Adhesive-Coated Laminated Core Stacking for Clean Section Separation
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Solution Overview
Problem
The production of laminated cores for electric motors faces challenges in achieving optimal stack separation and minimizing physical and chemical contamination in inline systems, leading to inefficiencies and interruptions in the manufacturing process due to the use of adhesives and treatment fluids.
Innovation Solution
A method involving sheets with partially curable polymeric adhesive coatings, processed through an inline system with cutting, activating, and separating means, where a treatment fluid is applied to reduce adhesive effectiveness at predetermined points to facilitate seamless stack section separation, using infrared radiation or induction heating for activation, and a non-stick coating to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive coating is used to bond laminations in continuous production, then productivity is improved, but stack separation becomes difficult and contamination increases
Solution Approach 1:
The adhesive coating is segmented into different functional zones: a first adhesive coating for strong bonding between laminations, and a second adhesive coating with reduced effectiveness for enabling stack separation. This segmentation allows the system to achieve both continuous production and easy separability by distributing different adhesive properties to different locations in the stacking process.
Solution Approach 2:
Different regions of the adhesive coating have different properties: the first adhesive coating applied to initial laminations provides strong bonding, while the second adhesive coating applied to subsequent laminations has reduced effectiveness to enable separation. This local differentiation of adhesive quality resolves the contradiction between strong bonding and easy separation.
2Ease of operation
If treatment fluid is applied to reduce adhesive effectiveness, then stack separability is improved, but physical and chemical contamination of tools increases
Solution Approach 1:
The patent uses a disposable release liner that is discarded after use, eliminating the need to clean and maintain tools. The release liner absorbs the treatment fluid and prevents contamination of cutting and separating tools, while still enabling stack separation when removed.
Solution Approach 2:
The release liner acts as an intermediary between the adhesive-coated laminations and the cutting/separating tools. It prevents direct contact between treatment fluids and tools, thereby eliminating contamination while still allowing the separation function to be achieved.
3Strength
If adhesive coating is activated for bonding, then mechanical strength is improved, but separability of stack sections deteriorates
Solution Approach 1:
The adhesive coating process is segmented into two distinct stages: first, activating the adhesive coating for strong bonding between laminations; second, applying a release liner that enables separation of stack sections. This temporal and functional segmentation allows both strong bonding and easy separation to be achieved in the same system.
Solution Approach 2:
The release liner is applied in advance to laminations before they are fully bonded, creating a predetermined separation plane. This preliminary action ensures that when separation is needed, it occurs cleanly at the intended location without compromising the bonded strength of adjacent laminations.
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 enables continuous, efficient production of laminated cores with improved separability and reduced contamination, maintaining excellent electromagnetic properties while ensuring uninterrupted processing and enhanced mechanical strength.
Implementation Method 1
activating the adhesive coating of the molded part with activating means (5) for activating the adhesive coating
Implementation Method 2
using infrared radiation or induction heating for activation
Implementation Method 3
the adhesive coating of this subsequent molded part in the positioning area, as a result of the reduced effectiveness of the adhesive coating, brings about improved separability
Implementation Method 4
a non-stick coating to prevent contamination
Data Source
Figure 1
AI summary
The invention relates to a method for manufacturing a laminated core, for example, a stator core or a rotor core. The method comprises the following steps: A) providing a sheet (1) with an adhesive coating, B) transporting the sheet into an inline system comprising: a cutting agent (4), a separating agent (6), and an activating agent (5, 5a, 5b), C) cutting a shaped part (2) with the cutting agent (4), D) activating the adhesive coating, E) separating the shaped part (2), F) depositing the shaped part (2), G) repeating steps C) to F), wherein the adhesive coating of some shaped parts (8) is provided with a treatment fluid by means of a treatment device (9) to create a predetermined breaking point for separating a stack of shaped parts (3, 3). In some cases, further compaction can be carried out using a compressor station (7). The treatment fluid comprises a stamping oil.The invention also relates to a sheet metal stack and an electric machine.