Laminated Iron Core Bonding With Fusion Accelerator Coating
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Solution Overview
Problem
The existing methods for manufacturing laminated cores using electrical steel sheets face challenges in improving adhesive properties and manufacturing productivity, particularly in minimizing compression and heating during the punching and laminating process.
Innovation Solution
A method involving the application of a fusion accelerator containing a silane coupling agent, a curing agent, and a non-polar solvent on the electrical steel sheet before punching, which includes coating and drying the accelerator, followed by laminating and compressing the metal parts at lower temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding, clamping, or interlocking methods are used to laminate electrical steel sheets, then the structural integrity of the laminated core is ensured, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary substance between electrical steel sheets to achieve lamination. This adhesive layer simplifies the manufacturing process by replacing complex mechanical fastening methods (welding, clamping, interlocking) with a simpler coating and bonding process, while still ensuring reliable structural integrity of the laminated core
Solution Approach 2:
The patent replaces mechanical fastening systems (welding, clamping, interlocking) with a chemical bonding system using adhesive layers. This substitution eliminates the need for complex mechanical devices and processes, reducing manufacturing complexity while maintaining the reliability of the laminated core structure
2Strength
If high-temperature and high-pressure methods are used for laminating electrical steel sheets, then strong adhesive bonds are achieved, but energy consumption and manufacturing cost increase
Solution Approach 1:
The patent changes the bonding parameters by using adhesive layers that can achieve strong bonds at lower temperatures and pressures compared to traditional methods. The adhesive composition and application parameters are optimized to provide sufficient bonding strength without requiring extreme thermal and mechanical conditions, thereby reducing energy consumption
Solution Approach 2:
The patent uses composite adhesive materials with specific formulations designed to achieve optimal bonding at reduced temperatures and pressures. These adhesive compositions contain polymers and additives that provide strong adhesion between steel sheets without requiring the high energy input of traditional lamination methods
3Strength
If adhesive layers are coated on electrical steel sheets before punching, then adhesive properties are improved, but additional coating processes increase manufacturing time
Solution Approach 1:
The patent applies adhesive layers to the electrical steel sheets before the punching process. This preliminary action ensures that the adhesive is already in position and can immediately bond sheets together during lamination, improving adhesive properties while the coating process itself is designed to be efficient and rapid
4Productivity
If compression and heating are minimized during punching, then manufacturing productivity is improved, but adhesive bonding may be insufficient without adequate compression
Solution Approach 1:
The patent optimizes the compression parameters during lamination to achieve sufficient adhesive bonding with minimized compression forces and heating. The adhesive formulation and application method are designed to provide strong bonding at lower compression levels, enabling faster production cycles while maintaining adequate adhesive strength
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 enhances the adhesive properties of the laminated core and improves manufacturing productivity by achieving excellent adhesive strength at lower temperatures and pressures, compared to traditional high-temperature and high-pressure methods.
Implementation Method 1
coating the strip with a fusion accelerator including a silane coupling agent
Implementation Method 2
coating the strip with a fusion accelerator including a silane coupling agent, a curing agent, and a solvent
Implementation Method 3
coating the strip with a fusion accelerator including a silane coupling agent, a curing agent, and a solvent
Implementation Method 4
laminating the metal parts and attaching the metal parts to each other by compression
Data Source
AI summary
The present disclosure relates to a method for manufacturing an electrical steel sheet laminate, the method comprising the steps of: preparing an electrical steel sheet strip including an adhesive layer; coating the strip with a fusion accelerator including a silane coupling agent, a curing agent, and a solvent; fabricating metal parts from the strip; and laminating the metal parts and attaching same to each other by compression.