Multilayer Motor Lamination Stamping With Room-Temperature Adhesive Bonding
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Solution Overview
Problem
Current methods for producing electric motor rotor and stator laminations using thin sheet steel face challenges with mechanical mating or welding, requiring significant heat curing processes for adhesives like epoxy, leading to increased energy usage and cycle time.
Innovation Solution
A method involving the use of anaerobic or cyanoacrylate adhesives that cure at room temperature or slightly elevated temperatures, applied in multiple stages to join thin sheet materials before stamping, eliminating the need for high-temperature curing and optimizing adhesive application patterns to enhance bonding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy adhesives are used to join thin sheet materials, then strong bonding is achieved, but high-temperature curing is required which increases energy usage and cycle time
Solution Approach 1:
The patent changes the chemical parameters of the adhesive system by switching from epoxy-based adhesives (requiring high-temperature curing) to anaerobic adhesives (curing at room temperature or slightly elevated temperatures). This parameter change in adhesive chemistry enables the same bonding function to be achieved without the harmful high-temperature curing process, thereby reducing energy consumption and cycle time while maintaining bonding strength.
Solution Approach 2:
The patent replaces the thermal curing mechanism (heat-based chemical reaction) with a chemical curing mechanism (anaerobic polymerization). Instead of relying on high-temperature heat activation to cure the adhesive, the system uses the absence of oxygen and ambient or slightly elevated temperatures to initiate and complete the curing process, substituting a mechanical/chemical approach for a thermal one.
2Strength
If epoxy adhesives are used to join thin sheet materials, then strong bonding is achieved, but cycle time is increased due to high-temperature curing requirements
Solution Approach 1:
The patent changes the curing temperature parameter from high-temperature (epoxy requirement) to room temperature or slightly elevated temperatures (anaerobic adhesive capability). This parameter change in the curing process enables significantly reduced cycle times while maintaining adequate bonding strength for the application, directly addressing the time loss issue.
Solution Approach 2:
The patent replaces the time-consuming thermal curing process with a faster chemical curing process. The anaerobic adhesive cures through polymerization in the absence of oxygen at ambient or slightly elevated temperatures, eliminating the need for prolonged high-temperature exposure and thereby reducing the overall cycle time while achieving the required bond strength.
3Manufacturing precision
If multiple layers of thin sheet material are stamped individually, then each layer can be precisely formed, but production efficiency is reduced
Solution Approach 1:
The patent merges multiple individual stamping operations into a single multilayer stamping process. By bonding thin sheet materials together to form a multilayer stack before stamping, the system can stamp multiple layers simultaneously in one operation, thereby maintaining the precise formation of each layer while significantly improving production efficiency through combined processing.
Solution Approach 2:
The patent performs the adhesive bonding of multiple thin sheet layers as a preliminary action before the stamping operation. This preliminary bonding creates a stable multilayer stack that can be handled and stamped as a single unit, enabling subsequent high-speed stamping of multiple layers without the layers separating or misaligning, thus maintaining precision while boosting 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 approach reduces production time and costs by forming multilayer laminations efficiently, utilizing existing high-speed stamping techniques without the need for elevated temperatures, resulting in improved electromagnetic performance and reduced material handling.
Implementation Method 1
The adhesives for creating the bonds between the layers to form the multilayer construction, and later in the process to produce the lamination stack, are of either anaerobic or cyanoacrylate technology. The anaerobic adhesives cure in the absence of oxygen
Implementation Method 2
The cyanoacrylate adhesive is derived from ethyl cyanoacrylate and related esters
Data Source
AI summary
A method and system for creating a bonded lamination stack for rotors and stators includes a multilayer roll feeder that receives upper and lower layers of sheet material. A first adhesive is applied between the layers prior to combining the layers in the multilayer roll feeder into a multilayer material sheet. A further adhesive is applied to the multilayer material sheet prior to stamping rotor and stator plates from the same section of the multilayer sheet. The rotor and stator plates having the further adhesive are vertically stacked and bonded together. The adhesives may be applied in specific locations corresponding to the area of material that becomes the rotor and stator to reduce contaminating the stamping punch. The rotor plate is punched from material disposed radially inward from the material of the stator plate.