Particle-Controlled Coating for Laminated Sheet Bonding
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Solution Overview
Problem
Existing methods for applying adhesive coatings to laminated sheets in electric motor cores are inefficient in controlling the amount of coating used, leading to suboptimal stacking factors and bond strength, as they lack precise control over particle size and volume of the coating, which affects the magnetic properties and insulation within the core.
Innovation Solution
A method and apparatus that measure and control the particle size of liquid coatings, such as adhesives, accelerators, or thermal barriers, by using a particle generating chamber with a coating pattern delimiting mask and a control device to adjust operating parameters, ensuring the particle size falls within a set range for precise application on laminated sheets of varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive coating is applied to bond laminated sheets, then bond strength between laminates is improved, but stacking factor decreases due to space occupied by adhesive
Solution Approach 1:
The invention changes the physical state and size parameters of the adhesive coating by controlling particle generation conditions (pressure, temperature, gas flow rate) to produce adhesive particles within a specific size range (1-100 micrometers). This parameter control allows the adhesive to occupy minimal space while maintaining effective bonding area, thus improving bond strength while minimizing the reduction in stacking factor
Solution Approach 2:
The invention applies adhesive particles locally at the bonding interfaces between laminated sheets rather than coating entire surfaces. The particle generation device delivers adhesive particles precisely where needed at the laminate interfaces, ensuring bond strength is achieved only at critical bonding locations while minimizing overall adhesive volume and its impact on stacking factor
2Manufacturing precision
If particle size of liquid coating is controlled, then coating quantity and quality are improved, but device complexity increases due to particle generation chamber and measurement systems
Solution Approach 1:
The invention incorporates a feedback control system where a particle size measurement device continuously monitors the generated adhesive particles and provides data to a control device. The control device adjusts generation parameters (pressure, temperature, gas flow) in real-time based on measured particle size, ensuring consistent coating quality and quantity control while automating the complexity of particle generation management
Solution Approach 2:
The invention replaces traditional mechanical coating systems with a particle generation system that uses gas dynamics and controlled expansion to generate and deliver adhesive particles. This substitution allows for more precise control of coating parameters through gas flow and pressure control rather than mechanical application, improving manufacturing precision while the complexity is managed through automated control systems
3Volume of moving object
If amount of adhesive coating is reduced to improve stacking factor, then space occupied by adhesive is minimized, but bond strength between laminates is weakened
Solution Approach 1:
The invention changes the adhesive application from continuous liquid coating to controlled particle deposition. By generating adhesive particles within a specific size range (1-100 micrometers) and controlling their delivery, the system achieves effective bonding with minimal adhesive volume. The particle size and distribution parameters are optimized to ensure sufficient bond strength while minimizing the volume occupied by adhesive, thus improving stacking factor
Data Source
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AI summary
The present invention consists of a method and apparatus for the application of particle size-controlled liquid coatings on sheets of varying geometries, which are stacked and compacted. Such coatings can be adhesives, accelerators, insulators or thermal barriers. The method and apparatus allows the size of the particles in suspension of the coating to be measured for each application, in order to control the quantity used.