Laminated Core Bonding Using Axial Channel Heating
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Solution Overview
Problem
Existing methods for producing lamination packs face challenges in achieving reliable thermal bonding and separation, particularly when the shape of the sheet metal laminations reduces heat conduction, leading to inconsistent bonding and high processing costs.
Innovation Solution
A method and device that utilize a brake sleeve for thermal activation of bonding varnish, combined with an additional inductor device or radiant heater inserted into the axial channel of the lamination packs, to ensure consistent and reliable thermal bonding, while preventing premature activation of the bonding varnish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat is applied via the brake sleeve through the outer edges of the sheet metal laminations, then thermal bonding of the bonding varnish is activated, but the bonding is not reliable when the outer edges are reduced in size
Solution Approach 1:
The patent introduces a second heating dimension by inserting a heating device through the axial channel (central opening) of the lamination pack. This adds internal heating capability to complement the external brake sleeve heating, ensuring reliable bonding even when outer edges are too small to conduct sufficient heat.
Solution Approach 2:
The heating device is inserted into the axial channel formed by the lamination packs themselves. The lamination pack structure provides the housing for the heating device, creating a nested arrangement where the heater is positioned within the central opening of the stacked laminations.
2Reliability
If additional heating device is inserted into the axial channel, then thermal bonding reliability is improved, but device complexity increases
Solution Approach 1:
The lamination pack structure itself (the axial channel formed by the stacked laminations) serves as the housing for the heating device. This eliminates the need for a separate dedicated housing structure, reducing overall device complexity while maintaining the dual-heating functionality.
3Reliability
If the brake sleeve is heated to activate bonding varnish, then lamination bonding is achieved, but premature activation may occur causing unwanted adhesion between stacks
Solution Approach 1:
The patent applies heating locally at two specific locations: the outer edges via the brake sleeve and the center via the inserted heating device. This localized dual-heating approach ensures uniform temperature distribution across the lamination pack, activating bonding varnish only where needed and preventing premature activation in other areas.
4Adaptability or versatility
If sheet metal laminations are stamped with reduced outer edges for winding accommodation, then core functionality is improved, but heat conduction for bonding is insufficient
Solution Approach 1:
The patent compensates for the reduced heat conduction at the outer edges by introducing heating from the central dimension (axial channel). This multi-dimensional heating approach ensures adequate temperature distribution despite the reduced outer edge geometry required for winding accommodation.
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 achieves simple, uncomplicated, and highly reliable thermal bonding of lamination packs, improving processing efficiency and reducing the risk of inconsistent bonding or separation issues.
Implementation Method 1
the sheet metal laminations of the lamination packs, lying on top of one another and with outer edges resting against the inside of the brake sleeve, are acted on with heat from the brake sleeve via the outer edges of the sheet metal laminations
Implementation Method 2
an additional device for heating the lamination packs is at least temporarily positioned in an axial channel formed by the lamination packs in order to additionally heat the lamination packs
Implementation Method 3
a brake sleeve in which the sheet metal laminations of the lamination packs are acted on with heat from the brake sleeve via the outer edges of the sheet metal laminations so that the bonding varnish is thermally activated, bonding the laminations to one another
Data Source
AI summary
The invention relates to a method for stamping and forming packs of sheet metal laminations coated with a bonding varnish to form lamination packs, wherein a brake sleeve is provided in which the sheet metal laminations of the lamination packs, lying on top of one another and with outer edges resting against the inside of the brake sleeve, are acted on with heat from the brake sleeve via the outer edges of the sheet metal laminations so that the bonding varnish is thermally activated, bonding the laminations to one another, characterized in that an additional device for heating the lamination packs is at least temporarily positioned in an axial channel formed by the lamination packs in order to additionally heat the lamination packs.