CN107250431B - 电磁钢板及电磁钢板的制造方法 - Google Patents
电磁钢板及电磁钢板的制造方法 Download PDFInfo
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Abstract
一种电磁钢板,其在钢板表面具有绝缘覆膜,所述绝缘覆膜含有:由磷酸金属盐100质量份和平均粒径0.05~0.50μm的有机树脂1~50质量份构成的粘结剂;和相对于前述粘结剂的固体成分100质量份的含量为0.1~10.0质量份的碳数2~50的羧酸系化合物,前述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。该电磁钢板具备冲裁加工后的端面防锈性良好的绝缘覆膜。
Description
技术领域
本发明涉及电磁钢板以及电磁钢板的制造方法。
背景技术
通常使用电磁钢板制造电动机和变压器等电气设备的情况下,首先将环箍(hoop)状的电磁钢板冲裁加工为规定形状,将所冲裁的电磁钢板层叠后固着,制造铁芯。接着,在铁芯的齿等卷缠铜丝后,使清漆浸渗于铁芯,对于铁芯喷粉体涂料等,进行烧结干燥。进而,在干燥后的铁芯安装铜丝连接用的接头(terminal)、凸缘(flange)和轴承等,固定于外壳,由此制造电动机和变压器等。
在此,为了防止在所层叠的钢板之间流通电流、降低铁损而提高磁特性,在电磁钢板的表面涂布绝缘覆膜。
在电磁钢板的表面实施的绝缘覆膜需要绝缘性,而另一方面,为了提高加工电磁钢板时的操作性,也需要焊接性、滑动性、密合性、耐热性和涂装性等绝缘性以外的覆膜特性。
作为这种电磁钢板的绝缘覆膜,例如已知将有机树脂作为主要成分的绝缘覆膜、将铬酸盐或磷酸盐等无机酸盐作为主要成分的绝缘覆膜、以及将无机酸盐和有机树脂的混合物作为主要成分的绝缘覆膜等。
通常,将有机树脂作为主要成分的绝缘覆膜的耐热性低、将无机酸盐作为主要成分的绝缘覆膜在加工时容易由钢板剥离,因此以往大多使用将无机酸盐和有机树脂的混合物作为主要成分的绝缘覆膜作为绝缘覆膜。
例如作为关于电磁钢板的绝缘覆膜的技术,以前在日本特公昭50-15013号公报中公开了下述技术:使用将重铬酸盐、和乙酸乙烯酯-丙烯酸系树脂共聚物、丁二烯-苯乙烯共聚物、或丙烯酸系树脂等有机树脂乳液作为主要成分的处理液来形成绝缘覆膜。
另外,日本特开2002-317276号公报中公开了下述技术:在含有磷酸盐和铬酸盐的绝缘覆膜溶液中配混具有规定的亲水亲油平衡(HLB、Hydrophile-Lipophile Balance)值的非离子性或阴离子性表面活性剂规定量、提高了润湿性的绝缘覆膜剂。
另外,近年由于对于环境问题的意识提高,不使用含有6价铬的铬酸水溶液地形成绝缘覆膜的技术的开发得到进展。作为这种技术,例如在日本特开平06-330338号公报中公开了以特定比率配混硼酸及胶态二氧化硅中的任意一种以上、特定组成的磷酸盐、和特定粒径的有机树脂的乳液,烧结于钢板的技术。根据该技术,虽然使用不含有铬化合物的处理液,但是具有与含有铬化合物的以往的绝缘覆膜同等的覆膜特性,并且即使在解除应力退火后也可以保持优异的滑动性。
另外,关于由于这种不含有铬酸的绝缘覆膜所造成的对电磁钢板的加工性的影响,也进行了开发。例如日本特开平11-80971号公报中公开了将磷酸金属盐和有机树脂作为主要成分、利用光电子分光分析法测得的碳1s峰和磷2s峰具有特定强度的处理液涂布于电磁钢板并进行烧结,由此提高电磁钢板的冲裁性的技术。进而,日本特开平11-80971号公报中公开了通过在将磷酸金属盐和有机树脂作为主要成分的处理液中含有沸点或升华点为100℃以上的水溶性有机化合物特定量,可以进一步提高电磁钢板的冲裁性。
另外,日本特开2002-47576号公报中公开了关于以特定比率含有特定金属离子的磷酸二氢盐、和膦酸化合物的电磁钢板的绝缘覆膜用处理液、以及使用了该绝缘覆膜用处理液的电磁钢板处理方法的技术。
进而,日本特开2008-31245号公报中公开了关于对于各种钢板赋予良好的防锈性并且能够用碱脱脂液容易地去除,能够作为金属加工油等使用的润滑剂组合物的技术。
另外,日本特开2010-261063号公报中公开了关于含有多价金属的磷酸二氢盐、螯合剂、多胺、和合成树脂的电磁钢板的绝缘覆膜形成用处理液的技术。
现有技术文献
专利文献
专利文献1:日本特公昭50-15013号公报
专利文献2:日本特开2002-317276号公报
专利文献3:日本特开平06-330338号公报
专利文献4:日本特开平11-80971号公报
专利文献5:日本特开2002-47576号公报
专利文献6:日本特开2008-31245号公报
专利文献7:日本特开2010-261063号公报
发明内容
发明要解决的问题
另一方面,近年,在中国和东南亚地区工业化进展,建设了很多制造电动机和变压器等的工厂。因此在这种地区,电磁钢板的用量大幅增长,但是该地区由于温度比较高并且湿度高,因此电磁钢板的防锈成为问题。
具体而言,加工电磁钢板的情况下,将冲裁后的电磁钢板层叠、制造铁芯,将铁芯用清漆等固定后,进行卷线和涂装。在此,在所冲裁的电磁钢板的端面,铁素体部分露出,因此非常容易生锈。
但是,对于电磁钢板进行冲裁加工的情况下,加工时使用冲裁油,因此在所冲裁的电磁钢板的端面附着冲裁油。因此,通常电磁钢板的端面通过冲裁油而防锈,在冲裁后的端面不会立即产生锈。
但是,由于冲裁工序与后续工序的工序处理能力的差异等,在冲裁工序后,有可能将所冲裁的电磁钢板保管一定期间。另外,根据电动机和变压器,所冲裁的电磁钢板不仅在工厂内转送,而且有可能在工厂之间转送。
需要即使在这种情况下,在所层叠的铁芯的端面部分也不会产生锈。因此,对于电磁钢板,不仅要求钢板表面的耐蚀性提高,还要求所谓的端面防锈性提高。
在此,上述的日本特公昭50-15013号公报和日本特开2002-317276号公报中公开的绝缘覆膜由于含有铬化合物,从环境问题的观点考虑使用上存在问题。另外,利用了上述的日本特开平06-330338号公报、日本特开平11-80971号公报、日本特开2002-47576号公报、日本特开2008-31245号公报和日本特开2010-261063号公报中公开的技术的电磁钢板,存在冲裁后的端面防锈性不好的问题。
因此,本发明是鉴于上述问题而提出的,本发明的目的在于,提供具备即使不含有铬化合物的情况下,除了绝缘性之外,密合性、耐蚀性、外观和冲裁后的端面防锈性也良好的绝缘覆膜的电磁钢板。
用于解决问题的方案
本发明的主旨为以下的(1)~(6)。
(1)一种电磁钢板,其在钢板表面具有绝缘覆膜,所述绝缘覆膜含有:由磷酸金属盐100质量份和平均粒径0.05~0.50μm的有机树脂1~50质量份构成的粘结剂;和
相对于前述粘结剂的固体成分100质量份的含量为0.1~10.0质量份的碳数2~50的羧酸系化合物,
前述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。
(2)根据前述(1)所述的电磁钢板,其中,前述绝缘覆膜含有相对于前述粘结剂的固体成分100质量份为0.5~10质量份的多元醇。
(3)根据前述(1)或(2)所述的电磁钢板,其中,前述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
(4)一种电磁钢板的制造方法,其包括:将100质量份的磷酸金属盐、和按照树脂固体成分计为1~50质量份的平均粒径0.05~0.50μm的有机树脂的乳液混合,制造粘结剂液的步骤;
在前述粘结剂液中混合相对于前述粘结剂液的固体成分100质量份为0.1~10.0质量份的碳数2~50的羧酸系化合物,制造处理液的步骤;和
将前述处理液涂布于电磁钢板的表面、进行烧结干燥的步骤,
前述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。
(5)根据前述(4)所述的电磁钢板的制造方法,其中,在前述制造处理液的步骤中,在前述粘结剂液中进一步混合相对于前述粘结剂液的固体成分100质量份为0.5~10质量份的多元醇。
(6)根据前述(4)或(5)所述的电磁钢板的制造方法,其中,前述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
发明的效果
如以上说明那样,本发明中,将以特定比率含有磷酸金属盐、特定的平均粒径的有机树脂、和碳数2~50的羧酸系化合物的绝缘覆膜形成于电磁钢板的表面。由此,本发明提供具备冲裁层叠时的端面防锈性良好并且密合性、耐蚀性和外观良好的绝缘覆膜的电磁钢板。
具体实施方式
以下对于本发明的优选实施方式进行详细说明。
本发明涉及电磁钢板和电磁钢板的制造方法。具体而言,本发明涉及作为电气设备等的铁芯材料使用的电磁钢板和该电磁钢板的制造方法,特别是涉及具有端面防锈性良好并且不含有铬酸的绝缘覆膜的电磁钢板和该电磁钢板的制造方法。
本发明的电磁钢板为在表面形成有绝缘覆膜的电磁钢板。另外,绝缘覆膜为混合、分散有由磷酸金属盐100质量份和平均粒径0.05~0.50μm的有机树脂1~50质量份构成的粘结剂、和相对于该粘结剂的固体成分100质量份的含量为0.1~10.0质量份的碳数2~50的羧酸系化合物的覆膜。
首先对于本实施方式中形成绝缘覆膜的电磁钢板进行说明。
本实施方式中,形成绝缘覆膜的电磁钢板可以合适地使用按照质量%计至少含有Si:0.1%以上、Al:0.05%以上、Mn:0.01%以上,余量为Fe和杂质的无方向性电磁钢板。Si、Al和Mn随着含量增加而使电磁钢板的电阻增加、使磁特性提高,但是另一方面使加工性降低。因此,优选Si的含量不足4.0质量%、Al的含量不足3.0质量%、Mn的含量不足2.0质量%。另外,其它的S、N和C等任意添加元素的含量优选分别不足100ppm、更优选不足20ppm。
本实施方式中,例如可以将具有上述钢成分的板坯加热到1150~1250℃,进行热轧、卷取为卷材状,根据需要以热轧板的状态在800℃~1050℃的温度范围内进行退火后,冷轧到0.15~0.5mm左右,进一步在750~1100℃下退火,将进行了退火的钢板用作电磁钢板。
另外,对于形成绝缘覆膜的电磁钢板的表面,在涂布后述的处理液之前,可以实施任意的前处理,例如可以实施利用碱等进行的脱脂处理、或者利用盐酸、硫酸或磷酸等进行的酸洗处理等。另外,涂布后述的处理液之前的电磁钢板的表面,也可以不实施这种前处理、仍然为最终退火后的表面。
进而,本实施方式中,对于形成绝缘覆膜的电磁钢板而言,表面粗糙度(Ra)优选为1.0μm以下、更优选为0.1μm以上且0.5μm以下。需要说明的是,Ra不足0.1μm的情况下,存在在冷轧工序成本升高的倾向,Ra超过1.0μm的情况下,占空系数(占積率)降低,因此不优选。需要说明的是,电磁钢板的表面粗糙度(Ra)能够根据JIS法(JIS B0601)测定。
接着对于本实施方式中形成于电磁钢板的表面的绝缘覆膜进行说明。
本实施方式中,绝缘覆膜中含有的磷酸金属盐为将磷酸和金属离子作为主要成分的水溶液干燥时的固体成分,在绝缘覆膜中作为粘结剂发挥功能。作为磷酸金属盐中含有的磷酸的种类,没有特别限定,但是优选为正磷酸、偏磷酸、多磷酸等。作为磷酸金属盐中含有的金属离子的种类,没有特别限定,但是优选为Al、Mg、Ca、Co、Li、Mn、Ni、Sr、Ti和Zn等,特别是更优选为Al、Mg和Zn。制造磷酸金属盐的溶液的情况下,例如优选在正磷酸等磷酸中混合上述金属离子的氧化物、碳酸盐或氢氧化物来制造。
另外,磷酸金属盐可以单独使用也可以混合两种以上来使用。另外,可以仅使用磷酸金属盐、也可以进一步加入磷酸或硼酸等。
本实施方式中,绝缘覆膜中含有的有机树脂在绝缘覆膜中作为粘结剂发挥功能。上述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。这些有机树脂通常在市面上出售,能够容易地获得。另外,对于各树脂的乳液也能够同样地获得。
作为丙烯酸系树脂,可以更合适地利用使用丙烯酸甲酯、丙烯酸乙酯、丙烯酸正丁酯、丙烯酸异丁酯、丙烯酸正辛酯、丙烯酸异辛酯、丙烯酸2-乙基己酯、丙烯酸正壬酯、丙烯酸正癸酯、或丙烯酸正十二烷基酯等作为单体,进一步共聚丙烯酸、甲基丙烯酸、马来酸、马来酸酐、富马酸、巴豆酸或衣康酸等具有官能团的单体,或者(甲基)丙烯酸2-羟基乙酯、(甲基)丙烯酸2-羟基丙酯、(甲基)丙烯酸3-羟基丁酯、2-羟基乙基(甲基)烯丙基醚等具有羟基的单体而成的丙烯酸系树脂。
另外,作为环氧树脂,例如可以使用使胺改性环氧树脂与羧酸酐反应而成的环氧树脂。具体而言,可以合适地使用使异丙醇胺、单丙醇胺、单丁醇胺、单乙醇胺、二亚乙基三胺、亚乙基二胺、丁基胺、丙基胺、异佛尔酮二胺、四氢糠基胺、二甲苯二胺、己基胺、壬基胺、三亚乙基四胺、四亚甲基五胺、和二氨基二苯基砜等胺作用于双酚A-二缩水甘油基醚、双酚A-二缩水甘油基醚的己内酯开环加成物、双酚F-二缩水甘油基醚、双酚S-二缩水甘油基醚、酚醛清漆缩水甘油基醚、和二聚酸缩水甘油基醚等环氧树脂使其改性,并且与琥珀酸酐、衣康酸酐、马来酸酐、柠康酸酐、酞酸酐、和偏苯三酸酐等羧酸酐反应而成的环氧树脂。
作为聚酯树脂,例如可以合适地使用对苯二甲酸、间苯二甲酸、邻苯二甲酸、萘二羧酸、联苯二羧酸、琥珀酸、己二酸、癸二酸、富马酸、马来酸、马来酸酐、衣康酸和柠康酸等二羧酸,与乙二醇、1,2-丙二醇、1,3-丙二醇、1,4-丁二醇、1,5-戊二醇、新戊二醇、1,6-己二醇、三甘醇、一缩二丙二醇、和聚乙二醇等二元醇反应而成的聚酯树脂。进而,也可以使用上述聚酯树脂与丙烯酸、甲基丙烯酸、马来酸、富马酸、衣康酸、柠康酸、或甲基丙烯酸酐等接枝聚合而成的聚酯。
上述各有机树脂可以为乳液、也可以为水溶性树脂。有机树脂为乳液的情况下,有机树脂可以为上述的各有机树脂的一种或两种以上的混合物。另外,有机树脂为乳液的情况下,有机树脂的平均粒径优选为0.05~0.50μm。有机树脂的平均粒径不足0.05μm的情况下,处理液中、有机树脂容易聚集,绝缘覆膜的均匀性降低。另外,有机树脂的平均粒径超过0.50μm的情况下,液体的稳定性降低。进而,上述有机树脂为乳液时的有机树脂的平均粒径优选为0.10μm以上、优选为0.30μm以下。
需要说明的是,有机树脂的平均粒径指的是有机树脂的一次颗粒近似为球形时的直径的个数平均值(即,有机树脂的一次颗粒的个数平均粒径),例如可以通过激光衍射和散射法(基于JIS Z8825-1的方法)测定。
对于磷酸金属盐和有机树脂的混合比率而言,相对于磷酸金属盐100质量份,有机树脂的总计为1~50质量份。有机树脂的混合比率不足1质量份的情况下,有机树脂的浓度过低,因此容易产生聚集,其结果涂布液的稳定性降低。另一方面,有机树脂的混合比率超过50质量份的情况下,所形成的绝缘覆膜的耐热性降低,所以不合适。
需要说明的是,磷酸金属盐和有机树脂作为绝缘覆膜的粘结剂发挥功能。绝缘覆膜的膜厚优选为0.3~5.0μm左右、更优选为0.5~2.0μm。
在此,本实施方式中,绝缘覆膜中含有的碳数2~50的羧酸系化合物作为防锈成分使用,含有于粘结剂中。上述羧酸系化合物指的是具有至少一个羧基的羧酸化合物、作为该羧酸化合物与金属的盐的羧酸盐化合物、或者羧酸化合物和羧酸盐化合物的混合物。这些成分由于在对于电磁钢板进行冲裁加工时,容易在冲裁油溶出,因此可以提高附着于所冲裁的电磁钢板的端面的冲裁油的防锈性。因此,根据本发明,可以提高电磁钢板的冲裁后的端面防锈性。
作为碳数2~50的羧酸化合物,对于单羧酸而言,可列举出月桂酸、硬脂酸等直链脂肪酸、以及具有环烷烃核的饱和羧酸、苯甲酸等芳香族羧酸衍生物等。另外,对于二羧酸而言,可列举出琥珀酸、烷基琥珀酸、烷基琥珀酸半酯、链烯基琥珀酸、链烯基琥珀酸半酯、琥珀酸酰亚胺等琥珀酸衍生物,羟基脂肪酸、巯基脂肪酸、肌氨酸衍生物、邻苯二甲酸等芳香族羧酸衍生物,以及蜡或含有凡士林的氧化物等的氧化蜡等。
作为碳数2~50的羧酸盐化合物,可列举出上述的羧酸化合物与金属的盐。需要说明的是,作为上述金属,可列举出钴、锰、锌、铝、钙、钡、锂、镁和铜等。
羧酸系化合物的碳数为2~50。碳数不足2,即,碳数为1的甲酸及其盐由于挥发性高,不仅不能期待通过含有而实现的效果,而且有毒。另一方面,若碳数超过50则由于羧酸系化合物的粘性高,因此附着于端面的面积减少,其结果,防锈效果差。羧酸系化合物优选碳数为5以上、优选为30以下。
羧酸系化合物优选具有碳数4~20的直链或支链的烷基或链烯基、更优选具有碳数8~14的直链的烷基或链烯基。作为具有碳数4~20的直链或支链的烷基或链烯基的羧酸系化合物,可列举出烷基琥珀酸、烷基琥珀酸半酯、链烯基琥珀酸、链烯基琥珀酸半酯、烷基苯甲酸、链烯基苯甲酸、烷基水杨酸、链烯基水杨酸、烷基邻苯二甲酸、和链烯基邻苯二甲酸、以及它们的盐等。
羧酸系化合物的含量,相对于粘结剂的固体成分100质量份为0.1~10.0质量份。需要说明的是,含量不足0.1质量份的情况下,不能得到作为防锈成分的效果。另一方面,含量超过10.0质量份的情况下,产生发粘。进而,这些防锈成分的混合物的含量相对于粘结剂的固体成分100质量份、优选为0.3质量份以上、优选为3.0质量份以下。
本实施方式中,将羧酸系化合物添加到涂布液的情况下,可以使用各种表面活性剂、将上述的羧酸系化合物乳液化后混合。对于用于羧酸系化合物的乳液化的表面活性剂没有特别限定,例如优选为非离子系表面活性剂,具体而言,更优选为聚氧亚乙基烷基醚、聚氧亚乙基烷基苯基醚、或聚氧亚乙基烷基酯等。
另外,本发明中,为了提高耐蚀性、外观,根据需要也能够将膦酸化合物添加到绝缘覆膜。作为膦酸化合物,可以合适地使用膦酸、膦酸盐、氨基三亚甲基膦酸、氨基三亚甲基膦酸盐、羟基乙烷膦酸、以及羟基乙烷膦酸盐及其衍生物,特别是可以更合适地使用1-1羟基乙叉基-1,1-二膦酸。
膦酸化合物的含量相对于磷酸金属盐的固体成分100质量份优选为5~50质量份。膦酸化合物的含量不足5质量份的情况下,不能确认通过含有而实现的效果,因此不优选。另一方面,膦酸化合物的含量超过50质量份的情况下,产生发粘,因此不优选。进而,膦酸化合物的含量相对于磷酸金属盐的固体成分100质量份更优选为8质量份以上、更优选为25质量份以下。
另外,本发明中,可以进一步将多元醇添加到绝缘覆膜。本发明中使用的多元醇指的是1分子内具有2个以上羟基并且充分溶解于本发明的绝缘覆膜的涂布液的多元醇。作为这种多元醇的具体例,可列举出例如二甘醇、三甘醇、四乙二醇、丙二醇、1,4-丁二醇、2,3-丁二醇、2-甲基-2,4-戊二醇、2-乙基-2,4-己二醇、甘油等。
多元醇相对于绝缘覆膜的含量,相对于磷酸金属盐的固体成分100质量份优选为0.5~10质量份。多元醇的含量不足0.5质量份的情况下,形成有绝缘覆膜的电磁钢板的外观劣化,因此不优选。另一方面,多元醇的含量超过10质量份的情况下,产生发粘,因此不优选。进而,多元醇的含量相对于磷酸金属盐的固体成分100质量份更优选为1质量份以上、更优选为5质量份以下。
进而,本发明中,为了提高耐损伤性等,在形成绝缘覆膜的涂布液中,可以进一步配混硅酸盐和氧化铝溶胶等水溶性无机物来使用,也可以进一步配混含有各种表面活性剂等的表面张力降低剂来使用。另外,在形成绝缘覆膜的涂布液中,可以进一步添加氧化钛和碳酸钙等着色颜料或体质颜料、磷酸锌和磷酸钙等防锈剂、增稠剂、分散剂、成膜助剂、消泡剂、有机溶剂以及防腐剂等来使用。
本实施方式中,对于具有上述组成的电磁钢板涂布混合有上述成分的涂布液后,进行加热、烧结干燥,由此可以制造在表面形成有绝缘覆膜的电磁钢板。
需要说明的是,将涂布液涂布到电磁钢板的表面的情况下,对于涂布方式没有特别限定。例如可以使用辊涂机方式将涂布液涂布到电磁钢板的表面,也可以使用喷雾方式、浸渍方式等涂布方式将涂布液涂布到电磁钢板的表面。
另外,对于用于将涂布液烧结干燥的加热方式没有特别限定,能够使用通常的辐射炉或热风炉等,另外,也可以使用感应加热方式等利用电加热的方式。
在此,涂布液的烧结干燥条件,例如对于加热温度而言,优选处于150~400℃的范围内,对于烧结时间而言,优选为5~30秒。另外,加热温度更优选处于260~380℃的范围内。加热温度低于150℃的情况下,烧结后有可能在绝缘覆膜中残留水分,因此不优选。另一方面,加热温度超过400℃的情况下,所添加的有机树脂有可能氧化,因此不优选。进而,烧结时间不足5秒的情况下,烧结有可能不均匀,因此不优选。另一方面,烧结时间超过30秒的情况下,所添加的防锈剂残留于绝缘覆膜中的比率有可能降低,因此不优选。
实施例
首先准备含有Si:3.0质量%、Al:0.8质量%、Mn:0.5质量%,余量为Fe和杂质,板厚为0.30mm,表面粗糙度按照Ra(中心线平均粗糙度)计为0.28μm的无方向性电磁钢板。
接着将正磷酸、和Al(OH)3、Mg(OH)2等各金属氢氧化物、氧化物、或碳酸盐以磷酸金属盐的浓度为40质量%的方式溶解于水,进行混合搅拌,由此制造磷酸金属盐的水溶液。
接着合成以下所示的6种有机树脂,分别形成30质量%乳液溶液。另外,为了进行比较,准备市售的聚氨酯树脂、聚乙烯树脂,分别形成30质量%乳液溶液。进而,以表1所示的比率将磷酸金属盐的水溶液、和有机树脂的30质量%乳液溶液混合,制造表1所示的组成的粘结剂处理液。
需要说明的是,表1所示的粘结剂处理液No.11通过将铬酸镁的水溶液、和丙烯酸系树脂3的30质量%乳液溶液混合来制造。前述铬酸镁的水溶液,通过将铬酸酐溶解于规定量的纯水后、将当量的氧化镁搅拌的同时缓慢溶解来制造。
(1)丙烯酸系树脂1
使甲基丙烯酸甲酯40质量%、苯乙烯单体30质量%、甲基丙烯酸2-羟基乙酯10质量%、乙二醇甲基丙烯酸酯20质量%共聚,合成丙烯酸系树脂1。
(2)丙烯酸系树脂2
使丙烯酸甲酯20质量%、苯乙烯单体30质量%、丙烯酸异丁酯25质量%、丙烯酸4-羟基丁酯20质量%、二甲基丙烯酸乙二醇酯5质量%共聚,合成丙烯酸系树脂2。
(3)丙烯酸系树脂3
使丙烯酸甲酯40质量%、丙烯酸乙酯40质量%、苯乙烯单体20质量%共聚,合成丙烯酸系树脂3。
(4)丙烯酸系树脂4
使丙烯酸酯40质量%、丙烯酸二甲酯40质量%、苯乙烯单体20质量%共聚,合成丙烯酸系树脂4。
(5)环氧树脂(含有羧基的环氧树脂)
将双酚A环氧树脂用单乙醇胺改性后,接枝聚合琥珀酸酐,合成含有羧基的环氧树脂。
(6)聚酯树脂(含有羧基的聚酯树脂)
使对苯二甲酸二甲酯40质量%和新戊二醇40质量%共聚后,接枝聚合富马酸10质量%和偏苯三酸酐10质量%,合成含有羧基的聚酯树脂。
[表1]
需要说明的是,表1中,“-”表示不含有添加剂。另外,表1中的比率为进行了固体成分换算而得到的比率。
利用激光散射和衍射法进行测定,结果丙烯酸系树脂1的平均粒径为0.15μm、丙烯酸系树脂2的平均粒径为0.14μm、丙烯酸系树脂3的平均粒径为0.16μm、丙烯酸系树脂4的平均粒径为0.35μm、环氧树脂的平均粒径为0.20μm、聚酯树脂的平均粒径为0.11μm。
另外,在表1所示的粘结剂处理液含有规定量的表2所示的羧酸系化合物的防锈剂、或其它的防锈剂,制造涂布液。
[表2]
需要说明的是,表2中的防锈剂的含量为粘结剂处理液中的固体成分设为100质量份时的比率。另外,表2中,“-”表示不含有防锈剂。
在对电磁钢板表面涂布处理液中,使用辊涂机方式,以粘结剂膜厚约为0.5μm的方式调整辊压下量等。干燥使用热风炉进行,进行烧结干燥。所得到的各实施例和比较例的评价测定结果如表3所示。
以下对于上述制造的各实施例和比较例的评价方法进行详细说明。
对于绝缘性而言,基于根据JIS法(JIS C2550)测定的层间电阻,不足3Ω·cm2/块评价为“×”、3Ω·cm2/块以上且不足10Ω·cm2/块评价为“△”、10Ω·cm2/块以上且不足30Ω·cm2/块评价为“○”、30Ω·cm2/块以上评价为“◎”。需要说明的是,对于绝缘性,将评价为“◎”或“○”的样品作为合格。
对于密合性而言,在10mm、20mm、30mm的直径的各金属棒卷缠粘贴有粘胶带的钢板样品,由钢板样品剥离粘胶带,以剥离后的绝缘覆膜的剥离痕迹进行评价。即使10mmφ的弯曲也没有剥离绝缘覆膜的情况设为“10mmφOK”,即使20mmφ的弯曲也没有剥离绝缘覆膜的情况设为“20mmφOK”,即使30mmφ的弯曲也没有剥离绝缘覆膜的情况设为“30mmφOK”,30mmφ的弯曲时绝缘覆膜剥离的情况设为“30mmφOUT”。需要说明的是,对于密合性,将评价为“10mmφOK”、“20mmφOK”或“30mmφOK”的样品作为合格。
耐蚀性根据JIS法的盐水喷雾试验(JIS Z2371)进行,对于经过4小时后的样品以10分进行评价。评价基准如下所述。需要说明的是,对于耐蚀性,将评价为7分以上的样品作为合格。
10:没有产生锈
9:锈产生为极少量(面积率0.1%以下)
8:锈产生的面积率=超过0.1%且0.25%以下
7:锈产生的面积率=超过0.25%且0.50%以下
6:锈产生的面积率=超过0.50%且1%以下
5:锈产生的面积率=超过1%且2.5%以下
4:锈产生的面积率=超过2.5%且5%以下
3:锈产生的面积率=超过5%且10%以下
2:锈产生的面积率=超过10%且25%以下
1:锈产生的面积率=超过25%且50%以下
对于端面防锈性而言,使用间隙(clearance)10%的没有涂油的切断机,将涂布有各绝缘覆膜的电磁钢板切断,使切断后的端面一致作为评价面进行评价。使切断后的电磁钢板在温度50℃、湿度90%的恒温恒湿槽经过48小时,此后的评价面的锈产生面积率与耐蚀性同样地进行评价。评价基准如下所述。需要说明的是,对于端面防锈性,将评价为7分以上的样品作为合格。
10:没有产生锈
9:锈产生为极少量(面积率0.1%以下)
8:锈产生的面积率=超过0.1%且0.25%以下
7:锈产生的面积率=超过0.25%且0.50%以下
6:锈产生的面积率=超过0.50%且1%以下
5:锈产生的面积率=超过1%且2.5%以下
4:锈产生的面积率=超过2.5%且5%以下
3:锈产生的面积率=超过5%且10%以下
2:锈产生的面积率=超过10%且25%以下
1:锈产生的面积率=超过25%且50%以下
根据外观,评价绝缘覆膜的膜厚的均匀性,在绝缘覆膜存在光泽、平滑且均匀的情况评价为“5”、存在光泽但是均匀性稍差的情况评价为“4”、稍微存在光泽、平滑但是均匀性差的情况评价为“3”、光泽少、平滑性稍差、均匀性差的情况评价为“2”、光泽、均匀性、平滑性差的情况评价为“1”。需要说明的是,对于外观,将评价为“4”以上的样品作为合格。
占空系数根据JIS法(JIS C2550)测定。需要说明的是,对于占空系数,将99.4%以上的样品作为合格。
以上的电磁钢板的评价结果汇总示于表3。
[表3]
通过参照表3中所示的结果,可知本发明的效果。
根据表3的结果可知,本发明的实施例1~7,端面防锈性良好并且冲裁后的锈产生少。另外可知,本发明的实施例1~7,绝缘性、密合性、耐蚀性、外观和占空系数都良好。具体而言,可知实施例1~7相对于具备含有铬化合物的绝缘覆膜的参考例,具有大致同等的绝缘性、密合性、耐蚀性、端面防锈性、外观和占空系数。
另一方面可知,比较例1~9相对于本发明的实施例1~7,绝缘性、密合性、耐蚀性、端面防锈性、外观和占空系数都差。具体而言,比较例1及2由于有机树脂的含量处于本发明的范围之外,因此端面防锈性降低。另外,比较例3由于防锈剂的含量多于本发明的范围,因此密合性和占空系数降低并且外观劣化。比较例4由于防锈剂的含量少于本发明的范围,因此端面防锈性降低,比较例9由于不含有防锈剂,因此端面防锈性降低。进而,比较例5由于防锈剂的种类与本发明中规定的防锈剂不同,因此端面防锈性降低,比较例6及7由于有机树脂的种类与本发明中规定的有机树脂不同,因此端面防锈性降低并且外观劣化。比较例8由于防锈剂的碳数超过50,因此绝缘性和占空系数降低并且外观劣化。
如以上说明那样,本发明的实施方式的电磁钢板,由于端面防锈性优异,能够提高绝缘性、密合性、耐蚀性、外观和占空系数,因此能够提高电动机和变压器的制造效率。
以上对于本发明的优选实施方式进行了详细说明,但是本发明不被上述例子所限定。若为具有本发明所属技术领域中的通常的知识的技术人员,则在权利要求书中记载的技术思想的范畴内能够想到各种变更例或修正例是显而易见的,对于它们而言,当然了解为属于本发明的技术范围内。
Claims (10)
1.一种电磁钢板,其在钢板表面具有绝缘覆膜,
所述绝缘覆膜含有:由磷酸金属盐100质量份和平均粒径0.05~0.50μm的有机树脂1~50质量份构成的粘结剂;和
相对于所述粘结剂的固体成分100质量份的含量为0.1~10.0质量份的碳数2~50的羧酸系化合物,
所述羧酸系化合物不包括直链脂肪酸、且为选自具有环烷烃核的饱和羧酸、苯甲酸、芳香族羧酸衍生物、琥珀酸、琥珀酸衍生物、羟基脂肪酸、巯基脂肪酸、肌氨酸衍生物、芳香族羧酸衍生物、氧化蜡中的1种以上,
所述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。
2.根据权利要求1所述的电磁钢板,其中,所述绝缘覆膜含有相对于所述粘结剂的固体成分100质量份为0.5~10质量份的多元醇。
3.根据权利要求1所述的电磁钢板,其中,所述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
4.根据权利要求2所述的电磁钢板,其中,所述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
5.根据权利要求1~4中的任一项所述的电磁钢板,其中,所述羧酸系化合物为选自琥珀酸、烷基琥珀酸、烷基琥珀酸半酯、链烯基琥珀酸、链烯基琥珀酸半酯、琥珀酸酰亚胺、羟基脂肪酸、巯基脂肪酸、肌氨酸衍生物、邻苯二甲酸、蜡或含有凡士林的氧化物中的1种以上。
6.一种电磁钢板的制造方法,其包括:将100质量份的磷酸金属盐、和按照树脂固体成分计为1~50质量份的平均粒径0.05~0.50μm的有机树脂的乳液混合,制造粘结剂液的步骤;
在所述粘结剂液中混合相对于所述粘结剂液的固体成分100质量份为0.1~10.0质量份的碳数2~50的羧酸系化合物,制造处理液的步骤;和
将所述处理液涂布于电磁钢板的表面、进行烧结干燥的步骤,
所述羧酸系化合物不包括直链脂肪酸、且为选自具有环烷烃核的饱和羧酸、苯甲酸、芳香族羧酸衍生物、琥珀酸、琥珀酸衍生物、羟基脂肪酸、巯基脂肪酸、肌氨酸衍生物、芳香族羧酸衍生物、氧化蜡中的1种以上,
所述有机树脂为选自丙烯酸系树脂、环氧树脂和聚酯树脂中的一种以上。
7.根据权利要求6所述的电磁钢板的制造方法,其中,在所述制造处理液的步骤中,在所述粘结剂液中进一步混合相对于所述粘结剂液的固体成分100质量份为0.5~10质量份的多元醇。
8.根据权利要求6所述的电磁钢板的制造方法,其中,所述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
9.根据权利要求7所述的电磁钢板的制造方法,其中,所述羧酸系化合物具有碳数4~20的直链或支链的烷基或链烯基。
10.根据权利要求6~9中任一项所述的电磁钢板的制造方法,其中,所述羧酸系化合物为选自琥珀酸、烷基琥珀酸、烷基琥珀酸半酯、链烯基琥珀酸、链烯基琥珀酸半酯、琥珀酸酰亚胺、羟基脂肪酸、巯基脂肪酸、肌氨酸衍生物、邻苯二甲酸、蜡或含有凡士林的氧化物中的1种以上。
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