Electric Strip Laminate Bonding via Pre-applied Hot Melt Adhesive
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Solution Overview
Problem
The continuous strip method for producing electric strip laminates faces challenges in achieving reproducibility at high strip speeds due to parameter fluctuations, particularly in adhesive application and cross-linking, which affects coil stability and efficiency.
Innovation Solution
The method involves coating one electric strip with a thermally activatable hot melt adhesive lacquer, activating it, and pressing it against another electric strip at a temperature below the activation temperature, allowing for high-speed bonding without additional adhesive application, and utilizing a second electric strip at ambient temperature to accelerate cooling and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to both flat sides of the middle electric strip in a continuous strip method, then integral bonding of electric strips is achieved, but parameter fluctuations (strip speed, adhesive application) negatively affect adhesive cross-linking and coil stability
Solution Approach 1:
The patent extracts the adhesive application step from the continuous strip method, using only pre-applied hot melt adhesive lacquer on the electric strips without additional adhesive application during the bonding process. This eliminates parameter fluctuations related to adhesive application and cross-linking, thereby improving coil stability and reproducibility while maintaining integral bonding strength.
Solution Approach 2:
The hot melt adhesive lacquer is pre-applied to the electric strips before the bonding process. This preliminary action ensures that the adhesive is already in position and properly distributed, eliminating the need for additional adhesive application steps and reducing parameter fluctuations that would otherwise affect cross-linking and coil stability.
2Reliability
If adhesive application and cross-linking are performed carefully to ensure coil stability, then reliable bonding is achieved, but the process complexity and time increase
Solution Approach 1:
The patent removes the complex adhesive application and cross-linking steps from the bonding process by relying solely on the pre-applied hot melt adhesive lacquer. This extraction simplifies the overall process while maintaining coil stability, as the hot melt adhesive lacquer provides sufficient bonding strength without requiring additional adhesive application or extensive cross-linking control.
Solution Approach 2:
The patent changes the bonding parameters by using hot melt adhesive lacquer with a specific melting point range, allowing bonding to occur through thermal activation rather than through complex adhesive application and cross-linking processes. This parameter change simplifies the process while maintaining reliability.
3Productivity
If high strip speeds are used in the continuous strip method, then productivity increases, but parameter fluctuations negatively affect adhesive cross-linking and reproducibility
Solution Approach 1:
The patent extracts the adhesive application step that is sensitive to speed fluctuations, using only the pre-applied hot melt adhesive lacquer. This allows the process to maintain high strip speeds without the reproducibility issues that arise from parameter fluctuations in adhesive application and cross-linking at high speeds.
Solution Approach 2:
The hot melt adhesive lacquer is pre-applied to the electric strips before the high-speed bonding process. This preliminary action ensures that the adhesive is already in position and properly distributed, allowing the process to run at high strip speeds without the reproducibility issues that would otherwise arise from speed-related parameter fluctuations in adhesive application.
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 enhances reproducibility and stability by ensuring strong integral bonding, reducing energy expenditure, and allowing for rapid winding of the electric strip laminate into a coil, even at high speeds, while maintaining the adhesive's functionality.
Implementation Method 1
the first hot melt adhesive lacquer on the first electric strip is thermally activated
Implementation Method 2
the electric strips are pressed against each other on their flat sides with the activated first hot melt adhesive lacquer layer between these flat sides
Implementation Method 3
the second electric strip is supplied to this pressing process at a temperature below the activation temperature of the first hot melt adhesive lacquer layer on the first electric strip
Data Source
AI summary
A continuous strip method for producing an electric strip laminate which is wound into a coil is proposed in which at least two electric strips are pressed against each other on their flat sides and are integrally bonded to form an electric strip laminate and in a further step, this electric strip laminate is wound into a coil. More particularly, a first electric strip is coated on at least one of its flat sides with a first thermally activatable hot melt adhesive lacquer, the first hot melt adhesive lacquer on the first electric strip is thermally activated, and then the electric strips are pressed against each other on their flat sides with the activated first hot melt adhesive lacquer layer between these flat sides and a second electric strip is supplied to this pressing process at a temperature below the activation temperature of the first hot melt adhesive lacquer layer on the first electric strip.