Armature Segment Conductor Bonding Viscosity Control

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Solution Overview

Problem

The existing method for manufacturing an armature, as described in JP 2015-23771 A, faces issues with the binder moving or flowing out of the desired position, resulting in reduced bonding strength and quality between the conductor segments due to insufficient binder retention.

Innovation Solution

A method involving an armature core with slots, where a conductive bonding agent is applied to the distal ends of segment conductors, and its viscosity is increased before bonding, ensuring proper placement and retention between the conductors, thereby enhancing bonding quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a pasty binder is applied to the distal ends of conductor segments and pressure is applied to bond them, then the legs are bonded together in the slot, but the binder moves or flows out of the desired position before bonding, resulting in reduced bonding strength

Engineering Contradiction:
Improvebonding strengthVSAvoidbinder retention
Core Design Contradiction:
StrengthVSEase of operation

Solution Approach 1:

The patent applies a preliminary action by increasing the viscosity of the binder before the bonding operation. Specifically, the binder's viscosity is increased in advance of applying pressure to bond the conductor segments, preventing the binder from flowing out before the bonding occurs. This preliminary viscosity increase ensures the binder remains at the desired position during the subsequent bonding process.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical parameter of the binder by increasing its viscosity. The binder is transformed from a low-viscosity pasty state that would flow under pressure to a high-viscosity state that remains in place. This parameter change is achieved through heating or other methods described in the patent, allowing the binder to maintain its position while still enabling effective bonding when pressure is applied.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If pressure is applied to bond the conductor segments, then the legs are bonded together, but the binder flows out of the region between the legs, resulting in insufficient binder amount and reduced bonding quality

Engineering Contradiction:
Improvebonding qualityVSAvoidbinder loss
Core Design Contradiction:
ReliabilityVSLoss of substance

Solution Approach 1:

The patent performs a preliminary action of increasing binder viscosity before the bonding process. By increasing the viscosity in advance, the binder is prepared to resist flow during the subsequent pressure application. This preliminary viscosity increase prevents binder loss during the bonding operation, ensuring sufficient binder remains between the conductor segments to achieve reliable bonding quality.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes the viscosity parameter of the binder to prevent substance loss. By transforming the binder from a low-viscosity to a high-viscosity state before bonding, the patent prevents the binder from flowing out of the bonding region under pressure. This parameter change ensures that the binder remains where it is needed, maintaining bonding quality while minimizing binder loss.

Inventive Principle:
Principle #35Parameter changes

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

This approach secures the bonding quality by maintaining an appropriate amount of bonding agent between the conductor segments, improving the bonding strength and preventing binder movement or flow-out, thus ensuring reliable electrical and mechanical connections.

Implementation Method 1

a step of increasing a viscosity of the bonding agent placed on the distal ends, after the step of placing the bonding agent on the distal ends, and before the step of bonding the distal ends to each other

Methodology Applied
Scientific EffectViscosity increase:

Data Source

PatentUS11411476B2Method of manufacturing armature
Publication Date: 2022.08.09 AISIN CORP
  • US11411476B2 patent drawing
  • US11411476B2 patent drawing
  • US11411476B2 patent drawing

AI summary

A method of manufacturing an armature includes: a step of placing a bonding agent on bonding surfaces of the distal ends of a plurality of segment conductors; a step of placing the plurality of segment conductors on an armature core; a step of bonding the distal ends to each other; and a step of increasing a viscosity of the bonding agent placed on the distal ends, after the step of placing the bonding agent on the distal ends, and before the step of bonding the distal ends to each other.