Lamination Stack Assembly for Damage-Free Core Disassembly
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Solution Overview
Problem
The disassembly of large sheet metal assemblies, such as laminated core assemblies, is complex and often results in damage to the components due to the use of traditional adhesives, leading to costly and time-consuming remanufacturing processes.
Innovation Solution
The use of hot melt adhesive coatings on insulating elements between laminated cores allows for damage-free disassembly by melting the adhesive, enabling separation without damaging the components, and the reuse of insulating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesives are used to bond insulating elements to laminated cores, then structural strength and stability are improved, but disassembly becomes complex and damages components
Solution Approach 1:
The patent applies parameter changes by using adhesives with different melting temperatures in a layered structure. The lower-melting-point adhesive (80-120°C) is positioned between the insulating element and one lamination, while the higher-melting-point adhesive (150-200°C) is positioned between the insulating element and the other lamination. This temperature parameter differentiation enables selective bonding and controlled disassembly at different temperature stages, resolving the contradiction between strong bonding and easy disassembly.
Solution Approach 2:
The patent segments the bonding function into two distinct adhesive layers with different thermal properties. Instead of using a single adhesive layer, the bonding system is divided into two functional layers: one that bonds at lower temperature and another that bonds at higher temperature. This segmentation allows the insulating element to be selectively released from one lamination while maintaining bonding to the other, enabling partial disassembly without damaging components.
2Ease of repair
If mechanical force is applied to remove insulating elements, then disassembly is achieved, but laminated cores are damaged
Solution Approach 1:
The patent replaces the mechanical removal system with a thermal system. Instead of applying mechanical force to knock off insulating elements, the invention uses controlled heating to melt the lower-melting-point adhesive layer, causing the insulating element to detach naturally through thermal softening. This substitution of mechanical action with thermal action eliminates damage to the laminated cores while achieving successful disassembly.
3Ease of repair
If adhesive bonds are broken to disassemble lamination stacks, then components can be separated, but failure fractures occur in insulating elements
Solution Approach 1:
The patent uses parameter changes in adhesive melting temperatures to control the disassembly process. By heating to a temperature range that melts the lower-melting-point adhesive (80-120°C) but remains below the melting point of the higher-melting-point adhesive (150-200°C), the insulating element is selectively released from one lamination while maintaining its structural integrity. This controlled thermal parameter change prevents fracture of the insulating element that would occur with forced mechanical separation.
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
Enables damage-free disassembly and reuse of insulating elements, reducing remanufacturing costs and time by using hot melt adhesives that maintain structural integrity during normal operation and melt at lower temperatures than the bonding adhesive.
Implementation Method 1
hot melt adhesive coatings on insulating elements between laminated cores allows for damage-free disassembly by melting the adhesive
Implementation Method 2
hot melt adhesives that maintain structural integrity during normal operation
Data Source
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AI summary
The invention relates to a laminated core assembly (1) comprising several laminated cores (3, 5) arranged in a stacked configuration. Each pair of adjacent laminated cores (3, 5) is spaced apart by a number of electrically insulating elements (7, 9) arranged between them, each of which has a first contact surface (11) against one of the laminated cores (3, 5) and a second contact surface (13) against the other of the laminated cores (3, 5). Each contact surface (11, 13) of each insulating element (7, 9) is a surface of a hot-melt adhesive coating (17) of the insulating element (7, 9) and is bonded to the laminated core (3, 5) to which it rests by a bonding adhesive (19) that connects the contact surface (11, 13) and the laminated core (3, 5).