Laminated Iron Core Resin Coupling Distortion

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Solution Overview

Problem

The existing methods for bonding laminated iron core pieces using resin often result in increased distortion, leading to resin cracking and associated issues like poor motor assembly, breakage, noise, and vibration, due to the spring back force and increased distortion with thinner strip materials or simultaneous blanking of multiple pieces.

Innovation Solution

A laminated iron core design and manufacturing method that incorporates through holes or recesses filled with resin, where the resin's strength and the iron core pieces' properties are optimized to satisfy the formula (T×S)/η > {(4×E×δ×w×t³)/L³}×n, ensuring the resin withstands distortion-induced stress and preventing cracks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the strip material is thinned to improve motor performance, then the motor efficiency is improved, but the distortion in the iron core piece increases

Engineering Contradiction:

Improvemotor efficiencyVSAvoiddistortion in iron core piece

Core Design Contradiction:

Use of energy by moving objectVSShape

Solution Approach 1:

The patent applies preliminary action by pre-forming coupling parts (through holes or recesses) in the iron core pieces before lamination, and pre-calculating the required resin amount using the provided formula based on expected distortion values. This allows the resin to be positioned and sized optimally to counteract the spring back force that will occur after molding, preventing crack formation while maintaining thin strip material for high efficiency.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If simultaneous blanking of multiple iron core pieces is performed to improve productivity, then the production efficiency is improved, but the distortion in the iron core piece increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoiddistortion in iron core piece

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The patent applies preliminary action by pre-forming coupling parts in iron core pieces before lamination, and pre-calculating the required resin amount using the provided formula based on expected distortion values. This allows the resin to be positioned and sized optimally to counteract the spring back force that will occur after molding, preventing crack formation while maintaining thin strip material for high efficiency.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If resin is used to bond iron core pieces to reduce short circuit and improve occupancy rate, then the electrical performance is improved, but the resin may crack due to spring back force from distortion

Engineering Contradiction:

Improveelectrical performanceVSAvoidresin crack resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies parameter changes by using the provided formula to calculate the optimal resin amount based on multiple parameters including distortion value, Young's modulus, plate thickness, width, distance between coupling parts, number of laminations, and safety factor. By adjusting these parameters, particularly the resin cross-sectional area S, the solution ensures the resin has sufficient strength to resist spring back force while maintaining electrical performance through proper bonding.

Inventive Principle:

Principle #35Parameter changes

4Strength

If the resin amount is increased to prevent crack, then the strength is improved, but the occupancy rate decreases

Engineering Contradiction:

Improveresin crack resistanceVSAvoidoccupancy rate

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

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 effectively prevents resin cracking, ensuring high-quality laminated iron cores with improved motor performance by setting the resin's withstand load above the distortion-induced reaction force, thereby enhancing assembly reliability and reducing noise and vibration.

Implementation Method 1

the coupling parts are filled with resins to mutually couple the iron core pieces adjacent in the lamination direction

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

stress acts on the bonded resin 91 by a spring back force due to the distortion

Methodology Applied

Scientific EffectElastic recovery: Elastic Recovery

Data Source

PatentUS10170962B2Laminated iron core and manufacturing method of laminated iron core

Publication Date: 2019.01.01 MITSUI HIGH TEC INC

AI summary

A laminated iron core includes laminated iron core pieces, in which coupling parts are formed so as to communicate in a lamination direction of the laminated iron core pieces, and the coupling parts are filled with resins. The laminated iron core satisfies the following formula: (T×S)/η>{(4×E×δ×w×t3)/L3}×n, where T is a strength (N/mm2) of the resin; S is a cross-sectional area (mm2) of the coupling part or the resin; E is a Young's modulus (N/mm2) of the strip material; δ is a distortion amount (mm) of the iron core piece; w is a width (mm) of the iron core piece in a radial direction; t is a plate thickness (mm) of the iron core piece; n is the number of laminated iron core pieces; L is a distance (mm) between the coupling parts adjacent in the circumferential direction; and η is a safety factor.