Stacked Core Manufacturing Adhesive Application Oil Removal
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Solution Overview
Problem
Existing methods for manufacturing stacked cores face challenges in adhesive performance due to oil residue, leading to wear of punches and suboptimal blanking quality, and are limited by the type of adhesives that can be used within the die.
Innovation Solution
A method and apparatus for manufacturing stacked cores that involve forming core members from a metal plate, applying adhesive to individual members outside the die, and stacking them with a control unit managing the process to ensure precise adhesive placement and oil removal, allowing for the use of various adhesive types, including anaerobic and thermosetting adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press oil is applied to the coil member to suppress wear of the punch and improve blanking quality, then punch wear is reduced and blanking quality is improved, but the adhesion performance of the adhesive is affected when oil remains on the metal plate
Solution Approach 1:
The patent applies preliminary action by removing oil from the metal plate before adhesive application. The oil removal step is performed in advance to ensure the surface is clean, allowing the adhesive to bond effectively without oil interference, thus resolving the contradiction between maintaining lubrication benefits and ensuring adhesion performance
Solution Approach 2:
The patent extracts the harmful oil residue from the metal plate surface through a dedicated oil removal step. This extraction process separates the beneficial lubrication function (achieved during blanking) from the harmful residue that interferes with adhesion, allowing the adhesive to contact the clean metal surface directly
2Adaptability or versatility
If adhesive is applied inside the die during the stacking process, then the manufacturing process is simplified, but the type of adhesive that can be used is limited
Solution Approach 1:
The patent segments the manufacturing process into distinct steps: blanking, oil removal, adhesive application, and stacking. By separating the adhesive application step from the die-based blanking process, the patent enables the use of diverse adhesive types (including anaerobic and thermosetting adhesives) without complicating the die design, thus resolving the contradiction between versatility and complexity
Solution Approach 2:
The patent introduces an intermediary step (oil removal) between blanking and adhesive application. This intermediary process prepares the surface by removing oil residues, creating an optimal bonding surface that accommodates various adhesive types while maintaining a clear separation between the blanking die and adhesive application mechanisms
3Productivity
If adhesive is applied to the metal plate with oil remaining, then the manufacturing process continues without interruption, but the adhesion performance is compromised
Solution Approach 1:
The patent performs oil removal as a preliminary action before adhesive application. This pre-treatment step ensures the metal surface is free from oil residues that would compromise bonding, allowing the subsequent adhesive application and stacking to proceed efficiently without rework, thus resolving the contradiction between productivity and bonding quality
Data Source
AI summary
A method of manufacturing a stacked core includes: forming a stack by stacking a plurality of core members, each of the plurality of core members including one or more blanked members blanked by a die from a metal plate along a predetermined shape; removing one core member of the plurality of core members from the stack; supplying adhesive to the one core member removed from the stack; and stacking the one core member next to an adjacent core member of the plurality of core members so that the adhesive is placed between the one core member and the adjacent core member.