Laminated Core Bonding by Simultaneous Heating and Pressurization
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Solution Overview
Problem
Existing methods for adhering soft magnetic material sheets in laminated cores, such as electrical steel sheets, are inefficient due to separate units for heating and pressurizing, limiting the number of sheets that can be adhered at once and requiring repeated adhesion processes.
Innovation Solution
A manufacturing method and apparatus that utilize a heating part to simultaneously pressurize and heat a partial region of the outermost soft magnetic material sheet, enabling efficient adhesion of multiple sheets by exhibiting adhesive ability through heating, with the adherable insulating coating covering at least 50% of the sheet surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate units are used for heating and pressurizing electrical steel sheets, then the adhesion process can be performed, but the manufacturing efficiency is reduced and repeated adhesion processes are required
Solution Approach 1:
The patent combines the heating unit and pressurizing unit into a single integrated adhesion apparatus. The heating part and pressurizing part work simultaneously on the electrical steel sheets, eliminating the need for separate heating and pressurizing steps. This integration allows multiple sheets to be adhered in one operation, significantly improving manufacturing efficiency and eliminating repeated adhesion processes.
2Productivity
If electrical steel sheets are adhered one by one during lamination, then the lamination process is simple, but the adhesion process must be repeated many times reducing efficiency
Solution Approach 1:
The patent applies preliminary heating to the electrical steel sheets before lamination, so that when the sheets are stacked and pressurized, the adhesion occurs immediately without requiring repeated heating cycles. The heating part heats the sheets in advance, and then the pressurizing part applies pressure to bond multiple sheets simultaneously in a single operation, dramatically reducing the number of repeated adhesion cycles needed.
3Reliability
If the insulating coating covers the entire sheet surface, then insulation properties are improved, but adhesive ability is reduced until heating is applied
Solution Approach 1:
The patent utilizes the temperature-dependent properties of the insulating coating. The coating is designed to maintain its insulating properties at room temperature but transforms to exhibit adhesive ability when heated to a specific temperature range. The heating part raises the temperature of the coated sheets, causing the coating to change from an insulating state to an adhesive state, thereby achieving both insulation and adhesion requirements.
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 allows for the efficient adhesion of all sheets at once, reducing manufacturing time and compressive stress, while ensuring secure adhesion and improved insulation properties.
Implementation Method 1
a heating part is brought into contact with a partial region of a sheet surface of an outermost soft magnetic material sheet to simultaneously pressurize and heat the region
Implementation Method 2
a pressurization processing means that performs processing for making the heating part to be brought into contact with an outermost soft magnetic material sheet to pressurize the soft magnetic material sheet
Data Source
AI summary
Heating parts (212a to 212l, 222a to 222l) are brought into contact with planned heating regions (11a to 11l) of outermost electrical steel sheets (10a, 10b) of an electrical steel sheet group (100), to simultaneously pressurize and heat the planned heating regions (11a to 11l).