Silicon Steel Insulating Coating for Thin-Film Lamination Bonding
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Solution Overview
Problem
Conventional silicon steel coatings, such as C-3 type self-bonding and C-5 type phosphate-based coatings, face limitations in cost, lamination coefficient, thermal stability, weldability, and bonding strength, which hinder their widespread application in advanced motors requiring high fixation strength, low magnetic vibration noise, and efficiency.
Innovation Solution
A novel insulating coating comprising a water-soluble metal inorganic salt, a water dispersible organic emulsion, a structure reinforcing additive, and a solvent, with a specific solid content ratio, that provides lamination bonding effects similar to C-3 type coatings while maintaining the heat resistance and weldability of C-5 type coatings, and achieving bonding strength suitable for motor core applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If C-3 type self-bonding coating is used to achieve lamination bonding effect, then bonding strength is improved, but cost increases and film thickness becomes too thick (≥3 μm)
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using phosphate-based inorganic coating materials instead of organic resin-based self-bonding coatings. This parameter change enables the coating to achieve bonding strength through phosphate crystalline structures formed during heat treatment, while maintaining a thin film thickness of 0.5-1.5 μm that does not compromise lamination coefficient.
Solution Approach 2:
The patent creates a composite coating system by combining phosphate-based inorganic materials with specific organic binders that can withstand high temperatures. This composite approach allows the coating to exhibit both bonding properties (through phosphate crystallization) and thermal stability (through the heat-resistant binder matrix), resolving the contradiction between bonding strength and film thickness.
2Strength
If C-3 type self-bonding coating is used to achieve lamination bonding effect, then bonding strength is improved, but price increases
Solution Approach 1:
The patent replaces expensive organic resin-based self-bonding coatings with cheaper phosphate-based inorganic coating materials. The phosphate-based coating uses readily available inorganic materials that can be applied at lower costs while achieving comparable bonding strength through controlled crystallization during heat treatment, thereby reducing production costs.
Solution Approach 2:
The patent changes the material composition from organic resin to phosphate-based inorganic materials, which fundamentally alters the bonding mechanism and cost structure. The inorganic phosphate coating materials are generally less expensive than specialized organic self-bonding resins, and the bonding effect is achieved through thermal crystallization rather than organic polymer crosslinking, reducing material costs.
3Quantity of substance
If C-5 type phosphate-based coating is used to reduce cost and maintain thin film thickness, then cost decreases and film thickness is reduced, but bonding strength becomes insufficient
Solution Approach 1:
The patent incorporates preliminary bonding agents and crystallization promoters in the coating formulation that activate during subsequent heat treatment processes. This preliminary preparation ensures that when the coating is heated during motor assembly or operation, the phosphate materials crystallize in a controlled manner to form strong inter-laminar bonds, achieving bonding strength despite the thin initial film thickness.
Solution Approach 2:
The patent utilizes phase transition of phosphate materials during heat treatment to achieve bonding. The coating materials undergo crystallization phase transitions when heated, transforming from amorphous or poorly crystalline states to well-defined crystalline structures that provide strong bonding between laminations. This phase transition mechanism enables bonding strength development in thin coatings without requiring thick film application.
4Strength
If self-bonding coating with organic resin is used to achieve bonding, then bonding effect is achieved, but heat resistance decreases (cannot withstand 750°C or above)
Solution Approach 1:
The patent creates a composite coating system combining phosphate-based inorganic materials with high-temperature-resistant organic binders. The inorganic phosphate components provide bonding through crystallization, while the heat-resistant organic matrix (such as polyvinylidene fluoride or polyacrylonitrile-based binders) maintains structural integrity at temperatures of 750°C and above, preventing coating degradation and maintaining bonding effectiveness.
Solution Approach 2:
The patent replaces organic resin-based bonding mechanisms with inorganic phosphate crystallization mechanisms. Instead of relying on organic polymer crosslinking that degrades at high temperatures, the bonding is achieved through inorganic phosphate crystal formation and interlocking structures that remain stable at elevated temperatures, substituting the bonding mechanism to achieve both bonding strength and heat resistance.
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 coating enhances the bonding strength and thermal stability of silicon steel plates, improving the fixation strength and reducing vibration noise of motor cores, thereby increasing motor efficiency and reducing manufacturing costs, while being environmentally friendly and suitable for large-scale production.
Implementation Method 1
an insulating coating... that can be coated on the surface of a substrate of a silicon steel plate and form a coating on the substrate
Data Source
AI summary
The present disclosure relates to an insulating coating, which comprises the following components: a water-soluble metal inorganic salt A containing a water-soluble phosphate A1, which comprises a water-soluble phosphate of at least one of aluminum, zinc, magnesium and manganese; a water dispersible organic emulsion B, which comprises at least one of an epoxy emulsion and a curing agent thereof, polyester, polyurethane, polyacrylate and an ethylene-vinyl acetate copolymer; an additive C, which comprises at least one of a structure reinforcing additive C1 and a heat-resistance reinforcing additive C2, wherein the structure reinforcing additive C1 comprises an inorganic nanoparticulate matter, and the heat-resistance reinforcing additive C2 is selected from at least one of boric acid and a water-soluble salt of molybdenum, tungsten, vanadium or titanium; an auxiliary agent D1 and a solvent D2, wherein the solid content ratio of the water-soluble metal inorganic salt A to the water dispersible organic emulsion B is (35-85):(15-65) in part by mass. In addition, the present disclosure further relates to a silicon steel plate, and the surface of the substrate thereof is provided with a coating layer formed by the insulating coating of the present disclosure.