Patent ID: 8209850

Claim:
A method for manufacturing pencil cores having a substantially circular cross-section, comprising the steps of: providing a continuous strip of electrical steel; cutting the continuous strip to create a plurality of starting strips as laminations each having a length longer than a desired length of the pencil cores being manufactured and having a strip width at least equal to or larger than a desired diameter of said cross-section of the pencil cores being manufactured, said starting strips being provided with a bonding layer either before or after the cutting into the starting strips; stacking the starting strips into a stack and heating and curing the stack to create a bonded stack; machining the bonded stack to said substantially circular cross-section; and without a de-burring operation and without a de-smearing operation after said machining, cutting the machined bonded stack to create a plurality of said pencil cores of said desired length without welds at end faces of the pencil cores to hold the laminations together.