Annealing Separator for Oriented Electrical Steel
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Solution Overview
Problem
Existing annealing separators for oriented electrical steel sheets are expensive and have poor workability, with materials like kaolinite exhibiting inadequate coating properties, limiting the improvement of iron loss and magnetic properties due to insufficient adhesion and coating tension.
Innovation Solution
A composition comprising magnesium oxide, magnesium hydroxide, and aluminum hydroxide, along with ceramic powders, is used to form an Al—Si—Mg composite coating on the steel sheet, enhancing adhesion and coating tension by diffusing into the oxide layer and improving thermal expansion coefficient differences, thereby reducing iron loss and improving transformer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive additives such as rare earth elements or kaolinite are introduced into the annealing separator to improve coating tension and adhesion, then the magnetic properties and iron loss are improved, but the cost increases and workability is considerably lowered
Solution Approach 1:
The patent changes the chemical composition parameters of the annealing separator by introducing specific metal elements (Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Mo, or W) at controlled concentrations (0.1-5 wt% each) into the MgO-based separator. This parameter optimization achieves improved coating tension and adhesion without using expensive rare earth elements or kaolinite, thereby maintaining workability while enhancing magnetic properties and reducing iron loss.
Solution Approach 2:
The patent replaces expensive rare earth elements and kaolinite with more economical metal additives that can be effectively incorporated into the MgO-based annealing separator. These cheaper alternatives (common metal elements at controlled concentrations) achieve the desired coating tension and adhesion improvements without the high cost and poor workability associated with traditional additives.
2Loss of energy
If the coating tension by forsterite is increased to improve transformer efficiency and iron loss, then the magnetic properties are improved, but the adhesion and coating properties become insufficient
Solution Approach 1:
The patent creates a composite annealing separator by combining MgO (which forms forsterite coating) with specific metal elements (Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Mo, or W). This composite structure enables the formation of a forsterite coating with enhanced adhesion and coating tension, simultaneously improving iron loss reduction while maintaining strong adhesion to the steel sheet surface.
Solution Approach 2:
The patent introduces specific metal elements at controlled concentrations (0.1-5 wt% each) into the MgO-based annealing separator to locally enhance the coating properties. These metal elements concentrate at the interface between the forsterite coating and steel sheet, improving adhesion and coating tension specifically where needed, while the bulk MgO structure maintains its forsterite-forming capability for iron loss reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides an oriented electrical steel sheet with improved adhesion, insulation properties, and reduced iron loss, enabling the production of high-efficiency transformers with low power dissipation by optimizing the coating tension and adhesion of the Al—Si—Mg composite.
Implementation Method 1
enhancing adhesion and coating tension by diffusing into the oxide layer
Implementation Method 2
a forsterite (2MgO.SiO2) layer consisting of a reaction of silicon oxide (SiO2) produced on the surface of the material in a primary recrystallization annealing process of the electric steel sheet material and magnesium oxide (MgO) used as an annealing separator
Implementation Method 3
functionally prevents fusion between the plates in the coil state
Implementation Method 4
may have the effect of improving the iron loss of the material by giving a tensile strength to the material due to the difference in thermal expansion coefficient between the material and the primary coating
Data Source
AI summary
The present invention has been made in an effort to provide an annealing separator component for an oriented electrical steel sheet, an oriented electrical steel sheet, and a manufacturing method thereof. According to an exemplary embodiment of the present invention, an annealing separator composition for an oriented electrical steel sheet, includes: 100 weight parts of at least one of magnesium oxide and magnesium hydroxide; and 5 to 200 weight parts of aluminum hydroxide.