Laminated Iron Core Bonding With Integrated Press and Partial Heating
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Solution Overview
Problem
The existing manufacturing method for laminated iron cores is inefficient due to the need to move core materials between heating and lamination positions, and there is a risk of core material adherence to the press machine cylinder, leading to improper lamination and potential repair needs.
Innovation Solution
A manufacturing method that involves pressing electrical steel sheets with a die to form unit iron cores, followed by lamination and selective heating of the uppermost unit iron core's surface at partial regions to achieve partial adherence to lower layers, thereby eliminating the need for separate heating and lamination positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core material is conveyed to a heating position and then to a lamination position in sequence, then the coating adhesive ability can be activated, but the manufacturing efficiency is reduced due to multiple movement steps
Solution Approach 1:
The patent combines the heating function and lamination function into a single integrated die structure. The heating unit is incorporated directly into the die, allowing the core material to be heated and laminated in one location without requiring separate conveyance steps between heating position and lamination position, thereby improving manufacturing efficiency while maintaining reliable adhesive activation
Solution Approach 2:
The die is designed with multi-functionality, serving both as a pressing tool for lamination and as a heating device. By integrating the heating unit into the die structure, the same equipment performs multiple functions (pressing and heating), eliminating the need for separate heating and lamination stations and reducing the number of movement steps required
2Reliability
If the core material is heated while magnetically attracted to the press machine cylinder, then the adhesive ability is activated, but the core material may adhere to the cylinder causing improper lamination and requiring repairs
Solution Approach 1:
The patent extracts the heating function from the press machine cylinder and relocates it to a dedicated heating unit integrated into the die structure. This separation prevents the core material from adhering to the cylinder during heating, as the heating now occurs in a controlled die environment where the material is constrained by the die cavity rather than magnetically attracted to a cylindrical surface
Solution Approach 2:
The die acts as an intermediary structure that mediates between the heating process and the lamination process. The heating unit, integrated into the die, provides controlled heating while the die cavity itself serves as the lamination mold, preventing direct contact between the heated core material and the press machine cylinder that would cause unwanted adhesion
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 increases the efficiency of laminated iron core manufacturing by eliminating the need for core material movement between heating and lamination, reducing the risk of adherence issues, and ensuring proper lamination without requiring frequent press machine repairs.
Implementation Method 1
heating the sheet surface of the unit iron core of an uppermost layer at a plurality of partial regions to make the unit iron core of the uppermost layer to be partially adhered to the unit iron core of a lower layer
Implementation Method 2
an adhesive that exhibits adhesive ability through heating, provided to a sheet surface thereof
Data Source
AI summary
A manufacturing method of a laminated iron core includes: a step of pressing, with a die (2), an electrical steel sheet having a coating containing an adhesive that exhibits adhesive ability through heating, provided to a sheet surface thereof, to obtain a unit iron core (1); and a step of laminating the unit iron cores (1) pressed with the die (2), and heating the sheet surface of the unit iron core (1) of an uppermost layer at a plurality of partial regions to make the unit iron core (1) of the uppermost layer to be partially adhered to the unit iron core (1) of a lower layer thereof at a plurality of regions. As above, by performing the presswork and the lamination substantially simultaneously as a series of operation, it is possible to increase the efficiency of manufacture of the laminated iron core without increasing the man-hour.