CN103666364A - Organic insulating binder for metal soft-magnetic composite material and method for preparing metal soft-magnetic composite material - Google Patents
Organic insulating binder for metal soft-magnetic composite material and method for preparing metal soft-magnetic composite material Download PDFInfo
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Abstract
The invention discloses an organic insulating binder for a metal soft-magnetic composite material and a magnet preparation method thereof. The organic insulating binder is composed of liquid A and liquid B, wherein the liquid A is a 0.2%-0.6% silane coupling agent; the liquid B is an insulated coating liquid which is formed by mixing 10wt%-30wt% of alicyclic epoxy resin, 5wt%-15wt% of methyl hexahydrophthalic anhydride, 20wt%-60wt% of silicon resin and 10wt%-40wt% of dimethyl benzene, wherein total dosage of the liquid B is 0.5%-1.5%. The preparation method comprises the following steps: uniformly coating a layer of liquid A silane coupling agent on the surface of metal powder; then, coating the liquid B coating liquid; and preparing the metal soft-magnetic composite material by the steps such as drying, profiling, degreasing and thermal-treating. Compared with an organic binder with other components, the organic substance insulating binder disclosed by the invention has a high heat-resistant temperature and good binding effect, can reduce dosage, so that content of non-magnetic substances is reduced, thereby facilitating improving magnetic conductivity of a magnet and lowering loss. The metal soft-magnetic composite material prepared by adopting the preparation method disclosed by the invention has better magnetic performance and frequency stability.
Description
Technical field
The invention belongs to metal powder metallurgy and field of magnetic material, a kind of resistant to elevated temperatures organic insulation binding agent that particularly soft magnetic metal matrix material is used, and adopt this insulating adhesive to prepare the method for soft magnetic metal matrix material.
Background technology
Soft magnetic metal matrix material (the Soft Magnetic Composites that utilizes powder metallurgy technology to produce, SMCs) become the focus of core material research and development, it has the advantage of siliconized plate magnetic core high magnetic permeability and the low eddy-current loss of FERRITE CORE concurrently, that a kind of to take high-purity iron powder or fe-based alloy powder be raw material, after the coated insulation medium layer of ferrous powder granules surface, powder compression is become to desired shape, and the block materials obtaining by thermal treatment, sometimes also claim " insulating wrapped ferrocart core ".Its made parts are widely used in the electromagnetic devices such as transformer, motor, electro-magnet, reactance coil, barretter.
Before 100 years, US Patent No. Patent 874908 has just reported that employing iron-resin compounded makes soft magnetic materials, but the but seldom application of this matrix material, and this is because its equal prematurities of condition such as performance, preparation technology and the market requirement.Yet along with raw-material improvement and new forming technique occur and the development of modern industry to product demand, this situation is changed gradually.Since this matrix material of the later stage nineties 20th century, at motor, had application, and part replaces lamination silicon steel material gradually.Because eddy-current loss and the noise of lamination silicon steel when the high frequency obviously increases, therefore SMCs material is used widely under AC high frequency.And because SMCs material is to be prepared by powder metallurgical technique, it has the feature of near-net-shape, and material use efficiency is high, consumption is few, and the various abnormal members that can be shaped, so its range of application further expands.
At present, soft magnetic metal matrix material mainly comprises pure iron, iron silicon, iron sial, iron nickel, iron nickel molybdenum, and amorphous & nanocrystallines such as FeCuNbSiB out newly developed in recent years.The significant parameter of soft magnetic metal composite property is saturation induction density, magnetic permeability, quality factor, power loss and frequency response characteristic, and when some application-specific, (as motor stator, rotor) also needs to consider mechanical property.
Except the performance of adopted powder stock properties influence soft-magnetic composite material, the insulating compound adopting and binding agent are very crucial.By adding insulating compound, can improve the resistivity of magnet, to reduce power loss, thereby improve the high frequency characteristics of magnet, but insulating compound is excessive, can improve the internal air gap rate of magnet, cause saturation induction density and magnetic permeability to decline, the power density of loss magnetic core.Insulation layer can reduce eddy-current loss effectively, but the effect of insulation layer is as air gap, thereby has also reduced magnetic permeability.Conventionally with reducing thickness of insulating layer, improving density and heat-treat to eliminate or reduce stress and partly recover magnetic permeability.
In the prior art, people have carried out a large amount of research work to the insulating adhesive of magnetic.Insulating adhesive is mainly divided into three kinds: a kind of is organism, and another kind is inorganics, and another is exactly the mixture of organism and inorganics.As Chinese invention patent CN1516204 discloses a kind of organic insulation coating, it is characterized in that insulating compound used is epoxies binding agent, a kind of as in 607 epoxy resin, 609 epoxy resin, W-6A magnetic binding agent, W-6C magnetic binding agent, the diluent of binding agent is organic solvent dehydrated alcohol, acetone, vinyl acetic monomer.The heat resisting temperature of above-mentioned organic insulation binding agent is lower, so overwhelming majority binding agent all decomposes when high-temperature heat treatment.
Simultaneously, US Patent No. P6419877 adopts organism thermoplastic resin to do insulating adhesive, what Japanese patent laid-open 11-189803 adopted is organism polyvinyl alcohol and poly-butyral resin, and what Chinese patent CN1373481A, Chinese patent CN1232375C, Chinese patent CN1518011A adopted is organism polyimide/resol, silicone resin etc.
Organism is that plasticity simple and easy to do, powder is good, bond effect is good as the advantage of insulating adhesive, and shortcoming is poor heat resistance.
Summary of the invention
First technical problem to be solved by this invention is to provide a kind of soft magnetic metal matrix material organic insulation binding agent, this insulating adhesive has good insulativity, cohesiveness double effects, there is good high thermal resistance simultaneously, be conducive to improve compacting pressure and thermal treatment temp or reduce the content of binding agent, thereby improve density, the intensity of magnet and improve magnetic permeability and the power loss of high frequency lower magnet.
Second technical problem to be solved by this invention is to provide a kind of method that adopts organic insulation binding agent to prepare soft magnetic metal matrix material, and the method technique is simple, easy to operate, is applicable to the preparation of multiple non-retentive alloy powder core.
The present invention is that the technical scheme that above-mentioned first technical problem of solution is taked is: a kind of soft magnetic metal matrix material organic insulation binding agent, it is characterized in that: component is comprised of A liquid and B liquid, wherein A liquid is 0.2 ~ 0.6% silane coupling agent, B liquid is to be the insulating wrapped liquid that 10 ~ 30% cycloaliphatic epoxy resins, 5 ~ 15% methyl hexahydrophthalic anhydrides, 20 ~ 60% silicone resin and 10 ~ 40% dimethylbenzene mix by mass ratio, total consumption of B liquid is 0.5 ~ 1.5%, and above A liquid, B liquid usage percentage are the mass percent that accounts for metal-powder quality.
As preferably, the quality ratio range of described cycloaliphatic epoxy resin and methyl hexahydrophthalic anhydride is 1 ~ 4:1.
The present invention is that the technical scheme that above-mentioned second technical problem of solution taked is: a kind of soft magnetic metal matrix material that adopts is prepared the method for soft magnetic metal matrix material with organic insulation binding agent, it is characterized in that comprising the following steps:
1) preparing metal soft-magnetic composite material organic insulation binding agent: A liquid is 0.2 ~ 0.6% silane coupling agent, B liquid is to be the insulating wrapped liquid that 10 ~ 30% cycloaliphatic epoxy resins, 5 ~ 15% methyl hexahydrophthalic anhydrides, 20 ~ 60% silicone resin and 10 ~ 40% dimethylbenzene mix by mass ratio, total consumption of B liquid is 0.5 ~ 1.5%, and above A liquid, B liquid usage percentage are the mass percent that accounts for metal-powder quality;
2) load weighted A liquid is added in metal-powder and mixed, add again the B liquid configuring to mix after evenly and be coated, subsequently compound dried;
3) material after drying separated broken and sieved, mixing after adding lubricant;
4), by compound press forming, carry out subsequently drying defatted and hot setting;
5) finally heat-treat, remove stress.
As preferably, the quality ratio range of described cycloaliphatic epoxy resin and methyl hexahydrophthalic anhydride is 1 ~ 4:1.
As preferably, described metal-powder is to have that certain particle size distributes and mean particle size mixes and obtains with a certain amount of nano-oxide at the metallic magnetic powder of 20~60 μ m.
Preferred again, described metallic magnetic powder is one or more powder mixs in pure Fe powder, Fe-Si powder, Fe-Si-Al powder, Fe-Ni powder or Fe-Ni-Mo powder, metal-powder is to adopt one or more in atomization, reduction, airflow milling or chemical process to combine preparation, and described nano-oxide is the nanometer Al that accounts for mass percent 0.1-3%
2o
3, SiO
2, TiO
2or B
2o
3in one or more fillers.
As improvement, described step 2) drying course is at 100-200 ℃, to carry out dry solidification processing, insulation 30-180min.
Improve, sieving of described step 3) is to adopt 100-200 mesh sieve again, and described lubricant is one or more mix lubricant in KP-11, stearic acid, Zinic stearas, lithium stearate, the 0.1-0.8% that lubricant content is compound.
Further improve, the press forming of described step 4) adopts a kind of in colding pressing in die forming, temperature and pressure or hot pressing, and pressing pressure is 800~1500MPa, and described drying defatted is that pressed compact is carried out to 150-200 ℃, and the de-lubricant of insulation 60-180min is processed.
Finally, in the thermal treatment of described step 5), atmosphere is hydrogen or cracked ammonium reducing atmosphere, and treatment temp is 500~900 ℃, and soaking time is 30~240min, furnace cooling.
Compared with prior art, the invention has the advantages that: organic insulation binding agent of the present invention has the double effects of insulation, bonding, there is good high thermal resistance simultaneously, be conducive to improve compacting pressure and thermal treatment temp or reduce the content of binding agent, thereby improve density, the intensity of magnet and improve magnetic permeability and the power loss of high frequency lower magnet.Adopt the prepared soft magnetic metal matrix material of the present invention, have good magnetic property and frequency stability, along with the raising of frequency, permeability decay is very little, and under high frequency, magnetic loss is little, and preparation technology is simple, easy to operate.
Accompanying drawing explanation
Fig. 1 is the SEM photo of iron powder;
Fig. 2 is silicone resin hot weightless picture;
Fig. 3 is the mixed hot weightless picture of cycloaliphatic epoxy resin and methyl hexahydrophthalic anhydride;
Fig. 4 is the powder SEM photo after Coated with Organic Matter;
Fig. 5 is Fe distribution diagram of element;
Fig. 6 is Al distribution diagram of element;
Fig. 7 is O distribution diagram of element;
Fig. 8 is Si distribution diagram of element;
Fig. 9 is the SME photo after SMC thermal treatment.
Embodiment
Below in conjunction with accompanying drawing, embodiment is described in further detail the present invention.
Embodiment 1:
By the median size of using as soft-magnetic composite material, be the pure Fe powder of water atomization and the 1% nanometer Al of 38 μ m
2o
3mix; 0.5% silane coupling agent is joined in mixed powder and mixed, add 0.5% to mix the cycloaliphatic epoxy resin configuring in proportion (20%), methyl hexahydrophthalic anhydride (10%), silicone resin (40%), dimethylbenzene (30%) mixed solution subsequently; The material mixing is put into 120 ℃ of dry 2h of drying baker; By broken mistake 100 mesh sieves of cooled material solution; Gained powder adds the KP-11 mix lubricant of 0.1% content even.Be pressed into ф 16 * ф 8 * 5 rings by 1300MPa pressure, then through 150 ℃, insulation 120min is dry, and by the sample obtaining 650 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 60min finally carries out magnetism testing to sample on BH tester.Gained sample performance is shown in Table 1 (B
max=20mT).
Table 1
Frequency/kHz | 5 | 20 | 50 | 100 |
Magnetic permeability | 106.48 | 106.39 | 106.39 | 104.46 |
Pcv(kW/m 3) | 1.77 | 11.30 | 49.85 | 174.36 |
In table 1, result is compared with existing pure Fe soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay is very little; Under high frequency, magnetic loss is little.
Embodiment 2:
By the median size of using as soft-magnetic composite material, be the pure Fe powder of water atomization and the 2% nanometer Al of 24 μ m
2o
3mix; 0.6% silane coupling agent is joined in mixed powder and mixed, add 1.0% to mix the cycloaliphatic epoxy resin configuring in proportion (30%), methyl hexahydrophthalic anhydride (10%), silicone resin (30%), dimethylbenzene (30%) mixed solution subsequently; The material mixing is put into 150 ℃ of dry 2h of drying baker; By broken mistake 200 mesh sieves of cooled material solution; Gained powder adds the Zinic stearas mix lubricant of 0.7% content even.Be pressed into ф 16 * ф 8 * 5 rings by 1500MPa pressure, then through 150 ℃, insulation 120min is dry, and by the sample obtaining 700 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 30min finally carries out magnetism testing to sample on BH tester.
Gained sample performance is shown in Table 2 (B
max=20mT).
Table 2
Frequency/kHz | 5 | 20 | 50 | 100 |
Magnetic permeability | 103.68 | 103.24 | 102.96 | 101.57 |
Pcv (kW/m 3) | 1.42 | 10.17 | 41.69 | 154.78 |
In table 2, result is compared with existing pure Fe soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay is very little; Under high frequency, magnetic loss is little.
Embodiment 3:
By the median size of using as soft-magnetic composite material, be the pure Fe powder of water atomization and the 0.8% nanometer SiO of 45 μ m
2mix; 0.3% silane coupling agent is joined in mixed powder and mixed, add 1.5% to mix the cycloaliphatic epoxy resin configuring in proportion (30%), methyl hexahydrophthalic anhydride (15%), silicone resin (35%), dimethylbenzene (20%) mixed solution subsequently; The material mixing is put into 120 ℃ of dry 2h of drying baker; By broken mistake 100 mesh sieves of cooled material solution; Gained powder adds the Zinic stearas mix lubricant of 0.5% content even.Be pressed into ф 16 * ф 8 * 5 rings by 1000MPa pressure, then through 180 ℃, insulation 120min is dry, and by the sample obtaining 650 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 120min finally carries out magnetism testing to sample on BH tester.Gained sample performance is shown in Table 3 (B
max=20mT).
Table 3
Frequency/kHz | 5 | 20 | 50 | 100 |
Magnetic permeability | 112.93 | 112.62 | 112.04 | 109.49 |
Pcv (kW/m 3) | 1.95 | 12.58 | 56.73 | 180.54 |
In table 3, result is compared with existing pure Fe soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay is very little; Under high frequency, magnetic loss is little.
Embodiment 4:
By the median size of using as soft-magnetic composite material, be the water atomization Fe-3.5Si powder of 34 μ m and 0.5% nanometer Al
2o
3mix, 0.2% silane coupling agent is joined in powder and mixed, add 0.8% to mix the cycloaliphatic epoxy resin configuring in proportion (20%), methyl hexahydrophthalic anhydride (10%), silicone resin (50%), dimethylbenzene (20%) mixed solution subsequently; The material mixing is put into 120 ℃ of dry 2h of drying baker, and by broken mistake 100 mesh sieves of cooled material solution, gained powder adds 0.3% KP-11 mix lubricant even, be pressed into ф 16 * ф 8 * 5 rings by 1200MPa pressure.Through 150 ℃, insulation 120min is dry again.By the sample obtaining 750 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 60min finally carries out magnetism testing to sample on BH tester.Gained sample performance is shown in Table 4 (B
max=50mT).
Table 4
Frequency/kHz | 5 | 20 | 50 | 100 |
Magnetic permeability | 61.0 | 61.3 | 60.95 | 60.80 |
Pcv(kW/m 3) | 10.38 | 49.08 | 171.90 | 418.58 |
In table 4, result is compared with existing Fe-3.5Si soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay is little; Under high frequency, magnetic loss is little.
Embodiment 5:
By the median size of using as soft-magnetic composite material, be the water atomization Fe-6.5Si powder of 35 μ m and 0.2% nano-TiO
2mix; 0.5% silane coupling agent is joined in powder and mixed, add 1.0% to mix the cycloaliphatic epoxy resin configuring in proportion (30%), methyl hexahydrophthalic anhydride (20%), silicone resin (30%), dimethylbenzene (20%) mixed solution subsequently; The material mixing is put into 120 ℃ of dry 2h of drying baker; By broken mistake 100 mesh sieves of cooled material solution, gained powder adds 0.3% KP-11 mix lubricant even, be pressed into ф 16 * ф 8 * 5 rings by 1100MPa pressure.Through 150 ℃, insulation 120min is dry again.By the sample obtaining 800 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 60min finally carries out magnetism testing to sample on BH tester.Gained sample performance is shown in Table 5 (B
max=20mT).
Table 5
Frequency/kHz | 5 | 20 | 60 | 100 |
Magnetic permeability | 60.99 | 60.98 | 60.65 | 60.55 |
Pcv(kW/m 3) | 1.70 | 7.57 | 31.50 | 59.35 |
In table 5, result is compared with existing Fe-6.5Si soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay is little; Under high frequency, loss is little.
Embodiment 6:
By the median size of using as soft-magnetic composite material, be water atomization Fe-9Si-6Al powder and 0.6% nano-TiO of 53 μ m
2mix, 0.6% silane coupling agent is joined in powder and mixed, add 1.2% to mix the cycloaliphatic epoxy resin configuring in proportion (20%), methyl hexahydrophthalic anhydride (15%), silicone resin (40%), dimethylbenzene (25%) mixed solution subsequently; The material mixing is put into 150 ℃ of dry 2h of drying baker.By broken mistake 100 mesh sieves of cooled material solution; Gained powder adds the mix lubricant of 0.5%KP-11 even.Be pressed into ф 16 * ф 8 * 5 rings by 1300MPa pressure, then through 180 ℃, insulation 120min is dry, and by the sample obtaining 850 ℃ of thermal treatments in the sintering oven of cracked ammonium atmosphere, insulation 60min finally carries out magnetism testing to sample on BH tester.Gained sample performance is shown in Table 6 (B
max=50mT).
Table 6
Frequency/kHz | 5 | 20 | 50 | 100 |
Magnetic permeability | 67.41 | 67.12 | 66.24 | 65.06 |
Pcv(kW/m 3) | 1.88 | 9.96 | 54.36 | 149.24 |
In table 6, result is compared with existing Fe-9Si-6Al soft-magnetic composite material, and magnet prepared by the present invention has good permeability frequency characteristics, and along with the raising of frequency, permeability decay rate reduces; Under high frequency, magnetic loss is little.
Claims (10)
1. a soft magnetic metal matrix material organic insulation binding agent, it is characterized in that: component is comprised of A liquid and B liquid, wherein A liquid is 0.2 ~ 0.6% silane coupling agent, B liquid is to be the insulating wrapped liquid that 10 ~ 30% cycloaliphatic epoxy resins, 5 ~ 15% methyl hexahydrophthalic anhydrides, 20 ~ 60% silicone resin and 10 ~ 40% dimethylbenzene mix by mass ratio, total consumption of B liquid is 0.5 ~ 1.5%, and above A liquid, B liquid usage percentage are the mass percent that accounts for metal-powder quality.
2. soft magnetic metal matrix material organic insulation binding agent according to claim 1, the quality ratio range that it is characterized in that described cycloaliphatic epoxy resin and methyl hexahydrophthalic anhydride is 1 ~ 4:1.
3. adopt soft magnetic metal matrix material with organic insulation binding agent, to prepare a method for soft magnetic metal matrix material, it is characterized in that comprising the following steps:
1) preparing metal soft-magnetic composite material organic insulation binding agent: A liquid is 0.2 ~ 0.6% silane coupling agent, B liquid is to be the insulating wrapped liquid that 10 ~ 30% cycloaliphatic epoxy resins, 5 ~ 15% methyl hexahydrophthalic anhydrides, 20 ~ 60% silicone resin and 10 ~ 40% dimethylbenzene mixing diluents form by mass ratio, total consumption of B liquid is 0.5 ~ 1.5%, and above A liquid, B liquid usage percentage are the mass percent that accounts for metal-powder quality;
2) load weighted A liquid is added in metal-powder and mixed, add again the B liquid configuring to add to mix after evenly and be coated, subsequently compound dried;
3) material after drying separated broken and sieved, mixing after adding lubricant;
4), by compound press forming, carry out subsequently drying defatted and hot setting;
5) finally heat-treat, remove stress.
4. method according to claim 3, the quality ratio range that it is characterized in that described cycloaliphatic epoxy resin and methyl hexahydrophthalic anhydride is 1 ~ 4:1.
5. method according to claim 3, is characterized in that described metal-powder is that mean particle size mixes and obtains with a certain amount of nano-oxide at the metallic magnetic powder of 20~60 μ m.
6. method according to claim 5, it is characterized in that described metallic magnetic powder is one or more powder mixs in pure Fe powder, Fe-Si powder, Fe-Si-Al powder, Fe-Ni powder or Fe-Ni-Mo powder, metal-powder is to adopt one or more in atomization, reduction, airflow milling or chemical process to combine preparation, and described nano-oxide is the nanometer Al that accounts for mass percent 0.1-3%
2o
3, SiO
2, TiO
2or B
2o
3in one or more fillers.
7. method according to claim 3, is characterized in that in described step 2) drying course be that dry solidification is processed at 100-200 ℃, insulation 30-180min.
8. method according to claim 3, it is characterized in that sieving of described step 3) is to adopt 100-200 mesh sieve, described lubricant is one or more mix lubricant in KP-11, stearic acid, Zinic stearas, lithium stearate, the 0.1-0.8% that lubricant content is compound.
9. method according to claim 3, the press forming that it is characterized in that described step 4) adopts a kind of in colding pressing in die forming, temperature and pressure or hot pressing, pressing pressure is 800 ~ 1500MPa, described drying defatted is that pressed compact is carried out to 150 ~ 200 ℃, and the de-lubricant of insulation 60 ~ 180min is processed.
10. method according to claim 3, the heat treated atmosphere that it is characterized in that described step 5) is hydrogen or cracked ammonium reducing atmosphere, and treatment temp is 500 ~ 900 ℃, and soaking time is 30 ~ 240min, furnace cooling.
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WO2019029146A1 (en) * | 2017-08-10 | 2019-02-14 | 深圳市铂科新材料股份有限公司 | Method for producing metal soft magnetic powder core resistant to high temperature heat treatment |
CN109545537A (en) * | 2018-12-28 | 2019-03-29 | 东莞铭普光磁股份有限公司 | A kind of powder core and preparation method thereof |
CN111883328A (en) * | 2020-06-09 | 2020-11-03 | 山东精创磁电产业技术研究院有限公司 | Modified binder and method for preparing soft magnetic composite material by using same |
CN111883328B (en) * | 2020-06-09 | 2021-06-18 | 山东精创磁电产业技术研究院有限公司 | Modified binder and method for preparing soft magnetic composite material by using same |
CN113257561A (en) * | 2021-04-20 | 2021-08-13 | 深圳顺络电子股份有限公司 | Insulating coated alloy powder and preparation method thereof |
CN113257561B (en) * | 2021-04-20 | 2022-08-23 | 深圳顺络电子股份有限公司 | Insulating coated alloy powder and preparation method thereof |
CN114388214A (en) * | 2022-02-11 | 2022-04-22 | 青岛云路先进材料技术股份有限公司 | Atomized metal powder, insulating coating agent, magnetic powder core and preparation method thereof |
CN114513099A (en) * | 2022-03-02 | 2022-05-17 | 卓尔博(宁波)精密机电股份有限公司 | Preparation process of soft magnetic composite material stator |
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