Laminated Core Block Bonding to Limit Curing Deformation
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Solution Overview
Problem
Laminated cores formed by stacking and adhesive bonding deform due to stress generated by curing adhesive agent layers, especially with a large number of laminations, leading to convex or concave deformations.
Innovation Solution
A manufacturing method involving the use of separation layers and precise holding jigs to apply and cure adhesive agents in controlled conditions, restricting displacement during adhesive application and curing, ensuring high precision and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple core constituting plates are stacked and adhesively bonded to increase the number of laminations, then the productivity and electrical performance are improved, but the adhesive agent layers contract during curing and generate stress causing the laminated core to deform convexly in the stacking direction
Solution Approach 1:
The laminated core is divided into multiple blocks, each consisting of a predetermined number of core constituting plates. Separation layers are interposed between adjacent blocks to prevent continuous stress propagation. This segmentation allows each block to be independently managed during adhesive curing, reducing overall deformation while maintaining high lamination counts for improved productivity and electrical performance.
Solution Approach 2:
Separation layers are pre-positioned between adjacent core constituting plates before adhesive application. These separation layers create predetermined separation spaces that compensate for adhesive contraction during curing. By preparing this compensation mechanism in advance, the laminated core maintains its flat shape even when multiple plates are stacked, enabling high lamination counts without excessive deformation.
2Reliability
If the number of stacked core constituting plates is increased to improve electrical performance, then the electrical efficiency is improved, but the cumulative stress from adhesive contraction causes greater concave deformation
Solution Approach 1:
By dividing the laminated core into multiple blocks with separation layers between them, the cumulative stress from adhesive contraction is distributed and isolated across separate segments. This prevents the accumulation of concave deformation that would occur in a continuous stack, allowing higher lamination counts for improved electrical efficiency while maintaining shape stability.
Solution Approach 2:
Separation layers act as intermediary elements between adjacent blocks of core constituting plates. These layers provide physical separation and stress isolation, mediating the adhesive contraction forces to prevent them from causing cumulative concave deformation across the entire laminated core structure, thereby enabling higher lamination counts with maintained reliability.
3Strength
If adhesive bonding is applied to all adjacent core constituting plates to improve structural integrity, then the strength is improved, but the complexity of the manufacturing process increases due to the need for precise deformation control
Solution Approach 1:
The manufacturing process is segmented into manageable blocks rather than treating the entire laminated core as a single unit. This segmentation simplifies the adhesive application and curing process by limiting the number of plates bonded together at one time, reducing the complexity of deformation control while maintaining structural integrity through the block assembly approach.
Solution Approach 2:
Separation layers are pre-installed between blocks before adhesive bonding begins. This preliminary action creates built-in deformation compensation mechanisms that reduce the need for complex real-time control during the adhesive curing process, simplifying the overall manufacturing process while ensuring structural integrity of the final assembled laminated core.
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 the production of laminated cores with reduced deformation even with a large number of laminations, achieving high precision and stability.
Implementation Method 1
a primary adhesion step of applying a primary adhesive agent to the core laminate while the core laminate is held by a first holding jig; a primary adhesive agent curing step of curing the primary adhesive agent while the core laminate is held by the first holding jig
Implementation Method 2
a secondary adhesion step of applying a secondary adhesive agent to lamination surfaces between the blocks; and a secondary adhesive agent curing step of curing the secondary adhesive agent while the core laminate is held by a second holding jig
Implementation Method 3
for each of multiple blocks each consisting of a predetermined number of the core constituting plates, a separation layer is interposed between adjacent ones of the core constituting plates
Implementation Method 4
holding of the core laminate by the first holding jig and the second holding jig may be performed in a state in which the core laminate is pressed in a stacking direction while displacement in a direction perpendicular to the stacking direction is restricted
Implementation Method 5
the adhesive agent layers contract when cured, and as a result, stress is generated in the core constituting plates
Data Source
AI summary
A primary adhesive agent is applied to a core laminate in which separation layers are interposed between multiple blocks each consisting of a predetermined number of core constituting plates, the separation layers are removed after the primary adhesive agent is cured, a secondary adhesive agent is applied to lamination surfaces between the blocks, and the secondary adhesive agent is cured.