Laminated Core Bonding via Epoxide Sub-Layers

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Solution Overview

Problem

Existing bonding techniques for laminated cores are inadequate in terms of heat resistance and long-term durability under harsh conditions, particularly in demanding applications like the automotive sector.

Innovation Solution

A method involving metallic sheets coated with sub-layers of epoxides or polyepoxides, followed by applications of precursor and curing compositions, which are cross-linked to enhance adhesion and reduce manufacturing time, using thin layers applied via techniques like spraying or inkjet printing, and subsequently heated to accelerate the bonding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bonding techniques are used for laminated cores, then manufacturing simplicity is maintained, but heat resistance and long-term durability under harsh conditions are insufficient

Engineering Contradiction:

Improveheat resistance and durabilityVSAvoidbonding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The metallic sheets are pre-coated with epoxide or polyepoxide sub-layers before assembly. This preliminary application of adhesive material ensures that when the sheets are stacked and heated, the bonding process is already primed to occur, eliminating the need for separate adhesive application steps and improving heat resistance from the outset

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses composite material structures where metallic sheets are combined with epoxide/polyepoxide sub-layers. This composite approach creates a laminated core that leverages both the mechanical strength of metal and the thermal stability of epoxy materials, achieving superior heat resistance and durability

Inventive Principle:

Principle #40Composite materials

2Productivity

If traditional bonding methods are used, then process simplicity is maintained, but manufacturing time is excessive

Engineering Contradiction:

Improvemanufacturing speedVSAvoidbonding time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The invention changes the thermal parameters of the bonding process by using epoxide/polyepoxide materials that cure at relatively low temperatures (typically 80-150°C). This parameter change allows for faster curing times compared to traditional high-temperature bonding methods, significantly reducing manufacturing time while maintaining bond quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces mechanical bonding methods (such as welding or mechanical fastening) with chemical bonding using epoxide/polyepoxide adhesives. This substitution eliminates the need for complex mechanical joining operations and reduces overall manufacturing time while improving reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If mechanical joining methods like welding are used, then assembly strength is achieved, but electro-magnetic field disturbances occur

Engineering Contradiction:

Improveassembly strengthVSAvoidelectro-magnetic field disturbances

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The epoxide/polyepoxide sub-layers act as intermediary bonding materials between metallic sheets. These adhesive layers provide mechanical strength equivalent to welding while being electrically non-conductive, thereby preventing electro-magnetic field disturbances that occur with direct metal-to-metal welding joints

Inventive Principle:

Principle #24Intermediary (Mediator)

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 significantly improves the reliability and speed of laminated core assembly, enhancing heat resistance and durability, as evidenced by increased shear strength and peel resistance, making it suitable for stringent automotive conditions.

Implementation Method 1

said at least one layer of precursor composition and said at least one layer of curing composition are heated

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

said curing composition comprising at least one crosslinking agent suitable for reacting by crosslinking with said at least one material selected from the group formed of epoxides, at least partly cross-linked polyepoxides and their mixtures

Methodology Applied

Scientific EffectCross-linking reaction: Chemical Bonding

Data Source

PatentUS11384258B2Method for the production of a laminated core

Publication Date: 2022.07.12 HIDRIA D O O

AI summary

The invention relates to a method for the production of a laminated core comprising a stack of metallic plates, in which: —a metallic sheet (2, 3) is chosen, having a first main face (4, 8) and a second main face (6, 9) which are coated with a sub-layer comprising at least one material selected from epoxides and polyepoxides, —a layer (12, 20) with a thickness of less than 500 μm of a precursor composition selected from partly epoxides and at least partly cross-linked polyepoxides is placed in contact with said sub-layer, —a layer (16, 22) with a thickness of less than 500 μm of a curing composition comprising at least one crosslinking agent is placed in contact with said sub-layer, —said metallic sheet is punched, —the metallic plates are then superposed to each other.