中文简体
EnglishElectrical Steel Powder Coating
Industrial-grade protective coating solutions: environmentally friendly, durable, and cost-effective.
Intro to Electrical Steel Powder Coating
Electrical Steel Powder Coatings are extremely thin, high-performance insulating coatings applied to the surface of steel laminations used in the cores of electric motors, generators, and transformers. These coatings are typically based on specialized Epoxy or Inorganic chemistries and must serve a dual function: 1) Inter-Laminar Insulation: To provide a very thin, uniform, high-dielectric film that prevents short-circuiting between adjacent laminations (eddy current losses). 2) Thermal Stability: To withstand the high temperatures and pressure of the core assembly and motor operation. This application requires specialized, ultra-fine powders and unique application methods like Fluidized Bed Dipping or Roll Coating.
Insulation and Core Loss Reduction
The core of an electrical machine is built from hundreds of thin steel sheets (laminations). If these laminations are not insulated from one another, circulating eddy currents are induced in the core, leading to energy loss, heat generation, and reduced motor efficiency. Electrical steel powder coatings provide the necessary inter-laminar resistance to suppress these eddy currents. The coatings must be extremely thin (often ≤10 microns or 0.4 mils) to maximize the magnetic fill factor of the core. Performance is measured by Inter-Laminar Resistance (ILR) testing according to ASTM or IEC standards, where the resistance between stacked, coated sheets must exceed a specified minimum. The coating must also resist the high-pressure stacking and heat from subsequent coil winding and varnishing processes without fracturing or losing insulation integrity.
Specifications
| Property | Standard Electrical Steel Coating Value (ILR) |
| Chemical Base (Common) | Specialty Electrical Grade Epoxy or Inorganic |
| Film Thickness (Typical) | 3 to 10 microns (Ultra-Thin) |
| Primary Function | Inter-Laminar Electrical Insulation (Prevents Eddy Current Loss) |
| Inter-Laminar Resistance (ILR) | High (≥5Ω⋅cm2 typical) |
| Thermal Class | High (Often Class H or C) to withstand assembly/operation heat |
| Flexibility/Adhesion | Must withstand high pressure stacking/punching |
| Application Method | Fluidized Bed or Electrostatic Spray onto continuous strip/punched parts |
| Core Loss Focus | Maximizing Motor/Transformer Efficiency |
Application Fields
- Electric Motors and Generators: Stator and rotor laminations for maximum efficiency.
- Transformers: Core laminations for power and distribution transformers.
- Inductors and Reactors: Magnetic core components requiring insulation.
- High-Efficiency Devices: Any electrical machine where minimizing core loss is critical to performance.
- Automotive EV Motors: Laminations for high-performance electric vehicle propulsion systems.
Key Characteristics
- Ultra-Thin Film: Maximizes the magnetic fill factor and core efficiency.
- High Inter-Laminar Resistance: Dramatically reduces eddy current losses and heat generation.
- Excellent Thermal Stability: Withstands the heat and pressure of core stacking and winding.
- Uniform Coverage: Provides complete, pinhole-free insulation across the entire lamination surface.
- Improved Efficiency: Directly contributes to the high efficiency and reduced operational costs of electrical machines.
Comparison: Electrical Steel Powder vs. Traditional Insulation (e.g., C5)
| Feature | Electrical Steel Powder Coating | Inorganic Coating (e.g., C5) |
| Film Thickness | 3 to 10 microns (Higher) | <2 microns (Thinner) |
| Flexibility/Handling | Excellent (More robust coating) | Poor (Brittle, easy to damage) |
| Application Method | Powder Coating (Fluidized Bed/Spray) | Chemical/Roll Coating (Inorganic wash) |
| Thermal Class | High (Often up to Class H or C) | Varies (Good thermal stability) |
| Core Loss Performance | Very Good (High ILR) | Excellent (Minimal thickness) |
Why choose us
Customization: We have a strong R&D team,and we can develop and produce products according to different requirement of customers.
Cost: We have our own raw material production center.So we can offer the most favourable price and good-quality products directly.
Quality: We have our own testing lab and the most advanced and complete inspection equipment, which can ensure the quality of our products.
Capacity: Our annual production capacity is over 30000 tons, we can meet the needs of different customers with diverse purchase quantity.
Service: We focus on developing high-quality products for top-end markets. Our products are in line with international standards, and are mainly exported to Europe, America, Southeast Asia, South America and other destinations around the world.
Shipment: We are only 200 kilometers away from the Shanghai Port and 230 kilometers to Ningbo port, it is very convenient and efficient to ship goods to any other countries.
Customization
Quality
Capacity
Service
Shipment
Frequently Asked Questions (FAQs)
- Q: Why is the coating required to be so thin?
- A: The thickness of the coating adds non-magnetic material to the core. A thicker film reduces the "fill factor" (the amount of active magnetic steel) in the core volume, thereby reducing the motor's power density and efficiency.
- Q: Does this coating also provide corrosion protection?
- A: Yes. The Epoxy or inorganic base provides excellent corrosion protection, which is a key advantage over purely chemical/inorganic washes, protecting the core laminations from rust during storage and assembly.
- Q: Is the coating applied before or after the steel is punched into laminations?
- A: It can be applied either way, but it is often applied to the continuous steel strip before the punching process. The powder must be extremely robust to withstand the high shear forces of the punching dies without failing.
Selection Guide: Electrical Steel
Select Electrical Steel Powder Coating when:
- The component is a steel lamination for a high-efficiency motor, generator, or transformer core.
- The core requires a guaranteed high Inter-Laminar Resistance (ILR) to minimize eddy current losses.
- The coating must be ultra-thin (typically ≤10 microns) to maximize the core's magnetic fill factor.
- The application process requires a coating that is robust enough to withstand punching, stacking, and high heat.
- The final product demands the highest possible energy efficiency ratings.
