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.

Abstract: A shapeable lamination stack and method of manufacture. The lamination stack includes a plurality of interlocked laminations which may be stamped using a conventional progressive die. The laminations are stacked in a first stack shape wherein each of the laminations are mutually parallel and positioned perpendicular to linear axis. The laminations are relatively repositionable wherein the laminations form a second stack shape wherein at least one of the laminations is oriented non-parallel to another one of the laminations. The stack may also include spacing elements to separate a pair of laminations by a spacing volume. The spacing volume has a substantially uniform thickness when the stack is in the first stack shape and at least one of the spacing volumes has a non-uniform thickness when the stack is in the second stack shape. The spacing element may be lamination or a integral projection located on one of the laminations.