Embossed Spacers for Lamination Stack Detachment
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Solution Overview
Problem
Existing methods for detaching lamination stacks from a progressive stamping die reduce the strength of the bond between them, limiting their applicability, especially when multiple stacks are combined, and require costly control measures to prevent adhesive issues.
Innovation Solution
Producing spacers on both sides of the electric strip through embossing, which serve as a separate dividing element between lamination parts, allowing for a durable and easy detachment of stacks without compromising their integrity or increasing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spacers are provided on lamination parts to reduce contact area and facilitate detachment, then ease of operation improves, but strength of the bond between lamination stacks deteriorates
Solution Approach 1:
The patent divides the lamination part into multiple segments by introducing spacers that create separation zones. These spacers segment the contact area between lamination stacks, allowing the bond to be strong over most of the surface while having predetermined weak points for easy detachment. The spacers act as discrete segmentation elements that partition the bonding interface.
Solution Approach 2:
The patent applies local quality by creating non-uniform bonding characteristics across the lamination part surface. The spacers are strategically positioned to create localized reduction zones where adhesion is minimized, while the remaining areas maintain full bonding strength. This allows different regions of the lamination part to have different bonding qualities - strong in most areas, weak only at spacer locations for detachment.
2Reliability
If adhesive is provided only in specific sub-regions to prevent sticking, then reliability improves, but device complexity increases due to costly control measures
Solution Approach 1:
The patent implements self-service by designing the lamination part structure itself to prevent sticking, rather than relying on complex external control systems. The spacers are integral features of the lamination part that automatically create separation zones and prevent adhesive bridging between stacks. The structure serves its own function of preventing sticking through its geometric design, eliminating the need for sophisticated adhesive control mechanisms.
Solution Approach 2:
The patent applies preliminary action by pre-forming the spacers on the lamination part before the bonding process. These spacers are created in advance as permanent features that will automatically prevent sticking during stacking. The preliminary structuring of the lamination part with spacers eliminates the need for real-time control measures during the bonding and stacking operations.
3Ease of operation
If spacers reduce contact area for easier detachment, then ease of operation improves, but quantity of magnetically conductive material decreases
Solution Approach 1:
The patent applies partial action by introducing spacers that occupy only a small fraction of the total lamination part surface area. The spacer regions represent a minimal reduction in magnetically conductive material, while still providing sufficient detachment functionality. The majority of the lamination part surface remains intact and magnetically conductive, achieving the detachment function with minimal sacrifice of functional material.
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
Enables simple and reproducible detachment of lamination stacks with enhanced mechanical resilience and stability, preventing sticking and maintaining the stacks' durability and applicability, while reducing the risk of adhesive-related complications.
Implementation Method 1
in the first sub-region, spacers protruding from both flat sides of the electric strip are produced by means of embossing
Implementation Method 2
an adhesive layer, namely thermosetting hot-melt adhesive layers, covering the entire area of one or both of its flat sides
Data Source
AI summary
A method for connecting lamination parts to form a lamination stack in which lamination parts are stamped out from an electrical strip that is coated with an activatable adhesive layer on at least one of its flat sides and the stamped-out lamination parts are stacked and glued to form lamination stacks, wherein before the lamination parts are stamped out, the electrical strip is embossed in a first sub-region, which produces multiple protruding spacers on at least one flat side of the electrical strip, which spacers, after a first lamination part is stamped out from this first sub-region, facilitate a detachment of the stacked and glued lamination parts into lamination stacks.