Self-Bonding Electrical Steel Laminate With Si-Rich Interface Coating
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Solution Overview
Problem
Existing electrical steel sheets require costly fastening methods like welding, clamping, and interlocking for bonding, which can compromise noise, vibration, and adhesion characteristics, and lack effective long-term application workability.
Innovation Solution
An electrical steel sheet with a bonding coating layer containing a first and second interfacial layer, where 70 mol % or more of the Si content is in the second interfacial layer, utilizing a polyurethane adhesive resin and aminosilane coupling agents to enhance adhesive strength without traditional fastening methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening methods (welding, clamping, interlocking) are used to bond electrical steel sheets, then bonding strength is achieved, but noise characteristics deteriorate and manufacturing complexity increases
Solution Approach 1:
The patent replaces mechanical fastening methods (welding, clamping, interlocking) with a chemical bonding system using a bonding coating layer containing reactive components that form chemical bonds with the electrical steel sheets, thereby eliminating mechanical noise and vibration associated with traditional fastening methods
Solution Approach 2:
The bonding coating layer is formulated as a composite material system comprising a base resin, reactive coupling agents (silane or isocyanate), and optional fillers, creating a multi-phase composite that provides both adhesive strength and noise damping properties through its composition
2Strength
If traditional fastening methods are used for bonding, then bonding strength is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent merges the bonding function with the insulation coating function by applying the bonding coating layer during the existing insulation coating process, eliminating the need for separate fastening operations and reducing manufacturing process complexity
Solution Approach 2:
The bonding coating layer is designed to self-bond the electrical steel sheets through its own chemical properties without requiring external fastening devices or additional processing steps, making the bonding process self-contained and simplifying manufacturing
3Strength
If a bonding coating layer with high Si content in the second interfacial layer is used, then adhesive strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a quantitative parameter threshold (70 mol% or more of total Si content in the bonding coating layer should be present in the second interfacial layer) to ensure optimal adhesive strength while providing a clear manufacturing target that balances performance requirements with production feasibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables self-bonding of electrical steel sheets with improved adhesive strength, noise characteristics, vibration resistance, and long-term stability without the need for welding or interlocking, ensuring excellent tensile strength and peeling characteristics.
Implementation Method 1
utilizing a polyurethane adhesive resin and aminosilane coupling agents to enhance adhesive strength
Implementation Method 2
Insulation coatings are typically required to have electrical properties that suppress the generation of eddy current
Data Source
AI summary
The present invention relates to: an electrical steel sheet including: an electrical steel sheet; and a bonding coating layer positioned on the electrical steel sheet, and further including: a first interface layer positioned in the electrical steel sheet and brought into contact with the bonding coating layer; and a second interface layer positioned in the bonding coating layer and brought into contact with the first interface layer, in which 70 mol % or more of total Si content in the bonding coating layer including the second interface layer is present in the second interface layer.