Laminated Core Manufacturing Method for Rotary Electric Machines
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Solution Overview
Problem
The existing laminated core manufacturing methods for rotary electric machines face challenges such as poor productivity due to the need for multiple adhesive application steps, unstable adhesive strength, and increased maintenance costs, as well as assembly precision issues caused by adhesive protrusions and frequent die release characteristic deterioration.
Innovation Solution
A laminated core manufacturing method that involves pressing electrically insulating members onto the side surfaces of the laminated body using an adhesive or pressure-sensitive adhesive, reducing the number of joining positions and ensuring uniform adhesive thickness, thereby improving productivity and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is applied in two steps (temporary fastening and impregnating), then alignment of electromagnetic steel sheets is improved, but productivity deteriorates due to multiple processing steps
Solution Approach 1:
The patent combines the temporary fastening function and the final bonding function into a single adhesive application step. The adhesive serves dual purposes: it temporarily holds the laminated body during processing and provides permanent bonding between electromagnetic steel sheets, eliminating the need for separate temporary fastening and impregnating steps while maintaining alignment precision
Solution Approach 2:
The adhesive is designed to perform multiple functions simultaneously: it acts as both a temporary fastening agent during manufacturing and a permanent bonding agent for the final product. This multi-functionality reduces the number of processing steps required while ensuring both alignment and structural integrity
2Strength
If adhesive is applied to side surface of laminated body, then bonding between sheets is achieved, but adhesive strength becomes unstable due to difficulty in applying uniform thickness
Solution Approach 1:
The patent transitions from applying adhesive to the side surface (external application) to applying adhesive between the electromagnetic steel sheets (internal application). This dimensional change allows the adhesive to be distributed uniformly across the bonding interface through the lamination process itself, ensuring consistent thickness and stable bonding strength
Solution Approach 2:
The adhesive is applied as an intermediary layer between the electromagnetic steel sheets during the lamination process. This intermediary positioning allows for controlled, uniform distribution of the adhesive throughout the stack, ensuring consistent bonding thickness and strength across all sheets
3Ease of operation
If fluorocarbon resin coating is applied to jig, then die release characteristics are improved initially, but productivity deteriorates due to frequent reapplication needed during repeated production
Solution Approach 1:
The patent extracts the adhesive application process from the jig surface and applies it directly to the electromagnetic steel sheets during lamination. This eliminates the need for fluorocarbon resin coating on the jig entirely, removing the source of die release problems and the associated maintenance requirements while maintaining ease of operation
Solution Approach 2:
The patent adopts a approach where the adhesive is applied only where needed (between sheets) rather than coating the entire jig surface with expensive fluorocarbon resin. This reduces material costs and eliminates the need for frequent reapplication of the coating, improving productivity while maintaining ease of operation
4Strength
If adhesive protrudes from side surfaces, then bonding between sheets is achieved, but assembly precision deteriorates due to adhesive at contacting surfaces
Solution Approach 1:
The patent applies adhesive locally between the electromagnetic steel sheets during lamination rather than on the outer side surfaces. This localized application ensures bonding strength is achieved at the critical interfaces while preventing adhesive from protruding onto the assembly contact surfaces, thereby maintaining assembly precision
5Strength
If adhesive is impregnated between all electromagnetic steel sheets, then bonding strength is maximized, but productivity deteriorates due to large number of impregnation positions required
Solution Approach 1:
The patent combines the lamination process with the adhesive application process, applying adhesive between sheets during the single lamination operation rather than requiring separate impregnation steps for each sheet. This merging of processes achieves comprehensive bonding while maintaining high productivity
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 enhances productivity by stabilizing adhesive strength, reducing management and maintenance costs, and improving assembly precision by minimizing adhesive-related issues and die release characteristic degradation.
Implementation Method 1
a manufacturing method for a laminated core includes a bonding step in which insulating members are pressed onto side surfaces of a tooth portion... by means of at least one of an adhesive and a pressure-sensitive adhesive that is disposed between each of the side surfaces of the tooth portion and the insulating members
Implementation Method 2
by means of at least one of an adhesive and a pressure-sensitive adhesive that is disposed between each of the side surfaces of the tooth portion and the insulating members
Data Source
AI summary
A laminated core manufacturing method according to the present invention is a manufacturing method for a laminated core including: a laminated body that is configured by laminating core strips that are made of a magnetic material, the laminated body including: a core back portion; and a tooth portion; and electrically insulating members that are disposed on two side portions of the tooth portion, wherein the laminated core manufacturing method includes a bonding step in which the insulating members are pressed onto each of the side surfaces of the tooth portion of the laminated body so as to integrate the laminated body and also so as to fix the insulating members to the laminated body, by means of at least one of an adhesive and a pressure-sensitive adhesive that is disposed between each of the side surfaces of the tooth portion and the insulating members.