Grain-oriented electrical steel sheet with phosphide layer
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Solution Overview
Problem
Grain-oriented electrical steel sheets without a forsterite film face challenges in achieving uniform coating adhesion of insulation coatings, leading to local delamination and reduced tension on the base steel sheet, which affects iron loss characteristics.
Innovation Solution
A grain-oriented electrical steel sheet structure is developed with a crystalline phosphide-containing layer formed in the lower area of the insulation coating, in contact with an intermediate layer mainly containing silicon oxide, enhancing coating adhesion and maintaining insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an insulation coating is formed on a grain-oriented electrical steel sheet without a forsterite film, then the manufacturing process is simplified and cost is reduced, but the coating adhesion becomes uneven and local delamination occurs
Solution Approach 1:
An intermediate layer mainly containing silicon oxide is introduced between the base steel sheet and the insulation coating. This intermediate layer acts as a mediator that improves the bonding interface, preventing local delamination while allowing the manufacturing process to remain simplified and avoiding the need for a forsterite film.
2Loss of energy
If tension is increased on the base steel sheet to reduce iron loss, then energy efficiency is improved, but coating adhesion deteriorates
Solution Approach 1:
The chemical composition and physical properties of the intermediate layer are optimized to achieve a balance between tension application and coating adhesion. By controlling the silicon oxide content and layer characteristics, sufficient tension is applied to reduce iron loss while maintaining stable coating adhesion without delamination.
3Loss of energy
If the surface of the base steel sheet is made smooth to reduce iron loss, then energy efficiency is improved, but coating adhesion becomes insufficient
Solution Approach 1:
A composite layered structure is created consisting of the base steel sheet, silicon oxide intermediate layer, and insulation coating. This composite structure combines the benefits of a smooth surface for reduced iron loss with enhanced coating adhesion through the intermediate layer, resolving the contradiction between surface smoothness and coating bonding.
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 inclusion of a crystalline phosphide-containing layer improves the uniformity and stability of insulation coating adhesion, reducing iron loss and maintaining high surface tension on the base steel sheet, thereby enhancing the overall performance of the electrical steel sheet.
Implementation Method 1
the inhibitors such as AlN, MnS, and MnSe are finely precipitated in steel, and thereby, the secondary recrystallization is controlled
Implementation Method 2
an oxide layer is formed on the surface of the steel sheet
Implementation Method 3
have a function of applying tension to the base steel sheet to reduce the iron loss
Data Source
AI summary
A grain-oriented electrical steel sheet includes: a base steel sheet; an intermediate layer arranged in contact with the base steel sheet; and an insulation coating arranged in contact with the intermediate layer to be an outermost surface, in which the insulation coating has a crystalline phosphide-containing layer containing a crystalline phosphide in an area in contact with the intermediate layer when viewing a cross section whose cutting direction is parallel to a thickness direction.