Efficiency in serial production

compacore® full-faced bonded lamination stacks have revolutionized electric motors. They consist of voestalpine premium electrical steel combined with a new, full-surface bonding process. The innovative voestalpine development sets new standards:

  • Guaranteed electromagnetic characteristics of the stacks
  • Energy efficiency and improved motor characteristics
  • Economical large-scale production

Based on compacore® Backlack  

At voestalpine, the special compacore® Backlack is applied in liquid form to the entire surface of the electrical steel strip in a very thin layer (thickness down to one tenth of a hair). The baking varnish hardens during heat treatment. The innovative heat treatment during the manufacturing process activates adhesive strength.

Inline production as an innovation  

The compacore® lamination stacks are produced entirely inline using a single tool. The punched lamination stacks are bonded across the entire surface in the tool without impairing the effectiveness of the insulation layer. The airtight bonding ensures that the baking varnish protects the individual lamination stacks against corrosion, reduces power losses and prevents the motor from developing frequency humming. Noises caused by vibrating laminations are a thing of the past. A specially developed inline measurement system makes it possible for voestalpine to measure and guarantee specified electromagnetic properties. Especially in more delicate components, compacore® offers new geometrical design possibilities. Large components can be produced using this technology in a highly stable manner.

The benefits are convincing.

Higher efficiency

By reducing thermal loss caused by unwanted electromagnetic fields and vibrations, the motor's efficiency increases.

Better thermal management

The full-faced bonding ensures complete insulation and reduces interlaminar iron losses. It also provides best axial heat transfer. There is no metallic contact between the lamination stacks, thus hot spots can be eliminated.

Increased vehicle range

Reduced iron losses ensure highest energy efficiency and increase the vehicle range for battery-powered mobile applications. 

Quieter motors

The full-faced bonding improves the vibration characteristics, resulting in a quieter motor. 

Enhanced resilience

The bonded lamination stack forms a compact monoblock. This provides higher mechanical resilience during assembly and operation.

More design freedom

As a result of the full-faced bonding, there are no joining locations that need to be considered in the component design. Diameters can be reduced, resulting in increased design freedom.

Machinable

The stacks can be processed by mechanical machining. For example, rotors can be easily balanced in this way, making balancing discs obsolete.

Downsizing & weight reduction

Design freedom and machinability allow designers to eliminate components, reduce the dimensions and lower the weight of the motor.

Efficient serial production

The innovative baked self-bonding varnish and inline manufacturing ensure excellent reproducibility for small and large-scale production series. 

More information

voestalpine Automotive Components Nagold GmbH & Co. KG
www.voestalpine.com/compacore