shape punching stage25C includes a second die plate22C described later, a second die23C, an outer shape punching die hole26C, and an outer shape punch45C (seeFIG.5). The lower mold20includes a lower mold body21, a die plate22, and a die23. The die plate22and the die23are placed on the lower mold body21. The die plate22holds the die23. The die plate22includes the first die plate22A holding the first die23A and described later, and the second die plate22C holding the second die23C and described later. The die23includes the first die23A included in the inner shape punching stage25A, and the second die23C included in the outer shape punching stage25C. The die23has die holes26. The first die23A has the inner shape punching die hole26A serving as the die hole26. The second die23C has the outer shape punching die hole26C serving as the die hole26. An upper surface22T of the die plate22and an upper surface23T of the die23are located at the same or substantially the same height. More specifically, the upper surface22T of the first die plate22A and the upper surface23T of the first die23A are located at the same or substantially the same height as the upper surface22T of the second die plate22C and the upper surface23T of the second die23C. The lower mold body21includes the adhesive applying stage25B. The lower mold body21has an adhesive application through hole27.FIG.3does not show the adhesive applicator70(seeFIG.5).

The strip metal sheet W is intermittently conveyed to the lower mold20by a conveyor (not shown) located near the fabrication apparatus10. The strip metal sheet W is intermittently conveyed to the inner shape punching stage25A, the adhesive applying stage25B, and the outer shape punching stage25C in this order. The conveyor holds the strip metal sheet W in a wound state. The strip metal sheet W is conveyed to the lower mold20by an unillustrated unwinding device of the conveyor, and a remaining material of the pressed strip metal sheet W is conveyed from the lower mold20by an unillustrated winding device of the conveyor and wound by the winding device. Instead of the unwinding device and the winding device of the conveyor, the strip metal sheet W may be conveyed while being sandwiched between a pair of upper and lower rotation rolls respectively located at upstream and downstream sides of the fabrication apparatus10.

As illustrated inFIG.3, the die23of the lower mold20includes a plurality of lifters30. The lifters30bias the strip metal sheet W upward. While the strip metal sheet W is intermittently conveyed above the die plate22and the die23, the lifters30push the strip metal sheet W upward and hold the strip metal sheet W such that the strip metal sheet W is located above the upper surface22T of the die plate22and the upper surface23T of the die23by a predetermined distance. As illustrated inFIG.4, the lifters30are biased upward by biasing members32located on the die plate22. The biasing members32are, for example, coil springs. When the stripper plate60(seeFIG.1) moves downward and pushes the strip metal sheet W downward, the lifters30move downward against a biasing force of the biasing members32. Accordingly, the strip metal sheet W is pushed by the stripper plate60against the upper surface22T of the die plate22of the lower mold20(more specifically the upper surface22T of the first die plate22A and the upper surface22T of the second die plate22C) and the upper surface23T of the die23(more specifically the upper surface23T of the first die23A and the upper surface23T of the second die23C). On the other hand, when the stripper plate60moves upward and a pressing force of the stripper plate60is not applied to the strip metal sheet W any more, the lifters30move upward by a biasing force of the biasing members32. Accordingly, the lifters30hold the strip metal sheet W at a position above the lower mold20(more specifically the upper surface22T of the die plate22and the upper surface23T of the die23) by a predetermined distance. While the strip metal sheet W is intermittently conveyed, the strip metal sheet W moves above upper surfaces30A of the lifters30. The lower mold20also includes a restriction member28that restricts upward movement of the strip metal sheet W when the strip metal sheet W is lifted upward by the die23of the lower mold20and the lifters30. The restriction member28restricts an excessive increase of the distance between the strip metal sheet W and the lower mold20(more specifically the upper surface22T of the die plate22and the upper surface23T of the die23) to a predetermined distance or more.

As illustrated inFIG.5, the upper mold40is located above the lower mold20. The upper mold40is movable toward and away from the lower mold20. The upper mold40includes a plurality of punches45corresponding to the die holes26. The punches45include the inner shape punch45A and the outer shape punch45C. The inner shape punch45A is located above the inner shape punching die hole26A. The inner shape punch45A is insertable into the inner shape punching die hole26A. The outer shape punch45C is located above the outer shape punching die hole26C. The outer shape punch45C is insertable into the outer shape punching die hole26C. In the inner shape punching stage25A (seeFIG.3), after the upper mold40moves downward to approach the lower mold20, the strip metal sheet W is punched out by the inner shape punch45A and the inner shape punching die hole26A. Accordingly, inner shapes of the iron core elements5are defined in the strip metal sheet W. In the outer shape punching stage25C (seeFIG.3), after the upper mold40moves downward to approach the lower mold20, the strip metal sheet W is punched out by the outer shape punch45C and the outer shape punching die hole26C. Accordingly, outer shapes of the iron core elements5are defined in the strip metal sheet W to complete the iron core elements5(see alsoFIG.2), and the resulting iron core elements5are sequentially stacked in the outer shape punching die hole26C. As described later, since the lower surfaces of the completed iron core elements5are coated with an adhesive, when the iron core elements5are stacked, the iron core elements5stacked in the top-bottom direction are thereby bonded to each other.

As illustrated inFIG.5, the stripper plate60is included in the upper mold40. The stripper plate60is located at a position facing the die plate22of the lower mold20. The stripper plate60is movable upward and downward together with the upper mold40. The stripper plate60is movable downward to a lowest descending position LP (seeFIG.7C) that is the lowermost position. In punching the strip metal sheet W by the punches45, the stripper plate60restricts upward and downward movement of the metal sheet W at the lowest descending position LP. Even when the metal sheet W is located slightly above the lowest descending position LP, the stripper plate60can restrict upward and downward movements of the metal sheet W. When the stripper plate60moves to the lowest descending position LP, the stripper plate60pushes the strip metal sheet W that is being intermittently conveyed against the lower mold20(the die plate22and the die23in this example) such that the strip metal sheet W can be sandwiched between the stripper plate60and the lower mold20(the die plate22and the die23in this example). The stripper plate60pushes the strip metal sheet W against the upper surface22T of the die plate22and the upper surface23T of the die23. The stripper plate60has a punch insertion hole60A in which the inner shape punch45A is to be inserted, and a punch insertion hole60C in which the outer shape punch45C is to be inserted. When the upper mold40moves downward to cause the stripper plate60to push the strip metal sheet W against the die plate22and, in this state, the upper mold40further moves downward, the inner shape punch45A projects from the punch insertion hole60A to be inserted in the inner shape punching die hole26A, and the outer shape punch45C projects from the punch insertion hole60C to be inserted in the outer shape punching die hole26C.

As illustrated inFIG.3, the adhesive applicator70is included in the lower mold body21of the lower mold20. The adhesive applicator70is located between the inner shape punching stage25A and the outer shape punching stage25C. In this example embodiment, the expression “the adhesive applicator70is located between the inner shape punching stage25A and the outer shape punching stage25C” includes a case where the adhesive applicator70is located in the inner shape punching stage25A (e.g., the adhesive applicator70is located in the first die plate22A) and a case where the adhesive applicator70is located in the outer shape punching stage25C (e.g., the adhesive applicator70is located in the second die plate22C). In the example illustrated inFIG.3, a plurality of nozzles72of the adhesive applicator70are shown. The nozzles72are arranged at substantially regular intervals in a double-ring shape. The adhesive applicator70is located in the adhesive applying stage25B (see alsoFIG.5). More specifically, the adhesive applicator70is located in the adhesive application through hole27. The adhesive applicator70is located below the strip metal sheet W. The adhesive applicator70applies an adhesive onto a lower surface WL of the strip metal sheet W. The adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W while the strip metal sheet W is being conveyed from the inner shape punching stage25A to the outer shape punching stage25C. The adhesive applicator70according to this example embodiment applies the adhesive onto the lower surface WL of the strip metal sheet W by a non-contact application technique (e.g., jet dispensing or splaying). Examples of a liquid adhesive used in the adhesive applicator70include an epoxy adhesive, an acrylic adhesive, a silicon adhesive, and a urethane adhesive, and the liquid adhesive is not particularly limited as long as adhesiveness sufficient for obtaining the laminated core8is achieved. A method for curing the adhesive is not particularly limited, and examples of the curing method include a solvent evaporation type, a moisture curing type, a heat curing type, and a hardener mixed type.

As illustrated inFIGS.6A through6D, the adhesive applicator70includes a housing71, the nozzle72, a plunger73, and a supply tube74. The housing71includes an adhesive accommodating chamber71A that accommodates an adhesive. The housing71has an insertion hole71B in which the supply tube74is inserted. The adhesive accommodating chamber71A communicates with the insertion hole71B. The nozzle72is located in the housing71. The nozzle72communicates with the adhesive accommodating chamber71A. The nozzle72is located below the strip metal sheet W. A discharge port72A of the nozzle72is located below the upper surface22T of the die plate22and the upper surface23T of the die23that are uppermost surfaces of the lower mold20(seeFIG.5). The nozzle72ejects the adhesive onto the lower surface WL of the strip metal sheet W. The adhesive ejected from the discharge port72A of the nozzle72is applied onto the lower surface WL of the strip metal sheet W in the form of droplets. A portion of the plunger73is housed in the adhesive accommodating chamber71A of the housing. The plunger73slides in the adhesive accommodating chamber71A. The plunger73can open and close the insertion hole71B. The supply tube74is inserted in the insertion hole71B. The supply tube74is connected to an adhesive tank (not shown) that accommodates an adhesive. For example, when an application controller94of the controller90described later (seeFIG.1) drives a supply pump (not shown), for example, the adhesive is thereby supplied to the adhesive accommodating chamber71A through the supply tube74.

As illustrated inFIG.6A, while the adhesive applicator70does not operate, a major portion of the plunger73is housed in the adhesive accommodating chamber71A. At this time, since the insertion hole71B is closed by the plunger73, the adhesive accommodating chamber71A does not communicate with the insertion hole71B, and no adhesive is supplied to the adhesive accommodating chamber71A. As illustrated inFIG.6B, when a signal is supplied to the adhesive applicator70, the plunger73moves downward, and the insertion hole71B is opened so that the adhesive accommodating chamber71A communicates with the insertion hole71B. Accordingly, as indicated by arrow F1, the adhesive is supplied to the adhesive accommodating chamber71A through the supply tube74. As illustrated inFIG.6C, when filling of the adhesive accommodating chamber71A with the adhesive is completed, the plunger73moves upward. Accordingly, an adhesive G filling the adhesive accommodating chamber71A is discharged (ejected) from the nozzle72. At this time, the plunger73closes the insertion hole71B. As illustrated inFIG.6D, the adhesive G discharged (ejected) from the nozzle72is applied onto the lower surface WL of the strip metal sheet W, and the adhesive G adheres to the lower surface WL. When being applied (adhering) to the lower surface WL of the strip metal sheet W, the adhesive G ejected from the discharge port72A of the nozzle72in the form of droplets spreads over a wider range than an opening area of the discharge port72A.

As illustrated inFIG.1, the controller90is configured or programmed to control the upper mold40and the adhesive applicator70. The controller90includes, for example, a central processing unit (CPU) that executes an instruction of a control program, a ROM that stores programs to be executed by the CPU, a RAM that is used as a working area where programs are developed, and a storage device such as a memory that stores the programs and various types of data. The controller90is configured or programmed to include a movement controller92and the application controller94. The function of each unit of the controller90is implemented by a program. This program is downloaded through the Internet, for example. The program may be read from a recording medium such as a CD or a DVD. The function of each unit of the controller90may be implemented by a processor and/or a circuit.

The movement controller92is configured or programmed to control upward and downward movements of the stripper plate60. In this example embodiment, the movement controller92is configured or programmed to move the upper mold40upward and downward to thereby control upward and downward movements of the stripper plate60. The movement controller92is configured or programmed to control movements of the upper mold40toward and away from the lower mold20.

The application controller94is configured or programmed to control the adhesive applicator70. The application controller94is configured or programmed to control movement of the plunger73. While the stripper plate60is not located at the lowest descending position LP (seeFIG.7C) (more specifically, while the stripper plate60does not push the strip metal sheet W against the die plate22and the die23), the application controller94is configured or programmed to move the plunger73downward to complete filling of the adhesive accommodating chamber71A with the adhesive. While the stripper plate60is not located at the lowest descending position LP (seeFIG.7C), the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. While the stripper plate60does not push the strip metal sheet W against the lower mold20(the die plate22and the die23in this example), for example, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. The expression “while the stripper plate60does not push the strip metal sheet W against the lower mold20(i.e., the die plate22and the die23in this example) herein includes a case where no gap is present between the stripper plate60and the strip metal sheet W (i.e., the stripper plate60is in contact with the strip metal sheet W) and a gap is present between the strip metal sheet W and the upper surface22T of the die plate22and the upper surface23T of the die23as illustrated inFIG.7A, and a case where a gap is present between the stripper plate60and the strip metal sheet W (i.e., the stripper plate60is not in contact with the strip metal sheet W) as illustrated inFIG.7B. That is, while a gap is at least partially present at least one of between lower mold20and the metal sheet W or between the metal sheet W and the stripper plate60, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the metal sheet W. As illustrated inFIGS.7A and7B, while the stripper plate60does not push the strip metal sheet W against the lower mold20(the die plate22and the die23in this example), since the lifters30cause the strip metal sheet W to move upward, a gap is present between the strip metal sheet W and the lower mold20(the upper surface22T of the die plate22and the upper surface23T of the die23in this example). As illustrated inFIG.7C, in a case where the stripper plate60pushes the strip metal sheet W against the die plate22, no gap is present between the stripper plate60and the strip metal sheet W, and no gap is present between the strip metal sheet W and the lower mold20(the upper surface22T of the die plate22and the upper surface23T of the die23in this example).

While the stripper plate is not in contact with the strip metal sheet W, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. While the stripper plate60moves away from the lower mold20(i.e., while the stripper plate60moves upward), the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. While the stripper plate60moves toward the lower mold20(i.e., while the stripper plate60moves downward), the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. While conveyance of the strip metal sheet W is stopped, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. While the strip metal sheet W is conveyed (i.e., moves) from the inner shape punching stage25A to the outer shape punching stage25C, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W.

A non-limiting example of a method for fabricating the laminated core8will now be described. In this example embodiment, description will be given regarding a method for fabricating the laminated core8will while focusing on one of the iron core elements5included in the laminated core8.FIG.8is a flowchart depicting the method for fabricating the laminated core8. As shown inFIG.8, the method for fabricating the laminated core8includes a conveyance step (step S10), a descending step (step S20), an inner shape punching step (step S30), an ascending step (step S40), a conveyance step (step S50), a descending step (step S60), an ascending step (step S70), an adhesive applying step (step S80), a conveyance step (step S90), a descending step (step S100), an outer shape punching step (step S110), an ascending step (step S120), and a conveyance step (step S130). The conveyance step (step S10), the conveyance step (step S50), the conveyance step (step S90), and the conveyance step (step S130) are performed at the same or substantially the same time. The descending step (step S20), the descending step (step S60), and the descending step (step S100) are performed at the same or substantially the same time. The inner shape punching step (step S30) and the outer shape punching step (step S110) are performed at the same or substantially the same time. The ascending step (step S40), the ascending step (step S70), and the ascending step (step S120) are performed at the same or substantially the same time. As shown inFIG.9, in the method for fabricating the laminated core8according to this example embodiment, in one cycle in which the angle (crank angle) of the upper mold40passes a top dead point) (0°) and a bottom dead point (180°) and returns to the top dead point (360°) again, the conveyance steps (step S10, step S50, step S90, and step S130), the descending steps (step S20, step S60, and step S100), the inner shape punching step (step S30) and the outer shape punching step (step S110), the ascending steps (step S40, step S70, and step S120), the adhesive applying step (step S80), and the conveyance steps (step S10, step S50, step S90, and step S130) are performed in this order.

In the conveyance step (step S10), the strip metal sheet W is conveyed in a progressive direction D. A portion of the strip metal sheet W moves to a position above the inner shape punching stage25A.

In the descending step (step S20), when the upper mold40moves downward and the stripper plate60moves downward, the stripper plate60contacts the strip metal sheet W. When the upper mold40further moves downward, the stripper plate60thereby moves to the lowest descending position LP. At this time, in the inner shape punching stage25A, the strip metal sheet W is pushed by the stripper plate60against the upper surface22T of the die plate22and the upper surface23T of the die23. Accordingly, the stripper plate60, and the die plate22and the die23sandwich the strip metal sheet W.

In the inner shape punching step (step S30), while the stripper plate60is located at the lowest descending position LP, the strip metal sheet W is punched out by the inner shape punch45A to define an inner shape of the iron core element5. More specifically, when the upper mold40further moves downward, the strip metal sheet W pushed against the upper surface22T of the die plate22and the upper surface23T of the die23are punched out by the inner shape punch45A and the inner shape punching die hole26A so that an inner shape of the iron core element5is defined in the strip metal sheet W. In the inner shape punching step (step S30), the strip metal sheet W is sandwiched by the stripper plate60, and the die plate22and the die23. Step S30is performed in the middle of step S20.

In the ascending step (step S40), when the upper mold40moves upward and the stripper plate60moves upward, a pressing force of the stripper plate60against the strip metal sheet W decreases accordingly. Then, the lifters30cause the strip metal sheet W to move away from the upper surface22T of the die plate22and the upper surface23T of the die23. When the upper mold40further moves upward and the stripper plate60further moves upward, the stripper plate60is separated from the strip metal sheet W in the inner shape punching stage25A.

In the conveyance step (step S50), the strip metal sheet W is conveyed in the progressive direction D. A portion of the strip metal sheet W having the inner shape of the iron core element5moves to a position above the adhesive applying stage25B.

In the descending step (step S60), in a manner similar to step S20, in the adhesive applying stage25B, the strip metal sheet W is pushed by the stripper plate60against the upper surface22T of the die plate22and the upper surface23T of the die23. Accordingly, the stripper plate60, and the die plate22and the die23sandwich the strip metal sheet W.

In the ascending step (step S70), when the upper mold40moves upward and the stripper plate60moves upward, a pressing force of the stripper plate60against the strip metal sheet W decreases accordingly. Then, the lifters30cause the strip metal sheet W to be separated from the upper surface22T of the die plate22and the upper surface23T of the die23. When the upper mold40further moves upward and the stripper plate60further moves upward, the stripper plate60is separated from the strip metal sheet W in the adhesive applying stage25B.

In the adhesive applying step (step S80), the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. More specifically, while the stripper plate60is not located at the lowest descending position LP, the adhesive applicator70located below the strip metal sheet W applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. For example, while the stripper plate60is not in contact with the strip metal sheet W, the adhesive applicator70located below the strip metal sheet W applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S80, the adhesive is applied (ejected) onto a predetermined region of a portion of the lower surface WL of the strip metal sheet W having the inner shape of the iron core element5. Step S80may be performed after step S70or in the middle of step S70. While the stripper plate60does not push the strip metal sheet W against the die plate22and the die23, the adhesive applicator70may apply (eject) the adhesive onto the lower surface WL of the strip metal sheet W. That is, while a gap is at least partially present at least one of between the lower mold20and the metal sheet W or between the metal sheet W and the stripper plate60, the adhesive applicator70may apply (eject) the adhesive onto the lower surface WL of the strip metal sheet W. In the case where step S80is performed in the middle of step S70, step S80starts immediately after completion of step S60in the example shown inFIG.9, but step S80may start at an interval after completion of step S60. In step S80, while the stripper plate60moves away from the lower mold20(i.e., moves upward), the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S80, while conveyance of the strip metal sheet W is stopped, the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S80, while the metal sheet W is conveyed, the adhesive applicator70may apply (eject) the adhesive onto the lower surface WL of the strip metal sheet W. At this time, a conveyance speed of conveying the metal sheet W may be constant, or the conveyance speed may decrease while the adhesive is applied onto the lower surface WL of the metal sheet W.

In the conveyance step (step S90), the strip metal sheet W is conveyed in the progressive direction D. A predetermined portion of the strip metal sheet W to which the adhesive is applied moves to a position above the outer shape punching stage25C.

In the descending step (step S100), in a manner similar to step S20, the strip metal sheet W is pushed by the stripper plate60against the upper surface22T of the die plate22and the upper surface23T of the die23in the outer shape punching stage25C. Accordingly, the stripper plate60, and the die plate22and the die23sandwich the strip metal sheet W.

In the outer shape punching step (step S110), while the stripper plate60is located at the lowest descending position LP, the strip metal sheet W is punched out by the outer shape punch45C to define an outer shape of the iron core element5. More specifically, when the upper mold40further moves downward, the strip metal sheet W pushed against the upper surface22T of the die plate22and the upper surface23T of the die23is punched out by the outer shape punch45C and the outer shape punching die hole26C so that an outer shape of the iron core element5is defined in the strip metal sheet W. The resulting iron core element5is pushed by the outer shape punch45C and sequentially stacked in the outer shape punching die hole26C. Since the lower surfaces of the resulting iron core elements5are coated with the adhesive, when the iron core elements5are sequentially stacked on the iron core elements5already stacked in the outer shape punching die hole26C, the laminated core8including the plurality of iron core elements5stacked in the top-bottom direction and bonded to each other is thereby fabricated. In step S110, the strip metal sheet W is sandwiched between the stripper plate60, and the die plate22and the die23. Step S110is performed in the middle of step S100.

In the ascending step (step S120), when the upper mold40moves upward and the stripper plate60moves upward, a pressing force of the stripper plate60against the strip metal sheet W thereby decreases. Then, the lifters30separate the strip metal sheet W from the upper surface22T of the die plate22and the upper surface23T of the die23. When the upper mold40further moves upward and the stripper plate60further moves upward, the stripper plate60is separated from the strip metal sheet W in the outer shape punching stage25C.

In the conveyance step (step S130), the strip metal sheet W is conveyed in the progressive direction D. A portion of the strip metal sheet W having the outer shape of the iron core element5(i.e., remaining material) is conveyed to the outside of the fabrication apparatus10.

In the manner described above, in the apparatus10for fabricating a laminated core according to this example embodiment, while the stripper plate60is not located at the lowest descending position LP, the application controller94of the controller90is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. In the example described above, in applying the adhesive onto the lower surface WL of the strip metal sheet W from the adhesive applicator70, since the stripper plate60is not located at the lowest descending position LP, the distance between the strip metal sheet W and the adhesive applicator70is wide. Thus, the adhesive applied from the adhesive applicator70adheres to a wide range of the lower surface WL of the strip metal sheet W. Accordingly, the stacked iron core elements5are securely bonded to each other so that the laminated core8with high rigidity can be thereby fabricated.

In the apparatus10for fabricating a laminated core according to this example embodiment, while the stripper plate60does not push the metal sheet W against the lower mold20, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the metal sheet W. In this example, while the adhesive applicator70applies the adhesive onto the lower surface WL of the metal sheet W, since the stripper plate60does not push the metal sheet W, the distance between the strip metal sheet W and the adhesive applicator70is wide. Accordingly, the adhesive can be applied to a wide range of the lower surface WL of the metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, while a gap is at least partially present at least one of between the lower mold20and the metal sheet W or between the metal sheet W and the stripper plate60, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the metal sheet W. In this example, in applying the adhesive onto the lower surface WL of the metal sheet W from the adhesive applicator70, since the gap is present as described above, the distance between the strip metal sheet W and the adhesive applicator70is wide. Accordingly, the adhesive can be applied to a wide range of the lower surface WL of the metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, while the stripper plate60is not in contact with the strip metal sheet W, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. In this example, in applying the adhesive onto the lower surface WL of the strip metal sheet W from the adhesive applicator70, since the stripper plate60is not in contact with the strip metal sheet W, the distance between the strip metal sheet W and the adhesive applicator70further increases. Thus, the adhesive applied from the adhesive applicator70adheres to a wider range of the lower surface WL of the strip metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W while the stripper plate60moves away from the lower mold20. In this example, since the direction of an airflow generated when the stripper plate60moves and the direction of application of the adhesive coincide with each other, the adhesive can be more reliably applied onto the lower surface WL of the strip metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, while conveyance of the strip metal sheet W is stopped, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W. In this example, the adhesive can be more reliably applied to a predetermined position on the lower surface WL of the strip metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, the adhesive applicator70is located between the inner shape punching stage25A and the outer shape punching stage25C, and applies the adhesive onto the lower surface WL of the metal sheet W while the metal sheet W is conveyed from the inner shape punching stage25A to the outer shape punching stage25C. In this example, since the plurality of nozzles72of the adhesive applicator70can be arranged in a direction orthogonal to the progressive direction D of the metal sheet W in a plan view, for example, the inner shape punching stage25A and the outer shape punching stage25C can be placed in compact space in the progressive direction D. That is, the fabrication time can be shortened.

In the apparatus10for fabricating a laminated core according to this example embodiment, the adhesive applicator70includes the nozzle72that is located below the strip metal sheet W and ejects the adhesive onto the lower surface WL of the strip metal sheet W. In this example, since the nozzles72can eject the adhesive, the adhesive can be applied onto a wider range of the lower surface WL of the strip metal sheet W.

In the apparatus10for fabricating a laminated core according to this example embodiment, the discharge port72A of the nozzle72is located below the upper surface22T of the die plate22and the upper surface23T of the die23that are uppermost surfaces of the lower mold20. In this example, since the distance between the discharge port72A of the nozzle72and the lower surface WL of the strip metal sheet W in the top-bottom direction further increases, the adhesive can be applied onto a wider range of the lower surface WL of the strip metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), while the stripper plate60is not located at the lowest descending position LP, the adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W. In this example, in applying the adhesive onto the lower surface WL of the strip metal sheet W, since the stripper plate60is not located at the lowest descending position LP, the distance between the strip metal sheet W and the adhesive applicator70is wide. Thus, the adhesive applied from the adhesive applicator70adheres to a wide range of the lower surface WL of the strip metal sheet W. Accordingly, the laminated iron core elements5are securely bonded to each other so that the laminated core8with high rigidity can be thereby fabricated.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), while the stripper plate60does not push the metal sheet W against the lower mold20, the adhesive applicator70may apply the adhesive onto the lower surface WL of the metal sheet W. In this example, while the adhesive applicator70applies the adhesive onto the lower surface WL of the metal sheet W, since the stripper plate60does not push the metal sheet W, the distance between the strip metal sheet W and the adhesive applicator70is wide. Accordingly, the adhesive can be applied to a wide range of the lower surface WL of the metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), while a gap is at least partially present at least one of between the lower mold20and the metal sheet W or between the metal sheet W and the stripper plate60, the adhesive applicator70may apply the adhesive onto the lower surface WL of the metal sheet W. In this example, in applying the adhesive onto the lower surface WL of the metal sheet W from the adhesive applicator70, since the gap is present as described above, the distance between the strip metal sheet W and the adhesive applicator70is wide. Accordingly, the adhesive can be applied to a wide range of the lower surface WL of the metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), while the stripper plate60is not in contact with the strip metal sheet W, the adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W. In this example, in applying the adhesive onto the lower surface WL of the strip metal sheet W, since the stripper plate60is not in contact with the strip metal sheet W, the distance between the strip metal sheet W and the adhesive applicator70further increases. Thus, the adhesive applied from the adhesive applicator70adheres to a wider range of the lower surface WL of the strip metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), the adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W while the stripper plate60moves away from the lower mold20. In this example, since the direction of an airflow generated when the stripper plate60moves and the direction of application of the adhesive coincide with each other, the adhesive can be more reliably applied onto the lower surface WL of the strip metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), while conveyance of the strip metal sheet W is stopped, the adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W. In this example, the adhesive can be more reliably applied to a predetermined position on the lower surface WL of the strip metal sheet W.

In the method for fabricating a laminated core according to this example embodiment, in the adhesive applying step (step S80), the adhesive applicator70ejects the adhesive onto the lower surface WL of the strip metal sheet W. In this example, since the adhesive can be ejected, the adhesive can be applied to a wider range of the lower surface WL of the strip metal sheet W.

The foregoing description is directed to the example embodiments of the present disclosure. The example embodiments described above, however, are merely examples, and the present disclosure can be performed in various modes.

In the example embodiments described above, the adhesive applicator70applies the adhesive onto the lower surface WL of the strip metal sheet W by the non-contact application technique, but the present disclosure is not limited to this example. The adhesive applicator70may bring an adhesive bulging from the nozzles72into contact with the strip metal sheet W to transfer the adhesive onto the lower surface WL.

In the example embodiments described above, while the stripper plate60does not push the strip metal sheet W against the die plate22and the die23, the application controller94moves the plunger73downward to fill the adhesive accommodating chamber71A with the adhesive, but the present disclosure is not limited to this example. While the stripper plate60pushes the strip metal sheet W against the die plate22and the die23, the application controller94may move the plunger73downward to complete filling of the adhesive accommodating chamber71A with the adhesive. The application controller94may cause the plunger73to move downward and start filling of the adhesive accommodating chamber71A with the adhesive while the stripper plate60pushes the strip metal sheet W against the die plate22and the die23, whereas the application controller94may complete filling of the adhesive accommodating chamber71A with the adhesive while the stripper plate60does not push the strip metal sheet W against the die plate22and the die23.

In the example embodiments described above, the lower mold body21of the lower mold20, the die plate22, and the die23are separate components, but may be integrated as necessary. For example, the die plate22and the die23may be integrated, or the die plate22, the die23, and the lower mold body21may be integrated.

In the example embodiments described above, the upper surface23T of the die23and the upper surface22T of the die plate22are located at the same or substantially the same height, but the present disclosure is not limited to this example. For example, the upper surface23T of the die23may be located below the upper surface22T of the die plate22. In this case, the stripper plate60pushes the strip metal sheet W against the upper surface22T of the die plate22.

In the example embodiments described above, the die plate22and the die23are placed on the lower mold body21, but the present disclosure is not limited to this example. For example, the die plate22and the die23may be fitted in a recess that is recessed downward from the upper surface21T of the lower mold body21such that the upper surface21T of the lower mold body21, the upper surface22T of the die plate22, and the upper surface23T of the die23are located at the same or substantially the same height. In this case, the stripper plate60pushes the strip metal sheet W against the upper surface21T of the lower mold body21, the upper surface22T of the die plate22, and the upper surface23T of the die23.

In the example embodiments described above, in the method for fabricating the laminated core8, the adhesive applying step (step S80) is performed in the middle of or after the ascending step (step S70), but as shown inFIG.10, the adhesive applying step (step S180) may be performed in the middle of or before the descending step (step S60). In step S180, the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. More specifically, while the stripper plate60is not in contact with the strip metal sheet W, the adhesive applicator70located below the strip metal sheet W applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S180, the adhesive is applied (ejected) onto a predetermined region of a portion of the lower surface WL of the strip metal sheet W having the inner shape of the iron core element5. In step S180, while the stripper plate60does not push the strip metal sheet W against the die plate22and the die23, the adhesive applicator70may apply (eject) the adhesive onto the lower surface WL of the strip metal sheet W. In step S180, while the stripper plate60moves toward the lower mold20(i.e., moves downward), the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S180, while conveyance of the strip metal sheet W is stopped, the adhesive applicator70applies (ejects) the adhesive onto the lower surface WL of the strip metal sheet W. In step S180, while the metal sheet W is conveyed, the adhesive applicator70may apply (eject) the adhesive onto the lower surface WL of the strip metal sheet W.

In the example embodiments described above, while conveyance of the strip metal sheet W is stopped, the application controller94is configured or programmed to cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W, but the present disclosure is not limited to this example. While the strip metal sheet W is conveyed in the progressive direction D, the application controller94may cause the adhesive applicator70to apply the adhesive onto the lower surface WL of the strip metal sheet W.

In the example embodiments described above, when the stripper plate60moves to the lowest descending position LP, the stripper plate60pushes the metal sheet W against the lower mold20and sandwich the metal sheet W together with the lower mold20, but the present disclosure is not limited to this example. For example, when the stripper plate60moves to the lowest descending position LP, a gap enough to restrict upward and downward movements of the metal sheet W may be present between the lower surface of the stripper plate60and the upper surface of the lower mold20.

In the example embodiments described above, the plurality of nozzles72of the adhesive applicator70are arranged at substantially regular intervals in a double-ring shape, but the present disclosure is not limited to this example. For example, as illustrated inFIG.11, the plurality of nozzles72may be arranged at substantially regular intervals in a direction orthogonal to the progressive direction D in a plan view.

While example embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.