CN102690112A - 一种用于宽频抗电磁干扰的锰锌铁氧体材料及其制造方法 - Google Patents
一种用于宽频抗电磁干扰的锰锌铁氧体材料及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种用于宽频抗电磁干扰的锰锌铁氧体材料,它按摩尔百分比包括如下配方:三氧化二铁:42.05-46.05mol%,四氧化三锰:32.51-35.51mol%,氧化锌:18.55-20.35mol%,氧化铜:1.05-1.68mol%,氧化钙:0.25-0.45mol%。其制造方法包括:配料混合→造粒→预烧→粗粉碎→二次配料细磨→喷雾造粒→三次配料、检测包装。本发明有效地降低了软磁铁氧体抗干扰材料的制造成本;具有优良的宽频抗干扰特性-从低频到高频,集镍锌、镁锌材料特性之优点,可同时替代;不含镍、镉、钴等金属元素,不会对环境造成污染,比镍锌材料更环保。
Description
技术领域
本发明涉及一种抗干扰磁芯材料及其制造方法技术领域,具体涉及一种用于宽频抗电磁干扰的锰锌铁氧体材料及其制造方法。
背景技术
当今社会已步入电子信息时代,信息高速公路、卫星通信、移动通信、计算机应用等的高速发展,电子产品越来越趋向高速、宽带、高灵敏度、高密集度和小型化。但是电磁干扰现象日益严重,并成为影响系统正常工作的明显障碍,甚至对人身安全以及军事保密安全造成很大危害。
软磁铁氧体属于磁介质型吸波材料,相应的抗电磁干扰磁芯相当于低通滤波器,能较好的解决电源线、信号线和连接器的高频干扰抑制问题。软磁铁氧体抗干扰材料主要有镍锌铁氧体和锰锌铁氧体和镁锌铁氧体三种材料,镍锌铁氧体材料存在制造成本高,主要原料氧化镍每吨在20万元左右,同时镍锌材料含有镍、镉、钴等金属元素,会对环境造成污染。相对来说,锰锌材料价格比较低廉,而且不含上述对环境有污染的金属元素。
发明内容
发明目的:本发明的目的是为了弥补现有技术的不足,提供一种配方独特的用于宽频抗电磁干扰的锰锌铁氧体材料。
本发明的另一目的是为了提供如上所述的一种用于宽频抗电磁干扰的锰锌铁氧化材料的制造方法。
本发明采用的技术方案:一种用于宽频抗电磁干扰的锰锌铁氧体材料,它按摩尔百分比包括如下配方:
三氧化二铁:42.05-46.05mol%,
四氧化三锰:32.51-35.51mol%,
氧化锌:18.55-20.35mol%,
氧化铜:1.05-1.68mol%,
氧化钙:0.25-0.45mol%。
如上所述的用于宽频抗电磁干扰的锰锌铁氧体材料的制造方法,它包括如下步骤:
(1)配料混合:将原料三氧化二铁、四氧化三锰、氧化锌加入锥形混料器混合均匀,送入振磨机强混,使混合振磨后料粉平均粒度为1.1-1.3μm;
(2)造粒:将混合料粉送入造粒机料仓,开启造粒机,调整轧制压力至8-11mPa,使轧制的料粉颗粒呈圆柱状;
(3)预烧:回转窑高温区温度升至900-920℃,开启送料器以0.3m/min的进料速度将粒料均匀地送入回转窑,回转窑炉管转速设为3-5转/min,颗粒料在回转窑内螺旋式前行由红色转变为黑色通过冷却区温度降至50-60℃;
(4)粗粉碎:开启振磨机,开启送料器将预烧好的颗粒送入振磨机,送料速度控制在10-12kg/min;
(5)二次配料细磨:将粗粉碎后的粉料送入砂磨机中加入纯水,料水比为1:0.62,加入氧化铜和氧化钙,砂磨时间60-90min,粉料转变为料浆状态粉体粒径控制在1.0-1.25μm;将细磨后料浆注入料浆池,然后分别加入PVA胶水、分散剂、消泡剂,搅拌10-15min后备用;
(6)喷雾造粒:开启压力泵将二次配料细磨后的料浆以1.9-2.0mPa的压力沿喷枪管道进入旋流室,在旋流室内,料浆在涡旋片内高速旋转,形成近似自由涡流,通过喷枪喷嘴喷出料浆,在干燥塔内雾化,料浆遇到热空气,大部分水分蒸发,转变为颗粒;
(7)三次配料、检测包装:将喷雾造粒后的颗粒料加入硬脂酸锌,送入混料机混合3-5min,检测包装。
作为优选,所述粗粉碎后粉粒的粒径控制在1.0-2.5μm。
作为优选,所述二次配料细磨中的料浆池内溶质质重设定为4500kg,然后分别加入10%PVA胶水450kg、分散剂1500ml、消泡剂1000ml。
作为优选,所述干燥塔的进口温度设为300-350℃,出口温度设为140-160℃。
作为优选,所述喷雾造粒后的颗粒粒径为60-200目,峰值为120目。
作为优选,所述硬脂酸锌的添加量为0.2%。
有益效果:本发明具有如下优点:〔1〕有效地降低了软磁铁氧体抗干扰材料的制造成本,通常镍锌铁氧体抗干扰材料每吨35000元左右,而锰锌铁氧体抗干扰材料每吨仅为15000元左右;
〔2〕具有优良的宽频抗干扰特性,从低频到高频,集镍锌、镁锌材料特性之优点,可同时替代。
〔3〕不含镍、镉、钴等金属元素,不会对环境造成污染,比镍锌材料更环保。
具体实施方式
下面结合具体实施例对本发明作进一步说明:
实施例1:
一种用于宽频抗电磁干扰的锰锌铁氧体材料,按摩尔百分比它的配方组成为:三氧化二铁42.05mol%,四氧化三锰32.51mol%,氧化锌20.35mol%,氧化铜1.68mol%,氧化钙0.41mol%。
它的制备工艺为:
(1)配料混合:将原料三氧化二铁、四氧化三锰、氧化锌加入锥形混料器混合均匀,送入振磨机强混,使混合振磨后料粉平均粒度为1.1μm;
(2)造粒:将混合料粉送入造粒机料仓,开启造粒机,调整轧制压力至8mPa,使轧制的料粉颗粒呈圆柱状;
(3)预烧:回转窑高温区温度升至900℃,开启送料器以0.3m/min的进料速度将粒料均匀地送入回转窑,回转窑炉管转速设为3转/min,颗粒料在回转窑内螺旋式前行由红色转变为黑色通过冷却区温度降至50℃;
(4)粗粉碎:开启振磨机,开启送料器将预烧好的颗粒送入振磨机,送料速度控制在10kg/min,粉粒的粒径控制在1.0μm。
(5)二次配料细磨:将粗粉碎后的粉料送入砂磨机中加入纯水,料水比为1:0.62,加入氧化铜和氧化钙,砂磨时间60min,粉料转变为料浆状态粉体粒径控制在1.0μm;将细磨后料浆注入料浆池,设定料浆池内溶质质重为4500kg,然后分别加入10%PVA胶水450kg、分散剂1500ml、消泡剂1000ml,搅拌10min后备用;
(6)喷雾造粒:开启压力泵将二次配料细磨后的料浆以1.9mPa的压力沿喷枪管道进入旋流室,在旋流室内,料浆在涡旋片内高速旋转,形成近似自由涡流,通过喷枪喷嘴喷出料浆,在干燥塔内雾化,料浆遇到热空气,大部分水分蒸发,转变为颗粒。塔内进口温度控制为300℃℃,出口温度控制为150℃,颗粒料粒径为60目;
(7)三次配料、检测包装:将喷雾造粒后的颗粒料加入0.2%的硬脂酸锌,送入混料机混合3min,检测包装。
实施例2、实施例3:
一种用于宽频抗电磁干扰的锰锌铁氧体材料,按摩尔百分比它的配方组成具体见表1:
表1:锰锌铁氧体材料配方组成
三氧化二铁 | 四氧化三锰 | 氧化锌 | 氧化铜 | 氧化钙 | |
实施例2 | 44.05mol% | 34.01mol% | 20.23mol% | 1.36mol% | 0.35mol% |
实施例3 | 46.05mol% | 32.51mol% | 20.13mol% | 1.05mol% | 0.26mol% |
生产工艺流程与实施例1基本相同,具体工艺条件一一对应表2:
表2:锰锌铁氧体材料的制造工艺
上述实施例中使用的分散剂为磁性材料专用分散剂,型号BWY-507,生产厂家为浙江临安越洋助剂有限公司;消泡剂为正辛醇,含量大于等于98.0%,生产厂家为江苏宜兴市辉煌化学试剂厂。
Claims (7)
1.一种用于宽频抗电磁干扰的锰锌铁氧体材料,其特征在于:它按摩尔百分比包括如下配方:
三氧化二铁:42.05-46.05mol%,
四氧化三锰:32.51-35.51mol%,
氧化锌:18.55-20.35mol%,
氧化铜:1.05-1.68mol%,
氧化钙:0.25-0.45mol%。
2.一种如权利要求1所述的用于宽频抗电磁干扰的锰锌铁氧体材料的制造方法,其特征在于它包括如下步骤:
(1)配料混合:将原料三氧化二铁、四氧化三锰、氧化锌加入锥形混料器混合均匀,送入振磨机强混,使混合振磨后料粉平均粒度为1.1-1.3μm;
(2)造粒:将混合料粉送入造粒机料仓,开启造粒机,调整轧制压力至8-11mPa,使轧制的料粉颗粒呈圆柱状;
(3)预烧:回转窑高温区温度升至900-920℃,开启送料器以0.3m/min的进料速度将粒料均匀地送入回转窑,回转窑炉管转速设为3-5转/min,颗粒料在回转窑内螺旋式前行由红色转变为黑色通过冷却区温度降至50-60℃;
(4)粗粉碎:开启振磨机,开启送料器将预烧好的颗粒送入振磨机,送料速度控制在10-12kg/min;
(5)二次配料细磨:将粗粉碎后的粉料送入砂磨机中加入纯水,料水比为1:0.62,加入氧化铜和氧化钙,砂磨时间60-90min,粉料转变为料浆状态粉体粒径控制在1.0-1.25μm;将细磨后料浆注入料浆池,然后分别加入PVA胶水、分散剂、消泡剂,搅拌10-15min后备用;
(6)喷雾造粒:开启压力泵将二次配料细磨后的料浆以1.9-2.0mPa的压力沿喷枪管道进入旋流室,在旋流室内,料浆在涡旋片内高速旋转,形成近似自由涡流,通过喷枪喷嘴喷出料浆,在干燥塔内雾化,料浆遇到热空气,大部分水分蒸发,转变为颗粒;
(7)三次配料、检测包装:将喷雾造粒后的颗粒料加入硬脂酸锌,送入混料机混合3-5min,检测包装。
3.根据权利要求2所述的用于宽频抗电磁干扰的锰锌铁氧化材料的制造方法,其特征在于:所述粗粉碎后粉粒的粒径控制在1.0-2.5μm。
4.根据权利要求2所述的用于宽频抗电磁干扰的锰锌铁氧化材料的制造方法,其特征在于:所述二次配料细磨中的料浆池内溶质质重设定为4500kg,然后分别加入I0%PVA胶水450kg、分散剂1500ml、消泡剂1000ml。
5.根据权利要求2所述的用于宽频抗电磁干扰的锰锌铁氧体材料的制造方法,其特征在于:所述干燥塔的进口温度设为300-350℃,出口温度设为140-160℃。
6.根据权利要求2所述的用于宽频抗电磁干扰的锰锌铁氧体材料的制造方法,其特征在于:所述喷雾造粒后的颗粒粒径为60-200目,峰值为120目。
7.根据权利要求2所述的用于宽频抗电磁干扰的锰锌铁氧体材料的制造方法,其特征在于:所述硬脂酸锌的添加量为0.2%。
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