TWI629165B - 電磁鋼板及電磁鋼板之製造方法 - Google Patents
電磁鋼板及電磁鋼板之製造方法 Download PDFInfo
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Abstract
一種電磁鋼板,其係於鋼板表面具有絕緣覆膜,該絕緣覆膜係包含:由磷酸金屬鹽100質量份及平均粒徑為0.05~0.50μm之有機樹脂1~50質量份所構成的黏合劑、與相對於前述黏合劑之固體含量100質量份的含量為0.1~10.0質量份的碳數2~50之羧酸系化合物;前述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。該電磁鋼板係具備衝切加工後之端面防鏽性良好的絕緣覆膜。
Description
本發明係有關於電磁鋼板及電磁鋼板之製造方法。
一般而言,在使用電磁鋼板製造馬達及變壓器等的電力設備時,首先係將箍狀的電磁鋼板衝切加工成規定形狀,層合經衝切之電磁鋼板後,予以固接,來製造鐵芯。其次,對鐵芯的齒部等捲繞銅線後,使清漆含浸於鐵芯中,對鐵芯噴灑粉體塗料等,再進行烘烤乾燥。進而,對乾燥後的鐵芯安裝銅線連接用之端子、凸緣及軸承等,再予以固定於外殼上而製成馬達及變壓器等。
於此,電磁鋼板的表面上,為了防止電流在層合的鋼板間流動,減少鐵損耗而提升磁特性,而塗佈有絕緣覆膜。
電磁鋼板表面所施加的絕緣覆膜係要求絕緣性;另一方面,為了提升對電磁鋼板進行加工時的作業性,亦要求熔接性、滑動性、密接性、耐熱性及塗裝性等的絕緣性以外的覆膜特性。
作為此種電磁鋼板之絕緣覆膜,已知有例如以有機樹脂為主成分者、以鉻酸鹽或磷酸鹽等的無機酸鹽為主成分者、及以無機酸鹽與有機樹脂的混合物為主成分等。
一般而言,以有機樹脂為主成分者,其耐熱性較低;以無機酸鹽為主成分者,在加工時容易由鋼板剝落,因此,以往係大多使用以無機酸鹽與有機樹脂的混合物為主成分者作為絕緣覆膜。
舉例而言,作為電磁鋼板之絕緣覆膜相關之技術,以往,在特公昭50-15013號公報中揭露有一種使用以重鉻酸鹽、與乙酸乙烯酯-丙烯酸樹脂共聚物、丁二烯-苯乙烯共聚物、或、丙烯酸樹脂等的有機樹脂乳液為主成分的處理液來形成絕緣覆膜的技術。
又,在日本特開2002-317276號公報中揭露有一種對含有磷酸鹽與鉻酸鹽的絕緣覆膜溶液摻混規定量之具有規定之HLB(Hydrophile-Lipophile Balance)值的非離子性或陰離子性界面活性劑,來提升浸潤性的絕緣覆膜劑相關之技術。
此外,近年來,由於環保意識高漲,而持續進行不使用含有六價鉻之鉻酸水溶液來形成絕緣覆膜的技術之開發。就此種技術而言,例如,在日本特開平06-330338號公報中揭露一種以特定比例摻混特定組成之磷酸鹽、硼酸及膠體二氧化矽中的任1種以上、與特定粒徑之有機樹脂的乳液,並對鋼板進行烘烤的技術。據此技
術,雖然不使用不含鉻化合物的處理液,但具有與含有鉻化合物之習知絕緣覆膜同等的覆膜特性,而且,在消除應變退火後也可保持優良的滑動性。
又,關於此種不含有鉻酸之絕緣覆膜對電磁鋼板的加工性所造成的影響,也有人對其持續加以研討。例如,在日本特開平11-80971號公報中揭露一種藉由將以磷酸金屬鹽及有機樹脂為主成分,且根據光電子分光分析法所測得之碳1s峰及磷2s峰具有特定之強度等的處理液塗佈於電磁鋼板上並進行烘烤,來提升電磁鋼板之衝切性的技術。再者,在日本特開平11-80971號公報中,其揭露透過使以磷酸金屬鹽與有機樹脂為主成分的處理液含有特定量之沸點或昇華點為100℃以上的水溶性有機化合物,可進一步提升電磁鋼板之衝切性。
另外,在日本特開2002-47576號公報中揭露一種以特定比例含有特定金屬離子之磷酸二氫鹽與膦酸化合物的電磁鋼板之絕緣覆膜用處理液及使用該絕緣覆膜用處理液之電磁鋼板處理方法相關之技術。
再者,在日本特開2008-31245號公報中揭露一種可對各種鋼板賦予良好的防鏽性,而且能以鹼脫脂液容易地去除,可作為金屬加工油等使用的潤滑劑組成物相關之技術。
又,在日本特開2010-261063號公報中揭露一種含有多價金屬的磷酸二氫鹽、螯合劑、多胺、與合成樹脂的電磁鋼板之絕緣覆膜形成用處理液相關之技術。
[專利文獻1]日本特公昭50-15013號公報
[專利文獻2]日本特開2002-317276號公報
[專利文獻3]日本特開平06-330338號公報
[專利文獻4]日本特開平11-80971號公報
[專利文獻5]日本特開2002-47576號公報
[專利文獻6]日本特開2008-31245號公報
[專利文獻7]日本特開2010-261063號公報
另一方面,近年來,在中國及東南亞地區隨著工業化的進展,而大量建設供製造馬達及變壓器等的工廠。因此,於此地區內,電磁鋼板的用量大幅增加;然而,該地區較為高溫,而且濕度較高,從而電磁鋼板的防鏽便成為一大課題。
具體而言,對電磁鋼板進行加工時,係層合衝切後之電磁鋼板來製造鐵芯,繼而以清漆等固定鐵芯後,進行繞線及塗裝。於此,在經衝切之電磁鋼板的端面,由於基底鐵部分會露出,而極容易生鏽。
惟,對電磁鋼板進行衝切加工時,由於在加工時使用了衝切油,因此在經衝切之電磁鋼板的端面會附
著有衝切油。從而,通常,電磁鋼板的端面係藉由衝切油來防鏽,使衝切後之端面不會立即生鏽。
然而,由於衝切步驟與下一步驟的步驟處理能力之差異等,有時需在衝切步驟後將經衝切之電磁鋼板存放一定期間。又,隨馬達及變壓器而異,經衝切之電磁鋼板也有時會在工廠間移送,而非僅在工廠內。
在此種情況下,需使層合之鐵芯的端面部分不會生鏽。因此,電磁鋼板不僅要求鋼板表面之耐蝕性,也要求所謂的端面防鏽性的提升。
於此,上述之特公昭50-15013號公報及日本特開2002-317276號公報所揭露之絕緣覆膜由於含有鉻化合物,由環保方面而言在使用上有問題。又,採用上述之日本特開平06-330338號公報、日本特開平11-80971號公報、日本特開2002-47576號公報、日本特開2008-31245號公報及日本特開2010-261063號公報所揭露之技術的電磁鋼板有所謂衝切後之端面防鏽性不佳的問題。
因此,本發明係有鑑於上述問題而完成者,本發明目的在於提供一種在不含有鉻化合物的情況下,仍具備絕緣性、以及密接性、耐蝕性、外觀及衝切後之端面防鏽性良好的絕緣覆膜的電磁鋼板。
本發明之要旨為以下(1)~(6)。
(1)一種電磁鋼板,其係於鋼板表面具有絕
緣覆膜,該絕緣覆膜係包含:由磷酸金屬鹽100質量份及平均粒徑為0.05~0.50μm之有機樹脂1~50質量份所構成的黏合劑、與相對於前述黏合劑之固體含量100質量份的含量為0.1~10.0質量份的碳數2~50之羧酸系化合物;前述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。
(2)如前述(1)之電磁鋼板,其中前述絕緣覆膜,相對於前述黏合劑之固體含量100質量份係含有0.5~10質量份的多元醇。
(3)如前述(1)或(2)之電磁鋼板,其中前述羧酸系化合物係具有碳數為4~20之直鏈或分支的烷基或烯基。
(4)一種電磁鋼板之製造方法,其係包含:將磷酸金屬鹽100質量份、與以樹脂固體含量計為1~50質量份的平均粒徑為0.05~0.50μm之有機樹脂的乳液混合,來調製黏合劑液的步驟;對前述黏合劑液混合相對於前述黏合劑液之固體含量100質量份為0.1~10.0質量份的碳數2~50之羧酸系化合物,來調製處理液的步驟;及將前述處理液塗佈於電磁鋼板的表面,進行烘烤乾燥的步驟;前述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。
(5)如前述(4)之電磁鋼板之製造方法,其中在調製前述處理液的步驟中,對前述黏合劑液進一步混合相對於前述黏合劑液之固體含量100質量份為0.5~10質量份的多元醇。
(6)如前述(4)或(5)之電磁鋼板之製造方法,其中前述羧酸系化合物係具有碳數為4~20之直鏈或分支的烷基或烯基。
如以上所說明,於本發明中,係於電磁鋼板的表面形成有以特定比例包含磷酸金屬鹽、特定平均粒徑之有機樹脂、與碳數2~50之羧酸系化合物的絕緣覆膜。藉此,本發明可提供一種具備經衝切層合時之端面防鏽性良好,而且密接性、耐蝕性及外觀亦良好的絕緣覆膜的電磁鋼板。
以下,就本發明之較佳實施形態詳細加以說明。
本發明係有關於電磁鋼板及電磁鋼板之製造方法。具體而言,本發明係有關於一種作為電力設備等的鐵芯材料使用的電磁鋼板及該電磁鋼板之製造方法,尤其係有關於一種具有端面防鏽性良好,而且含有不鉻酸之絕
緣覆膜的電磁鋼板及該電磁鋼板之製造方法。
本發明之電磁鋼板係於表面形成有絕緣覆膜的電磁鋼板。又,絕緣覆膜係混合:由磷酸金屬鹽100質量份及平均粒徑為0.05~0.50μm之有機樹脂1~50質量份所構成的黏合劑、與相對於前述黏合劑之固體含量100質量份的含量為0.1~10.0質量份的碳數2~50之羧酸系化合物,並使其分散而成的覆膜。
首先,就本實施形態中形成有絕緣覆膜的電磁鋼板加以說明。
於本實施形態中,形成有絕緣覆膜的電磁鋼板可適宜使用以質量%計至少含有Si:0.1%以上、Al:0.05%以上、Mn:0.01%以上,且其餘部分為Fe及雜質的無方向性電磁鋼板。就Si、Al及Mn而言,會隨著含量的增加,使電磁鋼板的電阻增加,而提升磁特性,但另一方面會降低加工性。因此,較佳的是Si的含量未達4.0質量%,Al的含量未達3.0質量%,Mn的含量未達2.0質量%。又,其他的S、N及C等的任意添加元素的含量較佳為分別未達100ppm,更佳為未達20ppm。
於本實施形態中,例如,可使用將具有上述鋼成分之鋼胚加熱至1150~1250℃,進行熱軋並予以捲繞成線圈狀,視需求在熱軋板的狀態下以800℃至1050℃的溫度範圍進行退火後,冷軋成0.15~0.5mm左右,再進一步以750~1100℃進行退火者作為電磁鋼板。
又,形成有絕緣覆膜的電磁鋼板的表面,在
塗佈後述之處理液前,可實施任意的前處理,例如可實施使用鹼等的脫脂處理、或使用鹽酸、硫酸或者磷酸等的酸洗處理等。又,塗佈後述之處理液前的電磁鋼板的表面,也可未實施此類前處理,而為最終退火後之狀態的表面。
再者,於本實施形態中,就形成有絕緣覆膜的電磁鋼板,其表面粗糙度(Ra)較佳為1.0μm以下,更佳為0.1μm以上0.5μm以下。此外,當Ra未達0.1μm時,有在冷軋步驟中成本提高的傾向;Ra超過1.0μm時,則佔空因數會降低而不佳。另外,電磁鋼板的表面粗糙度(Ra)可依據JIS法(JIS B0601)來測定。
其次,就本實施形態中形成於電磁鋼板的表面的絕緣覆膜加以說明。
於本實施形態中,絕緣覆膜所含之磷酸金屬鹽為乾燥以磷酸與金屬離子為主成分的水溶液時的固體成分,在絕緣覆膜中係發揮作為黏合劑之機能。就磷酸金屬鹽所含之磷酸的種類,不特別限定,較佳為正磷酸、偏磷酸、聚磷酸等。就磷酸金屬鹽所含之金屬離子的種類,不特別限定,較佳為Al、Mg、Ca、Co、Li、Mn、Ni、Sr、Ti、及Zn等,尤以Al、Mg、及Zn為更佳。欲調製磷酸金屬鹽的溶液時,係以例如對正磷酸等的磷酸混合上述金屬離子的氧化物、碳酸鹽或氫氧化物來調製為佳。
又,磷酸金屬鹽可單獨使用,亦可混合2種以上使用。又,可僅使用磷酸金屬鹽,也可進一步添加磷酸或硼酸等。
於本實施形態中,絕緣覆膜所含之有機樹脂在絕緣覆膜中係發揮作為黏合劑之機能。上述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。此等有機樹脂一般係於市場販售,可容易地取得。又,對於各樹脂的乳液也可同樣地取得。
作為丙烯酸樹脂,可更適當地使用:使用丙烯酸甲酯、丙烯酸乙酯、丙烯酸正丁酯、丙烯酸異丁酯、丙烯酸正辛酯、丙烯酸異辛酯、丙烯酸2-乙基己酯、丙烯酸正壬酯、丙烯酸正癸酯、或者、丙烯酸正十二酯等作為單體,進一步共聚合具有丙烯酸、甲基丙烯酸、馬來酸、馬來酸酐、富馬酸、巴豆酸或者伊康酸等的官能基之單體、或(甲基)丙烯酸2-羥基乙酯、(甲基)丙烯酸2-羥基丙酯、(甲基)丙烯酸3-羥基丁酯、2-羥基乙基(甲基)烯丙基醚等具有羥基之單體者。
又,作為環氧樹脂,可使用例如使羧酸酐與胺改質環氧樹脂反應而得者。具體而言,可適當地使用:使雙酚A-二環氧丙基醚、雙酚A-二環氧丙基醚之己內酯開環加成物、雙酚F-二環氧丙基醚、雙酚S-二環氧丙基醚、酚醛環氧丙基醚、及、二聚酸環氧丙基醚等的環氧樹脂與異丙醇胺、單丙醇胺、單丁醇胺、單乙醇胺、二伸乙三胺、乙二胺、丁胺、丙胺、異佛爾酮二胺、四氫糠胺、苯二甲胺、己胺、壬胺、三伸乙四胺、四伸甲五胺、及、二胺基二苯基碸等的胺作用而予以改質,再使琥珀酸酐、伊康酸酐、馬來酸酐、檸康酸酐、鄰苯二甲酸酐、及、偏
苯三甲酸酐等的羧酸酐與其反應而得者。
作為聚酯樹脂,可適當地使用例如使對苯二甲酸、間苯二甲酸、鄰苯二甲酸、萘二羧酸、聯苯二羧酸、琥珀酸、己二酸、癸二酸、富馬酸、馬來酸、馬來酸酐、伊康酸、及、檸康酸等的二羧酸與乙二醇、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、三乙二醇、二丙二醇、及、聚乙二醇等的二醇反應而得的聚酯樹脂。再者,亦可使用對上述之聚酯樹脂接枝聚合丙烯酸、甲基丙烯酸、馬來酸、富馬酸、伊康酸、檸康酸、或、甲基丙烯酸酐等而得者。
上述之各有機樹脂可為乳液,亦可為水溶性樹脂。當有機樹脂為乳液時,有機樹脂可為上述之各有機樹脂的1種或2種以上的混合物。又,當有機樹脂為乳液時,有機樹脂的平均粒徑較佳為0.05~0.50μm。有機樹脂的平均粒徑未達0.05μm時,在處理液中有機樹脂更容易凝聚,致絕緣覆膜的均勻性降低。又,有機樹脂的平均粒徑超過0.50μm時,則液體的穩定性會降低。再者,上述有機樹脂為乳液時的有機樹脂的平均粒徑較佳為0.10μm以上,較佳為0.30μm以下。
此外,有機樹脂的平均粒徑係指使有機樹脂之1次粒子與球形近似時之直徑的個數平均值(亦即,有機樹脂之1次粒子的個數平均粒徑),例如,可藉由雷射繞射及散射法(依據JIS Z8825-1之方法)來測定。
就磷酸金屬鹽與有機樹脂的混合比率,相對
於磷酸金屬鹽100質量份,有機樹脂的合計為1~50質量份。有機樹脂的混合比率未達1質量份時,由於有機樹脂的濃度過低,而容易發生凝聚,其結果,塗佈液的穩定性降低。另一方面,有機樹脂的混合比率超過50質量份時,形成之絕緣覆膜的耐熱性會降低,而不適宜。
此外,磷酸金屬鹽及有機樹脂係發揮作為絕緣覆膜的黏合劑之機能。絕緣覆膜的膜厚較佳為0.3~5.0μm左右,更佳為0.5~2.0μm。
於此,於本實施形態中,絕緣覆膜所含之碳數2~50之羧酸系化合物係作為防鏽成分使用,含於黏合劑中。上述羧酸系化合物係指具有至少一個羧基的羧酸化合物、屬該羧酸化合物與金屬之鹽的羧酸鹽化合物、或、羧酸化合物與羧酸鹽化合物的混合物。此等成分由於在對電磁鋼板進行衝切加工時容易向衝切油溶出,因此可提升附著於經衝切之電磁鋼板的端面之衝切油的防鏽性。因此,根據本發明,可提升電磁鋼板之衝切後之端面防鏽性。
作為碳數2~50之羧酸化合物,以單羧酸而言,可舉出月桂酸、硬脂酸等的直鏈脂肪酸、及、具有環烷烴核的飽和羧酸、苯甲酸等的芳香族羧酸衍生物等。又,以二羧酸而言,可舉出琥珀酸、烷基琥珀酸、烷基琥珀酸半酯、烯基琥珀酸、烯基琥珀酸半酯、琥珀酸醯亞胺等的琥珀酸衍生物、羥基脂肪酸、巰基脂肪酸、肌胺酸衍生物、鄰苯二甲酸等的芳香族羧酸衍生物、及、包含蠟或
礦脂之氧化物等的氧化蠟等。
作為碳數2~50之羧酸鹽化合物,可舉出上述之羧酸化合物與金屬的鹽。此外,作為上述金屬,可舉出鈷、錳、鋅、鋁、鈣、鋇、鋰、鎂、及銅等。
羧酸系化合物係碳數為2~50。碳數未達2,亦即碳數為1的甲酸及其鹽由於揮發性較高,不僅無法期望有因含有而產生的效果,而且有毒。另一方面,碳數若超過50,由於羧酸系化合物的黏性較高,附著於端面的面積變少,其結果,防鏽效果較差。羧酸系化合物較佳為碳數為5以上,較佳為30以下。
羧酸系化合物較佳具有碳數為4~20之直鏈或分支的烷基或烯基,更佳具有碳數為8~14之直鏈的烷基或烯基。作為具有碳數為4~20之直鏈或分支的烷基或烯基的羧酸系化合物,可舉出烷基琥珀酸、烷基琥珀酸半酯、烯基琥珀酸、烯基琥珀酸半酯、烷基苯甲酸、烯基苯甲酸、烷基水楊酸、烯基水楊酸、烷基鄰苯二甲酸、及、烯基鄰苯二甲酸、以及、此等的鹽等。
羧酸系化合物的含量,相對於黏合劑之固體含量100質量份為0.1~10.0質量份。此外,當含量未達0.1質量份時,無法獲得作為防鏽成分的效果。另一方面,含量超過10.0質量份時則會發黏。再者,此等防鏽成分的混合物的含量,相對於黏合劑之固體含量100質量份,較佳為0.3質量份以上,較佳為3.0質量份以下。
於本實施形態中,在將羧酸系化合物添加於
塗佈液時,也可以使用各種界面活性劑,將上述之羧酸系化合物乳液化後再加以混合。使用於羧酸系化合物之乳液化的界面活性劑不特別限定,例如,較佳為非離子系界面活性劑,具體而言,更佳為聚氧乙烯烷基醚、聚氧乙烯烷基苯基醚、或、聚氧乙烯烷基酯等。
又,於本發明中,為了提高耐蝕性及美觀性,也可視需求將膦酸化合物添加於絕緣覆膜。作為膦酸化合物,可適宜使用膦酸、膦酸鹽、胺基三亞甲基膦酸、胺基三亞甲基膦酸鹽、羥基乙烷膦酸、以及、羥基乙烷膦酸鹽及其衍生物,尤其可更適宜使用1-1羥基亞乙基-1,1-二膦酸。
膦酸化合物的含量,相對於磷酸金屬鹽之固體含量100質量份,較佳為5~50質量份。膦酸化合物的含量未達5質量份時,無法看出因含有而產生的效果,因而不佳。另一方面,膦酸化合物的含量超過50質量份時則會發黏,因而不佳。再者,膦酸化合物的含量,相對於磷酸金屬鹽之固體含量100質量份,更佳為8質量份以上,更佳為25質量份以下。
又,於本發明中,亦可進一步將多元醇添加於絕緣覆膜。本發明中使用的多元醇,係表示1分子內具有2個以上之羥基,而且可充分溶解於本發明之絕緣覆膜的塗佈液者。作為此類多元醇的具體例,可舉出例如二乙二醇、三乙二醇、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。
多元醇相對於絕緣覆膜的含量,相對於磷酸金屬鹽之固體含量100質量份,較佳為0.5~10質量份。多元醇的含量未達0.5質量份時,形成有絕緣覆膜之電磁鋼板的美觀性會劣化,因而不佳。另一方面,多元醇的含量超過10質量份時則會發黏,因而不佳。再者,多元醇的含量,相對於磷酸金屬鹽之固體含量100質量份,更佳為1質量份以上,更佳為5質量份以下。
更者,於本發明中,形成絕緣覆膜的塗佈液中,以提升耐損傷性等為目的,亦可進一步摻混矽酸鹽及氧化鋁溶膠等的水溶性無機物而使用,也可進一步摻混包含各種界面活性劑等的表面張力降低劑而使用。又,形成絕緣覆膜的塗佈液中,亦可進一步添加氧化鈦及碳酸鈣等的著色顏料或體質顏料、磷酸鋅及磷酸鈣等的防鏽劑、增黏劑、分散劑、成膜助劑、消泡劑、有機溶媒、以及、防腐劑等而使用。
於本實施形態中,藉由對具有上述之組成的電磁鋼板,塗佈混有上述之成分的塗佈液後,進行加熱予以烘烤乾燥,可製造表面形成有絕緣覆膜的電磁鋼板。
此外,在將塗佈液塗佈於電磁鋼板的表面時,塗佈方式不特別限定。例如,可利用輥塗佈方式將塗佈液塗佈於電磁鋼板的表面,也可利用噴霧方式、浸漬方式等的塗佈方式將塗佈液塗佈於電磁鋼板的表面。
又,用以對塗佈液進行烘烤乾燥的加熱方式
亦不特別限定,可使用一般的輻射爐或熱風爐等,又,亦可使用感應加熱方式等藉由電加熱的方式。
於此,就塗佈液的烘烤乾燥條件,例如,以加熱溫度而言較佳為150~400℃的範圍,以烘烤時間而言較佳為5~30秒。又,加熱溫度更佳為260~380℃的範圍。加熱溫度未達150℃時,有在烘烤後水分殘留於絕緣覆膜中之虞,因而不佳。另一方面,加熱溫度超過400℃時,則有添加之有機樹脂氧化之虞,因而不佳。再者,烘烤時間未達5秒時,有烘烤變得不均勻之虞,因而不佳。另一方面,烘烤時間超過30秒時,則有添加之防鏽劑在絕緣覆膜中殘留的比例降低之虞,因而不佳。
首先,準備含有Si:3.0質量%、Al:0.8質量%、Mn:0.5質量%,其餘部分為Fe及雜質,板厚為0.30mm,表面粗糙度以Ra(中心線平均粗糙度)表示為0.28μm的無方向性電磁鋼板。
其次,將正磷酸與Al(OH)3、Mg(OH)2等的各金屬氫氧化物、氧化物、或碳酸鹽溶解於水中,使磷酸金屬鹽的濃度成為40質量%,再加以混合攪拌,而調製成磷酸金屬鹽的水溶液。
接著,合成出以下所示之6種有機樹脂,並分別調成30質量%乳液溶液。又,為了用來比較,而準備市售之胺基甲酸酯樹脂、聚乙烯樹脂,並分別調成30
質量%乳液溶液。進而,以表1所示之比例混合磷酸金屬鹽的水溶液與有機樹脂的30質量%乳液溶液,調製成表1所示之組成的黏合劑處理液。
此外,表1所示之黏合劑處理液No.11係藉由混合鉻酸鎂的水溶液與丙烯酸樹脂3的30質量%乳液溶液而調製。前述鉻酸鎂的水溶液係藉由將鉻酸酐溶解於規定量的純水後,一面將當量之氧化鎂攪拌一面緩緩地使其溶解而調製。
將甲基丙烯酸甲酯40質量%、苯乙烯單體30質量%、甲基丙烯酸2-羥基乙酯10質量%、甲基丙烯酸乙二醇酯20質量%共聚合,合成出丙烯酸樹脂1。
將丙烯酸甲酯20質量%、苯乙烯單體30質量%、丙烯酸異丁酯25質量%、丙烯酸4-羥基丁酯20質量%、二甲基丙烯酸乙二醇酯5質量%共聚合,合成出丙烯酸樹脂2。
將丙烯酸甲酯40質量%、丙烯酸乙酯40質量%、苯乙烯單體20質量%共聚合,合成出丙烯酸樹脂3。
將丙烯酸酯40質量%、丙烯酸二甲酯40質量%、苯乙烯單體20質量%共聚合,合成出丙烯酸樹脂4。
將雙酚A環氧樹脂以單乙醇胺改質後,使琥珀酸酐與其進行接枝聚合,合成出含有羧基之環氧樹脂。
將對苯二甲酸二甲酯40質量%與新戊二醇40質量%共聚合後,使富馬酸10質量%及偏苯三甲酸酐10質量%與其進行接枝聚合,合成出含有羧基之聚酯樹脂。
[表1]
此外,於表1中,「-」係表示未含有添加劑。又,表1中的比例係為經過固體含量換算的比例。
以雷射散射及繞射法進行測定的結果,丙烯酸樹脂1的平均粒徑為0.15μm,丙烯酸樹脂2的平均粒徑為0.14μm,丙烯酸樹脂3的平均粒徑為0.16μm,丙烯
酸樹脂4的平均粒徑為0.35μm,環氧樹脂的平均粒徑為0.20μm,聚酯樹脂的平均粒徑為0.11μm。
另外,使表1所示之黏合劑處理液含有規定量的表2所示之羧酸系化合物之防鏽劑、或、其他的防鏽劑,調製成塗佈液。
此外,表2中之防鏽劑的含量為將黏合劑處理液中之固體含量設為100質量份的比例。又,於表2中,「-」係表示不含有防鏽劑。
處理液對電磁鋼板的表面的塗佈係採用輥塗佈方式,調整輥軋縮量等,使黏合劑膜厚成為約0.5μm。
乾燥係使用熱風爐進行,予以烘烤乾燥。將所得之各實施例及比較例的評定測定結果示於表3。
以下,就上述所製造之各實施例及比較例的評定方法,詳細加以說明。
絕緣性係基於依據JIS法(JIS C2550)所測得的層間電阻,將未達3Ω‧cm2/片者評為「×」;將達3Ω‧cm2/片以上且未達10Ω‧cm2/片者評為「△」;將達10Ω‧cm2/片以上且未達30Ω‧cm2/片者評為「○」;將達30Ω‧cm2/片以上者評為「◎」。此外,就絕緣性,係以評定為「◎」或「○」之試樣作為合格。
密接性係對直徑10mm、20mm、30mm的各金屬棒捲繞黏貼有膠帶的鋼板試樣,以從鋼板試樣剝除膠帶後之絕緣覆膜的剝離痕跡來評定。將在10mmΦ的彎曲下絕緣覆膜也未剝離者評為「10mmΦOK」;將在20mmΦ的彎曲下絕緣覆膜也未剝離者評為「20mmΦOK」;將在30mmΦ的彎曲下絕緣覆膜也未剝離者評為「30mmΦOK」;將在30mmΦ的彎曲下絕緣覆膜經剝離者評為「30mmΦOUT」。此外,密接性係以評定為「10mmΦOK」、「20mmΦOK」或「30mmΦOK」之試樣作為合格。
耐蝕性係依據JIS法之鹽水噴霧試驗(JIS Z2371)進行,係針對經過4小時後的試樣以10分評定來進行。評定基準如下。此外,耐蝕性係以評定為7分以上之試樣作為合格。
10:無生鏽
9:生鏽為極少量(面積率0.1%以下)
8:生鏽之面積率=超過0.1%且為0.25%以下
7:生鏽之面積率=超過0.25%且為0.50%以下
6:生鏽之面積率=超過0.50%且為1%以下
5:生鏽之面積率=超過1%且為2.5%以下
4:生鏽之面積率=超過2.5%且為5%以下
3:生鏽之面積率=超過5%且為10%以下
2:生鏽之面積率=超過10%且為25%以下
1:生鏽之面積率=超過25%且為50%以下
端面防鏽性係使用間隙10%之未塗油的裁切機裁切塗佈有各絕緣覆膜的電磁鋼板,使裁切後的端面一致,作為評定面來評定。使裁切後的電磁鋼板在溫度50℃、濕度90%的恆溫恆濕槽中歷時48小時,與耐蝕性同樣地評定其後之評定面的生鏽面積率。評定基準如下。此外,端面防鏽性係以評定為7分以上之試樣作為合格。
10:無生鏽
9:生鏽為極少量(面積率0.1%以下)
8:生鏽之面積率=0.1%超過0.25%以下
7:生鏽之面積率=0.25%超過0.50%以下
6:生鏽之面積率=超過0.50%且為1%以下
5:生鏽之面積率=超過1%且為2.5%以下
4:生鏽之面積率=超過2.5%且為5%以下
3:生鏽之面積率=超過5%且為10%以下
2:生鏽之面積率=超過10%且為25%以下
1:生鏽之面積率=超過25%且為50%以下
將根據外觀評定絕緣覆膜之膜厚的均勻性的絕緣覆膜有光澤,呈平滑且呈均勻者評為「5」;將有光澤但均勻性稍差者評為「4」;將略有光澤、呈平滑但均勻性較差者評為「3」;將光澤較少、平滑性略差且均勻性較差者評為「2」;將光澤、均勻性、平滑性較差者評為「1」。此外,外觀係以評定為「4」以上之試樣作為合格。
佔空因數係依據JIS法(JIS C2550)來測定。此外,就佔空因數而言,係以為99.4%以上之試樣作為合格。
將以上之電磁鋼板的評定結果彙整示於表3。
[表3]
藉由參照表3所示之結果,本發明之效果極為明顯。
根據表3之結果,可知本發明之實施例1~7,其端面防鏽性良好,且衝切後之生鏽較少。又,可知本發明之實施例1~7,其絕緣性、密接性、耐蝕性、外觀及佔空因數均良好。具體而言,可知實施例1~7,相對於具備含鉻化合物之絕緣覆膜的參考例,具有約略同等的絕緣性、密接性、耐蝕性、端面防鏽性、外觀及佔空因數。
另一方面,可知比較例1~9其絕緣性、密接性、耐蝕性、端面防鏽性、外觀及佔空因數,相對於本發
明之實施例1~7均較差。具體而言,就比較例1及2,由於其有機樹脂的含量偏處於本發明之範圍外,以致端面防鏽性降低。又,就比較例3,由於其防鏽劑的含量多於本發明之範圍,使得密接性及佔空因數降低,而且外觀劣化。就比較例4,由於其防鏽劑的含量少於本發明之範圍,致端面防鏽性降低;就比較例9,由於不含防鏽劑,而使得端面防鏽性降低。再者,就比較例5,由於其防鏽劑的種類與本發明所規定的防鏽劑不同,致端面防鏽性降低;就比較例6及7,由於其有機樹脂的種類與本發明所規定的有機樹脂不同,致端面防鏽性降低,而且外觀劣化。就比較例8,由於防鏽劑的碳數超過50,以致絕緣性及佔空因數降低,而且外觀劣化。
如以上所說明,本發明實施形態之電磁鋼板由於端面防鏽性優良,可提升絕緣性、密接性、耐蝕性、外觀及佔空因數,因此可提升馬達及變壓器的製造效率。
以上,既已就本發明之較佳實施形態詳細加以說明,惟本發明不限於所述各例。只要為本發明所屬技術領域具有通常知識者,應理解顯然在申請專利範圍所記載之技術思想的範疇內,可思及各種變更例或修正例,且此等變更例或修正例亦理所當然屬於本發明之技術範圍。
Claims (6)
- 一種電磁鋼板,其係於鋼板表面具有絕緣覆膜,該絕緣覆膜係包含:由磷酸金屬鹽100質量份及平均粒徑為0.05~0.50μm之有機樹脂1~50質量份所構成的黏合劑、與相對於前述黏合劑之固體含量100質量份的含量為0.1~10.0質量份的碳數2~50之除了直鏈脂肪酸之外的單羧酸、二羧酸及氧化蠟;前述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。
- 如請求項1之電磁鋼板,其中前述絕緣覆膜,相對於前述黏合劑之固體含量100質量份係含有0.5~10質量份的多元醇。
- 如請求項1或2之電磁鋼板,其中前述羧酸系化合物係具有碳數為4~20之直鏈或分支的烷基或烯基。
- 一種電磁鋼板之製造方法,其係包含:將磷酸金屬鹽100質量份、與以樹脂固體含量計為1~50質量份的平均粒徑為0.05~0.50μm之有機樹脂的乳液混合,來調製黏合劑液的步驟;對前述黏合劑液混合相對於前述黏合劑液之固體含量100質量份為0.1~10.0質量份的碳數2~50之羧酸系化合物,來調製處理液的步驟;及將前述處理液塗佈於電磁鋼板的表面,進行烘烤乾燥的步驟;前述有機樹脂為選自丙烯酸樹脂、環氧樹脂及聚酯樹脂的1種以上。
- 如請求項4之電磁鋼板之製造方法,其中在調製前述處理液的步驟中,對前述黏合劑液進一步混合相對於前述黏合劑液之固體含量100質量份為0.5~10質量份的多元醇。
- 如請求項4或5之電磁鋼板之製造方法,其中前述羧酸系化合物係具有碳數為4~20之直鏈或分支的烷基或烯基。
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