Ferromagnetic Core Lamination Gluing With Transfer-Printed Adhesive
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing ferromagnetic cores of electric machines, such as those described in US2015097463A1 and DE102018110951A1, fail to ensure precision and repeatability in applying adhesive material to laminations, leading to spillage, non-uniform thickness, and health hazards from harmful compounds, while also neglecting laminate irregularities and burrs.
Innovation Solution
A plant and method utilizing a transfer element with impressions corresponding to lamination outlines, combined with a printing device and controlled application units, to apply adhesive material uniformly and precisely, while protecting against laminate irregularities and harmful compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spraying techniques are used to apply adhesive material, then application speed is improved, but manufacturing precision deteriorates due to inability to reach certain areas and affect areas outside the contour
Solution Approach 1:
A transfer element (roller or belt) is introduced as an intermediary between the adhesive application device and the metal laminate. The transfer element receives adhesive material through printing devices and transfers it to the laminate surface, enabling precise control of adhesive placement while maintaining high-speed production capability
Solution Approach 2:
The traditional spraying mechanical system is replaced with a printing-based application system using transfer elements. This substitution allows for more precise control of adhesive material placement through impression-based transfer mechanisms rather than aerosol spray patterns
2Ease of manufacture
If adhesive material is applied without well-defined impressions, then application simplicity is improved, but manufacturing precision deteriorates due to superimpositions and non-uniform thickness
Solution Approach 1:
The transfer element is pre-formed with specific impressions or patterns that define the exact locations and quantities of adhesive material to be applied. This preliminary structuring of the transfer element ensures uniform adhesive distribution and prevents superimpositions before the adhesive even contacts the laminate
Solution Approach 2:
The transfer element features localized impressions with varying depths, shapes, and distributions tailored to specific application requirements. Each impression is designed to deposit a precise amount of adhesive at a specific location, creating non-uniform adhesive patterns where uniformity is not desired and controlled uniformity where required
3Area of stationary object
If adhesive material overflows from recesses on the roller, then application coverage is improved, but manufacturing precision deteriorates due to compromised uniform distribution and spillage
Solution Approach 1:
The design parameters of the transfer element impressions are carefully controlled, including depth, width, spacing, and shape. These parameters are optimized to ensure that adhesive material is transferred completely within the desired boundaries without overflowing, while still achieving full coverage of the required areas
Solution Approach 2:
The transfer element creates precise copies or impressions of the desired adhesive pattern on the laminate surface. Each impression on the transfer element is replicated exactly onto the laminate, ensuring uniform distribution and preventing spillage beyond the intended application areas
4Manufacturing precision
If printing processes are used to apply adhesive, then manufacturing precision is improved, but reliability deteriorates due to sensitivity to laminate variations, burrs, and foreign bodies
Solution Approach 1:
The transfer element acts as a cushioning intermediary that absorbs and compensates for variations in laminate surface conditions. Irregularities, burrs, and foreign bodies on the laminate do not directly contact the adhesive application mechanism, preventing process disruptions while the transfer element's compliance allows for successful adhesive transfer
Solution Approach 2:
The transfer element serves as a protective intermediary between the adhesive application system and the laminate. It shields the precision printing mechanism from damage caused by laminate defects while ensuring reliable adhesive transfer to the surface, thereby improving both process stability and reliability
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
Ensures precise and repeatable adhesive application, preventing spillage and uniform thickness, and protects against laminate irregularities and health hazards, resulting in high-quality ferromagnetic cores.
Implementation Method 1
a printing device and at least one transfer element on which the printing device deposits the adhesive material according to one or more impressions of a shape corresponding to the outline of each of the laminations
Data Source
AI summary
A plant (10) and a method are described for manufacturing ferromagnetic cores of electric machines formed by a plurality of laminations which are packed and joined together by gluing in a blanking/punching tool (15) to which a continuous metal laminate (11) of ferromagnetic material is fed. In addition to the blanking/punching tool, the plant comprises at least one unit (21) for applying an adhesive material to a surface of the continuous metal laminate, at least one unit (25) for applying an activating compound to the opposite surface of the continuous metal laminate and at least one control unit (22) for controlling the application of the adhesive material and the activating compound into the respective application units. The unit for applying an adhesive material to a surface of the continuous metal laminate comprises a printing device (23, 60) and at least one transfer element (28, 51) on which the printing device deposits the adhesive material according to one or more impressions of a shape corresponding to the outline of each of the laminations. The adhesive material is then applied by the at least one transfer element to a surface of the continuous metal laminate according to the outline of each lamination, which is defined by the impressions.