Electrical steel sheet and manufacturing method thereof

1. An electrical steel sheet, comprising:

a steel strip for an electrical steel sheet; and

an insulating film formed at a surface of the steel strip and containing metal phosphate and organic resin,

wherein

at least a part of the metal phosphate includes at least one kind of crystal structure selected from the group consisting of a cubic system, a tetragonal system, a hexagonal system, and an orthorhombic system, and

the organic resin contains at least one kind selected from the group consisting of an acryl-based resin, an epoxy-based resin, and a polyester resin having a carboxyl group or a hydroxyl group at a surface of an emulsion particle for one part by mass to 50 parts by mass relative to 100 parts by mass of the metal phosphate.

2. The electrical steel sheet according to claim 1 , wherein the steel strip is for a non-oriented electrical steel sheet.

3. The electrical steel sheet according to claim 1 , wherein 20 mass percent or more of the metal phosphate includes the at least one kind of crystal structure.

4. The electrical steel sheet according to claim 1 , wherein 50 mass percent or more of the metal phosphate includes the at least one kind of crystal structure.

5. The electrical steel sheet according to claim 1 , wherein at least a part of the metal phosphate includes a crystal structure of the cubic system or the orthorhombic system.

6. The electrical steel sheet according to claim 2 , wherein at least a part of the metal phosphate includes a crystal structure of the cubic system or the orthorhombic system.

7. The electrical steel sheet according to claim 3 , wherein at least a part of the metal phosphate includes a crystal structure of the cubic system or the orthorhombic system.

8. The electrical steel sheet according to claim 4 , wherein at least a part of the metal phosphate includes a crystal structure of the cubic system or the orthorhombic system.

9. The electrical steel sheet according to claim 1 , wherein the insulating film does not contain chromic acid.

10. The electrical steel sheet according to claim 1 , wherein the insulating film is formed by:

coating a treatment solution on the surface of the steel strip to form a coating film; and

baking the coating film,

wherein a solution of a mixture of the metal phosphate and the organic resin is manufactured;

a polyhydric alcohol compound is added to the solution of the mixture to form the treatment solution; and

the treatment solution containing the solution of the mixture and the polyhydric alcohol compound is manufactured.

11. The electrical steel sheet according to claim 1 , wherein the steel strip contains, in mass %:

Si: 0.1% or more and less than 4.0%;

Al: 0.05% or more and less than 3.0%;

Mn: 0%-1.0%;

S: less than 0.01%;

N: less than 0.01%; and

C: less than 0.01%.

12. The electrical steel sheet according to claim 10 , wherein the baking of the coating film is performed by:

heating the steel strip to which the treatment solution is coated up to 230° C. to 360° C. with a rate of 25° C./sec to 65° C./sec;

next retaining the steel strip at the temperature of 230° C. to 360° C. for 10 seconds to 30 seconds; and

next cooling the steel strip to 100° C. with a rate of 20° C./sec to 85° C./sec.

13. The electrical steel sheet according to claim 1 , wherein the insulating film is an organic film.