Electrical Steel Sheet Adhesive Coating for Scratch Resistance
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Solution Overview
Problem
Electrical steel sheets face challenges in securing excellent adhesion and surface characteristics, particularly in forming insulating films that inhibit eddy currents and abrasion, while maintaining magnetic properties and cost-effectiveness.
Innovation Solution
The application of distinct adhesive layers on the upper and lower surfaces of electrical steel sheets, with specific resin and hardener compositions, to enhance adhesion and surface characteristics, allowing for bonding without conventional fastening methods and improving magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single adhesive layer is formed on the electrical steel sheet, then the manufacturing process is simple, but the surface characteristics and adhesion are insufficient
Solution Approach 1:
The adhesive layer is segmented into two distinct layers with different properties: a lower adhesive layer with higher hardness (H or higher) for wear resistance and structural bonding, and an upper adhesive layer with lower hardness (F or lower) for surface protection and reduced abrasion. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between manufacturing simplicity and adhesion reliability.
Solution Approach 2:
Different regions of the adhesive coating are given different qualities through the two-layer structure. The lower layer near the steel sheet has high hardness for strong bonding and wear resistance, while the upper layer has low hardness for surface protection and reduced friction. This local differentiation of properties achieves both durability and surface characteristics without complicating the overall manufacturing process.
2Strength
If conventional fastening methods (welding, clamping, interlocking) are used to bond electrical steel sheets, then the bonding strength is sufficient, but the magnetic properties are degraded
Solution Approach 1:
The patent replaces mechanical fastening methods (welding, clamping, interlocking) with a chemical bonding system using adhesive layers. The adhesive layers provide sufficient bonding strength through chemical adhesion to the steel sheet surface, eliminating the need for mechanical fasteners that would degrade magnetic properties. The adhesive layers achieve both bonding strength and magnetic property preservation simultaneously.
3Object-affected harmful factors
If the adhesive layer is made hard to prevent scratch defects, then the surface protection is improved, but the adhesion to the steel sheet is reduced
Solution Approach 1:
The adhesive system is segmented into two layers with opposite hardness characteristics. The lower layer has high hardness (H or higher) to prevent scratch defects and provide wear resistance, while the upper layer has low hardness (F or lower) to maintain good adhesion and surface characteristics. This segmentation resolves the contradiction between scratch protection and adhesion by assigning different hardness requirements to different layers.
Solution Approach 2:
The adhesive coating is formulated as a composite structure with two distinct material layers. The lower layer uses hard adhesive material for wear resistance and scratch protection, while the upper layer uses soft adhesive material for optimal adhesion and surface properties. This composite material approach allows the system to exhibit both hard and soft characteristics simultaneously, resolving the contradiction between scratch prevention and adhesion.
Data Source
AI summary
An embodiment of the present invention provides an electrical steel sheet including: an upper adhesive layer positioned on an upper surface of an electrical steel sheet; and an lower adhesive layer positioned on a lower surface of the electrical steel sheet, wherein the upper adhesive layer has a pencil hardness of F or lower, and the lower adhesive layer has a pencil hardness of H or higher.