Bonded Stacked Core Processing for Fast Curing and Punching

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Solution Overview

Problem

Existing methods for manufacturing bonded and stacked cores face challenges in achieving high productivity while ensuring sufficient bonding strength, as the interaction between press working oil and curing accelerators affects punching workability and bonding efficiency.

Innovation Solution

Applying a curing accelerator with an average viscosity of 0.01 Pa·s to 100 Pa·s to the steel sheet surfaces before press working oil, ensuring high concentration and minimizing interference with adhesives, thereby enhancing bonding strength and productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the content of curing accelerator is increased to achieve higher curing accelerating effect, then bonding speed and bonding strength are improved, but the ratio of press working oil is reduced which deteriorates punching workability

Engineering Contradiction:

Improvebonding speedVSAvoidpunching workability

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent divides the application process into two separate steps: first applying press working oil for punching, then applying curing accelerator for bonding. This segmentation allows each substance to perform its function at optimal concentration without interfering with the other, resolving the contradiction between bonding speed and punching workability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The press working oil is applied before the curing accelerator in a sequential process. By performing the punching operation first with adequate oil lubrication, then applying the curing accelerator afterward, the patent ensures both punching workability and bonding effectiveness are maintained at high levels

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If curing accelerator is applied in diluted state with press working oil, then application process is simplified, but the concentration of curing accelerator is reduced which deteriorates curing accelerating effect

Engineering Contradiction:

Improveapplication process complexityVSAvoidcuring accelerating effect

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent separates the application of press working oil and curing accelerator into distinct steps, preventing dilution of the curing accelerator. This segmentation maintains high concentration of the curing accelerator while still simplifying the overall process by eliminating the need for separate mixing equipment or complex dosing systems

Inventive Principle:

Principle #1Segmentation

3Productivity

If adhesive and curing accelerator are applied simultaneously, then application steps are reduced, but the curing accelerator may interfere with adhesive performance

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbonding quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies adhesive and curing accelerator at different stages: adhesive is applied to the steel sheet component, then after stacking, curing accelerator is applied to initiate bonding. This segmentation ensures proper adhesive placement and prevents interference, while still achieving rapid curing and maintaining high manufacturing efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adhesive is applied in advance to the steel sheet component before stacking. This preliminary action ensures the adhesive is properly positioned and can work effectively when the curing accelerator is subsequently applied, maintaining both bonding quality and manufacturing efficiency

Inventive Principle:

Principle #10Preliminary action

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

The method achieves higher productivity with sufficient bonding strength, particularly suitable for manufacturing stators for rotary electric machines with improved performance and reduced manufacturing costs.

Implementation Method 1

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

Methodology Applied

Scientific EffectCuring acceleration: Catalysis

Implementation Method 2

performing press working on a strip-shaped steel sheet with a press working oil applied to one surface or both surfaces thereof

Methodology Applied

Scientific EffectLubrication: Lubrication

Data Source

PatentUS12479199B2Bonded and stacked core manufacturing method and bonded and stacked core manufacturing apparatus

Publication Date: 2025.11.25 NIPPON STEEL CORPORATION

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.