High-Frequency Induction Heater for Bonded Laminated Core Manufacturing
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Solution Overview
Problem
Conventional adhesive laminated core manufacturing apparatuses face challenges with slow adhesive hardening, misalignment of laminar members, adhesive leakage, and product quality issues due to thermal deformation and misalignment, leading to defective products and increased costs.
Innovation Solution
A bonded-type laminated core member manufacturing apparatus utilizing a high-frequency heater with a coil wound around a hardening hole for rapid adhesive hardening, combined with a guide and squeezer for precise alignment, and a pincher to prevent falling, along with a blocking material for thermal insulation and cooling paths to maintain product accuracy and reduce thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resistance heater is used to harden the adhesive, then the adhesive can be hardened, but the hardening process is slow and non-uniform, and breaking of the heater may happen
Solution Approach 1:
The patent replaces the resistance heater (thermal conduction system) with an induction heater (electromagnetic induction system). The induction heater generates a magnetic field that induces eddy currents in the adhesive, causing rapid and uniform heating through electromagnetic energy conversion. This substitution eliminates the slow and non-uniform heating problems of resistance heaters while avoiding heater breakage, as there is no direct physical contact between the heating element and the workpiece.
Solution Approach 2:
The patent changes the heating method from resistive thermal conduction to electromagnetic induction, fundamentally altering the heating parameters. The induction heater operates at higher frequencies, enabling rapid heating of the adhesive without the limitations of resistance heater thermal conductivity and contact issues. This parameter change achieves both fast hardening and improved reliability.
2Reliability
If a resistance heater is used for adhesive hardening, then the adhesive can be hardened, but thermal deformation and damage to peripheral parts occur
Solution Approach 1:
The induction heater is designed to concentrate electromagnetic energy specifically at the adhesive location between laminar members. The magnetic field is localized to the gap where the adhesive is applied, enabling selective heating of only the adhesive layer without significantly heating the surrounding steel sheets, dies, or other peripheral components. This local quality approach prevents thermal deformation and damage to sensitive parts while achieving effective adhesive hardening.
Solution Approach 2:
The induction heater acts as an intermediary that transfers energy wirelessly through electromagnetic fields. The magnetic field penetrates the non-magnetic or low-magnetic adhesive layer and induces heating without direct thermal contact with surrounding components. This intermediary mechanism isolates the heating process from the peripheral parts, preventing heat transfer-induced deformation and damage.
3Ease of manufacture
If adhesive is applied using conventional nozzles, then adhesive can be applied, but leakage and pollution occur at the nozzle outlet
Solution Approach 1:
The patent replaces the mechanical nozzle-based adhesive application system with a non-contact adhesive coating method. Adhesive is applied through a coating unit that deposits the adhesive layer onto the steel sheet without using traditional nozzles. This eliminates the nozzle outlet leakage and pollution problems inherent in pressure-based nozzle systems, as there is no narrow outlet where adhesive can leak or clog.
Solution Approach 2:
The patent extracts and removes the problematic nozzle component from the adhesive application system. By eliminating the nozzle entirely and using an alternative coating mechanism, the source of leakage and pollution (the nozzle outlet) is completely removed from the system, preventing these harmful effects.
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
The solution enables rapid adhesive hardening, stable alignment, reduced thermal deformation, minimized adhesive leakage, and improved product quality by synchronizing adhesive application and blanking processes, resulting in increased productivity and reduced defect rates.
Implementation Method 1
a high-frequency heater to harden the adhesive located between the laminar members, the high-frequency heater including a coil wound on the circumference of a hardening hole which accommodates the laminar members and forming a passage of high-frequency current
Implementation Method 2
blocking material for thermal insulation
Data Source
AI summary
Disclosed herein is a bonded-type laminated core member manufacturing apparatus comprising an adhesive application unit to apply an adhesive to a material being continuously transferred, and a laminating unit to integrate laminar members laminated within a laminating hole by blanking the material, a laminated core member being manufactured by interlayer adhesion between the laminar members, wherein the laminating unit includes a high-frequency heater to harden the adhesive located between the laminar members, the high-frequency heater including a coil wound on the circumference of a hardening hole which accommodates the laminar members and forming a passage of high-frequency current. In accordance with the present invention, the adhesive is rapidly hardened by high-frequency induction heating and thus the integration time of the laminated core member is shortened, and accuracy of the laminating unit, which integrates the laminar members, i.e., straightness of the laminating hole to pass the laminar members, is stably maintained and, thus, misalignment of the laminated core members is prevented and management of product quality is facilitated.