Adhesive resin composition coated electrical steel sheet and method for producing same

Abstract

An adhesive resin composition-coated electromagnetic steel sheet comprising: a steel sheet; and an adhesive resin composition film on at least one surface of the steel sheet, wherein the adhesive resin composition film is a semi-cured product of an adhesive resin composition composed of a curing agent and an adhesive resin containing at least partially a thermosetting resin, the maximum penetration λ of the adhesive resin composition film at 100-300°C is at least 3% and less than 100%, as measured by thermomechanical analysis according to JIS K 7196:2012, a portion of the curing agent in the adhesive resin composition film is present in a crystalline state, and the area ratio of the curing agent in the crystalline state in a cross section, parallel to the surface of the steel sheet, of the adhesive resin composition film is 0.10-40%.

Description

[Technical Field]

[0001] The present invention relates to an adhesive resin composition coated electrical steel sheet and a method for producing the same. [Background technology]

[0002] Iron cores used in motors and the like are assembled by punching out electromagnetic steel sheets into a predetermined shape, shearing them, and then laminating and bonding them together. A known bonding method is to use a thermosetting adhesive, which can bond the sheets together without causing processing distortion or thermal distortion, provides insulation between the laminated steel sheets, increases eddy current resistance, reduces iron loss, and also has excellent heat resistance under actual usage conditions.

[0003] The most common method for laminating and bonding magnetic steel sheets with a thermosetting adhesive is to laminate and thermocompress the magnetic steel sheets after punching and shearing them.Methods for applying a thermosetting adhesive to the magnetic steel sheet surface can be broadly divided into two types depending on the timing of application of the thermosetting adhesive.

[0004] One method is to apply a thermosetting adhesive to the magnetic steel sheets after punching. This method can be further divided into two methods: one in which the thermosetting adhesive is sprayed onto the surface of the magnetic steel sheets with a spray or other method just before shearing, and then shearing and laminating them; and one in which the laminated core is immersed in adhesive liquid after punching, shearing, and lamination are completed, and the adhesive is allowed to penetrate between the laminated magnetic steel sheets.

[0005] The other method is to apply a thermosetting adhesive to at least one surface of an electrical steel sheet in advance, dry the sheet, and then punch and shear the sheet, followed by lamination. Hereinafter, an electrical steel sheet having an adhesive resin composition coating, in which a thermosetting adhesive is applied to at least one surface of the electrical steel sheet and then dried, may be referred to as an "adhesive resin composition-coated electrical steel sheet."

[0006] Among these methods for laminating and fixing magnetic steel sheets, the latter has attracted attention in recent years because it is superior in terms of handling of adhesive application, uniformity, productivity, and the like.

[0007] In the latter method, first, an adhesive resin composition-coated electrical steel sheet (semi-finished product) is obtained, which has a semi-cured adhesive resin composition coating obtained by stopping the curing reaction of a thermosetting adhesive applied to the surface of the electrical steel sheet midway. This is then used to manufacture an iron core (product). The adhesive resin composition-coated electrical steel sheet is manufactured by applying a thermosetting adhesive based on a mixture of a thermosetting adhesive resin and a curing agent to the surface of a wide electrical steel sheet, followed by heating. The manufactured adhesive resin composition-coated electrical steel sheet is then wound into a coil and stored. Furthermore, the adhesive resin composition-coated electrical steel sheet may be unwound from the coil, slit to the punching width, and then wound into a coil again, and stored again.

[0008] Iron cores are manufactured by punching, shearing, laminating, and thermocompression bonding adhesive resin composition-coated electrical steel sheets. Therefore, not only is there a need for a technology for uniformly coating the adhesive resin composition film on the steel sheet surface, but there is also a need for a technology for preventing defects such as poor peeling between the steel sheets when the steel sheets are wound up and unwound into a coil and insufficient adhesive strength after thermocompression bonding.

[0009] It should be noted that, in general, the processes from applying the thermosetting adhesive when manufacturing adhesive resin composition-coated electrical steel sheets to thermocompression bonding when manufacturing iron cores are not continuous. Therefore, the manufacturing process for adhesive resin composition-coated electrical steel sheets (semi-finished products) includes storage and transportation steps from the completion of drying until the start of punching. Furthermore, the storage period can be extremely long, lasting several months or more. Furthermore, steel sheets may be stored for several weeks in a ship's hold, which can experience a high-temperature, humid environment of approximately 50°C during transportation. During this storage period, the adhesive resin composition coating of the adhesive resin composition-coated electrical steel sheets is in a semi-cured state (non-equilibrium state) in which the irreversible curing reaction has stopped midway.

[0010] Therefore, adhesive resin composition-coated electrical steel sheets are very unstable. Therefore, if the sheet is stored for a long period of time in a high-temperature, humid environment after the adhesive has been applied and dried, defects such as those described in (A) and (B) below are likely to occur. Note that a high-temperature, humid environment is, for example, the environment inside a warehouse on a ship sailing near the equator, where the storage temperature is around 50°C. (A) Adhesive blocking: During storage, a curing reaction of the adhesive resin progresses between the surfaces of the adhesive resin composition coating, resulting in adhesive bonding between the stacked and stored steel sheets. (B) Decrease in adhesive strength: The adhesive resin composition film hardens excessively during storage. As a result, the adhesive resin does not soften sufficiently even when heated for thermocompression bonding, and the adhesive resin cannot penetrate into the irregularities on the adherend surface, failing to exert an anchoring effect and resulting in a decrease in adhesive strength between laminated steel sheets.

[0011] Therefore, a technique has been disclosed that solves this instability by controlling the curing state of the adhesive resin. Patent Document 1 discloses a technique in which an adhesive resin that coats an electromagnetic steel sheet has a Tg (glass transition temperature) or softening temperature of 60°C or higher. By vitrifying the adhesive resin at around room temperature, it is possible to prevent stickiness on the adhesive layer surface and adhesive blocking. This technique is effective when an adhesive resin composition-coated electromagnetic steel sheet is punched and thermocompressed immediately after drying to manufacture an iron core.

[0012] Furthermore, Patent Documents 2 to 4 disclose techniques for suppressing the curing reaction at room temperature by using a latent curing agent as a curing agent for a thermosetting resin. Here, a latent curing agent is a curing agent to which latency has been imparted, as explained, for example, in Non-Patent Document 1. The latency of the curing agent makes it possible to suppress the reaction at room temperature, and by applying an external stimulus trigger such as heat, light, moisture, or pressure, the curing reaction of the thermosetting resin can be rapidly promoted.

[0013] Furthermore, Patent Documents 5 and 6 suggest that blocking during storage can be prevented by coating the magnetic steel sheet with an adhesive resin that hardens with a latent hardener. [Prior art documents] [Patent documents]

[0014] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-260910 [Patent Document 2] Japanese Patent Publication No. 2020-100727 [Patent Document 3] Japanese Patent Application Publication No. 2017-031268 [Patent Document 4] Japanese Patent Application Laid-Open No. 2014-152236 [Patent Document 5] Japanese Patent Application Publication No. 6-182296 [Patent Document 6] Japanese Patent Application Publication No. 11-162724

[0015] [Non-Patent Document 1] Journal of the Adhesion Society of Japan, vol.53, No.4(2017), pp.122-128 Summary of the Invention [Problem to be solved by the invention]

[0016] However, Patent Document 1 does not disclose a method for suppressing the curing reaction during storage of an adhesive resin composition-coated electrical steel sheet. The method of Patent Document 1 may cause adhesion-induced blocking in the general production of adhesive resin composition-coated steel sheets, which involves long-term storage, and may also result in a decrease in adhesive ability during thermocompression bonding.

[0017] Patent Documents 2 to 4 disclose techniques for minimizing the reaction between the resin and the curing agent in the adhesive liquid before application to the steel sheet, and for maintaining a viscosity that makes the adhesive easy to apply even during storage of the adhesive (storage stabilization of the adhesive liquid and prolongation of the pot life), but they do not disclose anything about the stability of the adhesive resin in an adhesive resin composition-coated electrical steel sheet that has undergone a heating process by drying.

[0018] Patent Documents 5 and 6 do not disclose the state of the latent curing agent in the adhesive resin after heat drying. Once heated in the drying process, the curing agent often changes state and loses its latency. Therefore, unless the state of the latent curing agent in the adhesive resin composition film after drying is controlled, it is difficult to suppress the progress of the curing reaction during storage, which can lead to adhesion-related blocking and a decrease in adhesive ability.

[0019] Furthermore, according to estimation results using the time-temperature conversion rule for the reaction activation energy and viscoelasticity of the curing agent and the reaction activation energy of the curing agent, the diffusion of the curing agent into the adhesive resin and the reaction with the adhesive resin, which occurs on the order of several months at room temperature, often corresponds to the order of several minutes at the curing temperature. Therefore, if the diffusion rate of the curing agent into the adhesive resin in the adhesive resin composition coating of the adhesive resin composition-coated electrical steel sheet or the reaction rate with the adhesive resin is reduced, the curing rate in the thermocompression bonding step when using this to manufacture an iron core also decreases, which can result in reduced productivity of the iron core.

[0020] As mentioned above, the manufacturing process from the application of a thermosetting adhesive when manufacturing an adhesive resin composition-coated electrical steel sheet (semi-finished product) to the thermocompression bonding when manufacturing an iron core (finished product) is generally not continuous. Therefore, during the period from obtaining the adhesive resin composition-coated electrical steel sheet (from the completion of drying of the adhesive) to the start of punching, the adhesive resin composition coating is stored in a semi-cured (non-equilibrium) state in which the irreversible curing reaction is stopped midway. As a result, preventing blocking and a decrease in adhesive strength during storage (especially during long-term storage) has been an issue. Additionally, the thermocompression bonding process when manufacturing an iron core using an adhesive resin composition-coated electrical steel sheet must be able to cure in a short time, enabling efficient production of iron cores.

[0021] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an adhesive resin composition-coated electrical steel sheet that can prevent adhesive blocking and a decrease in adhesive strength even when stored for a long period of time after the adhesive has been applied and dried, and that allows the adhesive resin composition coating to harden in a short time during the thermocompression bonding step when manufacturing iron cores. [Means for solving the problem]

[0022] The present invention has been made to solve the above-mentioned problems, and is summarized as follows: an adhesive resin composition coated electrical steel sheet and a method for producing the same.

[0023] (1) An adhesive resin composition coated electrical steel sheet having a steel sheet and an adhesive resin composition coating on at least one surface of the steel sheet, the adhesive resin composition coating is a semi-cured product of an adhesive resin composition comprising an adhesive resin containing at least a thermosetting resin in part and a curing agent, the adhesive resin composition coating has a maximum penetration λ of 3% or more and less than 100% at 100 to 300°C, as measured by thermomechanical analysis according to JIS K 7196:2012; a part of the curing agent is present in a crystalline state in the adhesive resin composition coating, an area ratio of the crystalline curing agent in the cross section of the adhesive resin composition coating parallel to the surface of the steel sheet is 0.10 to 40%; Adhesive resin composition coated electrical steel sheet.

[0024] (2) The area ratio of the crystalline curing agent is 0.70 to 20%. An adhesive resin composition coated electrical steel sheet according to (1) above.

[0025] (3) The adhesive resin composition coating has a softening start temperature Tss of 50°C or higher and a maximum penetration λ of 15% or higher at 100 to 300°C, as measured by thermomechanical analysis according to JIS K 7196:2012. An adhesive resin composition coated electrical steel sheet according to (1) or (2) above.

[0026] (4) The thermosetting resin includes one or more selected from an epoxy resin, an acrylic resin, a urethane resin, and an unsaturated polyester resin. An adhesive resin composition coated electrical steel sheet according to any one of (1) to (3) above.

[0027] (5) The curing agent includes one or more selected from an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent. An adhesive resin composition coated electrical steel sheet according to any one of (1) to (4) above.

[0028] (6) A method for producing an adhesive resin composition coated electrical steel sheet according to any one of (1) to (4) above, a coating step of coating a liquid thermosetting adhesive containing the adhesive resin and the curing agent onto at least one surface of the steel plate; a heating, drying, and solidification step of heating the steel plate to which the thermosetting adhesive has been applied and then cooling the steel plate to form an adhesive resin composition coating on the surface of the steel plate, The heating temperature in the heating, drying and solidifying step is a temperature T within a temperature range of 100 to 250°C, The heating time in the heating, drying and solidifying step satisfies the following formula (i): A method for manufacturing an electrical steel sheet coated with an adhesive resin composition. 0.8≦t / t0≦18.0 (i) However, the meanings of the symbols in the above formula (i) are as follows: t: heating time in the heating, drying and solidification step t0: the time required to form an adhesive resin composition coating having a softening starting temperature of 50°C when the thermosetting adhesive is dried at the temperature T

[0029] (7) Glass transition temperature Tg of the adhesive resin uc is 30°C or higher, The heating temperature in the heating, drying and solidifying step is a temperature T within a temperature range of 100 to 190°C, The heating time in the heating, drying and solidifying step satisfies the following formula (ii): A method for producing an adhesive resin composition coated electrical steel sheet according to (6) above. 1.3≦t / t0≦15.0 (ii) Here, the meanings of the symbols in the above formula (ii) are as follows: t: heating time in the heating, drying and solidification step t0: the time required to form an adhesive resin composition coating having a softening starting temperature of 50°C when the thermosetting adhesive is dried at the temperature T

[0030] (8) The adhesive resin contains 50% by mass or more of a thermosetting resin selected from the group consisting of an epoxy resin, an acrylic resin, a urethane resin, and an unsaturated polyester resin, based on the total amount of the adhesive resin. A method for producing an adhesive resin composition coated electrical steel sheet according to (6) or (7) above.

[0031] (9) The curing agent includes one or more selected from an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent. Any of the above (6) to (8) A method for producing an adhesive resin composition-coated electrical steel sheet according to claim 1. [Effects of the Invention]

[0032] According to the present invention, an adhesive resin composition-coated electrical steel sheet can be obtained that can prevent adhesive blocking and deterioration of adhesive ability even when stored for a long period of time after the adhesive has been applied and dried, and that can cure the adhesive resin composition coating in a short time when thermocompression bonded. [Brief explanation of the drawings]

[0033] [Figure 1] FIG. 2 is a diagram for explaining a method for analyzing the softening start temperature Tss and the maximum penetration λ of an adhesive resin composition film. [Figure 2] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electrical steel sheet of Example 1, parallel to the surface of the steel sheet. [Figure 3] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 2, parallel to the surface of the steel sheet. [Figure 4] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 5, parallel to the surface of the steel sheet. [Figure 5] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 6, parallel to the surface of the steel sheet. [Figure 6] 10 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 7, parallel to the surface of the steel sheet. [Figure 7] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 11, taken parallel to the surface of the steel sheet. [Figure 8]10 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electromagnetic steel sheet of Example 12, taken parallel to the surface of the steel sheet. [Figure 9] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electrical steel sheet of Comparative Example 2, taken parallel to the surface of the steel sheet. [Figure 10] 1 is a polarizing microscope image of a cross section of the adhesive resin composition coating of the adhesive resin composition coated electrical steel sheet of Comparative Example 3, taken parallel to the surface of the steel sheet. DETAILED DESCRIPTION OF THE INVENTION

[0034] The present invention will be described in detail below, starting with a focus, specific embodiments based on the focus, and usage. However, the following description of the constituent elements is an example (typical example) of the embodiment of the present invention, and the present invention is not limited to the following content unless the gist of the present invention is changed.

[0035] <Points of focus of the present invention> (Control guidelines) In order to solve the above problems, the present inventors conducted the following investigations.

[0036] When adhesive resin composition-coated steel sheets are stored in a high-temperature, humid environment for an extended period (e.g., several months), the curing agent in the adhesive resin composition film diffuses into the adhesive resin, causing a slow curing reaction (hereinafter referred to as the "slow curing reaction") to proceed within the adhesive resin composition film. Therefore, unless the slow curing reaction within the adhesive resin composition film during storage is suppressed, it is difficult to prevent adhesive blocking and a decrease in adhesive strength due to excessive curing of the adhesive resin composition film. On the other hand, if the reaction rate of the curing reaction of the adhesive resin composition film is slowed too much, the curing reaction will not proceed in a short time during thermocompression bonding. This results in reduced productivity of the iron core.

[0037] Therefore, the present inventors have focused on the following points and carried out investigations to prevent adhesion blocking and a decrease in adhesive ability during storage.

[0038] 1) Elementary process of slow hardening reaction First, the slow curing reaction that occurs in the adhesive resin composition coating during storage of the adhesive resin composition-coated electrical steel sheet can be broken down into the following three elementary processes. (a) Dissolution of hardener (b) Diffusion of hardener into adhesive resin (c) Collision and reaction of the hardener with adhesive resin molecules

[0039] Therefore, in order to suppress the progress of the slow curing reaction within the adhesive resin composition coating during storage of the adhesive resin composition-coated electrical steel sheet, it is necessary to reduce either the dissolution rate, diffusion rate, or reaction activity of the curing agent.

[0040] In the present invention, the dissolution of the curing agent (a) is suppressed and the slow curing reaction is inhibited in view of the following points: Specifically, the slow curing reaction is inhibited by using a curing agent that is at least partially crystallized at room temperature and by allowing a certain amount of the crystalline curing agent (hereinafter sometimes referred to as "curing agent crystals") to remain in the adhesive resin composition coating.

[0041] First, focusing on (b) and (c), the disadvantages of inhibiting the slow hardening reaction are as follows: To suppress the slow curing reaction within the adhesive resin composition film by suppressing the diffusion of the curing agent into the adhesive resin (b) and the collision and reaction of the curing agent with the adhesive resin molecules (c), it is necessary to suppress the thermal mobility of the adhesive resin phase molecules and increase the activation energy of the curing reaction at room temperature, respectively. However, the former requires increasing the crystallization temperature or glass transition temperature (Tg) of the adhesive resin. As a result, the diffusion of the curing agent slows down even during thermocompression bonding, requiring higher temperatures for thermocompression bonding. Furthermore, the latter often also slows the curing reaction rate of the adhesive resin composition film during thermocompression bonding, impairing the productivity of iron cores.

[0042] On the other hand, focusing on (a), the merits of leaving a certain amount of hardener in a crystalline state are as follows. The dissolution of the curing agent (a) can be controlled by changing its state. Furthermore, because the changes in the state of the curing agent between crystallization and dissolution are thermodynamically reversible, even if the crystals dissolve due to heating, they can be precipitated by appropriately heating and cooling the curing agent during the heating, drying, and solidification process. Furthermore, the crystallized curing agent can remain stable in the adhesive resin composition coating without dissolving at room temperature. Therefore, if a certain amount of the curing agent remains in a crystalline state in the adhesive resin composition coating applied to the electrical steel sheet, the slow curing reaction can be stably suppressed. Additionally, because solubility can be controlled independently of the thermal mobility and reactivity of the adhesive resin phase molecules, even when these are controlled as described above for short-term curing during the thermocompression bonding process, the slow curing reaction can be stably suppressed during storage.

[0043] Next, a specific embodiment will be described.

[0044] <Adhesive resin composition coated electrical steel sheet> The present invention relates to an adhesive resin composition-coated electrical steel sheet having a steel sheet and an adhesive resin composition coating on at least one surface of the steel sheet, wherein the adhesive resin composition coating is a semi-cured product of an adhesive resin composition comprising an adhesive resin containing at least a portion of a thermosetting resin and a curing agent, wherein the adhesive resin composition coating has a maximum penetration λ of 3% or more and less than 100% at 100 to 300°C as measured by thermomechanical analysis according to JIS K 7196:2012, wherein the curing agent is partially present in the adhesive resin composition coating in a crystalline state, and wherein the area fraction of the crystalline curing agent in a cross section of the adhesive resin composition coating parallel to the surface of the steel sheet is 0.10 to 40% (hereinafter, this may be referred to as the "adhesive resin composition-coated electrical steel sheet of the present invention").

[0045] By adopting such a configuration, the following effects can be obtained during storage of the adhesive resin composition-coated electrical steel sheet of the present invention and during each step of thermocompression bonding.

[0046] During storage, the following effects are obtained: ·Prevents adhesion degradation and adhesion blocking: Because a certain amount of curing agent is present in the adhesive resin composition coating in a crystalline state that is difficult to dissolve in the adhesive resin, dissolution of the curing agent in the adhesive resin can be suppressed during storage of the adhesive resin composition-coated electrical steel sheet. As a result, diffusion and migration of the curing agent can be suppressed within the adhesive resin composition coating, at the interface between the adhesive resin composition coating and the steel sheet, and at the interface between adhesive resin composition coatings when adhesive resin composition-coated electrical steel sheets are stacked together, for example by winding them into a coil. This suppresses slow curing reactions within the adhesive resin composition coating and reactions between the adhesive resin composition coating and the adherend during storage, preventing a decrease in adhesive ability and adhesive blocking.

[0047] The thermocompression bonding process provides the following effects. - Short-time curing of adhesive resin composition coating during thermocompression bonding: By dissolving the curing agent remaining in a crystalline state during storage during thermocompression bonding, diffusion into the adhesive resin is promoted, enabling the adhesive resin composition film to cure in a short period of time. Furthermore, by maintaining the curing agent in a crystalline state, dissolution of the curing agent is suppressed, thereby suppressing the slow curing reaction within the adhesive resin composition film during storage. Therefore, it is possible to use a catalyst and / or accelerator that accelerates the reaction activation energy. By adding these, it is possible to achieve both rapid curing of the adhesive resin composition film during thermocompression bonding and suppression of the slow curing reaction within the adhesive resin composition film during storage of the adhesive resin composition-coated electrical steel sheet. It should be noted that the use of a catalyst and / or accelerator to accelerate the reaction activation energy is not essential.

[0048] [Steel plate] The steel sheet excluding the adhesive resin composition coating in the adhesive resin composition coated electrical steel sheet of the present invention (sometimes referred to as "electrical steel sheet") is not particularly limited, and any known steel sheet can be applied.

[0049] [Adhesive resin composition film] The adhesive resin composition coating is a layer formed on at least one surface of the steel sheet, and is a semi-cured product of an adhesive resin composition comprising an adhesive resin and a curing agent. The adhesive resin composition coating, which is a semi-cured product of a thermosetting adhesive resin composition, can exhibit adhesive properties when heated and pressurized, so that adhesive resin composition-coated magnetic steel sheets can be bonded to each other by stacking the adhesive resin composition-coated magnetic steel sheets and thermocompression bonding them.

[0050] [Adhesive resin composition] The adhesive resin composition comprises an adhesive resin containing at least a part of a thermosetting resin and a curing agent. The adhesive resin composition in the adhesive resin composition coating is in a semi-cured state where curing has progressed partially.

[0051] [Adhesive resin] The adhesive resin exhibits thermosetting properties and therefore contains at least a thermosetting resin. As described above, the adhesive resin composition consists of an adhesive resin containing at least a thermosetting resin and a curing agent. Therefore, the adhesive resin refers to the components of the adhesive resin composition excluding the curing agent (unreacted curing agent). A thermosetting resin is a resin that undergoes three-dimensional polymer crosslinking and hardens when heated during use, possibly with the aid of a catalyst. In the adhesive resin composition coating, a portion of the thermosetting resin has undergone a crosslinking reaction with the curing agent, and the remainder remains unreacted.

[0052] [Hardening agent] The curing agent contained in the adhesive resin composition is a compound that reacts with functional groups contained in the thermosetting resin to form a three-dimensional structure and cure the adhesive resin composition, and at least a portion of the curing agent crystallizes at room temperature. That is, a portion of the curing agent is present in a crystalline state in the adhesive resin composition coating. The curing agent used in the present invention may be any agent that can crystallize at room temperature and that can exist in a crystalline state in the adhesive resin composition coating. It is possible to use only curing agents that can crystallize at room temperature, or to use a combination of a curing agent that can crystallize at room temperature and a curing agent that does not crystallize at room temperature. Note that the curing agent in the adhesive resin composition coating refers to the unreacted curing agent component that has not reacted with the thermosetting resin.

[0053] [Semi-cured product] The adhesive resin composition that forms the adhesive resin composition coating is a semi-cured product in which curing has progressed partially. A semi-cured product is an adhesive resin composition in which curing has not progressed to 100%. In the present invention, the semi-cured state is determined using the maximum penetration described below as an index. Specifically, if the maximum penetration measured by thermomechanical analysis according to JIS K 7196:2012 is 3% or more but less than 100%, it is determined to be in a semi-cured state.

[0054] [Amount of crystalline curing agent in adhesive resin composition coating] The adhesive resin composition-coated electrical steel sheet of the present invention contains a certain amount of crystalline curing agent (curing agent crystals) in the adhesive resin composition coating. The amount of curing agent crystals in the adhesive resin composition coating can be measured using the area ratio of the crystalline curing agent in a cross section of the adhesive resin composition coating parallel to the surface of the steel sheet. In the adhesive resin composition-coated electrical steel sheet of the present invention, the area ratio of the crystalline curing agent in a cross section of the adhesive resin composition coating parallel to the surface of the steel sheet (hereinafter sometimes referred to as the "area ratio of curing agent crystals") is 0.10 to 40%. The area ratio of the curing agent crystals is measured and quantified by the method described below.

[0055] If the area ratio of the hardener crystals is less than 0.10%, there are two possible scenarios, but neither will yield the desired performance. One is when the hardener content itself is insufficient, and the other is when most of the hardener dissolves in the adhesive resin after drying is complete, leaving no hardener in a crystalline state. In the former case, it becomes difficult to ensure the adhesive strength and heat resistance after thermocompression bonding. In the latter case, the hardener diffuses and reacts during storage, causing adhesive blocking, or it has already overcured, resulting in a loss of adhesive ability during thermocompression bonding.

[0056] The area ratio of the curing agent crystals must be 0.10% or more for the following reason: When a curing agent with a high dissolution rate is used, most of the curing agent crystals may dissolve due to heating during the heat-drying-solidification process. However, if 0.10% or more remains after drying, the curing agent can recrystallize and precipitate using these as nuclei during storage. As a result, even with a curing agent with a high dissolution rate (e.g., DDS), the slow curing reaction can be stably suppressed. On the other hand, if the area ratio of the curing agent crystals is less than 0.10%, there are no recrystallization nuclei, and the dissolved curing agent diffuses into the adhesive resin composition coating without crystallizing, facilitating the slow curing reaction.

[0057] On the other hand, if the area ratio of the curing agent crystals exceeds 40%, the reaction rate of the adhesive resin composition film is too slow, and the curing reaction does not proceed within a short time during thermocompression bonding. Furthermore, stress concentrates at the interface between the adhesive resin phase and the curing agent crystals during punching and shearing, causing the adhesive resin composition film to break. Furthermore, if the curing agent is in excess of the adhesive resin, the area ratio of the curing agent crystals will also be excessive. In this case, some of the curing agent may remain unreacted in the adhesive resin composition film even after thermocompression bonding. Stress may concentrate at the interface between the remaining excess curing agent crystals and the adhesive resin, reducing the strength and toughness of the adhesive resin composition film. Furthermore, when the iron core is heated during continuous operation, the curing agent crystals dissolve, plasticizing the adhesive resin composition film and reducing its strength and heat resistance.

[0058] [Preferable range of area ratio of crystalline curing agent in a cross section of adhesive resin composition coating parallel to the surface of the steel sheet] The preferred area ratio of hardener crystals is 0.50 to 30%. By making it 0.50% or more, most of the hardener is prevented from dissolving and diffusing, further suppressing slow reactions during storage. By making it 30% or less, it is possible to further prevent a decrease in strength and toughness due to excess hardener. For the same reasons, it is more preferably 0.50 to 25%, and even more preferably 0.70 to 20%.

[0059] [Method for quantifying the area ratio of crystalline curing agent in a cross section of an adhesive resin composition coating parallel to the surface of a steel sheet] Because the curing agent crystals have optical anisotropy, they appear bright when observed through a polarizing filter arranged in a crossed Nicol configuration. On the other hand, because the adhesive resin is optically isotropic, they appear dark. Therefore, by using this difference, it is possible to distinguish between the adhesive resin phase, which is mainly composed of adhesive resin other than the curing agent crystals, and the curing agent crystals. Specifically, the adhesive resin composition coating coating on the steel sheet is observed in a cross section parallel to the steel sheet surface using a polarizing microscope. More specifically, the polarizing microscope can be an Olympus BX53M microscope or a Nikon LV150N upright microscope.

[0060] A polarizing filter (e.g., Olympus U-AN360-3, U-POTP3, etc.) is then set in a crossed Nicol position, and the image is observed at 100 to 800x magnification. The magnification can be selected appropriately within this range depending on the ease of identifying the curing agent crystal image. A color photograph is then taken, and the RGB color tones are separated to extract only the G component. The image is then binarized using image processing software (e.g., Keyence VHX5000 image processing software) to determine the area ratio of the bright phase, thereby quantifying the area ratio of the crystalline curing agent in a cross section of the adhesive resin composition coating parallel to the surface of the steel sheet. This area ratio is the average value of values ​​measured and quantified in at least three arbitrarily selected fields of view.

[0061] [Softening temperature Tss and maximum penetration λ] The adhesive resin composition coating preferably has a softening onset temperature Tss of 50°C or higher, as measured in the penetration mode of a thermomechanical analyzer (TMA) in accordance with JIS K 7196:2012, and a maximum penetration λ of 15% or higher at 100 to 300°C. An adhesive resin composition coating that satisfies these softening onset temperature and maximum penetration λ is in a state in which curing has progressed appropriately, and the following effects are obtained.

[0062] By setting the softening start temperature Tss to 50°C or higher, adhesive blocking during storage of the resulting adhesive resin composition-coated electrical steel sheet can be prevented, further enhancing the effects of suppressing adhesive blocking and reducing deterioration in adhesive ability. There is no particular upper limit for the softening start temperature Tss, but it is preferably 100°C or lower. If the softening start temperature Tss exceeds 100°C, the adhesive resin composition coating is hard even in a semi-cured state, which can slow the diffusion rate of the curing agent into the adhesive resin during the thermocompression bonding step and make short-term curing difficult. Alternatively, the thermocompression bonding step requires high temperatures of over 250°C, which can prolong heating and cooling times and reduce productivity.

[0063] By setting the maximum penetration λ to 15% or more, excessive curing of the adhesive resin composition coating can be prevented, and the adhesive resin composition coating can be made easier to soften during thermocompression bonding.

[0064] In order to sufficiently soften the adhesive resin composition film during thermocompression bonding, the maximum penetration λ is preferably 30% or more, more preferably 60% or more. Furthermore, if the maximum penetration λ exceeds 95%, the degree of cure of the adhesive resin composition film is too low, the adhesive resin composition film is soft, and the adhesive resin composition may flow out during thermocompression bonding. Therefore, it is desirable to set the upper limit of the maximum penetration λ to 95% or less, more preferably 80% or less.

[0065] Therefore, the adhesive resin composition coating preferably has a maximum penetration λ of 15 to 95% and a softening onset temperature Tss of 50 to 100°C, more preferably a maximum penetration λ of 30 to 90% and a softening onset temperature Tss of 50 to 100°C, and even more preferably a maximum penetration λ of 60 to 80% and a softening onset temperature Tss of 50 to 100°C.

[0066] Here, the softening onset temperature Tss and the maximum penetration λ will be explained. FIG. 1 is a diagram illustrating a method for analyzing the softening onset temperature Tss and the maximum penetration λ of an adhesive resin composition film. The TMA curve shown in FIG. 1 is a typical TMA curve of an adhesive resin composition film of the present invention. The TMA curve can be obtained by measuring according to the method of JIS K 7196:2012, except that the measurement is performed on an adhesive resin composition film coated on a steel sheet. As shown in FIG. 1, the softening onset temperature Tss is defined as the intersection of a line extending toward a higher temperature from the linear portion of the TMA curve on the lower temperature side where the needle (indenter) begins to penetrate, and a line extending toward a lower temperature side from the tangent to the portion where the needle penetration speed is maximum.

[0067] The maximum penetration depth λ is defined as the percentage of the maximum needle penetration length (μm) divided by the thickness (μm) of the adhesive resin composition film ((maximum needle penetration length / thickness of adhesive resin composition film) × 100). The maximum needle penetration length (μm) can be determined from the TMA curve as shown in Figure 1. The measurement is performed in a 100% N2 atmosphere, with a temperature rise rate of 15°C / min, a pressure of 0.6 to 2.0 MPa, and an indenter tip diameter of 0.5 to 1.0 mm. The thickness of the adhesive resin composition film can be measured by cutting out a cross section of the adhesive resin composition-coated electrical steel sheet and observing it under a microscope.

[0068] [Uncured glass transition temperature Tg of adhesive resin] The glass transition temperature Tg (Tg uc ) is preferably 30°C or higher. uc If the softening temperature is less than 30°C, depending on the softening onset temperature (glass transition temperature at the onset of softening, Tss) of the desired adhesive resin composition film, a large amount of heat must be input during heating, drying, and solidification after the adhesive is applied to the steel sheet, and a considerable amount of the thermosetting adhesive resin composition must be cured in order to form an adhesive resin composition film with the desired softening onset temperature (for example, 50°C or higher). To achieve this, most of the curing agent must be dissolved by the heat during heating, drying, and solidification, and diffused into the adhesive resin composition film, and it may be difficult to leave a certain amount of curing agent in a crystalline state in the adhesive resin composition film.

[0069] Also, the Tg of the adhesive resin uc The Tg of the adhesive resin is preferably 80°C or less. uc If the temperature exceeds 80°C, the viscosity of the adhesive applied to the steel sheet will be too high, making it difficult to apply the adhesive uniformly.

[0070] In addition, the Tg of the adhesive resin uc can be calculated from the following formula (Fox's formula) by identifying the composition (ingredients and blending) of the adhesive resin that coats the steel sheet using nuclear magnetic resonance or pyrolysis gas chromatography.

[0071]

number

[0072] where ω i is the blending ratio (weight ratio) of component i, and Tg i is the glass transition temperature or softening temperature of component i. i can be determined by a known Tg or softening temperature measurement method, such as a method conforming to JIS K 7121:2012 or JIS K 7196:2012, using a differential scanning calorimeter (DSC) or a thermomechanical analyzer (TMA). Also, known values ​​listed in manufacturer catalogs, such as https: / / www.nscm.nipponsteel.com / epoxy / ec.html (as of April 2022), may be used.

[0073] The hardener does not actually vitrify, and the Tg uc Since the influence on Tg of the adhesive resin composition is small, uc This is used to determine the Tg of the adhesive resin. uc The Tg of the adhesive resin composition ucThe Tg can be determined by identifying the composition (ingredients and blending) of the adhesive resin composition using nuclear magnetic resonance or pyrolysis gas chromatography, preparing a measurement sample of the same composition, and using a differential scanning calorimeter (DSC) according to a method in accordance with JIS K 7121:2012. The measurement sample can be prepared, for example, by a method described in the Examples. Specifically, the adhesive resin composition is appropriately diluted with a solvent to prepare a liquid thermosetting adhesive. This liquid thermosetting adhesive is cast on a glass plate and then vacuum-dried to prepare a cast film. The Tg (midpoint glass transition temperature) of the prepared cast film is measured according to a method in accordance with JIS K 7121:2012, and this is used as the Tg of the adhesive resin composition. uc This can be done.

[0074] [Thermosetting resin] Specific examples of thermosetting resins include crosslinked resins such as epoxy resins, thermosetting acrylic resins, urethane resins, unsaturated polyester resins, phenolic resins, melamine resins, urea resins, and thermosetting polyimide resins. In the present invention, these resins can be used alone or in combination of two or more.

[0075] [Epoxy resin] Epoxy resins are resins containing two or more epoxy groups, which can be crosslinked with an appropriate curing agent to form a three-dimensional resin. Examples of epoxy resins include bisphenol-based (bisphenol A, bisphenol F, bisphenol AD), naphthalene-based, and cardo-based epoxy resins.

[0076] [Thermosetting acrylic resin] Examples of thermosetting acrylic resins include copolymers of acrylic esters or methacrylic esters with acrylic monomers having reactive functional groups such as hydroxyl groups, amino groups, N-methylol, N-alkoxymethylcarboxylate, allyl groups, and epoxy groups. Specific examples include copolymers of methyl acrylate or methyl methacrylate with one or more acrylic monomers having reactive functional groups such as acrylic acid, methacrylic acid, acrylamide, N-methylolacrylamide, N-(methoxymethyl)acrylamide, allyl methacrylate, acrylic glycidyl ether, and glycidyl methacrylate. Thermosetting acrylic resins can be crosslinked by utilizing the self-reactivity of the reactive functional groups, or by crosslinking and curing by reacting the reactive functional groups with curing agents such as amines.

[0077] [Urethane resin] Examples of urethane resins include resins composed of residues of polyfunctional isocyanate compounds and hydroxyl group-containing compounds. Specific examples include resins composed of aromatic polyisocyanates such as tolylene diisocyanate, diphenylmethane isocyanate, and polymethylene polyphenylene polyisocyanate, aliphatic polyisocyanates such as hexamethylene diisocyanate and xylene isocyanate, or mixtures thereof, and residues of hydroxyl group-containing compounds such as polyether polyol, polyester polyol, polyacrylate polyol, and polycarbonate polyol. Urethane resins can be crosslinked and cured by reaction with a curing agent such as an isocyanate-based curing agent or a polyol-based curing agent.

[0078] [Unsaturated polyester resin] Examples of unsaturated polyester resins include dehydration condensates of unsaturated dibasic acids such as maleic anhydride, fumaric acid, and itaconic acid, or compounds in which a portion of the acids has been substituted with a saturated dibasic acid such as phthalic anhydride, isophthalic acid, and terephthalic acid, and dihydric alcohols such as ethylene glycol, diethylene glycol, and propylene glycol, or compounds in which a portion of the alcohol has been substituted with a polyhydric alcohol such as glycerin or pentaerythritol. Unsaturated polyester resins can be crosslinked and cured by reaction with a curing agent such as an isocyanate-based curing agent.

[0079] [Other thermosetting resins] Examples of phenolic resins include resins containing two or more phenols (such as phenol and cresol). Examples include resins composed of residues of phenols and formaldehydes or aldehydes. Specific examples include phenol novolac resins, cresol novolac resins, cresol naphthol formaldehyde polycondensates, and triphenylmethane-type polyfunctional phenyl resins. Specific examples include phenol aralkyl resins. Examples of melamine resins include alkyl-etherified melamine resins and their substituted derivatives. Examples of urea resins include ethylene urea resins. Examples of thermosetting polyimide resins include resins composed of residues of polycarboxylic dianhydrides and diamine compounds. Specific examples include thermosetting polyimide resins such as maleimide polymers, bismaleimide polymers, aminobismaleimide polymers, and bismaleimide triazine polymers. These resins can also be cured by a crosslinking reaction with a curing agent.

[0080] [Suitable examples of thermosetting resins] Among the above thermosetting resins, the glass transition temperature Tg ucThe thermosetting resin preferably contains one or more selected from the group consisting of epoxy resin, acrylic resin, urethane resin, and unsaturated polyester resin, because there are many options for achieving a temperature of 30°C or higher, the curing reaction is fast at high temperatures, and the dispersion state of the curing agent is easy to manufacture. Among these, it is most preferable that the thermosetting resin contains an epoxy resin, from the viewpoints of economy, versatility, and ease of handling.

[0081] [Examples of suitable adhesive resins contained in thermosetting adhesives] The adhesive resin preferably contains one or more thermosetting resins selected from the group consisting of epoxy resins, acrylic resins, urethane resins, and unsaturated polyester resins, and the total content (total mass of these thermosetting resins / mass (total) of adhesive resins × 100 (%)) is 50 mass% or more. Adhesive resins containing less than 50 mass% of these thermosetting resins may not be able to fully utilize the properties of these thermosetting resins. Among these, adhesive resins containing 50 mass% or more of epoxy resin are most preferred from the standpoint of economy, versatility, and ease of handling.

[0082] The adhesive resin may contain a thermosetting resin, and may also contain organic or inorganic components other than the thermosetting resin. For example, it may contain thermoplastic resins; impact modifiers such as core-shell rubber and natural rubber; curing accelerators such as dimethylurea, boron trifluoride, and triphenylphosphine; known epoxy resin modifiers; reaction control agents (catalysts, etc.); surfactants; rust inhibitors; lubricants; antioxidants; antifoaming agents; coloring pigments, etc.

[0083] [Examples of hardeners] Specific examples of the curing agent include amine-based, amide-based, imidazole-based, acid anhydride-based, phenol-based, catalyst-based, etc. In the present invention, for example, it is possible to select a crystalline curing agent that crystallizes at room temperature from the following specific examples, either alone or in combination of two or more types.

[0084] [Amine-based curing agent] Examples of the amine-based curing agent include, but are not limited to, aliphatic amines, aromatic amines, and guanidine compounds.

[0085] [Aliphatic amines] Examples of aliphatic amines include, but are not limited to, diethylenetriamine, triethylenetetraamine, tetraethylenepentamine, m-xylenediamine, trimethylhexamethylenediamine, 2-methylpentamethylenediamine, isophoronediamine, 1,3-bisaminomethylcyclohexane, bis(4-aminocyclohexyl)methane, norbornenediamine, 1,2-diaminocyclohexane, benzoylamine, methylcyclohexylamine, and diazabicycloundecene.

[0086] [Aromatic amines] Examples of aromatic amines include, but are not limited to, diaminodiphenylmethane, m-phenylenediamine, diaminodiphenylsulfone (DDS), diethyltoluenediamine, trimethylenebis(4-aminobenzoate), polytetramethyleneoxide-di-p-aminobenzoate, methylaniline, and dimethylaniline.

[0087] [Guanidine compounds] Examples of guanidine compounds include, but are not limited to, dicyandiamide (DICY, cyanoguanidine) and its derivatives, methylguanidine, ethylguanidine, propylguanidine, butylguanidine, dimethylguanidine, trimethylguanidine, phenylguanidine, diphenylguanidine, and toluylguanidine.

[0088] [Amide-based curing agent] The amide-based curing agent is not limited to the following, but examples thereof include an amine-based curing agent to which an acid anhydride is added, and a hydrazide-based compound.

[0089] [Hydrazide compounds] Examples of hydrazide compounds include, but are not limited to, succinic acid dihydrazide, adipic acid dihydrazide, phthalic acid dihydrazide, isophthalic acid dihydrazide, terephthalic acid dihydrazide, p-oxybenzoic acid hydrazide, salicylic acid hydrazide, phenylaminopropionic acid hydrazide, and maleic acid dihydrazide.

[0090] [Imidazole curing agent] Imidazole-based curing agents include imidazole-isocyanuric acid compounds, diamino-6-[2-(2-methyl-1-imidazolyl)ethyl]-1,3,5-triazine (2MZ-AZINE), 1-cyanoethyl-2-ethyl-4-methylimidazole (CEMI), 2-ethyl-4-methylimidazole, and 2-undecylimidazole (C 11 Z) and others.

[0091] [Acid anhydride curing agent] Examples of acid anhydride curing agents include, but are not limited to, phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, maleic anhydride, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, methylnadic anhydride, hexahydrophthalic anhydride, and methylhexahydrophthalic anhydride.

[0092] [Phenol-based hardener] Examples of phenol-based curing agents include, but are not limited to, phenol novolac resins, cresol novolac resins, phenol aralkyl resins, cresol aralkyl resins, naphthol aralkyl resins, biphenyl-modified phenol resins, biphenyl-modified phenol aralkyl resins, dicyclopentadiene-modified phenol resins, aminotriazine-modified phenol resins, naphthol novolac resins, naphthol-phenol co-condensed novolac resins, naphthol-cresol co-condensed novolac resins, and allyl acrylic phenol resins.

[0093] [Catalytic curing agent] Examples of catalyst-type curing agents include, but are not limited to, cationic thermosetting catalysts, BF3-amine complexes, and 1,8-diazabicyclo[5.4.0]undec-7-ene.

[0094] The curing agent preferably contains one or more crystalline curing agents selected from the group consisting of amine-based curing agents, amide-based curing agents, and imidazole-based curing agents, because this allows for a fast curing reaction rate of the adhesive resin composition coating during thermocompression bonding, thereby enabling relatively easy curing of the adhesive resin composition coating in a short time. Among these, one or more crystalline curing agents selected from the group consisting of aromatic amines, guanidine compounds, amide-based curing agents, and imidazole-based curing agents are preferred, because this increases the temperature at which the curing reaction of the resin composition coating most easily proceeds. The use of such curing agents allows for a difference between the storage temperature of the adhesive resin composition-coated electrical steel sheet and the heating temperature during thermocompression bonding, making it easier to control the temperature rise rate during thermocompression bonding. From the perspectives of ease of handling and versatility, the curing agent most preferably contains one or more selected from the group consisting of dicyandiamide (DICY), diaminodiphenyl sulfone (DDS), and diamino-6-[2-(2-methyl-1-imidazolyl)ethyl]-1,3,5-triazine (2MZ-AZINE).

[0095] It should be noted that the adhesive resin composition coating of the adhesive resin composition-coated electrical steel sheet of the present invention only needs to contain the above-mentioned specific amount of curing agent in a crystalline state, and the types of adhesive resin and curing agent are not limited to those examples given above.

[0096] [Thickness of electrical steel sheet coated with adhesive resin composition] The thickness of the adhesive resin composition-coated electrical steel sheet of the present invention can be, for example, 0.10 mm or more and 0.50 mm or less. Note that this is simply the thickness range of known adhesive resin composition-coated electrical steel sheets that are commonly available, and the present invention is also applicable to adhesive resin composition-coated electrical steel sheets outside this range.

[0097] [Adhesive resin composition film thickness] The thickness of the adhesive resin composition coating in the adhesive resin composition-coated electrical steel sheet of the present invention is not particularly limited, but can be, for example, 2 to 10 μm. If it is less than 2 μm, it will not sufficiently penetrate into the surface irregularities of the adherend, making it difficult to exhibit an anchoring effect. If it exceeds 10 μm, the volume ratio of the adhesive resin composition coating to the laminated core will be too high, which may result in a deterioration in the magnetic properties of the laminated core.

[0098] <Manufacturing method> A method for producing an adhesive resin composition-coated electrical steel sheet that uses a preferred adhesive resin composition coating and achieves both good blocking suppression and sufficient adhesion will now be described. Note that the method for producing an adhesive resin composition-coated electrical steel sheet of the present invention is not limited to the production method described below.

[0099] The method for producing an adhesive resin composition-coated electrical steel sheet of the present invention can be a production method comprising an adhesive application step of applying a liquid thermosetting adhesive containing an adhesive resin and a curing agent to at least one surface of a steel sheet, and a heating, drying and solidification step of heating the steel sheet to which the thermosetting adhesive has been applied and then cooling it to form an adhesive resin composition coating on the surface of the steel sheet.

[0100] [Adhesive application process] The adhesive application step is a step of applying a liquid thermosetting adhesive containing an adhesive resin and a curing agent to at least one surface of the steel plate.

[0101] [Thermosetting adhesive] Thermosetting adhesives that can be used in the production of adhesive resin composition-coated electrical steel sheets are liquids containing an adhesive resin and a curing agent, and depending on the composition of the adhesive resin composition coating (semi-cured product) to be formed, may contain, in addition to the thermosetting resin and curing agent, thermoplastic resins; impact modifiers such as core-shell rubber and natural rubber; curing accelerators such as dimethylurea, boron trifluoride, and triphenylphosphine; known epoxy resin modifiers; reaction control agents (such as catalysts); surfactants; rust inhibitors; lubricants; antioxidants; antifoaming agents; coloring pigments, etc.

[0102] The thermosetting adhesive can be used as is if the adhesive resin composition that constitutes the adhesive resin composition coating is liquid in an uncured state, but if it is not liquid or if viscosity adjustment is required, a solvent is added to use the adhesive as a liquid composition containing the adhesive resin composition and the solvent. Examples of solvents that can be used include aromatic hydrocarbon solvents such as benzene, toluene, and xylene; alicyclic hydrocarbon solvents such as cyclohexane; ketone solvents such as acetone, methyl ethyl ketone, cyclohexanone (anone), and tetrahydrofuran (THF); and halogenated solvents such as methylene chloride, dichloroethane, and chloroform.

[0103] The thermosetting adhesive can be used as a liquid consisting of the adhesive resin composition (the adhesive resin composition itself), a liquid obtained by diluting the adhesive resin composition with a solvent, a liquid obtained by dispersing the adhesive resin composition in an emulsion state in a solvent, etc. The thermosetting adhesive can be a one-component type in which the adhesive resin and curing agent are mixed during the manufacturing stage of the thermosetting adhesive, or a two-component type in which the adhesive resin and curing agent are stored separately and mixed immediately before application.

[0104] The viscosity of the thermosetting adhesive is preferably 100 to 1500 mPas. If the viscosity is less than 100 mPas, it is difficult to apply the adhesive resin composition to a desired thickness. On the other hand, if the viscosity exceeds 1500 mPas, it is difficult to apply the adhesive composition uniformly and in a short time, and thickness unevenness occurs in the width and length directions, further reducing productivity.

[0105] The adhesive resin composition constituting the adhesive resin composition coating is as described above. From the viewpoints of versatility, cost, and performance versatility, the thermosetting adhesive preferably contains an epoxy resin. Furthermore, the thermosetting adhesive preferably contains 50 mass% or more of a thermosetting resin, more preferably 50 mass% or more of an epoxy resin. The curing agent preferably contains one or more selected from the group consisting of an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent. For example, a thermosetting adhesive containing one or more selected from the group consisting of an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent and containing 50 mass% or more of an epoxy resin is preferred. The ratio of the thermosetting resin to the curing agent can be adjusted appropriately depending on the types of thermosetting resin and curing agent. For example, the functional group equivalent of the curing agent relative to the functional group equivalent of the thermosetting resin can be 0.8 to 1.2.

[0106] The thermosetting adhesive is preferably a dispersion in which at least a portion of the curing agent is dispersed, and the particle size of the curing agent crystals dispersed in the thermosetting adhesive is preferably 2 to 20 μm. If the particle size of the curing agent crystals is less than 2 μm, handling is difficult, and in many cases, all of the curing agent dissolves due to the heat applied during the heat-drying and solidifying process. In this case, the unreacted curing agent that did not react with the thermosetting resin due to the heat is unlikely to recrystallize even if it becomes supercooled during the cooling process following the heat-drying and solidifying process, due to the absence of nucleating curing agent crystals. For this reason, it may be difficult to retain a predetermined amount of curing agent in a crystalline state in the adhesive resin composition film. Furthermore, if the particle size exceeds 20 μm, it is difficult to form a thin adhesive resin composition film of 10 μm or less on the surface of the steel sheet.

[0107] (adhesive application method) The specific application method of the thermosetting adhesive is not particularly limited and may be appropriately selected depending on the properties of the thermosetting adhesive, and may be, for example, a roll coater method, a gravure coater method, an air doctor coater method, a blade coater method, a knife coater method, a rod coater method, a kiss coater method, a bead coater method, a cast coater method, a rotary screen method, a dip coating method in which a steel sheet is coated while immersed in a liquid thermosetting adhesive, or a slot orifice coater method in which a steel sheet is coated with a liquid thermosetting adhesive by dropping it through an orifice.

[0108] In addition to these, other methods such as curtain coating, spray coating in which a liquid thermosetting adhesive is sprayed in mist using the principle of an atomizer, ink jet coating, and electrodeposition coating can also be used.

[0109] [Heating drying solidification process] The heat-drying and solidifying process is a process in which a steel plate coated with a thermosetting adhesive is heated and then cooled to form an adhesive resin composition coating on the surface of the steel plate. Heating causes a portion of the thermosetting resin and a portion of the curing agent in the thermosetting adhesive coated on the steel plate surface to react and harden, forming a semi-cured adhesive resin composition. When a solvent-containing thermosetting adhesive is used, heating causes a portion of the thermosetting resin and a portion of the curing agent to react, and the solvent in the thermosetting adhesive evaporates, forming a semi-cured adhesive resin composition. Furthermore, some of the curing agent may not dissolve during heating or may recrystallize upon cooling after heating. This results in an adhesive resin composition coating in which a predetermined amount of curing agent is dispersed in a crystalline state.

[0110] (Heating method) As the heating (baking) method, known heating and drying (baking) methods can be used, such as hot air drying, induction heating, infrared heating, and vacuum heating.

[0111] As a result of investigations conducted by the present inventors, it was found that in order to keep the area ratio of curing agent crystals in the cross section of the adhesive resin composition coating parallel to the surface of the steel sheet within the above-mentioned range, it is extremely important to control the heating (drying) conditions of the heating temperature (T) and heating time. Specifically, it is necessary to set the heating temperature T within the range of 100 to 250°C, and to control the heating time so as to satisfy the following formula (i) depending on the type of thermosetting adhesive used. 0.8≦t / t0≦18.0 (i) However, the meanings of the symbols in the above formula (i) are as follows: t: Heating time in the heating, drying and solidification process t0: The time required to form an adhesive resin composition coating having a softening temperature (Tss) of 50°C when the thermosetting adhesive is dried at temperature T

[0112] By setting t / t0 to 0.8 or more, the area ratio of the curing agent crystals can be set to 40% or less. Furthermore, by setting t / t0 to 18.0 or less, the area ratio of the curing agent crystals can be set to 0.10% or more. Here, the time t0 is determined as follows: First, a thermosetting adhesive is applied to the surface of a steel sheet. Then, the sheet is heated at temperature T for various times, and the Tss of the adhesive resin composition film formed on the steel sheet is measured using the method described above. From the measurement results, the heating time required to achieve Tss = 50°C at heating temperature T is determined, and this is designated as t0.

[0113] (Cooling method) After heating the steel sheet coated with a thermosetting adhesive, any known cooling method can be used. Air cooling, water cooling, mist cooling, or laminar flow cooling can be used in combination, and some of these methods can be used intermittently. The cooling rate is preferably 1 to 600°C / min. If the cooling rate is less than 1°C / min, the curing reaction of the adhesive resin composition progresses during cooling, making it difficult to leave the desired amount of curing agent crystals, or forming an adhesive resin composition coating with a maximum penetration λ of less than 15%. On the other hand, if the cooling rate exceeds 600°C / min, the cooling rate becomes uneven across different regions, and thermal stress resulting from the difference in linear expansion coefficients between the steel sheet and the adhesive resin is concentrated in the rapidly cooled region, potentially resulting in a deterioration in the magnetic properties of the steel sheet.

[0114] <Suitable manufacturing method> Furthermore, in order to ensure that the area ratio of the hardener crystals is 0.70 to 20%, and to ensure adhesion blocking resistance and short-time curing, the Tg uc is set to 30°C or higher, the heating temperature in the heating, drying and solidifying step is set to a temperature T within a temperature range of 100 to 190°C, and the heating time is preferably controlled so as to satisfy the following formula (ii) according to the type of thermosetting adhesive used. 1.3≦t / t0≦15.0 (ii) Here, the meanings of the symbols in the above formula (ii) are as follows: t: Heating time in the heating, drying and solidification process t0: The time required to form an adhesive resin composition coating having a softening temperature (Tss) of 50°C when the thermosetting adhesive is dried at temperature T

[0115] When the softening onset temperature Tss is desired to be 70°C or higher, t / t0 is preferably 2.0 or higher, and when the softening onset temperature Tss is desired to be 70°C or higher, t / t0 is preferably 8.0 or lower. When the maximum penetration λ is desired to be 20% or higher, t / t0 is preferably 8.0 or lower.

[0116] <How to use> (Storage method for electrical steel sheet coated with adhesive resin composition) The adhesive resin composition-coated electrical steel sheet of the present invention can be stored at room temperature and humidity without strict temperature and humidity control because an appropriate amount of curing agent remains in a crystalline state within the adhesive resin composition coating. Furthermore, even when transported by ship, adhesive blocking and adhesive blocking can be prevented, and deterioration of adhesive ability can be suppressed. Therefore, it can be stored using known steel sheet storage methods. Specifically, the adhesive resin composition-coated electrical steel sheet can be wound into a coil or cut into sheets and laminated, and stored at room temperature and humidity, either packaged in paper or resin, or unpackaged. For longer storage periods, it can also be stored at low temperatures in a refrigerator or freezer.

[0117] <Iron core manufacturing> The adhesive resin composition-coated electrical steel sheet of the present invention can be used to manufacture iron cores. For example, the adhesive resin composition-coated electrical steel sheet of the present invention is punched and sheared, laminated, and then thermocompression-bonded to manufacture an iron core. Iron cores are also sometimes called adhesive cores or motor cores.

[0118] (Punching and shearing method) The adhesive resin composition-coated magnetic steel sheets can be processed and laminated using known punching and shearing methods. Specifically, adhesive resin composition-coated magnetic steel sheets are continuously fed into a mold from a coil-shaped adhesive resin composition-coated magnetic steel sheet. At this time, processing oil is sprayed onto the adhesive resin composition-coated magnetic steel sheets just before they are loaded into the mold. Then, while feeding the adhesive resin composition-coated magnetic steel sheets into the mold, they are punched into desired shapes multiple times in sequence, and when all the desired shapes have been processed, they are sheared. Then, the sheared adhesive resin composition-coated magnetic steel sheets are dropped into a receiver in the mold and laminated.

[0119] (thermocompression bonding method) The iron core made of laminated adhesive resin composition-coated electromagnetic steel sheets can be crimped while applying pressure within a mold, or the iron core made of laminated adhesive resin composition-coated electromagnetic steel sheets can be removed from the mold and placed in a heating device for pressure application. Known heating methods can be used. Specifically, methods that can be used include hot air heating using a hot air flow from an oven or the like, electrical resistance heating using resistance heating, low-frequency or high-frequency induction heating using induction power, and infrared heating using radiant heat (near-infrared or far-infrared). Among these, heating using a near-infrared heater is preferred. Heating using a near-infrared heater has a fast heater response speed and can heat with a high energy density, allowing the iron core to be heated rapidly. As a result, it is relatively easy to heat the iron core to the curing temperature without significantly promoting the curing of the semi-cured adhesive resin composition that constitutes the adhesive resin composition coating.

[0120] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples as long as the gist of the present invention is not changed. [Example]

[0121] <Test material> [Steel plate] A non-oriented electrical steel sheet with a thickness of 0.35 mm was used. [Thermosetting adhesive] The raw materials used in the thermosetting adhesive are shown in Table 1. The formulation of the adhesive resin composition is shown in Table 2. The values ​​shown in Table 2 are the blending amounts (parts by mass) of each raw material when the total epoxy resin is 100 parts by mass.

[0122] [Table 1]

[0123] [Table 2]

[0124] <Formulation of adhesive resin composition and production of thermosetting adhesive> An adhesive resin composition was prepared by blending the resin raw materials, additives, curing agents, and curing accelerators according to the formulations shown in Table 2. A solvent was then added to the adhesive resin composition so that the solids concentration in the liquid was 40 mass %, and the resulting mixture was stirred and mixed at room temperature for 3 hours to obtain a thermosetting adhesive. The numbers of the thermosetting adhesives shown in Tables 3 to 5 correspond to the numbers of the adhesive resin compositions shown in Table 2.

[0125] <Tg uc Measurement of The thermosetting adhesive was cast onto a glass plate and then placed in a desiccator for 24 hours to dry under normal pressure. This was followed by a further 48 hours of vacuum drying at room temperature to remove the solvent. After vacuum drying, the cast film was removed from the glass plate and heated at 5°C / min using a differential scanning calorimeter (DSC) (Hitachi High-Tech Science Corporation). The uncured glass transition temperature (Tg) was measured in accordance with JIS K 7121:2012. The results are shown in Table 2.

[0126] Example 1 <Manufacture of adhesive resin composition coated electrical steel sheet> After cleaning the surface of a 220 × 200 mm non-oriented electrical steel sheet with acetone, thermosetting adhesive 1 was applied to the surface of the non-oriented electrical steel sheet (200 × 200 mm) using a roll coater (manufactured by Furnace Co., Ltd.) so that the film thickness after drying would be 4.5 μm. After application, the sheet was dried at 140°C for 2.5 minutes to remove the solvent, forming an adhesive resin composition coating. After drying, cooling water was sprayed onto the steel sheet surface and the sheet was cooled to room temperature to obtain an adhesive resin composition-coated electrical steel sheet. The steel sheet temperature was measured using a thermocouple attached to the overlap portion on the surface of the steel sheet.

[0127] <Examples 2 to 14> Adhesive resin composition-coated electrical steel sheets were obtained in the same manner as in Example 1, except that the thermosetting adhesives and drying conditions shown in Tables 3 to 5 were used.

[0128] <Measurement of the area ratio of hardener crystals> A polarizing filter (Olympus U-AN360-3) was set to cross Nicol on a upright microscope (Olympus BX53M), and a cross-section parallel to the steel plate surface of the adhesive resin composition film covering the steel plate was observed at a magnification of 100 to 800 times. At this time, the magnification was appropriately selected within the above range according to the ease of identifying the crystal image of the curing agent. Then, color photography was performed, the RGB color tone was divided, and only the G component was extracted, and then binarized using the internal image processing software of the Keyence VHX5000. Thus, the area ratio of the bright phase was determined. This operation was performed on three arbitrarily selected specimens, and the average value was taken as the area ratio.

[0129] Figures 2 to 10 show the polarized microscope images of Examples 1, 2, 5, 6, 7, 11, 12 and Comparative Examples 2 and 3 described later. Tables 3 to 6 show the calculated area ratios of the curing agent crystals.

[0130] <Measurement of Tss, λ, t0> A test piece was cut out from the electromagnetic steel sheet coated with the adhesive resin composition immediately after drying and embedded in an epoxy resin. After the epoxy resin was cured, it was polished to obtain a smooth cross-section of the steel sheet. The cross-section of the steel sheet was observed with a microscope, and the thickness of the adhesive resin composition film was measured. Further, a 7×7 mm test piece was cut out, set in a sample tube for the needle penetration mode of a thermomechanical analyzer (TMA, manufactured by Hitachi High-Technologies Corporation) with the adhesive application surface on the upper surface, and heated in the needle penetration mode from -50°C to 300°C at 5°C / min. Then, the penetration length of the TMA probe needle into the adhesive resin composition film coated on the steel plate surface was measured. Based on this data, Tss was determined. Also, based on this data, the maximum value of the needle penetration length was obtained, and λ was calculated. The results are shown in Tables 3 to 5.

[0131] Furthermore, electromagnetic steel sheets coated with a thermosetting adhesive on the surface so that the film thickness after drying was 4.5 μm were prepared as samples with the drying time varied at 140°C, and the needle penetration length into the adhesive resin composition film was measured in the TMA needle penetration mode under the same conditions. The correlation between the drying time and Tss when dried at the temperatures shown in Tables 3 to 5 was determined. Then, from this data, the time t0 when the Tss of the adhesive resin composition film reached 50°C was determined. The results are shown in Tables 3 to 5.

[0132] <Adhesive blocking test> Immediately after drying, two 50 x 50 mm pieces of adhesive resin composition-coated electrical steel sheets were cut out and stacked so that the adhesive surfaces overlapped by 40 x 50 mm. The stacked steel sheets were pressurized at 50°C at 8 MPa for 30 minutes. After unloading, a precision spring balance was used to measure the tensile shear bond strength between the adhesive surfaces and evaluated according to the following criteria. The greater the adhesive blocking between the adhesive composition resin layers, the greater the tensile shear bond strength. Therefore, adhesive blocking resistance was evaluated using the following scale (A>B>C>D indicates prevention effect). Each measurement was performed five times. A: 0.1kPa or less, B: More than 0.1kPa and less than 0.5kPa, C: More than 0.5kPa and less than 1kPa, D: More than 1kPa

[0133] <Adhesion blocking test> Two 50 x 50 mm pieces of adhesive resin composition-coated electrical steel sheets were cut immediately after drying and laminated so that the adhesive surfaces overlapped by 40 x 50 mm. The laminated steel sheets were pressurized at 8 MPa and placed in an oven (relative humidity 90%) set to maintain a sheet temperature of 50°C for 12 weeks. After 12 weeks, the laminated steel sheets were removed from the oven and unloaded. After unloading, the tensile shear bond strength between the adhesive surfaces was measured using a precision spring balance. As adhesive blocking between the adhesive composition resin layers progressed during storage, the tensile shear bond strength increased. Therefore, adhesive blocking resistance was evaluated using the following scale (A>B>C>D indicates effective prevention). Each measurement was performed five times. A: 0.1kPa or less, B: More than 0.1kPa and less than 0.5kPa, C: More than 0.5kPa and less than 1kPa, D: More than 1kPa

[0134] <Short-time curing during thermocompression bonding process> Two 100 x 25 mm pieces of adhesive resin composition-coated electrical steel sheets were cut immediately after drying and stacked so that the adhesive surfaces overlapped by 25 x 25 mm. The stacked steel sheets were pressurized at 1 MPa and heated to 200 °C at a rate of 5 °C / sec and held at 200 °C for 1 minute. After cooling to room temperature, the tensile shear bond strength before storage was measured in accordance with JIS K 6850:1999 (adhesion strength immediately after drying). Furthermore, a similar tensile shear bond strength test was performed using adhesive resin composition-coated electrical steel sheets stored in an oven (relative humidity 90%) at 50 °C for 12 weeks, and the tensile shear bond strength after storage was measured (adhesion strength after storage). Each measurement was performed five times. A: 10MPa or more, B: 5MPa or more but less than 10MPa, C: 1MPa or more but less than 5MPa, D: Less than 1MPa

[0135] [Table 3]

[0136] [Table 4]

[0137] [Table 5]

[0138] <Comparative Examples 1 to 3> An adhesive resin composition-coated electrical steel sheet was obtained in the same manner as in Example 1, except that the thermosetting adhesive and drying conditions shown in Table 6 were used.

[0139] Using the obtained adhesive resin composition-coated electrical steel sheets, Tss, λ, and the area ratio of curing agent crystals were measured in the same manner as in Examples 1 to 14, and further, an adhesive blocking test, an adhesion blocking test, and the possibility of short-time curing in the thermocompression bonding process were evaluated.

[0140] [Table 6]

[0141] <Comparative Example 4> A high molecular weight epoxy prepolymer (Mn = 6000) was prepared using bisphenol A epoxy (Epicoat 828 manufactured by Mitsubishi Chemical Corporation) according to Example 43 of JP-A-11-162724. Next, an acrylic resin consisting of methacrylic acid, styrene, and ethyl acrylate (mass ratio: 174 / 87 / 29) was polymerized. 267 parts of the high molecular weight epoxy prepolymer was dissolved in a solvent with 200 parts of the acrylic resin, and then an amine catalyst (diethylaminoethanol) was added. The mixture was stirred at 105°C for 3 hours. Deionized water was then added over 30 minutes to obtain an emulsion with a solids content of 25%. 5 parts of phenolic resin (bisphenol A resol type phenolic resin) and 20 parts of DICY were added to the emulsion per 100 parts of the resin in the emulsion to obtain an epoxy emulsion adhesive (thermosetting adhesive 6). The thermosetting adhesive 6 was then applied to the surface of the electrical steel sheet using a bar coater, dried for 10 minutes at 200°C within the sheet temperature range described in paragraph 0057 of the said patent publication, and cooled to obtain an adhesive resin composition coated electrical steel sheet.

[0142] Using the resulting adhesive resin composition-coated electrical steel sheet, Tss, λ, and the area ratio of curing agent crystals were measured in the same manner as in Examples 1 to 14, and an adhesive blocking test was also conducted, and the possibility of short-time curing during the thermocompression bonding step was evaluated. As a result, the area ratio of curing agent crystals was 0.00%, and, like Comparative Examples 2 and 3, the adhesive blocking resistance and adhesive strength after storage were D.

[0143] <Result> From Examples 1 to 14, it was found that an electrical steel sheet coated with an adhesive resin composition film made of a semi-cured product of the adhesive resin composition, in which the amount of curing agent crystals was controlled to a predetermined amount, suppressed adhesive blocking and adhesive blocking even when stored for a long period of time in a high-temperature, humid environment, and was able to cure in a short time during the thermocompression bonding process and exhibit adhesive strength.

[0144] On the other hand, Comparative Example 1 shows that when the area ratio of the curing agent crystals is outside the upper limit, sufficient adhesive strength cannot be obtained even when thermocompression bonding is performed immediately after drying. This is presumably due to the curing agent crystals remaining in the adhesive resin composition coating even after thermocompression bonding. Comparative Examples 2 to 4 show that when the amount of curing agent crystals is outside the lower limit, adhesive blocking occurs during storage and the adhesive strength after storage also decreases. This is presumably due to the curing agent dissolved during drying undergoing a slow curing reaction during storage. Furthermore, Comparative Example 4 shows that the adhesive resin composition-coated electrical steel sheet of the present invention cannot be easily produced using a known adhesive and a known method. Furthermore, because the components are outside the range of the present invention, adhesive blocking occurs during storage and the adhesive strength after storage also decreases, as in Comparative Examples 2 and 3.

[0145] Comparison of Examples 1, 2, and 8 with other Examples shows that when the area ratio of the curing agent crystals is 30.00% or more, the adhesive strength immediately after drying is slightly low. Furthermore, the adhesive strength after storage is also slightly low in Examples 1, 2, and 8. This is presumably because some curing agent crystals remain in the adhesive resin composition film even after thermocompression bonding, and these crystals become the starting point for a decrease in strength, causing a decrease in adhesive strength.

[0146] Furthermore, comparison of Examples 5, 10, 11, and 14 with other Examples shows that when the area ratio of the curing agent crystals is 0.10 to 0.60%, the adhesive blocking resistance tends to deteriorate slightly. This is presumably due to the slow curing reaction between the adhesive resin composition coatings during storage caused by the curing agent dissolved in the heating, drying, and solidification process.

[0147] Furthermore, when Examples 5 and 6 are compared, although Tss is the same, Example 6 has better adhesion blocking resistance than Example 5. This is presumably due to the following: In Example 5, the Tg uc In Example 6, the Tg of the adhesive resin composition 1 used was less than 30°C. ucis 30°C or higher. As a result, in order to make Tss 80°C in the heating, drying, and solidification step, a greater heat input is applied in Example 5. As a result, it is presumed that a greater amount of the curing agent in Example 5 dissolved in the heating, drying, and solidification step. In fact, the area ratio of the curing agent crystals is also smaller in Example 5. Therefore, it is presumed that in Example 5, where a greater amount of the curing agent was dissolved, a slow curing reaction was more likely to proceed during storage, resulting in slightly inferior adhesive blocking resistance.

[0148] Furthermore, a comparison of Example 1 with Examples 2 to 4, 6, 7, 9, and 14 indicates that adhesive resin composition-coated electrical steel sheets dried at 140°C for less than 1.1 x t0 hours have poor adhesive blocking resistance. This is presumably due to the adhesive resin composition not being sufficiently cured after drying. Furthermore, a comparison of Example 14 with Examples 2 to 4, 6, 7, and 9 indicates that adhesive resin composition-coated electrical steel sheets dried at 140°C for 15.0 x t0 hours have superior adhesive blocking resistance. This is presumably due to the progress of dissolution of curing agent crystals during the heating, drying, and solidification process, resulting in a slow curing reaction caused by the curing agent dissolved during storage. [Industrial Applicability]

[0149] According to the present invention, an adhesive resin composition-coated electrical steel sheet can be obtained that can prevent adhesive blocking and a decrease in adhesive strength even when stored for a long period of time after adhesive application and drying, and that can cure the adhesive resin composition coating in a short time during thermocompression bonding. Therefore, the adhesive resin-coated electrical steel sheet of the present invention can be suitably used as a material for iron cores (stators, rotors, etc.) for home appliances (air conditioners, vacuum cleaners, audio equipment, etc.) and motors for automobiles (HVs, EVs, etc.).

Claims

1. An adhesive resin composition coated electrical steel sheet having a steel sheet and an adhesive resin composition coating on at least one surface of the steel sheet, the adhesive resin composition coating is a semi-cured product of an adhesive resin composition comprising an adhesive resin containing at least a thermosetting resin in part and a curing agent, the adhesive resin composition coating has a maximum penetration λ of 3% or more and less than 100% at 100 to 300°C, as measured by thermomechanical analysis according to JIS K 7196:2012; a part of the curing agent is present in a crystalline state in the adhesive resin composition coating, an area ratio of the crystalline curing agent in the cross section of the adhesive resin composition coating parallel to the surface of the steel sheet is 0.10 to 40%; Adhesive resin composition coated electrical steel sheet.

2. the area ratio of the crystalline curing agent is 0.70 to 20%; An electrical steel sheet coated with the adhesive resin composition according to claim 1.

3. the adhesive resin composition coating has a softening start temperature Tss of 50°C or higher and a maximum penetration λ of 15% or higher at 100 to 300°C, as measured by thermomechanical analysis according to JIS K 7196:2012; An electrical steel sheet coated with the adhesive resin composition according to claim 1.

4. The thermosetting resin includes one or more selected from an epoxy resin, an acrylic resin, a urethane resin, and an unsaturated polyester resin. An electrical steel sheet coated with the adhesive resin composition according to claim 1.

5. The curing agent includes one or more selected from an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent. An adhesive resin composition coated electrical steel sheet according to any one of claims 1 to 4.

6. A method for producing an adhesive resin composition coated electrical steel sheet according to any one of claims 1 to 4, comprising: a coating step of coating a liquid thermosetting adhesive containing the adhesive resin and the curing agent onto at least one surface of the steel plate; a heating, drying, and solidification step of heating the steel plate to which the thermosetting adhesive has been applied and then cooling the steel plate to form an adhesive resin composition coating on the surface of the steel plate, The heating temperature in the heating, drying and solidifying step is a temperature T within a temperature range of 100 to 250°C, The heating time in the heating, drying and solidifying step satisfies the following formula (i): A method for manufacturing an electrical steel sheet coated with an adhesive resin composition. 0.8≦t / t ０ ≦18.0 ・・・(i) Here, the meanings of the symbols in the above formula (i) are as follows: t: heating time in the heating, drying and solidifying step t ０ : the time required to form an adhesive resin composition coating having a softening starting temperature of 50°C when the thermosetting adhesive is dried at the temperature T

7. The glass transition temperature Tg of the adhesive resin ｕｃ is 30°C or higher, The heating temperature in the heating, drying and solidifying step is a temperature T within a temperature range of 100 to 180°C, The heating time in the heating, drying and solidifying step satisfies the following formula (ii): A method for producing an adhesive resin composition-coated electrical steel sheet according to claim 6. .3≦t4 ０ ≦.... ・・・(ii) Here, the meanings of the symbols in the above formula (ii) are as follows: t: heating time in the heating, drying and solidifying step t ０ : the time required to form an adhesive resin composition coating having a softening starting temperature of 50°C when the thermosetting adhesive is dried at the temperature T

8. The adhesive resin contains 50 mass% or more of a thermosetting resin selected from an epoxy resin, an acrylic resin, a urethane resin, and an unsaturated polyester resin, based on the total amount of the adhesive resin. A method for producing an adhesive resin composition-coated electrical steel sheet according to claim 6.

9. The curing agent includes one or more selected from an amine-based curing agent, an amide-based curing agent, and an imidazole-based curing agent. A method for producing an adhesive resin composition-coated electrical steel sheet according to claim 6.

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