Thermally Activatable Adhesive Coating for Metal Sheet Stacks
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Solution Overview
Problem
Current methods for producing stacks of metal sheets, such as welding and interlocking, either damage the insulation layer or are time-consuming, limiting mass production efficiency and design flexibility.
Innovation Solution
A thermally activatable adhesive composition comprising an epoxy resin, latent curing agent, and accelerator, which can be activated quickly and cured at high temperatures, allowing for rapid and efficient joining of metal sheets without damaging the insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join metal sheets, then the connection strength is improved, but the insulation layer is damaged and eddy current losses increase
Solution Approach 1:
The patent replaces thermal welding processes with a mechanical adhesive bonding system. The adhesive composition chemically cures to form a strong bond between metal sheets without applying heat that would damage the insulation layer, thus eliminating eddy current losses while maintaining connection strength
Solution Approach 2:
The adhesive composition acts as an intermediary substance between metal sheets, providing both mechanical bonding strength and electrical insulation. This intermediary layer protects the insulation layer from direct thermal contact while still achieving secure connection
2Ease of manufacture
If interlocking is used to join metal sheets, then the manufacturing process is simplified, but the design freedom is limited and magnetic field is affected
Solution Approach 1:
The patent changes the bonding mechanism from mechanical interlocking to chemical adhesive bonding. This allows for continuous surface bonding instead of discrete mechanical connections, providing greater design flexibility and freedom while maintaining ease of manufacture through a streamlined process
3Object-affected harmful factors
If baked enamel is used to join metal sheets, then full-surface connection is achieved without damaging metal structure, but the production time is excessive
Solution Approach 1:
The patent modifies the curing parameters of the adhesive system by using a two-component epoxy adhesive that cures at lower temperatures and faster rates compared to traditional baked enamels. This reduces the production cycle time from 30-150 minutes to a much shorter duration while maintaining full-surface connection and metal structure integrity
Solution Approach 2:
The patent employs a composite adhesive system combining epoxy resin with specific curing agents and accelerators. This composite material formulation enables rapid curing at reduced temperatures, achieving both fast production cycles and gentle bonding that preserves metal structure
4Ease of manufacture
If traditional adhesives are used to join metal sheets, then the joining process is simplified, but the curing time is too long for mass production
Solution Approach 1:
The patent develops a composite adhesive formulation consisting of epoxy resin, curing agent, and accelerator in specific proportions. This composite material achieves rapid curing within minutes at elevated temperatures, making it suitable for mass production while maintaining process simplicity
Solution Approach 2:
The patent optimizes the chemical parameters of the adhesive system by selecting specific curing agents and accelerators that enable fast curing at controlled temperatures. This parameter optimization reduces curing time from hours to minutes, dramatically improving productivity while keeping the joining process simple
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
Enables rapid activation and curing of the adhesive, facilitating high-cycle-rate production of metal sheet stacks with preserved insulation integrity and design flexibility, suitable for large-scale mass production.
Implementation Method 1
A thermally activatable adhesive composition comprising an epoxy resin, latent curing agent, and accelerator, which can be activated quickly and cured at high temperatures
Implementation Method 2
thermally activatable adhesive composition... which can be activated quickly and cured at high temperatures
Data Source
AI summary
The present invention relates to a thermally activatable adhesive composition for use in a method for producing a stack of metal sheets from glued together sheet metal components, the use of the adhesive composition in a method for producing a stack of metal sheets from glued together sheet metal components, the method for producing a stack of metal sheets from glued together sheet metal components, a sheet metal component coated with the adhesive composition, and a stator or rotor core containing one or more of such sheet metal components.