Electromagnetic Induction Bonding for Composite Members

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Solution Overview

Problem

Existing methods for producing composite members by attaching a surface layer to a core member lack innovation and often result in damage to the surface layer or inadequate bonding, especially when using materials with high melting points or those difficult to form into a liquid state.

Innovation Solution

A method involving electromagnetic induction heating to melt and fuse a surface member with lower magnetism onto the outer peripheral surface of a core member, using an adhesive layer with a lower melting point to ensure secure bonding without damaging the surface or core materials, and allowing for various shapes and materials, including linear, particle, or fiber forms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional methods (immersion, plating, winding) are used to attach surface layers to core members, then production is simple and fast, but bonding strength is insufficient and surface damage occurs

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent utilizes phase transition (melting and solidification) of the surface member material to achieve bonding. The surface member is heated to its melting point, transformed into liquid state, and then solidified to fuse with the core member, creating strong metallurgical bonding without damaging the surface layer.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces conventional mechanical attachment methods (winding, clamping, plating) with electromagnetic induction heating. This substitution enables direct fusion bonding through controlled melting and solidification, achieving superior bonding strength without the limitations of mechanical methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If high melting point materials are used for surface members, then material selection is limited, but bonding process becomes difficult and surface damage occurs

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidsurface integrity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent changes the physical state parameter of the surface member from solid to liquid during bonding, then back to solid. By controlling the heating temperature to match the surface member's melting point and using electromagnetic induction for precise thermal control, the method enables bonding of diverse materials including those with high melting points without causing surface damage.

Inventive Principle:

Principle #35Parameter changes

3Strength

If electromagnetic induction heating is used to melt and fuse surface members, then bonding strength is enhanced, but energy consumption increases and process complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent employs electromagnetic induction heating where the surface member itself generates heat through induced eddy currents. This self-heating mechanism eliminates the need for external heat sources, reduces energy loss, and enables precise localized heating only at the bonding interface, thereby reducing overall energy consumption while achieving strong bonding.

Inventive Principle:

Principle #25Self-service

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 method securely fixes the surface member to the core member without shape damage, providing a novel production method that enhances bonding strength and flexibility, while allowing for diverse material selections based on functional requirements.

Implementation Method 1

electromagnetic induction heating the core member from outside the surface member to melt at least one of facing regions between the surface member and the core member with heat of the heated core member

Methodology Applied

Scientific EffectElectromagnetic induction heating: Electromagnetic Induction

Implementation Method 2

melt at least one of facing regions between the surface member and the core member with heat of the heated core member

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9944018B2Method for producing composite member

Publication Date: 2018.04.17 GUNZE LTD

AI summary

The invention provides a novel method for producing a composite member by fixing a surface member to the outer peripheral surface of a core member. A method for producing a composite member having a core member and a surface member fixed to the outer peripheral surface of the core member includes the surface member providing step of providing the surface member having magnetism lower than magnetism of the core member made of a conductive material on the outer peripheral surface of the core member, and the fusing step of electromagnetic induction heating the core member from outside the surface member to melt at least one of facing regions between the surface member and the core member with heat of the heated core member and fuse the surface member to the core member.