Divided Motor Core Lamination Curing for Ring Shape Accuracy
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Solution Overview
Problem
Existing methods for producing divided cores struggle with insufficient shape accuracy as both a single unit and as a whole, particularly in forming ring-shaped motor cores.
Innovation Solution
A method involving the arrangement of divided core laminates with a thermosetting adhesive, followed by heating and curing under controlled pressure using inner and outer molds, ensuring precise shape formation through steps of softening and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If divided core laminates are produced one by one and assembled into a ring-shaped motor core, then the production process is simple, but the shape accuracy of the motor core as a whole is insufficient
Solution Approach 1:
The motor core is divided into multiple divided core laminates that are produced separately and then assembled into a ring-shaped structure. Each laminate is formed with precise dimensional control, and the segmentation allows for modular production while maintaining overall shape accuracy through the curing process that bonds the laminates together in a fixed configuration.
Solution Approach 2:
The divided core laminates are pre-formed with precise shapes and dimensions before assembly. The preliminary formation of each laminate includes pre-positioning them in the correct spatial arrangement, and the thermosetting adhesive is applied in advance to prepare for bonding. This preliminary action ensures that when the laminates are assembled and cured, the final motor core achieves the required shape accuracy.
2Productivity
If multiple divided cores are arranged in a ring shape to improve productivity, then production efficiency increases, but shape stability during production deteriorates
Solution Approach 1:
The production system processes multiple divided core laminates simultaneously in parallel, rather than sequentially. Each laminate is formed and cured in its own designated position within the mold assembly, allowing high-volume production while maintaining individual shape stability. The segmentation of the curing process into separate zones prevents interference between adjacent laminates.
Solution Approach 2:
Multiple divided core laminates are nested or arranged concentrically within a ring-shaped mold structure. The inner mold defines the precise outer circumference, and the outer mold provides restraining force. This nested arrangement allows multiple laminates to be produced simultaneously while the mold structure maintains the spatial relationships and shape stability of each laminate during the curing process.
3Manufacturing precision
If divided core laminates are arranged along the outer circumferential surface of an inner mold to form a ring-shaped assembly, then shape accuracy as a single unit is improved, but the complexity of the production apparatus increases
Solution Approach 1:
The production apparatus uses a nested dual-mold structure where an inner mold is placed inside an outer mold. The inner mold defines the precise outer circumferential surface along which the divided core laminates are arranged, while the outer mold provides the restraining force. This nested configuration achieves high shape accuracy through the inner mold's precise geometry while the outer mold adds minimal structural complexity by simply surrounding the inner mold.
Solution Approach 2:
The inner mold features a precisely engineered curved outer circumferential surface that matches the desired shape of the divided core. By forming the laminates against this curved surface, the apparatus achieves high shape accuracy. The curvature of the inner mold eliminates the need for complex positioning mechanisms, as the curved geometry itself guides the laminate arrangement and ensures consistent shape reproduction.
4Ease of operation
If thermosetting adhesive is used to temporarily join core plate materials, then the laminates can be repositioned during assembly, but the curing process requires additional heating steps
Solution Approach 1:
The thermosetting adhesive exhibits parameter changes in its viscosity and bonding strength as a function of temperature. During assembly, the adhesive remains in a softer, more workable state that allows easy repositioning of laminates. Once the laminates are positioned correctly, the curing process raises the temperature to trigger a parameter change in the adhesive, transforming it into a rigid, permanent bond. This controlled parameter change enables both ease of assembly and strong final bonding.
Solution Approach 2:
The thermosetting adhesive undergoes a phase transition from a soft, repositionable state to a hard, cured state through controlled heating. During the assembly phase, the adhesive remains in a pliable phase that allows laminates to be easily adjusted and repositioned. When the curing heat is applied, the adhesive transitions to a solidified phase, locking the laminates in their final positions. This phase transition enables the dual requirement of ease of assembly followed by permanent fixation.
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
Improves shape accuracy of both the divided core as a single unit and the motor core as a whole by ensuring precise alignment and curing of the laminates.
Implementation Method 1
heating and holding the divided core assembly to and at a first temperature at which the thermosetting adhesive softens
Implementation Method 2
heating and holding the divided core assembly to and at a first temperature by a heater inside the inner mold and a heater inside the outer mold
Implementation Method 3
pressurizing and restraining the entire circumference of the divided core assembly by the outer mold
Data Source
Figure 1
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AI summary
The present invention provides a method for producing and an apparatus for producing a divided core that can improve shape accuracy as a divided core as a single unit and a motor core as a whole. That is, the present invention provides a method for producing a divided core, the method including Step (A) of arranging a plurality of divided core laminates in which a plurality of core plate materials constituting a divided core are temporarily joined together with a thermosetting adhesive and laminated on each other along an outer circumferential surface of an inner mold 1 to make a ring-shaped divided core assembly, Step (B) of disposing an outer mold 2 so as to surround an entire circumference of the divided core assembly, Step (C) of, while pressurizing and restraining the entire circumference of the divided core assembly by the outer mold 2, heating and holding the divided core assembly to and at a first temperature at which the thermosetting adhesive softens by a heater 3 inside the inner mold 1 and a heater 4 inside the outer mold 2, and Step (D) of, after an end of Step (C), heating the divided core assembly to a second temperature higher than the first temperature to cure the thermosetting adhesive. The present invention also provides an apparatus A for producing the divided core.