Laminated Core Bonding with Release Layers for Precise Separation

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Solution Overview

Problem

Existing methods for connecting sheet metal parts to form packages face challenges in reproducibility and shape accuracy due to adhesive leakage and difficulty in separating baked parts, particularly when using thermally activated adhesives with reaction accelerators.

Innovation Solution

A separating layer with a reaction accelerator and release agent is applied to the coatings of the sheet metal parts, reducing adhesion and increasing melt viscosity of the adhesive, preventing incomplete curing and adhesive leakage, and allowing for easier separation into precise sheet metal packages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a release agent is applied to facilitate separation of sheet metal parts, then the division into packages is easier, but the adhesive curing is delayed and adhesive may leak out during bonding

Engineering Contradiction:

Improveease of separationVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The release agent is applied locally only to specific areas where separation is needed, rather than uniformly across the entire surface. This localized application allows the adhesive to cure properly in bonding areas while facilitating separation only where required, thus maintaining dimensional accuracy while enabling easy package division.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The release agent is applied in controlled amounts to specific regions, providing just enough separation capability without excessive application that would interfere with adhesive bonding. This partial action ensures adequate release functionality while preventing adhesive leakage and maintaining curing quality.

Inventive Principle:

Principle #16Partial or excessive action

2Strength

If the adhesive is thermally activated with reaction accelerator, then a stable bond is created between sheet metal parts, but the bonded parts become difficult to divide or separate into packages

Engineering Contradiction:

Improvebond strengthVSAvoidease of separation

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The release agent is applied locally to specific areas where separation is needed, creating zones of reduced adhesion within the otherwise strongly bonded structure. This allows the bulk of the bonding area to maintain strong thermal activation bonding while specific local areas facilitate easy separation into packages.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The release agent creates segmented zones of different adhesion properties within the bonded structure, allowing the sheet metal parts to be divided into discrete packages by exploiting these pre-defined separation zones without compromising the overall bond strength of the assembled structure.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the release agent reduces adhesion between coatings, then separation is facilitated, but the adhesive may flow out during bonding under pressure

Engineering Contradiction:

Improveease of separationVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The release agent is applied locally to specific areas rather than uniformly across the entire surface. This localized application creates separation zones only where needed, while other areas maintain full adhesive bonding capability, preventing adhesive flow and maintaining dimensional accuracy in critical bonding regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The release agent is applied in controlled, partial amounts to specific regions, providing just enough separation capability without excessive application that would cause adhesive to flow out during bonding. This controlled partial action maintains dimensional accuracy while enabling separation.

Inventive Principle:

Principle #16Partial or excessive action

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 reproducibility and shape accuracy of laminated cores by preventing adhesive leakage and ensuring complete curing, facilitating the production of precisely shaped sheet metal packages with high consistency.

Implementation Method 1

the reaction accelerator in the release layer increases the melt viscosity of the adhesive in the first coating

Methodology Applied

Scientific EffectViscosity increase:

Implementation Method 2

a preferably thermally activated adhesive

Methodology Applied

Scientific EffectThermal activation: Heating

Implementation Method 3

the release agent reducing the adhesion between the first and second coatings

Methodology Applied

Scientific EffectAdhesion reduction:

Data Source

PatentEP4244056B1Method for connecting sheet metal parts to stacks of metal sheets

Publication Date: 2025.01.01 VOESTALPINE STAHL GMBH

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AI summary

The invention relates to a method for connecting sheet metal parts (2) in order to form laminated cores (3). The aim of the invention is to produce laminated cores with a precise shape in a reproducible manner. This is achieved in that a separating layer (22) is provided on the first and/or second coating (8, 9), said separating layer having a reaction accelerator (10) for the adhesive of the first coating (8) and a separating agent (19) in order to thus simplify the division of the sheet metal parts (2) into laminated cores (3).