Adhesive Laminate Core Manufacturing via Interlayer Division
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Solution Overview
Problem
Existing methods for manufacturing laminate cores, such as tap fixing and laser welding, face challenges like iron loss and thickness reduction, limiting their effectiveness, particularly in the adhesion fixing method where laminar members are integrated using adhesives.
Innovation Solution
An adhesive laminate core manufacturing apparatus that forms laminar members with a predetermined shape by transferring a strip-type material with an adhesive layer, using a protrusion-forming unit to create interlayer divisions and a blanking unit to integrate these members into a single body through interlayer adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tap fixing method or laser welding is used to integrate laminar members, then the laminate core can be manufactured, but iron loss occurs and thickness reduction in material limits the manufacturing effectiveness
Solution Approach 1:
The patent replaces mechanical fixing methods (tap fixing, laser welding) with an adhesive bonding system. The adhesive layer is applied between laminar members and cured to integrate them, eliminating the mechanical contact that causes iron loss and thickness reduction while maintaining structural integrity of the laminate core.
2Ease of manufacture
If adhesive is applied to integrate laminar members, then manufacturing costs are reduced and thickness reduction is addressed, but continuous manufacturing capability is not achieved
Solution Approach 1:
The patent implements continuous manufacturing by applying adhesive in a continuous layer between laminar members as they pass through the manufacturing apparatus. The adhesive application system operates continuously rather than in discrete steps, enabling uninterrupted production of laminate cores while maintaining cost effectiveness.
Solution Approach 2:
The adhesive is applied to the laminar members before they are fully assembled into the final laminate core structure. This preliminary application of adhesive prepares the surfaces for bonding in advance, allowing continuous flow of material through the manufacturing process and improving overall productivity.
3Ease of manufacture
If laminar members are integrated by adhesive bonding, then manufacturing costs are reduced, but precise integration and interlayer division control are challenging
Solution Approach 1:
The adhesive layer serves as an intermediary substance between laminar members, providing controlled bonding that allows for precise integration. The adhesive's viscosity and curing characteristics enable accurate positioning and division control during the manufacturing process, achieving both cost reduction and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous manufacturing of laminate cores with precise integration and interlayer division, reducing material thickness variation and improving manufacturing precision.
Implementation Method 1
laminar members integrated in a predetermined number into one body by interlayer adhesion therebetween
Data Source
AI summary
Disclosed is an adhesive laminate core manufacturing apparatus for successively forming lamina members of a predetermined shape while allowing a strip-shaped material, of which the surface is coated with an adhesive layer, to pass therethrough, and successively manufacturing laminate cores comprising the lamina members integrated, per predetermined sheet, by interlaminar bonding. The adhesive laminate core manufacturing apparatus according to one aspect of the present invention comprises: a protrusion forming unit pressing the material for the delamination of the laminate cores, so as to form interlaminar division protrusions on the surface of the material at each predetermined position along the longitudinal direction of the material; a blanking unit blanking the material so as to successively form the lamina members; and a lamination unit integrating the lamina members so as to successively manufacture the laminate cores. According to the present invention, the laminate cores, in which the predetermined sheets of the laminar members are integrated in an interlaminar bonding manner, can be continuously manufactured by using the strip-shaped material of which the surface is coated with the adhesive layer in advance.