Adhesively Laminated Stator Core With Partial Bonding for Low Iron Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric motor rotor cores fail to sufficiently suppress iron loss, which affects the efficiency and performance of electric motors.
Innovation Solution
An adhesively-laminated stator core is developed using stacked electrical steel sheets with insulation coatings and a two-agent type acrylic-based adhesive, where the adhesive is partially applied between the sheets to reduce stress and iron loss, allowing for efficient adhesion and manufacturing at room temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-component curing type adhesive is used to bond electrical steel sheets, then adhesion strength is improved, but iron loss cannot be sufficiently suppressed
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive from a two-component curing type to a one-component acrylic-based adhesive with specific functional groups (carboxyl, hydroxyl, or amino groups) that provide both adhesion strength and low iron loss characteristics through molecular structure optimization
Solution Approach 2:
The patent creates a composite adhesive system by combining acrylic-based polymer with specific functional additives and modifiers that work synergistically to achieve both strong adhesion and minimal iron loss, forming a multi-component composite material with optimized properties
2Strength
If adhesive is applied between all electrical steel sheets, then adhesion is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent segments the adhesion function by applying adhesive only at specific locations (interleaved pattern) rather than uniformly between all sheets, dividing the bonding task into strategic zones that maintain overall adhesion while reducing material and process complexity
Solution Approach 2:
The patent applies adhesive partially rather than completely between all steel sheets, using an interleaved bonding pattern that provides sufficient adhesion for structural integrity while significantly reducing the total amount of adhesive application and associated manufacturing steps
3Reliability
If insulation coating is applied on both surfaces of electrical steel sheets, then electrical insulation is improved, but adhesion between sheets deteriorates
Solution Approach 1:
The patent applies local quality by providing insulation coating on both surfaces for electrical protection, but selectively applying adhesive only at specific interleaved locations where the coating is either removed or penetrated, creating zones of different functional properties (insulation vs. adhesion) within the same interface
Solution Approach 2:
The patent introduces the acrylic-based adhesive with functional groups as an intermediary substance that chemically interacts with the insulation coating, allowing the adhesive to bond effectively through or with the coating layer, thus mediating between the electrical insulation requirement and the mechanical adhesion requirement
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
The solution effectively reduces iron loss and improves the productivity of electric motors by minimizing stress and thermal expansion differences between the adhesive and steel sheets, enhancing the core's magnetic properties and manufacturing efficiency.
Implementation Method 1
a plurality of electrical steel sheets which are stacked on one another and of which both surfaces are coated with insulation coatings, and adhesion parts which are disposed between the electrical steel sheets adjacent to each other in a stacking direction and cause the electrical steel sheets to be adhered to each other
Implementation Method 2
An adhesive forming the adhesion parts is a two-agent type acrylic-based adhesive which includes an acrylic-based compound, an oxidizer, and a reducer
Data Source
AI summary
An adhesively-laminated core for a stator capable of suppressing an iron loss of an electric motor and also having excellent productivity is provided. The adhesively-laminated core for a stator includes a plurality of electrical steel sheets which are stacked on one another and of which both surfaces are coated with insulation coatings, and adhesion parts which are disposed between the electrical steel sheets adjacent to each other in a stacking direction and cause the electrical steel sheets to be adhered to each other. All sets of the electrical steel sheets adjacent to each other in the stacking direction are adhered via the adhesion parts. An adhesive forming the adhesion parts is a two-agent type acrylic-based adhesive (SGA) which includes an acrylic-based compound, an oxidizer, and a reducer and in which a portion of the acrylic-based compound and the oxidizer are assigned to a first agent and the remaining portion of the acrylic-based compound and the reducer are assigned to a second agent. The adhesion parts are partially provided between the electrical steel sheets adjacent to each other in the stacking direction.