Traditional Lamination Methods Are Bottlenecking Joint Motor Performance
Rotary actuators and dexterous hand motors demand extreme performance across torque density, positioning accuracy, and thermal management. Traditional lamination assembly methods fall short under these high-frequency, miniaturized requirements:
- Interlocking (Rivet Stamping): Stamping dimples breaks surface insulation coating, causing localized eddy current short circuits and mechanical stress that degrades magnetic permeability.
- Laser Welding: Creates an electrical shorting line down the stack, generating severe heat during rapid reversals and warping ultra-thin 0.10mm laminations.
- Through-Bolts: Disrupts magnetic flux paths and wastes precious active space inside compact frameless motors.
In-Mold Bonding (Backlack): Technical Comparison
In-mold bonding technology utilizes electrical steel pre-coated with a cross-linking adhesive layer. Under precision heating and pressure curing directly within the stamping tool or specialized fixtures, hundreds of ultra-thin laminations are fused into a monolithic structure.
| Comparison Metric | Conventional Interlocking / Laser Welding | In-Mold Bonding Core (Backlack) | Direct Benefit for Robot Actuators |
|---|---|---|---|
| Packing Factor | 93% - 95% | ≥ 98% | Higher magnetic flux in same footprint = Boosted Torque Density |
| Inter-lamination Insulation | Damaged insulation at rivets/welds | 100% Inter-sheet Insulation | Dramatically Lower Core Loss & lower operating temp |
| Material Stress Damage | High localized stress from dimples | Zero Mechanical Damage | Uniform flux distribution = Minimized Cogging Torque |
| 0.10mm Sheet Compatibility | 0.10mm/0.15mm sheets easily deform | Optimized for 0.10mm Steel | Drastic reduction in high-frequency iron loss |
Key Advantages for Next-Gen Robotics
Zero Cogging Torque
Backlack stator cores feature complete structural symmetry, eliminating local magnetic reluctance variations caused by rivets. This minimizes cogging torque and torque ripple for whisper-smooth positioning.
0.10mm Mass Production Pathway
High frequency response is vital for servo responsiveness. Utilizing 0.10mm ultra-thin steel combats high-frequency core loss, and in-mold bonding is the premier pathway for stable volume production.
High Shear Strength
During jump landings, dynamic balancing, or sharp directional changes, the cross-linked polymer matrix provides exceptional structural rigidity, guaranteeing zero micro-displacement between laminations.
Our Custom Manufacturing Capabilities
As an advanced motor core manufacturing partner, we have engineered a rigorous production framework around custom Backlack processing:
- Precision Progressive Dies: Integrated stamping and in-mold heat/pressure curing keep concentricity and perpendicularity within micron tolerances for thin-walled frameless geometries.
- Exact Curing Profile Control: Strict governing of temperature ramp-up, holding pressure, and cooling cycles guarantees 100% bond strength while preventing resin overflow or slot clogging.
- Rapid Prototyping & Material Support: We support fast iteration speeds, providing full assistance from 0.10mm ultra-thin electrical steel selection to rapid Backlack prototyping and short-run production.
About Youyou Company
As a specialized motor core customization factory, Youyou Company provides advanced lamination solutions engineered to solve torque density, core loss, and cogging torque bottlenecks in next-generation robotic actuators. By integrating ultra-thin 0.10mm silicon steel stamping with rivet-free In-Mold Bonding (Backlack Technology), we empower robotics OEMs and motor developers to build high-power-density, whisper-smooth, and ultra-low-loss motor cores for humanoid robot joints, frameless servo motors, and dexterous hand slotless actuators.
Ready to eliminate cogging torque and boost joint actuator performance?
Contact our engineering team today to request 0.10mm Backlack stator samples and get a free In-Mold Bonding DFM evaluation for your robotic motors!
