WO2018179871A1 - 無方向性電磁鋼板の製造方法、モータコアの製造方法およびモータコア - Google Patents
無方向性電磁鋼板の製造方法、モータコアの製造方法およびモータコア Download PDFInfo
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- WO2018179871A1 WO2018179871A1 PCT/JP2018/004135 JP2018004135W WO2018179871A1 WO 2018179871 A1 WO2018179871 A1 WO 2018179871A1 JP 2018004135 W JP2018004135 W JP 2018004135W WO 2018179871 A1 WO2018179871 A1 WO 2018179871A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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Definitions
- the present invention relates to a method for producing a non-oriented electrical steel sheet, a method for producing a motor core using the electrical steel sheet, and a motor core made of the electrical steel sheet.
- motor cores are divided into stator cores and rotor cores.
- stator cores In order to meet the recent demands for miniaturization and higher output of HEV drive motors and the like, non-oriented electrical steel sheets used for stator cores have high magnetic flux density and low iron. Magnetic characteristics with excellent loss have been strongly demanded.
- the motor speed tends to be increased.
- the HEV drive motor has a large outer diameter, a large centrifugal force acts on the rotor core.
- the rotor core bridge part there is a very narrow part (1-2 mm) called the rotor core bridge part, and therefore the non-oriented electrical steel sheet used for the rotor core is required to have higher strength than before. It has become like this.
- the non-oriented electrical steel sheet used for the motor core has not only excellent magnetic properties but also high strength for the rotor core, and higher magnetic flux density and lower iron for the stator core. Ideally it is a loss.
- the required characteristics are greatly different between the rotor core and the stator core, but in manufacturing the motor core, it is the same from the viewpoint of increasing the material yield. It can be said that it is desirable to simultaneously extract the rotor core material and the stator core material from the raw steel plates, and then laminate the respective core materials and assemble them into the rotor core or the stator core.
- Patent Document 1 discloses a motor core in which a rotor and a stator are punched and laminated from the same steel sheet, and only the stator is subjected to strain relief annealing.
- the plate thickness used in the construction method is 0.15 mm or more and 0.35 mm or less, the yield strength of the steel sheet before strain relief annealing is 600 MPa or more, and the iron loss W 10/400 after strain relief annealing is 20 W / kg or less.
- Non-oriented electrical steel sheets have been proposed.
- the present invention has been made in view of the above-mentioned problems of the prior art, and its purpose is that a high-strength rotor core and a stator core having excellent magnetic properties after strain relief annealing can be manufactured from the same material.
- the present invention proposes a method for producing a grain-oriented electrical steel sheet and a method for producing a motor core using the non-oriented electrical steel sheet, and provides a motor core made of the non-oriented electrical steel sheet.
- a rotor core and a stator core are manufactured using a non-oriented electrical steel sheet in which the amounts of Si, Al, and Mn contained in the steel sheet are controlled within a predetermined range, and the cooling rate in the stress relief annealing of the stator core is 10 ° C /
- the cooling rate in the stress relief annealing of the stator core is 10 ° C /
- the present invention is C: 0.0050 mass% or less, Si: 2.5 to 6.5 mass%, Mn: 0.05 to 2.0 mass%, P: 0.2 mass% or less, S: 0.005 mass%
- Al 3 mass% or less
- N 0.005 mass% or less
- Ti 0.003 mass% or less
- Nb 0.005 mass% or less
- V 0.005 mass% or less
- the above Si, Al and Mn is the following formula (1); Si-2Al-Mn ⁇ 0 (1)
- the yield stress after the finish annealing is 400 MPa or more
- the iron loss W 10/400 (W / kg) after the strain relief annealing is expressed by the following formula (2) in relation to the sheet thickness t (mm); W 10/400 ⁇ 10 +
- the strain relief annealing is performed at a soaking temperature of 780 to 950 ° C. and a cooling rate from the soaking temperature to 650 ° C. being 10 ° C./min or less.
- the steel slab used in the method for producing the non-oriented electrical steel sheet of the present invention is characterized by further containing at least one component of the following groups A to D in addition to the component composition.
- groups A to D in addition to the component composition.
- . -Group A 0.0020 to 0.10 mass% in total of one or two selected from Mo and W Group B; Sn: 0.005 to 0.20 mass% and Sb: 0.005 to 0.20 mass% selected from one or two groups C Group; one or two selected from Ca and Mg 0.001 to 0.010 mass% in total Group D: one or more selected from Cu: 0.01 to 0.2 mass%, Ni: 0.05 to 1 mass%, and Cr: 0.01 to 0.5 mass%
- C 0.0050 mass% or less
- Si 2.5 to 6.5 mass%
- Mn 0.05 to 2.0 mass%
- P 0.2 mass% or less
- S 0.005 mass%
- Al 3 mass% or less
- N 0.005 mass% or less
- Ti 0.003 mass% or less
- Nb 0.005 mass% or less
- V 0.005 mass% or less
- Si Al and Mn is the following formula (1); Si-2Al-Mn ⁇ 0 (1)
- the rotor core material and the stator core material are simultaneously sampled from one non-oriented electrical steel sheet having a component composition consisting of Fe and inevitable impurities, and having a yield stress of 400 MPa or more.
- stator core material is laminated and subjected to strain relief annealing to form a stator core.
- the iron loss W 10/400 (W / kg) of the stator core after strain relief annealing is a plate.
- the method for manufacturing the motor core according to the present invention is characterized in that the strain relief annealing is performed at a soaking temperature of 780 to 950 ° C. and a cooling rate from the soaking temperature to 650 ° C. being 10 ° C./min or less.
- the non-oriented electrical steel sheet used in the method for manufacturing a motor core of the present invention is characterized in that it contains at least one component of the following groups A to D in addition to the component composition.
- groups A to D 0.0020 to 0.10 mass% in total of one or two selected from Mo and W Group B; Sn: 0.005 to 0.20 mass% and Sb: 0.005 to 0.20 mass% selected from one or two groups C Group; one or two selected from Ca and Mg 0.001 to 0.010 mass% in total Group D: one or more selected from Cu: 0.01 to 0.2 mass%, Ni: 0.05 to 1 mass%, and Cr: 0.01 to 0.5 mass%
- Ratio of the magnetostriction ⁇ 0-p (burned) after the above stress relief annealing to the average value ⁇ 0-p (raw) of the magnetostriction in the rolling direction and the direction perpendicular to the rolling at 0T ( ⁇ 0-p (burned) / ⁇ 0- p (raw)) is less than 0.8.
- the non-oriented electrical steel sheet used for the motor core of the present invention is characterized by further containing at least one component of the following groups A to D in addition to the component composition.
- groups A to D 0.0020 to 0.10 mass% in total of one or two selected from Mo and W Group B; Sn: 0.005 to 0.20 mass% and Sb: 0.005 to 0.20 mass% selected from one or two groups C Group; one or two selected from Ca and Mg 0.001 to 0.010 mass% in total Group D: one or more selected from Cu: 0.01 to 0.2 mass%, Ni: 0.05 to 1 mass%, and Cr: 0.01 to 0.5 mass%
- the rotor core that requires high strength and the stator core that requires high magnetic flux density and low iron loss can be manufactured from the same material steel plate, which contributes to the improvement of the productivity of the motor core.
- FIG. 3 is a graph showing the relationship between magnetostriction ⁇ 0-p (fired) after strain relief annealing and iron loss W 10/400 after strain relief annealing. It is a graph which shows the relationship between the cooling rate from soaking temperature in strain relief annealing, and the magnetostriction ratio ( ⁇ 0-p (annealing) / ⁇ 0-p (raw)) before and after the strain relief annealing.
- an L direction sample and a C direction sample of length: 280 mm ⁇ width: 30 mm are taken from the steel plate after the finish annealing, and rolling direction at 400 Hz and 1.0 T before strain relief annealing using a laser displacement meter.
- the average value ⁇ 0-p (raw) of the magnetostriction in the direction perpendicular to the rolling was measured.
- the JIS No. 5 tensile test piece which makes a rolling direction a tensile direction was extract
- the sample of 280 mm ⁇ 30 mm used for the magnetostriction measurement was subjected to soaking treatment at 850 ° C. ⁇ 1 hr, and then cooled from the soaking temperature to 650 ° C. at 8 ° C./min, and further to room temperature at 10 ° C./min.
- SRA simulating cooling strain relief annealing
- the iron loss W 10/400 was measured by the Epstein test method.
- FIG. 1 shows the relationship between the magnetostriction ⁇ 0-p (fired) after the stress relief annealing and the iron loss W 10/400 . From this figure, excellent iron loss characteristics are obtained when the magnetostriction ⁇ 0-p (fired) after strain relief annealing is 5.0 ⁇ 10 ⁇ 6 or less. Therefore, the iron loss characteristics after strain relief annealing are improved. It can be seen that it is effective to reduce the magnetostriction ⁇ 0-p (burning). The reason for this is considered to be that hysteresis loss deteriorates because magnetoelastic energy increases as magnetostriction increases.
- C 0.0023 mass%, Si: 3.45 mass%, Mn: 0.51 mass%, P: 0.01 mass%, S : 0.0016 mass%, Al: 0.8 mass%, N: 0.0018 mass%, O: 0.0023 mass%, Ti: 0.0014 mass%, Nb: 0.0006 mass%, and V: 0.0015 mass%
- a steel ingot obtained by melting and casting steel in a vacuum furnace is hot-rolled into a hot-rolled sheet having a thickness of 2.0 mm, and then the hot-rolled sheet is subjected to hot-rolled sheet annealing at 930 ° C. for 30 seconds.
- the cooling rate from the stress relief annealing temperature (825 ° C.) to 650 ° C. is in the range of 1 ° C./min to 30 ° C./min.
- strain relief annealing is performed, magnetostriction ⁇ 0-p (fired) after strain relief annealing is measured, and magnetostriction ratio before and after strain relief annealing ( ⁇ 0-p (fired) / ⁇ 0-p ( Raw)).
- FIG. 2 shows the relationship between the cooling rate during strain relief annealing and the magnetostriction ratio before and after strain relief annealing.
- FIG. 2 also shows that the cooling rate is preferably 10 ° C./min or less and more preferably 5 ° C./min or less in order to reduce the magnetostriction ratio, and therefore reduce the iron loss after strain relief annealing. .
- the non-oriented electrical steel sheet of the present invention needs to be able to simultaneously extract both the core material of the rotor core and the stator core from one material steel sheet.
- the rotor core has excellent magnetic properties.
- the stator core is required to have excellent magnetic properties after strain relief annealing. Therefore, the non-oriented electrical steel sheet of the present invention requires the following characteristics.
- Yield stress after finish annealing 400 MPa or more
- rotor cores are processed into a core shape by stamping etc., then laminated and clamped (fixed) by welding, caulking, etc. Therefore, strain relief annealing is not performed. Therefore, in order to use for a rotor core, the strength of the steel sheet after finish annealing is required to be high. Therefore, in the present invention, the yield stress of the steel sheet after finish annealing is defined as 400 MPa, preferably 450 MPa or more.
- the yield stress is an upper yield point when a JIS No. 5 tensile test piece is subjected to a tensile test in accordance with JIS Z 2241.
- stator core Iron loss after strain relief annealing W 10/400 : 10 + 25t or less (t: thickness (mm))
- stator core is generally subjected to strain relief annealing after the steel plate after finish annealing is processed into a core shape by punching or the like, laminated, clamped (fixed) by welding, caulking, or the like. Therefore, in order to use for a stator core, it is calculated
- the iron loss value depends on the plate thickness, the following equation (2) in relation to the plate thickness (mm): W 10/400 ⁇ 10 + 25t (2) It was necessary to meet. This is because when the iron loss value does not satisfy the above formula (2), the heat generation of the stator core is increased, and the motor efficiency is significantly reduced.
- the iron loss W 10/400 after strain relief annealing is the magnetostriction ⁇ 0-p (fire) after stress relief annealing.
- the magnetostriction ⁇ 0-p (fired) after strain relief annealing is limited to 5.0 ⁇ 10 ⁇ 6 or less in FIG. 1 where the iron loss W 10/400 satisfies the above expression (2). To do.
- the value of the magnetostriction ⁇ 0-p (burned) is the average value of the magnetostriction in the rolling direction and the direction perpendicular to the rolling measured at 400 Hz and 1.0 T.
- the ratio of the magnetostriction ⁇ 0-p (fired) after the stress relief annealing to the magnetostriction ⁇ 0-p (raw) before the stress relief annealing ( ⁇ 0-p (fired) / ⁇ 0-p (raw)) needs to be less than 0.8. Preferably it is 0.7 or less.
- the values of magnetostriction ⁇ 0-p (fired) and ⁇ 0-p (raw) are both average values of magnetostriction in the rolling direction and the direction perpendicular to the rolling measured at 400 Hz and 1.0 T.
- C 0.0050 mass% or less
- C contained in the product plate is a harmful element that forms carbides, causes magnetic aging, and deteriorates iron loss characteristics. Therefore, the upper limit of C contained in the material is limited to 0.0050 mass%. Preferably, it is 0.0040 mass% or less.
- the minimum of C is not prescribed
- Si has the effect of increasing the specific resistance of steel and reducing iron loss, and also has the effect of increasing the strength of steel by solid solution strengthening, so it is contained in an amount of 2.5 mass% or more.
- the upper limit is set to 6.5 mass%. Preferably, it is in the range of 3.0 to 6.5 mass%.
- Mn 0.05 to 2.0 mass% Mn, like Si, is an element useful for increasing the specific resistance and strength of steel, and is also an element that forms a sulfide and improves hot brittleness. Therefore, Mn is contained in an amount of 0.05 mass% or more. On the other hand, addition exceeding 2.0 mass% causes slab cracking and the like and deteriorates operability in steelmaking, so the upper limit is made 2.0 mass%. The range is preferably from 0.1 to 1.5 mass%.
- P 0.2 mass% or less P is a useful element used for adjusting the strength (hardness) of steel. However, if it exceeds 0.2 mass%, the steel becomes brittle and it becomes difficult to roll, so the upper limit is made 0.2 mass%.
- a minimum is not prescribed
- Al 3 mass% or less
- Al is a useful element that has the effect of increasing the specific resistance of steel and reducing iron loss. However, if it exceeds 3 mass%, it becomes difficult to roll, so the upper limit of Al is 3 mass%. Preferably it is 2 mass% or less.
- the Al content is in the range of more than 0.01 mass% and less than 0.1 mass%, fine AlN precipitates and iron loss increases, so Al is in the range of 0.01 mass% or less or 0.1 mass% or more. Is preferable.
- Al is preferably 0.01 mass% or less. More preferably, it is 0.003 mass% or less.
- S, N, Nb and V 0.005 mass% or less respectively
- S, N, Nb and V are elements that form fine precipitates and inhibit grain growth during strain relief annealing, which adversely affects iron loss characteristics.
- the upper limit is limited to 0.005 mass%, respectively.
- Ti 0.003 mass% or less
- Ti is an element that similarly forms fine precipitates and inhibits grain growth during strain relief annealing, and adversely affects iron loss characteristics.
- the upper limit is limited to 0.003 mass%.
- it is 0.002 mass% or less.
- the content (mass%) of Si, Al and Mn is the following formula (1): Si-2Al-Mn ⁇ 0 (1) It is necessary to satisfy and contain. Deviating from the above equation (1), that is, if the left side of the above equation (1) is less than 0, the hysteresis loss after finish annealing at 400 Hz and 1.0 T increases, and the magnetostriction ⁇ 0-p (raw) also increases. It is.
- the value on the left side of the above formula (1) is preferably 0.3 or more.
- the non-oriented electrical steel sheet of the present invention may further contain the following elements in addition to the essential components.
- Mo, W: 0.0020 to 0.10 mass% in total Mo and W are both effective elements for suppressing surface defects (hegging) of the non-oriented electrical steel sheet of the present invention. Since the steel plate of the present invention is a high alloy steel and the surface is easily oxidized, the occurrence rate of lashes due to surface cracking is high, but by adding a small amount of Mo, W, which is an element that enhances high temperature strength, the above cracks are generated. Can be suppressed. The above effect is not sufficient when the total content of Mo and W is less than 0.0020 mass%. On the other hand, adding more than 0.10 mass% only saturates the above effect and increases the alloy cost. is there. Therefore, when adding Mo and W, it is preferable to set it as the said range. More preferably, it is in the range of 0.0050 to 0.050 mass%.
- each Sn and Sb are effective in improving the recrystallization texture and improving the magnetic flux density and iron loss characteristics.
- addition of 0.005 mass% or more is required.
- the content is preferable to set the content in the range of 0.005 to 0.20 mass%, respectively. More preferably, each is in the range of 0.01 to 0.1 mass%.
- addition of 0.001 mass% or more is required in total of Ca and Mg, and on the other hand, when adding exceeding 0.010 mass%, an iron loss will raise on the contrary. Therefore, when adding Ca and Mg, the above range is preferable. More preferably, it is in the range of 0.003 to 0.008 mass%.
- Cu 0.01 to 0.2 mass% Cu has the effect of improving the texture and increasing the magnetic flux density, but in order to obtain the above effect, it is desirable to contain 0.01% by mass or more. On the other hand, if it exceeds 0.2 mass%, the above effect is saturated, so the upper limit is 0.2 mass%. More preferably, it is in the range of 0.05 to 0.15 mass%.
- Ni 0.05 to 1 mass%
- Ni has an effect of increasing the strength and specific resistance of steel, but in order to obtain the above effect, it is desirable to contain 0.05 mass% or more.
- the upper limit is set to 1 mass%. More preferably, it is in the range of 0.1 to 0.5 mass%.
- 0.5 mass% Cr 0.01 to 0.5 mass% Cr has the effect of increasing the specific resistance of the steel and reducing the iron loss. However, in order to obtain the above effect, it is desirable to contain 0.01% by mass or more. However, if it exceeds 0.5 mass%, the raw material cost increases, so the upper limit is set to 0.5 mass%. More preferably, it is in the range of 0.1 to 0.4 mass%.
- a steel having the above composition suitable for the present invention is melted by a generally known refining process using a converter, an electric furnace, a vacuum degassing apparatus, etc., and is continuously cast or ingot-bundled.
- a steel slab is formed, and the steel slab is hot-rolled by a generally known method to obtain a hot-rolled sheet.
- the hot-rolled sheet may be subjected to hot-rolled sheet annealing as necessary, and the soaking temperature in that case is preferably in the range of 800 to 1100 ° C. If it is less than 800 ° C, the effect of hot-rolled sheet annealing is small, and a sufficient effect of improving magnetic properties cannot be obtained. On the other hand, if it exceeds 1100 ° C, it is disadvantageous in terms of production cost, or brittle fracture during cold rolling ( There is a risk of promoting plate breakage).
- the hot-rolled sheet after the hot rolling or after the hot-rolled sheet annealing is then made into a cold-rolled sheet having a final thickness by one or more cold rollings sandwiching the intermediate annealing.
- the final cold rolling is preferably warm rolling at 200 ° C. or higher from the viewpoint of improving the magnetic flux density.
- the final plate thickness (product plate thickness) is preferably in the range of 0.1 to 0.3 mm. If the thickness is less than 0.1 mm, the productivity is lowered. On the other hand, if it exceeds 0.3 mm, the iron loss reduction effect is small.
- the cold-rolled sheet having the final thickness is then subjected to finish annealing, and this condition is preferably continuous annealing at 700 to 1000 ° C. for 1 to 300 seconds. If the soaking temperature is less than 700 ° C., recrystallization does not proceed sufficiently and good magnetic properties cannot be obtained, and in addition, the shape correction effect in continuous annealing cannot be obtained sufficiently. On the other hand, when the temperature exceeds 1000 ° C., the crystal grain size becomes coarse and the strength decreases. From the viewpoint of securing the strength after finish annealing required for the rotor core, it is desirable that the finish annealing be performed at a low temperature and in a short time as much as possible within a range in which shape correction is possible.
- the steel sheet after the finish annealing is preferably coated with an insulating film on the surface of the steel sheet in order to ensure insulation during lamination.
- an insulating film it is desirable to select an organic coating containing a resin in order to ensure good punchability, and to select a semi-organic or inorganic coating when emphasizing weldability.
- the stator core is generally manufactured by processing the steel sheet after finish annealing into a core shape by punching, etc., laminating and fixing, and then applying strain relief annealing.
- the annealing is preferably performed in an inert gas atmosphere under conditions of 780 to 950 ° C. ⁇ 0.1 to 10 hours. This is because if the stress relief annealing temperature is less than 780 ° C., the effect of improving the iron loss by the stress relief annealing is small, while if it exceeds 950 ° C., it is difficult to ensure insulation between the laminated steel sheets.
- a steel slab having various component compositions shown in Table 2 was heated at a temperature of 1100 ° C. for 30 minutes, and then hot-rolled to obtain a hot-rolled sheet having a thickness of 1.8 mm, and the hot-rolled sheet was 980 ° C. ⁇ 30 seconds.
- a cold-rolled sheet with various thicknesses shown in Table 3 is obtained by one cold rolling, and finish-annealing is performed on the cold-rolled sheet at the temperature shown in Table 3 for 10 seconds.
- L: 280 mm ⁇ C: 30 mm L direction sample and C: 280 mm ⁇ L: 30 mm C direction sample are cut out from the steel plate after finish annealing, and the steel plate after finish annealing is finished using a laser displacement meter.
- a JIS No. 5 tensile test piece was taken from the finished annealed product plate, subjected to a tensile test, and the yield stress was measured.
- the 280 mm ⁇ 30 mm L direction and C direction samples subjected to the magnetostriction measurement after the above-mentioned finish annealing were subjected to strain relief annealing that was soaked at the temperatures shown in Table 3 for 1 hour. At this time, the cooling rate from the soaking temperature of the strain relief annealing to 650 ° C. was changed as shown in Table 3.
- the magnetostriction ⁇ 0-p (fired) of the sample after strain relief annealing is measured with a laser displacement meter, and the magnetostriction ratio before and after strain relief annealing ( ⁇ 0-p (fired) / ⁇ 0-p (raw)).
- the iron loss W 10/400 after strain relief annealing was measured by the Epstein test.
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Abstract
Description
Si-2Al-Mn≧0 ・・・(1)
を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有する鋼スラブを熱間圧延し、冷間圧延し、仕上焼鈍し、歪取焼鈍する無方向性電磁鋼板の製造方法において、上記仕上焼鈍後の降伏応力が400MPa以上であり、上記歪取焼鈍後の鉄損W10/400(W/kg)が板厚t(mm)との関係で下記(2)式;
W10/400≦10+25t ・・・(2)
を満たし、さらに、上記歪取焼鈍後の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下で、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満となるよう、仕上焼鈍および歪取焼鈍の条件を調整することを特徴とする無方向性電磁鋼板の製造方法を提案する。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上
Si-2Al-Mn≧0 ・・・(1)
を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有し、降伏応力が400MPa以上である一つの無方向性電磁鋼板からロータコア材とステータコア材を同時に採取した後、上記ロータコア材は積層してロータコアとし、上記ステータコア材は積層し、歪取焼鈍を施してステータコアとするモータコアの製造方法において、上記歪取焼鈍後のステータコアの鉄損W10/400(W/kg)が板厚t(mm)との関係で、下記(2)式;
W10/400≦10+25t ・・・(2)
を満たし、かつ、上記歪取焼鈍後の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下であり、さらに、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満となるよう仕上焼鈍および歪取焼鈍の条件を調整することを特徴とするモータコアの製造方法を提案する。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上
Si-2Al-Mn≧0 ・・・(1)
を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有する同一の無方向性電磁鋼板から製造されたロータコアとステータコアからなるモータコアにおいて、上記ロータコアは、降伏応力が400MPa以上であり、
上記ステータコアは、鉄損W10/400(W/kg)が板厚t(mm)との関係で下記(2)式;
W10/400≦10+25t ・・・(2)
を満たし、かつ、400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下で、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満であることを特徴とするモータコアである。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上
本発明によれば、高強度が求められるロータコアと、高磁束密度、低鉄損が求められるステータコアを同一の素材鋼板から製造することができるので、モータコアの生産性の改善に寄与する。
歪取焼鈍後の鉄損W10/400に及ぼす歪取焼鈍後の磁歪の影響について調査するため、表1に示す成分組成を有する鋼を真空炉で溶解し、鋳造して得た鋼塊に熱間圧延を施し、板厚1.8mmの熱延板とした後、この熱延板に950℃×30秒の熱延板焼鈍を施し、酸洗し、冷間圧延して板厚0.25mmの冷延板とし、その後、該冷延板に、20vol%H2-80vol%N2の非酸化性雰囲気下で800℃×10秒の仕上焼鈍を施した。
次いで、上記仕上焼鈍後の鋼板から、長さ:280mm×幅:30mmのL方向サンプルおよびC方向サンプルを採取し、レーザ変位計を用いて歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)を測定した。また、上記仕上焼鈍後の鋼板から、圧延方向を引張方向とするJIS5号引張試験片を採取し、JIS Z 2241に準拠して引張試験を行い上降伏応力を測定した。
次いで、上記磁歪測定に用いた280mm×30mmのサンプルに、850℃×1hrの均熱処理後、該均熱温度から650℃までを8℃/minで冷却し、さらに、室温まで10℃/minで冷却する歪取焼鈍(SRA)を模擬した熱処理を施した後、再度、レーザ変位計で歪取焼鈍後の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)を測定するとともに、エプスタイン試験法で鉄損W10/400を測定した。
上記歪取焼鈍後の磁歪λ0-p(焼)と鉄損W10/400との関係を図1に示す。この図から、歪取焼鈍後の磁歪λ0-p(焼)が5.0×10-6以下で優れた鉄損特性が得られている、したがって、歪取焼鈍後の鉄損特性を改善するには、磁歪λ0-p(焼)を低減することが有効であることがわかる。この理由は、磁歪が大きくなると、磁気弾性エネルギーが大きくなるため、ヒステリシス損が劣化するためであると考えられる。
次いで、上記仕上焼鈍後の鋼板から、長さ:280mm×幅:30mmのL方向サンプルおよびC方向サンプルを採取し、レーザ変位計を用いて歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)を測定したところ、6.25×10-6であった。また、上記仕上焼鈍後の鋼板からJIS5号引張試験片を採取し、引張試験を行った結果、上降伏応力は520MPaであった。
次いで、上記磁歪測定を行ったサンプルに、825℃×1hrの歪取焼鈍を施した後、歪取焼鈍後の鉄損W10/400を測定したところ、大きなバラつきが生じていた。この原因について調査したところ、歪取焼鈍における均熱温度からの冷却速度が不均一であることが判明した。
図2に、歪取焼鈍時の冷却速度と歪取焼鈍前後の磁歪比との関係を示した。この図から、冷却速度が10℃/minを超えると、歪取焼鈍後の磁歪λ0-p(焼)が大きくなり、歪取焼鈍前後の磁歪比が高くなっていることがわかる。そのため、鉄損にバラツキが生じたものと考えられる。また、図2から、磁歪比を低減する、したがって、歪取焼鈍後の鉄損を低減するためには、冷却速度は10℃/min以下が好ましく、5℃/min以下がより好ましいこともわかる。
本発明の無方向性電磁鋼板は、一つの素材鋼板から、ロータコアとステータコアの両コア材を同時に採取できることが必要であるが、先述したように、ロータコアには、磁気特性に優れることに加えて、高強度であることが、一方、ステータコアには、歪取焼鈍後の磁気特性に優れることが求められている。
そこで、本発明の無方向性電磁鋼板は、以下の特性を必要とする。
ロータコアは、一般に、仕上焼鈍後の鋼板を打抜加工等でコア形状に加工した後、積層し、溶接やカシメ等でクランプ(固定)したものであり、歪取焼鈍が施されることはない。したがって、ロータコアに用いるためには、仕上焼鈍後の鋼板の強度が高いことが求められる。そこで、本発明では、仕上焼鈍後の鋼板の降伏応力で400MPa、望ましくは450MPa以上と規定する。ここで、上記降伏応力は、JIS5号引張試験片をJIS Z 2241に準拠して引張試験したときに上降伏点である。
一方、ステータコアは、一般に、仕上焼鈍後の鋼板を打抜加工等でコア形状に加工し、積層し、溶接やカシメ等でクランプ(固定)した後、歪取焼鈍が施される。したがって、ステータコアに用いるためには、歪取焼鈍後の鉄損特性に優れることが求められる。そこで、本発明では、歪取焼鈍後の鉄損特性を表す指標として、HEV駆動モータの駆動・制御条件に合わせ、鉄損W10/400(周波数:400Hz、磁束密度B=1.0T)を用いることとしたが、鉄損値は板厚に依存するため、板厚(mm)との関係において下記(2)式;
W10/400≦10+25t ・・・(2)
を満たすことを必要とした。これは、鉄損値が上記(2)式を満たさない場合、ステータコアの発熱が大きくなり、モータ効率が著しく低下するためである。
図1に示したように、歪取焼鈍後の鉄損W10/400は、歪取焼鈍後の磁歪λ0-p(焼)と強い相関があり、歪取焼鈍後の磁歪λ0-p(焼)を低くすることで、歪取焼鈍後の鉄損W10/400も低い値に管理できる。そこで、本発明においては、歪取焼鈍後の磁歪λ0-p(焼)を、図1において、鉄損W10/400が上記(2)式を満たす5.0×10-6以下に制限する。好ましくは、4.5×10-6以下である。なお、上記磁歪λ0-p(焼)の値は、400Hz、1.0Tで測定した圧延方向および圧延直角方向の磁歪の平均値である。
先述したように、歪取焼鈍における均熱温度からの650℃までの平均冷却速度が10℃/minを上回ると、歪取焼鈍後の磁歪λ0-p(焼)が歪取焼鈍前(仕上焼鈍後)の磁歪λ0-p(生)に対して大きくなり、鉄損W10/400が上昇する。そこで、本発明においては、歪取焼鈍後の鉄損特性を改善するため、歪取焼鈍前の磁歪λ0-p(生)に対する歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満であることを必要とする。好ましくは0.7以下である。なお、上記磁歪λ0-p(焼)およびλ0-p(生)の値は、いずれも、400Hz、1.0Tで測定した圧延方向および圧延直角方向の磁歪の平均値である。
C:0.0050mass%以下
製品板中に含まれるCは、炭化物を形成して磁気時効を起こし、鉄損特性を劣化させる有害元素である。そのため素材中に含まれるCの上限は0.0050mass%に制限する。好ましくは、0.0040mass%以下である。なお、Cの下限は、特に規定しないが、精錬工程での脱炭コストを抑制する観点から、0.0001mass%程度とするのが好ましい。
Siは、鋼の固有抵抗を高め、鉄損を低減する効果があり、また、固溶強化により鋼の強度を高める効果があるため、2.5mass%以上含有させる。一方、6.5mass%を超えると、圧延することが困難になるため、上限は6.5mass%とする。好ましくは3.0~6.5mass%の範囲である。
Mnは、Siと同様、鋼の固有抵抗と強度を高めるのに有用な元素であり、硫化物を形成して熱間脆性を改善する元素でもあるため、0.05mass%以上含有させる。一方、2.0mass%を超える添加は、スラブ割れ等を起こして製鋼での操業性を悪化するため、上限は2.0mass%とする。好ましくは0.1~1.5mass%の範囲である。
Pは、鋼の強度(硬さ)調整に用いられる有用な元素である。しかし、0.2mass%を超えると、鋼が脆化し、圧延することが困難となるため、上限は0.2mass%とする。なお、下限は特に規定しないが、精錬工程での脱Pコストを抑制する観点から、0.001mass%程度とするのが好ましい。好ましくは0.01~0.1mass%の範囲である。
Alは、Siと同様、鋼の比抵抗を高め、鉄損を低減する効果がある有用な元素である。しかし、3mass%を超えると、圧延することが困難になるため、Alの上限は3mass%とする。好ましくは2mass%以下である。
なお、Alの含有量が0.01mass%超え0.1mass%未満の範囲では、微細なAlNが析出して鉄損が増加するため、Alは0.01mass%以下もしくは0.1mass%以上の範囲とするのが好ましい。特に、Alを低減すると、集合組織が改善され、磁束密度が向上するので、磁束密度を重視する場合はAl:0.01mass%以下とするのが好ましい。より好ましくは0.003mass%以下である。
S,N,NbおよびVは、微細析出物を形成し、歪取焼鈍時の粒成長を阻害して鉄損特性に悪影響を及ぼす元素であり、特に、0.005mass%を超えると、その悪影響が顕著になるため、上限をそれぞれ0.005mass%に制限する。好ましくはそれぞれ0.003mass%以下である。
Tiは、同じく微細析出物を形成し歪取焼鈍時の粒成長を阻害して鉄損特性に悪影響を及ぼす元素であり、特に、0.003mass%を超えると、その悪影響が顕著になるため、上限を0.003mass%に制限する。好ましくは0.002mass%以下である。
本発明の無方向性電磁鋼板は、上記成分が上記所定の範囲の組成を満たすことに加えて、Si,AlおよびMnの含有量(mass%)が下記(1)式;
Si-2Al-Mn≧0 ・・・(1)
を満たして含有していることが必要である。
上記(1)式から外れる、すなわち、上記(1)式左辺が0未満となると、400Hz、1.0Tにおける仕上焼鈍後のヒステリシス損が大きくなり、磁歪λ0-p(生)も大きくなるためである。なお、上記(1)式左辺の値は、好ましくは0.3以上である。
Mo,W:合計で0.0020~0.10mass%
Mo,Wは、いずれも本発明の無方向性電磁鋼板の表面欠陥(ヘゲ)を抑制するのに有効な元素である。本発明の鋼板は、高合金鋼で表面が酸化され易いため、表面割れに起因するヘゲの発生率が高いが、高温強度を高める元素であるMo,Wを微量添加することで、上記割れを抑制することができる。上記効果は、Mo,Wの合計含有量が0.0020mass%を下回ると十分ではなく、一方、0.10mass%を超えて添加しても、上記効果が飽和し、合金コストが上昇するだけである。よって、Mo,Wを添加する場合は上記範囲とするのが好ましい。より好ましくは0.0050~0.050mass%の範囲である。
Sn,Sbは、再結晶集合組織を改善し、磁束密度、鉄損特性を改善する効果がある。上記効果を得るためには0.005mass%以上の添加が必要である。しかし、0.20mass%を超えて添加しても、上記効果が飽和する。よって、Sn,Sbを添加する場合は、それぞれ0.005~0.20mass%の範囲とするのが好ましい。より好ましくはそれぞれ0.01~0.1mass%の範囲である。
Ca,Mgは、いずれも安定な硫化物、セレン化物を形成し、歪取焼鈍時の粒成長性を改善する効果がある。上記効果を得るためには、Ca,Mgの合計で0.001mass%以上の添加が必要であり、一方、0.010mass%超え添加すると、却って鉄損が上昇してしまう。よって、Ca,Mgを添加する場合は上記範囲とするのが好ましい。より好ましくは0.003~0.008mass%の範囲である。
Cuは、集合組織を改善し、磁束密度を高める効果があるが、上記効果を得るためには0.01mass%以上含有させることが望ましい。一方、0.2mass%を超えると、上記効果が飽和するため、上限は0.2mass%とする。より好ましくは0.05~0.15mass%の範囲である。
Niは、鋼の強度や固有抵抗を高める効果があるが、上記効果を得るためには0.05mass%以上含有させることが望ましい。しかし、Niは高価であり、原料コストの増加を招くため、上限は1mass%とする。より好ましくは0.1~0.5mass%の範囲である。
Crは、鋼の固有抵抗を高めて鉄損を低減する効果があるが、上記効果を得るためには0.01mass%以上含有させることが望ましい。しかし、0.5mass%を超えると、原料コストの増加を招くため、上限は0.5mass%とする。より好ましくは0.1~0.4mass%の範囲である。
まず、本発明に適合する上記成分組成を有する鋼を、転炉や電気炉、真空脱ガス装置等を用いる通常公知の精錬プロセスで溶製し、連続鋳造法あるいは造塊-分塊圧延法で鋼スラブとし、この鋼スラブを通常公知の方法で熱間圧延して熱延板とする。
上記熱延板には、必要に応じて熱延板焼鈍を施してもよく、その場合の均熱温度は800~1100℃の範囲とするのが好ましい。800℃未満では、熱延板焼鈍の効果が小さく、十分な磁気特性改善効果が得られず、一方、1100℃を超えると、製造コスト的に不利となったり、冷間圧延時の脆性破壊(板破断)を助長したりするおそれがある。
なお、最終板厚(製品板厚)は、0.1~0.3mmの範囲とすることが好ましい。0.1mm未満では生産性が低下し、一方、0.3mm超えでは、鉄損低減効果が小さいためである。
次いで、上記仕上焼鈍後の鋼板から、L:280mm×C:30mmのL方向サンプル、および、C:280mm×L:30mmのC方向サンプルを切り出し、レーザ変位計を用いて仕上焼鈍後の鋼板の磁歪λ0-p(生)を測定するとともに、上記仕上焼鈍板の製品板からJIS5号引張試験片を採取し、引張試験を行い、降伏応力を測定した。
さらに、上記仕上焼鈍後の磁歪測定を行った280mm×30mmのL方向およびC方向サンプルに対して、表3に示す温度で1時間均熱する歪取焼鈍を施した。この際、歪取焼鈍の均熱温度から650℃までの冷却速度を表3に示したように変化させた。
次いで、上記歪取焼鈍後のサンプルについて、レーザ変位計で磁歪λ0-p(焼)を測定し、歪取焼鈍前後の磁歪比(λ0-p(焼)/λ0-p(生))を求めるとともに、エプスタイン試験で歪取焼鈍後の鉄損W10/400を測定した。
Claims (8)
- C:0.0050mass%以下、Si:2.5~6.5mass%、Mn:0.05~2.0mass%、P:0.2mass%以下、S:0.005mass%以下、Al:3mass%以下、N:0.005mass%以下、Ti:0.003mass%以下、Nb:0.005mass%以下およびV:0.005mass%以下を含有し、かつ、上記Si,AlおよびMnが下記(1)式を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有する鋼スラブを熱間圧延し、冷間圧延し、仕上焼鈍し、歪取焼鈍する無方向性電磁鋼板の製造方法において、
上記仕上焼鈍後の降伏応力が400MPa以上であり、
上記歪取焼鈍後の鉄損W10/400(W/kg)が板厚t(mm)との関係で下記(2)式を満たし、さらに、上記歪取焼鈍後の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下で、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満となるよう、仕上焼鈍および歪取焼鈍の条件を調整することを特徴とする無方向性電磁鋼板の製造方法。
記
Si-2Al-Mn≧0 ・・・(1)
W10/400≦10+25t ・・・(2) - 上記歪取焼鈍を、均熱温度を780~950℃とし、均熱温度から650℃までの冷却速度を10℃/min以下として行うことを特徴とする請求項1に記載の無方向性電磁鋼板の製造方法。
- 上記鋼スラブは、上記成分組成に加えてさらに、下記A~D群のうちの少なくとも1群の成分を含有することを特徴とする請求項1または2に記載の無方向性電磁鋼板の製造方法。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上 - C:0.0050mass%以下、Si:2.5~6.5mass%、Mn:0.05~2.0mass%、P:0.2mass%以下、S:0.005mass%以下、Al:3mass%以下、N:0.005mass%以下、Ti:0.003mass%以下、Nb:0.005mass%以下およびV:0.005mass%以下を含有し、かつ、上記Si,AlおよびMnが下記(1)式を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有し、降伏応力が400MPa以上である一つの無方向性電磁鋼板からロータコア材とステータコア材を同時に採取した後、上記ロータコア材は積層してロータコアとし、上記ステータコア材は積層し、歪取焼鈍を施してステータコアとするモータコアの製造方法において、
上記歪取焼鈍後のステータコアの鉄損W10/400(W/kg)が板厚t(mm)との関係で、下記(2)式を満たし、かつ、
上記歪取焼鈍後の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下であり、
さらに、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満となるよう仕上焼鈍および歪取焼鈍の条件を調整することを特徴とするモータコアの製造方法。
記
Si-2Al-Mn≧0 ・・・(1)
W10/400≦10+25t ・・・(2) - 上記歪取焼鈍を、均熱温度を780~950℃とし、均熱温度から650℃までの冷却速度を10℃/min以下として行なうことを特徴とする請求項4に記載のモータコアの製造方法。
- 上記無方向性電磁鋼板は、上記成分組成に加えてさらに、下記A~D群のうちの少なくとも1群の成分を含有することを特徴とする請求項4または5に記載のモータコアの製造方法。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上 - C:0.0050mass%以下、Si:2.5~6.5mass%、Mn:0.05~2.0mass%、P:0.2mass%以下、S:0.005mass%以下、Al:3mass%以下、N:0.005mass%以下、Ti:0.003mass%以下、Nb:0.005mass%以下およびV:0.005mass%以下を含有し、かつ、上記Si,AlおよびMnが下記(1)式を満たして含有し、残部がFeおよび不可避的不純物からなる成分組成を有する同一の無方向性電磁鋼板から製造されたロータコアとステータコアからなるモータコアにおいて、
上記ロータコアは、降伏応力が400MPa以上であり、
上記ステータコアは、鉄損W10/400(W/kg)が板厚t(mm)との関係で下記(2)式を満たし、かつ、400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(焼)が5.0×10-6以下で、歪取焼鈍前の400Hz、1.0Tでの圧延方向および圧延直角方向の磁歪の平均値λ0-p(生)に対する上記歪取焼鈍後の磁歪λ0-p(焼)の比(λ0-p(焼)/λ0-p(生))が0.8未満であることを特徴とするモータコア。
記
Si-2Al-Mn≧0 ・・・(1)
W10/400≦10+25t ・・・(2) - 上記無方向性電磁鋼板は、上記成分組成に加えてさらに、下記A~D群のうちの少なくとも1群の成分を含有することを特徴とする請求項7に記載のモータコア。
記
・A群;MoおよびWのうちから選ばれる1種または2種を合計で0.0020~0.10mass%
・B群;Sn:0.005~0.20mass%およびSb:0.005~0.20mass%のうちから選ばれる1種または2種
・C群;CaおよびMgから選ばれる1種または2種を合計で0.001~0.010mass%
・D群;Cu:0.01~0.2mass%、Ni:0.05~1mass%およびCr:0.01~0.5mass%のうちから選ばれる1種または2種以上
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US16/486,121 US11136645B2 (en) | 2017-03-30 | 2018-02-07 | Method for producing non-oriented electrical steel sheet, method for producing motor core, and motor core |
JP2019508687A JP6770260B2 (ja) | 2017-03-30 | 2018-02-07 | 無方向性電磁鋼板の製造方法、モータコアの製造方法およびモータコア |
MX2019011566A MX2019011566A (es) | 2017-03-30 | 2018-02-07 | Metodo para producir una lamina de acero electrico no orientado, metodo para producir un nucleo de motor, y nucleo de motor. |
CA3054114A CA3054114C (en) | 2017-03-30 | 2018-02-07 | Method for producing non-oriented electrical steel sheet, method for producing motor core, and motor core |
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CN110536971B (zh) | 2022-12-02 |
MX2019011566A (es) | 2019-11-18 |
CN110536971A (zh) | 2019-12-03 |
TW201837200A (zh) | 2018-10-16 |
KR20190118611A (ko) | 2019-10-18 |
CA3054114A1 (en) | 2018-10-04 |
US20190382867A1 (en) | 2019-12-19 |
JP6770260B2 (ja) | 2020-10-14 |
BR112019018081A2 (pt) | 2020-03-24 |
TWI672384B (zh) | 2019-09-21 |
JPWO2018179871A1 (ja) | 2019-07-11 |
CA3054114C (en) | 2021-09-07 |
EP3572535A1 (en) | 2019-11-27 |
KR102301751B1 (ko) | 2021-09-13 |
EP3572535A4 (en) | 2020-01-08 |
EP3572535B1 (en) | 2022-04-27 |
US11136645B2 (en) | 2021-10-05 |
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