Patents Assigned to L. H. Carbide Corporation
  • Patent number: 9685264
    Abstract: A stator core is formed from a continuous strip of wound sheet stock material, in which the sheet stock material is converted from the sheet stock to a formed material including winding slot cutouts. This strip of formed material is then wound into the stator core, with the winding slot cutouts in the formed material maintained at a substantially constant width throughout most of the radial extent of the resulting winding slots in the finished article. However, one or more of the radially innermost and radially outermost layers may define winding slot cutouts that are wider than the other winding slot cutouts. Where several radial layers are altered in this way, the cutout widths are progressively expanded such that the resulting winding slot has terminal ends with edges that are effectively “radiused” or rounded, thereby protecting windings near the edge of such slots.
    Type: Grant
    Filed: October 18, 2013
    Date of Patent: June 20, 2017
    Assignee: L.H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Patent number: 9479034
    Abstract: An apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces.
    Type: Grant
    Filed: June 13, 2014
    Date of Patent: October 25, 2016
    Assignee: L.H. Carbide Corporation
    Inventors: Thomas Neuenschwander, Barry A. Lee, Trevor Hirst
  • Patent number: 9099897
    Abstract: A method for securing the end sections of an annular laminated article, such as a stator core, which includes a plurality of serially joined sections, each section formed of a plurality of stacked, planar laminas. The article is initially manufactured in a liner form, and is then formed into an annular form with the end sections disposed adjacent one another. At least one tab associated with one of the end sections is displaced by a forming tool into a corresponding cavity of the other of the end sections to secure the end sections together. In another embodiment, a pair of tabs each associated with one of the end sections are respectively displaced toward one another and into corresponding respective cavities each associated with the other of the end sections to secure the end sections together.
    Type: Grant
    Filed: September 12, 2012
    Date of Patent: August 4, 2015
    Assignee: L.H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Publication number: 20140209728
    Abstract: A stator core is formed from a continuous strip of wound sheet stock material, in which the sheet stock material is converted from the sheet stock to a formed material including winding slot cutouts. This strip of formed material is then wound into the stator core, with the winding slot cutouts in the formed material maintained at a substantially constant width throughout most of the radial extent of the resulting winding slots in the finished article. However, one or more of the radially innermost and radially outermost layers may define winding slot cutouts that are wider than the other winding slot cutouts. Where several radial layers are altered in this way, the cutout widths are progressively expanded such that the resulting winding slot has terminal ends with edges that are effectively “radiused” or rounded, thereby protecting windings near the edge of such slots.
    Type: Application
    Filed: October 18, 2013
    Publication date: July 31, 2014
    Applicant: L.H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Patent number: 8786158
    Abstract: An apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces.
    Type: Grant
    Filed: August 18, 2011
    Date of Patent: July 22, 2014
    Assignee: L. H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee, Trevor Hirst
  • Publication number: 20140139067
    Abstract: A metal article, such as a stator core, is formed from a continuous strip of wound sheet stock material including winding slot cutouts. The winding slot cutouts are maintained at a substantially constant width throughout most of the radial extent of the winding slots in the finished article, except that one or more of the first and/or last wound layers (i.e., the radially innermost and radially outermost layers) may define winding slot cutouts that are wider than the other winding slot cutouts. Several radial layers may define cutout widths that are progressively expanded such that the resulting winding slot has terminal ends with edges that defining a stair-step profile that approximates a “radiused” or rounded edge. This rounded edge profile protects windings projecting radially into or outwardly from the winding slots near the edge of such slots.
    Type: Application
    Filed: October 17, 2013
    Publication date: May 22, 2014
    Applicant: L.H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Publication number: 20130062989
    Abstract: A method for securing the end sections of an annular laminated article, such as a stator core, which includes a plurality of serially joined sections, each section formed of a plurality of stacked, planar laminas. The article is initially manufactured in a liner form, and is then formed into an annular form with the end sections disposed adjacent one another. At least one tab associated with one of the end sections is displaced by a forming tool into a corresponding cavity of the other of the end sections to secure the end sections together. In another embodiment, a pair of tabs each associated with one of the end sections are respectively displaced toward one another and into corresponding respective cavities each associated with the other of the end sections to secure the end sections together.
    Type: Application
    Filed: September 12, 2012
    Publication date: March 14, 2013
    Applicant: L.H. CARBIDE CORPORATION
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Publication number: 20120043848
    Abstract: An apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces.
    Type: Application
    Filed: August 18, 2011
    Publication date: February 23, 2012
    Applicant: L.H. CARBIDE CORPORATION
    Inventors: Thomas R. Neuenschwander, Barry A. Lee, Trevor Hirst
  • Patent number: 7676906
    Abstract: A progressive die assembly and a method for manufacturing lamina stacks from a plurality of separate strips of stock material. The die assembly includes a plurality of feed pathways for the material strips, each feed pathway having an associated punch set. Each punch set includes one or more punches for stamping lamina features in the strip, as well as at least one blanking punch for blanking individual laminas from the strips. The die assembly additionally includes a choke assembly which is adapted to receive laminas which are blanked from each of the material strips by the blanking punches.
    Type: Grant
    Filed: October 26, 2007
    Date of Patent: March 16, 2010
    Assignee: L.H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Barry A. Lee
  • Patent number: 7600312
    Abstract: A progressive die assembly and method for manufacturing lamina stacks from a strip of substantially planar material, in which at least some of the individual laminas are formed with portions which extend from, or are otherwise not within, the plane of the material strip. The die assembly includes die stations having punches for punching features substantially within the plane of the strip corresponding to individual laminas, such as lamina profiles and lamina interlock features. Additionally, the die assembly also includes at least one forming station which includes a selectively actuable forming tool which is configured to form a lamina portion in the strip which is disposed outwardly of the strip plane, such as by bending a portion of the strip.
    Type: Grant
    Filed: July 12, 2005
    Date of Patent: October 13, 2009
    Assignee: L.H. Carbide Corporation
    Inventors: Barry A. Lee, Thomas R. Neuenschwander
  • Patent number: 7337531
    Abstract: A progressive die assembly and a method for manufacturing lamina stacks from a plurality of separate strips of stock material. The die assembly includes a plurality of feed pathways for the material strips, each feed pathway having an associated punch set. Each punch set includes one or more punches for stamping lamina features in the strip, as well as at least one blanking punch for blanking individual laminas from the strips. The die assembly additionally includes a choke assembly which is adapted to receive laminas which are blanked from each of the material strips by the blanking punches.
    Type: Grant
    Filed: October 6, 2004
    Date of Patent: March 4, 2008
    Assignee: L.H. Carbide Corporation
    Inventors: Thomas R Neuenschwander, Barry A Lee
  • Publication number: 20080047131
    Abstract: A progressive die assembly and a method for manufacturing lamina stacks from a plurality of separate strips of stock material. The die assembly includes a plurality of feed pathways for the material strips, each feed pathway having an associated punch set. Each punch set includes one or more punches for stamping lamina features in the strip, as well as at least one blanking punch for blanking individual laminas from the strips. The die assembly additionally includes a choke assembly which is adapted to receive laminas which are blanked from each of the material strips by the blanking punches.
    Type: Application
    Filed: October 26, 2007
    Publication date: February 28, 2008
    Applicant: L. H. CARBIDE CORPORATION
    Inventors: Thomas Neuenschwander, Barry Lee
  • Patent number: 7062841
    Abstract: A method of manufacturing a stack of interlocked laminations in a progressive die assembly having a choke. A strip of sheet stock material is provided and a plurality of laminations are stamped therein. Each of the laminations include at least one interlock feature and include first and second regions and a connecting section extending between the first and second regions. The laminations are separated from the sheet stock material and stacked in the choke with the first and second regions in a first orientation. The laminations are also interlocked substantially concurrently with the separation and stacking of the laminations. The interlocked stack of laminations is removed from the choke with the first and second regions in their first orientation. The stack is then formed into a second shape wherein the first and second regions have a second orientation and the connecting section therebetween has been deformed.
    Type: Grant
    Filed: October 8, 2002
    Date of Patent: June 20, 2006
    Assignee: L.H. Carbide Corporation
    Inventor: Thomas R Neuenschwander
  • Patent number: 6984913
    Abstract: An interlocked stack of laminations for rotors wherein each lamination includes a centrally located, circular indentation. The indentation provides corresponding projections and depressions in the laminas which may be interlocked by engagement of a projection in one lamina with an adjacent depression in an adjacent lamina.
    Type: Grant
    Filed: December 18, 2000
    Date of Patent: January 10, 2006
    Assignee: L.H. Carbide Corporation
    Inventor: Thomas R. Neuenschwander
  • Patent number: 6877214
    Abstract: A method of manufacturing a stack of interlock laminations and thereby shaping the stack of laminations into a desired shape. Each of the individual laminations is formed by a series of punching operations from sheet stock material. The laminations are blanked from the stock material, are stacked atop one another, and are interlocked in a choke. The laminations are thereafter repositioned to form the stack into a second shape. The stacking axis and the core axis may be either parallel or perpendicular to one another. The second shape of the core may be variable in that the second shape may be changed from time to time or may be continuously changed.
    Type: Grant
    Filed: November 5, 2002
    Date of Patent: April 12, 2005
    Assignee: L. H. Carbide Corporation
    Inventors: Thomas R. Neuenschwander, Steven D. Shane
  • Patent number: 6745458
    Abstract: A method of manufacturing an elongate stack of interlocked laminae in a die assembly. The method includes the steps of stamping a first lamina having generally opposed first and second edges in the strip stock material, stamping at least one first interlock means for engaging another lamina in the first lamina, separating the first lamina from the strip stock material, placing the first lamina into the choke passageway, the first and second edges of the first lamina frictionally engaging the choke passageway, stamping a second lamina having first and second elongate edges in the strip stock material, stamping at least one second interlock means for engaging another lamina in the second lamina, at least partially engaging the first and second interlocking means, separating the second lamina from the strip stock material, placing the second lamina into the choke passageway, and frictionally engaging the choke passageway along the first and second elongate edges of only one of the first and second laminae.
    Type: Grant
    Filed: December 13, 2001
    Date of Patent: June 8, 2004
    Assignee: L.H. Carbide Corporation
    Inventor: Thomas R. Neuenschwander
  • Patent number: 6742239
    Abstract: A progressive stamping die assembly apparatus and method in which strip stock material advances in a first direction through the apparatus and substantially simultaneously with the strip stock movement, a transversely moveable die station moves in opposite second and third directions substantially perpendicular to the first direction to one of a plurality of predetermined positions.
    Type: Grant
    Filed: October 1, 2002
    Date of Patent: June 1, 2004
    Assignee: L.H. Carbide Corporation
    Inventors: Barry Andrew Lee, Timothy L. Schrank
  • Patent number: 6725756
    Abstract: An apparatus for providing an improved two-piece punch construction. The two-piece punch construction includes a supporting member and a punch body. The supporting member includes an aperture in which the punch body is accurately located. The supporting member further includes a supporting surface for supporting the punch body during a punching operation. The punch is constructed by providing at least one through-hole in the supporting member which receives a WEDM wire. The aperture for locating the punch body in the supporting member is made with a WEDM process. The supporting member and punch body are secured together by brazing material.
    Type: Grant
    Filed: October 23, 2001
    Date of Patent: April 27, 2004
    Assignee: L.H. Carbide Corporation
    Inventor: Doug Brenneke
  • Patent number: 6636137
    Abstract: An ignition coil assembly having an inner core element formed from an interlocked stack of elongate laminae plates. Each of the laminae plates has a substantially common length and a substantially uniform width along the length thereof, with the length of each laminae plates being greater than a width thereof. A first one of the plurality of laminae plates being the widest laminae plate in the stack is located substantially in a center thereof with others of the laminae plates located above and below the first laminae plate and having progressively decreasing widths. Each of the laminae plates in the stack being interlocked to an adjacent laminae plate and the stack having substantially planar end surfaces that are provided with guide elements that are aligned substantially perpendicular to the widths of the plurality of laminae plates. The guide elements include notches and/or projections that can have various geometric shapes.
    Type: Grant
    Filed: November 9, 2000
    Date of Patent: October 21, 2003
    Assignee: L.H. Carbide Corporation
    Inventor: Thomas R. Neuenschwander
  • Patent number: 6530142
    Abstract: An indexing system for a die assembly for manufacturing a stack of laminae from sheet stock material in a punch press, the stack having a desired stack height and a skew angle, the stock material having a nominal thickness. The indexing system includes indexing means for producing a first indexing input movement in response to movement of the punch press, a motor for producing a second indexing input movement in response to a control signal, and differential means for combining the first and second indexing input movements into an indexing output movement and having first and second input means for respectively receiving the first and second indexing input movements. The first input means is coupled to the indexing means, and the second input means is coupled to the motor. The differential means also has output means for transmitting the indexing output movement; a rotatable choke barrel in which laminae are received and stacked.
    Type: Grant
    Filed: January 4, 2001
    Date of Patent: March 11, 2003
    Assignee: L. H. Carbide Corporation
    Inventor: Thomas R. Neuenschwander