Lamination Stack Bonding with Two-Stage Adhesive Activation
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Solution Overview
Problem
Current methods for producing stacks of laminations are inefficient and lack a simple, effective process for integrating laminations into electrical laminated cores, particularly in the production of rotor and stator cores for electric motors.
Innovation Solution
A method involving the coating of laminations with a bonding agent, followed by two-stage activation to form sheet metal laminates, which are then divided and re-bonded to create a stack, utilizing different parameters for each activation stage to optimize bonding and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-stage bonding methods are used to produce stacks of laminations, then the process is simpler, but the productivity and bonding quality are insufficient
Solution Approach 1:
The bonding process is segmented into two distinct stages: first bonding individual laminations to form sheet metal laminates, then bonding these laminates together to form the final stack. This segmentation allows each stage to be optimized independently, improving overall productivity while maintaining manageable process complexity through systematic division of the bonding operation.
Solution Approach 2:
Sheet metal laminates are pre-formed by bonding individual laminations together in a first bonding stage before being assembled into the final stack. This preliminary action creates intermediate components that can be handled and positioned more efficiently, thereby improving the overall production efficiency of the stacking process.
2Reliability
If laminations are bonded directly into final stacks, then the number of process steps is reduced, but the bonding quality and integration efficiency are insufficient
Solution Approach 1:
The bonding process is divided into two quality-assurance stages: first bonding laminations to form laminates with controlled adhesive distribution, then bonding laminates into stacks. This segmentation ensures each bonding interface achieves optimal adhesive coverage and strength, improving overall bonding quality while the modular laminate structure enhances production efficiency.
Solution Approach 2:
Different bonding parameters are applied in the two stages: the first bonding stage uses parameters optimized for lamination-to-laminate bonding, while the second stage uses parameters optimized for laminate-to-stack bonding. This parameter optimization at each stage ensures high bonding quality without compromising production efficiency.
3Productivity
If a two-stage bonding process is implemented, then bonding quality and productivity improve, but the process complexity increases
Solution Approach 1:
The manufacturing process is segmented into two standardized stages with defined inputs and outputs. This segmentation improves productivity through optimized bonding parameters at each stage while managing complexity through systematic process structure and clear stage boundaries.
Solution Approach 2:
The bonding apparatus is designed to perform both bonding stages using the same basic equipment, allowing it to function universally for both lamination-to-laminate bonding and laminate-to-stack bonding. This multi-functionality improves productivity through consistent equipment performance while avoiding the need for separate specialized equipment for each stage.
4Adaptability or versatility
If sheet metal laminates are divided and re-bonded, then the integration into electrical laminated cores is improved, but additional process steps are required
Solution Approach 1:
The sheet metal laminate is divided into multiple units that can be independently positioned and oriented before being re-bonded into the final stack. This segmentation provides adaptability for integrating different lamination configurations into electrical laminated cores while managing complexity through the modular nature of the laminate units.
Solution Approach 2:
Sheet metal laminates are pre-formed and divided into units before final stack assembly, allowing for optimized positioning and orientation during the re-bonding stage. This preliminary preparation enhances integration capability into electrical laminated cores while managing process complexity through advance preparation of standardized laminate units.
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 enables the efficient production of electrical laminated cores with improved bonding and integration of laminations, enhancing the efficiency and cost-effectiveness of stator and rotor core production.
Implementation Method 1
coating one or more laminations with a bonding agent; bonding a plurality of laminations to form a sheet metal laminate by means of a first activation of the bonding agent; bonding the plurality of sheet metal laminate units to form a stack of laminations by means of a second activation of the bonding agent
Data Source
AI summary
In order to provide a method by means of which stacks of laminations can be produced in a simple and efficient manner, it is provided that the method comprises the following: coating one or more laminations with a bonding agent; bonding a plurality of laminations to form a sheet metal laminate by means of a first activation of the bonding agent; dividing the sheet metal laminate to produce a plurality of sheet metal laminate units and/or separating out a plurality of sheet metal laminate units from the sheet metal laminate; and bonding the plurality of sheet metal laminate units to form a stack of laminations by means of a second activation of the bonding agent, one or more parameters differing from one another in the first activation and the second activation.