Electrical Steel Sheet Coating for Faster Bonded Core Stacking
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Solution Overview
Problem
Conventional methods for manufacturing bonded and stacked cores face challenges in achieving both high bonding strength and productivity, as the lubricating function of press working oil and the curing accelerating function of adhesives are not optimally balanced, leading to difficulties in obtaining both strong bonds and efficient manufacturing processes.
Innovation Solution
The use of an electrical steel sheet with an insulating coating containing a curing accelerator, which is dried and sealed before being mixed with press working oil, allowing for high concentration mixing with adhesives during bonding, thereby enhancing bonding strength and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the content of curing accelerator is increased to achieve higher curing accelerating effect, then bonding speed and productivity are improved, but the ratio of press working oil is reduced which may affect punching workability
Solution Approach 1:
The invention separates the functions of press working oil and curing accelerator by applying them at different stages: press working oil is applied before punching to ensure good punching workability, while curing accelerator is applied after punching to the bonded surface. This segmentation allows each substance to perform its function optimally without interfering with the other, resolving the contradiction between bonding speed and punching workability.
Solution Approach 2:
The press working oil is applied in advance before punching to ensure optimal punching conditions. The curing accelerator is then applied afterward to the bonded surface. This preliminary action sequence ensures that punching workability is not compromised by the presence of curing accelerator, while still achieving high bonding speed through sufficient curing accelerator application.
2Ease of manufacture
If curing accelerator is added to press working oil in diluted state, then application is simplified, but high concentration mixing with adhesive is difficult to achieve
Solution Approach 1:
The invention extracts the curing accelerator from the press working oil mixture and applies it separately to the bonded surface after punching. This extraction allows the press working oil to maintain its lubricating function without being diluted by curing accelerator, while the curing accelerator is applied in high concentration directly to where it is needed, ensuring both application simplicity and high concentration effectiveness.
Solution Approach 2:
The bonded surface acts as an intermediary medium where the curing accelerator is applied after punching. This intermediary approach allows the curing accelerator to be applied in high concentration directly to the bonding interface without being mixed with press working oil, ensuring both ease of application and high concentration effectiveness for rapid curing.
3Device complexity
If adhesive and curing accelerator are mixed in advance, then bonding process is simplified, but curing accelerator concentration is reduced due to mixing with press working oil
Solution Approach 1:
The adhesive is applied to the bonded surface in advance, and then the curing accelerator is applied afterward. This preliminary action sequence ensures that the adhesive is already in position before the curing accelerator is added, eliminating the need for pre-mixing while maintaining high curing accelerator concentration. The sequential application simplifies the process while preserving substance concentration.
Solution Approach 2:
The invention segments the bonding process into two distinct steps: first applying adhesive to the bonded surface, then separately applying curing accelerator. This segmentation avoids the dilution effect of pre-mixing with press working oil while keeping the process simple through clear sequential steps, resolving the contradiction between process simplicity and substance concentration.
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 enables the achievement of higher productivity while ensuring sufficient bonding strength in the manufacture of bonded and stacked cores, improving both the efficiency and quality of the manufacturing process.
Implementation Method 1
an insulating coating containing a curing accelerator, which is dried and sealed before being mixed with press working oil
Implementation Method 2
the curing accelerator... allowing for high concentration mixing with adhesives during bonding, thereby enhancing bonding strength
Data Source
AI summary
This electrical steel sheet contains: as a chemical composition, in a unit of mass %, 2.5% to 3.9% of Si; 0.001% to 3.0% of Al; and 0.05% to 5.0% of Mn, the remainder being Fe and impurities, and, on one surface or both surfaces thereof, an insulating coating containing a curing accelerator is formed.