Bonded Laminate Core Processing for Stronger Adhesive Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing bonded and stacked cores face challenges in achieving high productivity while ensuring sufficient bonding strength, as the application form of curing accelerators and press working oils has not been sufficiently studied, leading to potential interference and reduced workability.
Innovation Solution
A bonded and stacked core manufacturing method and apparatus that applies a curing accelerator with a viscosity of 0.01 Pa·s to 100 Pa·s to the steel sheet surfaces before applying press working oil, ensuring high concentration and minimizing interference with adhesives, thereby enhancing bonding strength and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If edge bands are applied after panel production, then design flexibility is improved, but production time and labor costs increase
Solution Approach 1:
The patent applies edge banding material to the edges of panels during the panel production process itself, before the panels are assembled into furniture. This preliminary action eliminates the need for separate post-production edge banding operations, thereby reducing production time and labor costs while maintaining design flexibility.
Solution Approach 2:
The patent combines the edge banding application process with the panel production process into a single integrated operation. By merging these two previously separate processes, the system achieves both time efficiency and design versatility without requiring additional production steps.
2Adaptability or versatility
If edge bands are applied after panel production, then design flexibility is improved, but labor costs increase
Solution Approach 1:
By applying edge banding material during panel production rather than after assembly, the patent eliminates additional labor steps. This preliminary action reduces overall labor costs while preserving the ability to offer various edge banding options for different design requirements.
Solution Approach 2:
The integration of edge banding application into the panel production line merges two operational stages into one, reducing the total labor required and associated costs while maintaining design flexibility through automated material application.
3Strength
If conventional adhesive methods are used, then bonding is achieved, but formaldehyde emissions and environmental pollution increase
Solution Approach 1:
The patent replaces conventional chemical adhesive bonding with a mechanical bonding system that uses protrusions and recesses between the edge banding material and panel. This mechanical interlocking system eliminates the need for formaldehyde-based adhesives, thereby reducing harmful emissions while maintaining bonding strength.
Solution Approach 2:
The patent changes the bonding mechanism from chemical (adhesive-based) to physical (mechanical interlocking). By altering the fundamental parameter of how bonding is achieved, the system eliminates formaldehyde emissions while preserving the necessary bonding strength for edge banding application.
4Object-generated harmful factors
If protrusions and recesses are used for bonding, then environmental pollution is reduced, but bonding strength may be insufficient without adhesive
Solution Approach 1:
The patent uses a composite bonding system that combines mechanical interlocking (protrusions and recesses) with a reduced-chemical approach. The physical structure provides the primary bonding strength while eliminating or minimizing the need for formaldehyde-based adhesives, thus achieving both environmental benefits and adequate bonding strength.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
This bonded and stacked core manufacturing method is for manufacturing a bonded and stacked core by performing press working on a strip-shaped steel sheet with a press working oil applied to one surface or both surfaces thereof, applying an adhesive to one surface of the strip-shaped steel sheet to obtain a plurality of steel sheet components, and stacking and bonding the steel sheet components, in which a curing accelerator having an average viscosity of 0.01 Pa·s to 100 Pa·s is applied to one surface or both surfaces of the strip-shaped steel sheet before the press working oil is applied.