CN104505209A - Metal soft magnetic composite powder cores and preparation method thereof - Google Patents
Metal soft magnetic composite powder cores and preparation method thereof Download PDFInfo
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- CN104505209A CN104505209A CN201410801542.9A CN201410801542A CN104505209A CN 104505209 A CN104505209 A CN 104505209A CN 201410801542 A CN201410801542 A CN 201410801542A CN 104505209 A CN104505209 A CN 104505209A
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Abstract
The invention provides metal soft magnetic composite powder cores and a preparation method thereof. By the metal soft magnetic composite powder cores and the preparation method thereof, the loss can be low, direct-current offset performance is high, and the cost is low. The metal soft magnetic composite powder cores are formed by annealing metal powders of iron silicon and metal powders of iron silicon aluminum in the mass ratio of 2.00-9.00:1. The preparation method of the metal soft magnetic composite powder cores comprises the following five steps of: preparing iron-silicon insulating preparatory materials coated with phosphoric acid; preparing iron-silicon-aluminum insulating preparatory materials coated with phosphoric acid and boric acid; preparing mixed insulating powders of iron silicon and iron silicon aluminum; performing compression molding on the mixed insulating powders; and performing heat treatment on the powder cores. The metal soft magnetic composite powder cores have the advantages of low loss, high direct-current offset performance, low noise, low cost and easiness in production and popularization.
Description
Technical field
The invention belongs to technical field of magnetic materials, be mainly used in big current low-loss application scenario, be specifically related to a kind of soft magnetic metal composite core and preparation method thereof.
Background technology
Metal soft magnetic powder core is the powder made with metal or alloy soft magnetic material, by a kind of novel soft magnetic material with good combination property of special technique compacting.It has the good characteristic of metal soft magnetic material high saturated magnetic induction and soft magnetic ferrites high resistivity concurrently, overcome again the shortcomings such as the large and soft magnetic ferrites saturation induction density of metal soft magnetic material eddy current loss is low to greatest extent simultaneously, there is permanent magnetic permeability, saturation induction density is higher, DC stacked ability is strong, the advantages such as operating frequency is wider, thus meet power electronic device miniaturization, high frequency, energy-saving, the development trend of high efficiency, be widely used in photovoltaic DC-to-AC converter, reactor, Switching Power Supply, in the modern power electronic devices such as ups power, as power factor correction inductance, output inductor, resonant inductance, the iron core of the devices such as EMI inductance and flyback transformer.
At present, the metal soft magnetic powder core that market is applied mostly is single material, comprising: ferrocart core, iron Si-Al Magnetic Powder Core, iron silica flour core, FeNiCo magnetic core and iron nickel powder core.Ferrocart core loss is comparatively large, DC stacked poor-performing, but because cheap range of application is wider.Fe-Si-Al magnetic core is cheap, and loss is lower, but DC stacked poor-performing, big current occasion cannot be used for.Iron silica magnetic particle core price is lower, have excellent DC stacked performance, but loss is very high, cannot be used for the low-loss occasion of requirement.FeNiCo magnetic core loss is minimum, but DC stacked performance is general, and between iron silica flour core and iron Si-Al Magnetic Powder Core, and its price is high, therefore applies less.Iron nickel powder core has the DC stacked performance suitable with iron silica flour core, but loss is far below iron silica flour core, because of but can be used for the best magnetic core of big current low-loss occasion at present, but be that therefore range of application is extremely restricted because its high cost equally.In recent years, in order to meet the application scenario of low-loss big current, researcher develops again amorphous nano crystalline flour core, but preparation cost is very high, and but technique is still immature at present.In addition, amorphous nano crystalline flour core is compared with iron sial, iron silicon, iron nickel powder core, and its maximum shortcoming is that the magnetostriction coefficient of alloy causes more greatly producing larger noise in alternating electromagnetic field, does not meet environmental requirement.This problem is not yet resolved at present.Visible, the metal soft magnetic powder core of single material, due to the restriction of cost or combination property, all cannot meet the application demand of big current low-loss low cost.The present invention prepares a kind of soft magnetism composite core based on low cost iron silicon and Fe-Si-Al magnetic, can meet the demand having low-loss and good DC stacked performance under big current concurrently.
Patent application CN201210389520.7 describes a kind of preparation method of high DC stacked performance Fe-Si-Al magnetic core.The method adopts the mixed-powder of iron sial metal dust and iron powder or permalloy powder (or mixture of two kinds of powder), but the doping powder mentioned in all embodiments is permalloy (Ni-Fe alloy), this can significantly improve powder core cost, and the DC stacked performance of powder core bad, for the product of magnetic permeability 60, only just decline 50% at 105Oe inductance.Patent application CN201210230453.4 describes a kind of nanocrystalline magnetic core preparation method of magnetic permeability 60, though this powder core has lower loss and more high DC stacked performance, but industry generally acknowledges that manocrystalline powders preparation cost is very high, and containing precious metal elements such as Ni, Nb in alloy, can significantly improve powder core cost.Patent application CN201210203772.6 describes a kind of nanocrystalline magnetic core preparation method, employing be Fe
73.5cu
1nb
3si
13.5b
9nanometer crystal alloy, cost is very high, and and undeclared properties of product.Patent application CN201310454647.7 and CN201310454203.3 describes the preparation method of the silicon-boron amorphous powder core of Modified Iron.Two application preparation method all adopt ferrum-silicon-boron amorphous powder mix with one or more modified powders of nickel powder, iron nickel powder, iron silica flour after powder.Amorphous powder industry generally acknowledges that preparation cost is higher, and significantly can improve powder core cost containing Ni element in modified powder, though and two modified powder core noise problem of application are improved, but still there is noise, obvious inferior position compared with the powder core such as iron silicon, iron sial, iron nickel not having noise.Patent CN201110391858.1 describes a kind of preparation method of iron-based composite magnetic powder core.The method adopts the mixed-powder of the non-crystalline flour of FeCuNbSiB and carbonyl iron dust, has the shortcoming of amorphous core, and this product uses the auxiliary material containing chromium, does not meet environmental requirement.Patent application CN201210509456.1 describes a kind of preparation method of iron silicon soft magnetic alloy powder core.The method adopts fast quenching ferro-silicium powder and the mixed-powder being atomized ferro-silicium powder, and use a large amount of organic solvent in preparation process, cost is higher, though the DC stacked performance of products obtained therefrom is higher, loss is too high and Q value is lower.Patent application CN201310414993.2 describes a kind of preparation method of high superposition low-loss metal powder core.The method adopts atomization Fe-Si-Al magnetic and the mixed-powder being atomized iron nickel powder, though products obtained therefrom has higher DC stacked performance and lower loss, but because of higher containing precious metal element nickel cost, this product uses the acid solution containing chromium in addition, does not meet environmental requirement.
In sum, provide a kind of simple to operate, production cost is low and the preparation process for magnetic powder core the being intended for big current low-loss application scenario technical barrier that to be those skilled in the art urgently to be resolved hurrily.
Summary of the invention
Be difficult to for prior art the difficult problem simultaneously realizing low-loss, high DC stacked performance, low cost, the invention provides a kind of low cost soft magnetic metal composite core and preparation method thereof.
A kind of soft magnetic metal composite core, is formed by the metal dust of iron silicon and the metal powder sintered of iron sial.Wherein, the mass ratio of iron silicon and iron sial is 2.00 ~ 9.00:1.The metal dust of iron silicon and the metal dust of iron sial are the particulate through insulation processing.
This soft magnetic metal composite core, under 100kHz/1V condition, inductance L is between 46.00 μ H ~ 50.00 μ H; Under 100kHz/1V condition, quality factor q is between 121.00 ~ 125.00; Under 100kHz condition: as DC stacked magnetic field H=100Oe, L
h/ L
0between 62.00% ~ 72.01%; As DC stacked magnetic field H=200Oe, L
h/ L
0between 35.00% ~ 41.49%; Under 50kHz/100mT condition, powder core loss P
cvat 440mW/cm
3~ 590mW/cm
3between.
The preparation method of soft magnetic metal composite core of the present invention, carries out as follows:
Step 1: preparation is coated with phosphatic iron silicon insulation pre-feed.
1) to sieve process: the spherical iron silicon (Fe getting aerosolization
93.5si
6.5) powder crosses 200 object screen clothes, obtains the iron Si powder after sieving.
2) insulating wrapped process: the mixing material adding phosphoric acid and alcohol in the iron Si powder after sieving, and stir, obtain the iron silicon slurry containing phosphoric acid.Subsequently, the iron silicon slurry containing phosphoric acid be heated to 90-120 DEG C and constantly stir, until the iron silicon slurry drying of phosphoric acid should be contained, obtaining and be coated with phosphatic iron silicon insulation powder.
3) binding agent is added: add silicone, zinc stearate to being coated with in phosphatic iron silicon insulation powder, and stir, obtain and be coated with phosphatic iron silicon insulation pre-feed.
Step 2: preparation is coated with phosphatic iron sial insulation pre-feed.
1) to sieve process: get sheet iron sial (Fe
85si
9.6al
5.4) powder crosses 200 object screen clothes, obtains the iron sial powder after sieving.
2) insulating wrapped process: the mixing material adding phosphoric acid, boric acid and alcohol in the iron sial powder after sieving, and stir, obtain the iron sial slurry containing phosphoric acid and boric acid.Subsequently, the iron sial slurry containing phosphoric acid and boric acid be heated to 90-120 DEG C and constantly stir, until the iron sial slurry drying of phosphoric acid and boric acid should be contained, obtaining and be coated with phosphatic iron sial insulation powder.
3) binding agent is added: add phenol resin, zinc stearate to being coated with in phosphatic iron sial insulation powder, and stir, obtain and be coated with phosphatic iron sial insulation pre-feed.
Step 3: the mix insulation powder of preparation iron silicon and iron sial.The phosphatic iron silicon insulation pre-feed that is coated with obtained by step 1 insulate pre-feed 2.00 ~ 9.00:1 Homogeneous phase mixing in mass ratio with the phosphatic iron sial that is coated with obtained by step 2, the mix insulation powder of acquisition iron silicon and iron sial.
Step 4: compressing.By hydraulic forming machine by shaping for the mix insulation stamping of powder of the iron silicon mixed that obtained by step 3 and iron sial, obtain the mix insulation blank of iron silicon and iron sial.Wherein, the compacting pressure of hydraulic forming machine is 18.6 ~ 21.7 tons/cm
2.
Step 5: heat treatment.Adopt nitrogen to make protective atmosphere, the anneal environment that the mix insulation blank being suppressed iron silicon and the iron sial obtained by step 4 is placed in 700 DEG C ~ 780 DEG C is incubated 30min ~ 120min, obtained soft magnetic metal composite core.
useful technique effect
Soft magnetic metal composite core of the present invention have concurrently low-loss (under 50kHz/100mT condition, P
cvminimum is 445mW/cm
3), high DC stacked performance (under 100kHz condition, during H=100Oe, L
h/ L
0be up to 72.01%.During H=200Oe, L
h/ L
0be up to 41.49%) and low noise, and low cost, be easy to the advantage of producing and promoting.The preparation method of soft magnetic metal composite core of the present invention, there is the advantages such as technique is simple, low raw-material cost, suitability for industrialized production, had by the soft magnetic metal composite core that a process for preparing that insulation property are high, magnetostriction coefficient is little, noiseless outstanding advantages in alternating electromagnetic field environment.Be in particular in following aspect:
The Fe that the present invention adopts
93.5si
6.5spherical gas-atomised powders and Fe
85si
9.6al
5.4irregular ball-milled powder is as raw material, and two kinds of cost of alloy are cheap.The Fe that the aerosolization legal system that the present invention adopts is standby
93.5si
6.5globular powder and be irregular Fe through the edge of ball-milling treatment
85si
9.6al
5.4flakelike powder, its magnetostriction coefficient is 0, thus avoids soft magnetic metal composite core of the present invention and produce noise problem at alternating electromagnetic field because of magnetostriction deformation.
Fe in the present invention
93.5si
6.5spherical gas-atomised powders carries out insulation processing by the mixed liquor of phosphoric acid and alcohol, and Fe
85si
9.6al
5.4irregular ball-milled powder carries out insulation processing by the mixed liquor of phosphoric acid, boric acid and alcohol, namely respectively two kinds of raw materials are insulated by different formulas, make the insulating barrier of coated last layer dense uniform around magnetic, avoid and use the acid solution of single a kind of insulating effect to cause the extent of corrosion of magnetic to differ, avoid in conventional method two kinds of different powder are directly mixed and the two kinds of powder adopting same insulating process to run into because of insulation degree different, the inadequate dense uniform of insulating barrier coated around magnetic and the poor problem of the bulk article consistency that causes.Meanwhile, separately insulation according to the change of magnetic proportioning, can regulate properties of product flexibly.
The present invention adopts acid solution (phosphoric acid, boric acid) to cook insulating compound, the effect of insulation is reached by the use amount increasing acid, do not add that conventional method uses as other insulating compounds such as mica, kaolin, glass dust, effectively can simplify production technology, reduce production cost, improve homogeneity of product.
The present invention adopts resin only as binding agent, does not play insulating effect, all can decompose, can not produce any impact to powdered insulation during the high temperature anneal.Resin as insulating compound, therefore cannot be carried out high-temperature heat treatment by the conventional method which avoid, and causes retaining in powder core large amount of organic and causes in the follow-up use procedure of product and occur serious aging problem.Or causing resin decomposition to affect insulation effect because having carried out high-temperature heat treatment, causing loss significantly to raise.
The present invention does not need to carry out dipping process, can reduce production link, reduces production cost, avoids impregnation to introduce large amount of organic simultaneously in powder core thus cause in the follow-up use procedure of product occurring serious aging problem.
Accompanying drawing explanation
Fig. 1 is soft magnetic metal composite core section X-ray energy spectrum (EDS) Element area profile of preparation in embodiment 1.
Fig. 2 is soft magnetic metal composite core section X-ray energy spectrum (EDS) Element area profile of preparation in embodiment 2.
Fig. 3 is soft magnetic metal composite core section X-ray energy spectrum (EDS) Element area profile of preparation in embodiment 3.
Embodiment
Now be described with reference to the accompanying drawings ins and outs of the present invention.
A kind of soft magnetic metal composite core, is annealed by the metal dust of iron silicon and the metal dust of iron sial and forms.Wherein, the mass ratio of iron silicon and iron sial is 2.00 ~ 9.00:1.The metal dust of iron silicon and the metal dust of iron sial are the particulate through insulation processing.
Furtherly, the structural formula of iron silicon particle is Fe
93.5si
6.5, and particle diameter is not more than the spherical powder of the aerosolization of 74 μm.The structural formula of iron silicon aluminium particle is Fe
85si
9.6al
5.4, and particle diameter is not more than the powder of the sheet through ball-milling treatment of 74 μm.
Furtherly, the Surface coating of iron silicon particle has had the phosphate particulate of insulating effect.The Surface coating of iron silicon aluminium particle has had the phosphate particulate of insulating effect.
Furtherly, described soft magnetic metal composite core,
Under 100kHz/1V condition, inductance L is between 46.00 μ H ~ 50.00 μ H;
Under 100kHz/1V condition, quality factor q is between 121.00 ~ 125.00;
Under 100kHz condition: as DC stacked magnetic field H=100Oe, L
h/ L
0between 62.00% ~ 72.01%; As DC stacked magnetic field H=200Oe, L
h/ L
0between 35.00% ~ 41.49%;
Under 50kHz/100mT condition, powder core loss P
cvat 445mW/cm
3~ 590mW/cm
3between.
The preparation method of soft magnetic metal composite core of the present invention, carries out as follows:
Step 1: preparation is coated with phosphatic iron silicon insulation pre-feed.
1) to sieve process: the spherical iron silicon (Fe getting aerosolization
93.5si
6.5) powder crosses 200 object screen clothes, obtains the iron Si powder after sieving.
2) insulating wrapped process: the mixing material adding phosphoric acid and alcohol in the iron Si powder after sieving, and stir, obtain the iron silicon slurry containing phosphoric acid.Subsequently, the iron silicon slurry containing phosphoric acid be heated to 90-120 DEG C and constantly stir, until the iron silicon slurry drying of phosphoric acid should be contained, obtaining and be coated with phosphatic iron silicon insulation powder.
3) binding agent is added: add silicone, zinc stearate to being coated with in phosphatic iron silicon insulation powder, and stir, obtain and be coated with phosphatic iron silicon insulation pre-feed.
Step 2: preparation is coated with phosphatic iron sial insulation pre-feed.
1) to sieve process: get sheet iron sial (Fe
85si
9.6al
5.4) powder crosses 200 object screen clothes, obtains the iron sial powder after sieving.
2) insulating wrapped process: the mixing material adding phosphoric acid, boric acid and alcohol in the iron sial powder after sieving, and stir, obtain the iron sial slurry containing phosphoric acid and boric acid.Subsequently, the iron sial powder containing phosphoric acid and boric acid be heated to 90-120 DEG C and constantly stir, until the iron sial slurry drying of phosphoric acid and boric acid should be contained, obtaining and be coated with phosphatic iron sial insulation paste.In this step, boric acid only plays the effect of pH value buffer, does not generate insulating barrier.
3) binding agent is added: add phenol resin, zinc stearate to being coated with in phosphatic iron sial insulation powder, and stir, obtain and be coated with phosphatic iron sial insulation pre-feed.
Step 3: the mix insulation powder of preparation iron silicon and iron sial.The phosphatic iron silicon insulation pre-feed that is coated with obtained by step 1 insulate pre-feed 2.00 ~ 9.00:1 Homogeneous phase mixing in mass ratio with the phosphatic iron sial that is coated with obtained by step 2, the mix insulation powder of acquisition iron silicon and iron sial.
Step 4: compressing.By hydraulic forming machine by shaping for the mix insulation stamping of powder of the iron silicon mixed that obtained by step 3 and iron sial, obtain the mix insulation blank of iron silicon and iron sial.Wherein, the compacting pressure of hydraulic forming machine is 18.6 ~ 21.7 tons/cm
2.
Step 5: heat treatment.Adopt nitrogen to make protective atmosphere, the mix insulation blank being suppressed iron silicon and the iron sial obtained is placed in the anneal environment of 700 DEG C ~ 780 DEG C is incubated 30min ~ 120min by step 4, obtained soft magnetic metal composite core.
Furtherly, in step 1, the mass ratio of iron Si powder, phosphoric acid and alcohol after sieving is 1:0.005 ~ 0.008:0.070.Wherein, the concentration of phosphoric acid is the liquid of 85%.
Furtherly, in step 1, be coated with phosphatic iron silicon insulation powder, silicone, zinc stearate mass ratio be 1:0.004 ~ 0.006:0.003 ~ 0.005.Wherein, silicone is liquid, and zinc stearate is solid state powder.
Furtherly, in step 2, the mass ratio of iron sial powder, phosphoric acid, boric acid and alcohol after sieving is 1:0.015 ~ 0.018:0.001 ~ 0.003:0.070.Wherein, the concentration of phosphoric acid is 85%, and boric acid is solid state powder.
Furtherly, in step 2, be coated with phosphatic iron sial insulation powder, phenol resin, zinc stearate mass ratio be 1:0.006 ~ 0.008:0.003 ~ 0.005.Wherein, phenol resin and zinc stearate are solid state powder.
Furtherly, in step 4, the mix insulation stamping of powder of iron silicon and iron sial is made the blank of annular.
embodiment 1:
Take the Fe that 1000g crosses 200 eye mesh screen screenings respectively
93.5si
6.5spherical gas-atomised powders and 1000g cross the Fe of 200 eye mesh screen screenings
85si
9.6al
5.4ball-milled powder.Take Fe respectively
93.5si
6.5the phosphoric acid solution of 85% concentration of powder weight 8 ‰ and Fe
93.5si
6.5the alcohol of powder weight 7%, adds Fe after both being mixed
93.5si
6.5powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Take Fe respectively
85si
9.6al
5.4phosphoric acid solution, the Fe of 85% concentration of powder weight 18 ‰
85si
9.6al
5.4the boric acid of powder weight 1 ‰ and Fe
85si
9.6al
5.4the alcohol of powder weight 7%, adds Fe after three being mixed
85si
9.6al
5.4powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Dried Fe is got respectively according to the ratio of mass ratio 7:3
93.5si
6.5powder and Fe
85si
9.6al
5.4powder.By dried Fe
93.5si
6.5powder mixes with the silicone of magnetic weight 5.5 ‰ and the zinc stearate of magnetic weight 3 ‰.By dried Fe
85si
9.6al
5.4powder mixes with the phenol resin of magnetic weight 8 ‰ and the zinc stearate of magnetic weight 3 ‰.To be insulated mixed Fe
93.5si
6.5powder and the mixed Fe of insulation
85si
9.6al
5.4powder mixes, and adopts hydraulic forming machine at 18.6 tons/cm
2pressure under be pressed into OD26.92 × ID14.73 × H11.18(and external diameter be 26.92mm, internal diameter is 14.73mm, highly for 11.18mm) annular powder core.Powder core is put into tube furnace that nitrogen makes protective atmosphere and be heated to 700 DEG C and with stove cooling after being incubated 30min, obtained soft magnetic metal composite core.
The section EDS Element area profile of soft magnetic metal composite core as shown in Figure 1.Visible, powder core inner containing iron silica magnetic particle particle and Fe-Si-Al magnetic particle, the periphery of two kinds of magnetic powder particle is coated with the insulating barrier of one deck containing P element and O element all comparatively equably.Iron silicon metal soft magnetic powder core adopts wire diameter Φ 0.71mm, the enamelled wire coiling 25 circle inductance coil of line length 0.9m, measures the powder core magnetic electricity performance obtained as follows:
(1) under 100kHz/1V condition, inductance L=49.25 μ H;
(2) under 100kHz/1V condition, Q=124.67;
(3) DC stacked performance: when 100kHz, H=100Oe, L
h/ L
0=62.57%; During H=200Oe, L
h/ L
0=35.09%;
(4) powder core loss: during 50kHz/100mT, P
cv=445mW/cm
3.
embodiment 2:
Take the Fe that 1000g screens through 200 eye mesh screens respectively
93.5si
6.5the Fe that spherical gas-atomised powders and 1000g screen through 200 eye mesh screens
85si
9.6al
5.4ball-milled powder.Take Fe respectively
93.5si
6.5the phosphoric acid solution of 85% concentration of powder weight 7 ‰ and Fe
93.5si
6.5the alcohol of powder weight 7%, adds Fe after both being mixed
93.5si
6.5powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Take Fe respectively
85si
9.6al
5.4phosphoric acid solution, the Fe of 85% concentration of powder weight 15 ‰
85si
9.6al
5.4the boric acid of powder weight 2 ‰ and Fe
85si
9.6al
5.4the alcohol of powder weight 7%, adds Fe after three being mixed
85si
9.6al
5.4powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Dried Fe is got respectively according to the ratio of mass ratio 8:2
93.5si
6.5powder and Fe
85si
9.6al
5.4powder.By dried Fe
93.5si
6.5powder and Fe
93.5si
6.5the silicone of powder weight 4 ‰ and Fe
93.5si
6.5the zinc stearate of powder weight 5 ‰ mixes.By dried Fe
85si
9.6al
5.4powder and Fe
85si
9.6al
5.4the phenol resin of powder weight 7 ‰ and Fe
85si
9.6al
5.4the zinc stearate of powder weight 5 ‰ mixes.To be insulated mixed Fe
93.5si
6.5powder and the mixed Fe of insulation
85si
9.6al
5.4powder mixes, and adopts hydraulic forming machine at 20.1 tons/cm
2pressure under be pressed into OD26.92 × ID14.73 × H11.18(and external diameter be 26.92mm, internal diameter is 14.73mm, highly for 11.18mm) annular powder core.Powder core is put into tube furnace that nitrogen makes protective atmosphere and be heated to 740 DEG C and with stove cooling after being incubated 60min, obtained soft magnetic metal composite core.
The section EDS Element area profile of soft magnetic metal composite core as shown in Figure 2.Visible, powder core inner containing iron silica magnetic particle particle and Fe-Si-Al magnetic particle, the periphery of two kinds of magnetic powder particle is coated with the insulating barrier of one deck containing P element and O element all comparatively equably.Iron silicon metal soft magnetic powder core adopts wire diameter Φ 0.71mm, the enamelled wire coiling 25 circle inductance coil of line length 0.9m, measures the powder core magnetic electricity performance obtained as follows:
(1) under 100kHz/1V condition, inductance L=48.19 μ H;
(2) under 100kHz/1V condition, Q=124.66;
(3) DC stacked performance: when 100kHz, H=100Oe, L
h/ L
0=66.89%; During H=200Oe, L
h/ L
0=38.52%;
(4) powder core loss: during 50kHz/100mT, P
cv=515mW/cm
3.
embodiment 3:
Take the Fe that 1000g screens through 200 eye mesh screens respectively
93.5si
6.5the Fe that spherical gas-atomised powders and 1000g screen through 200 eye mesh screens
85si
9.6al
5.4irregular ball-milled powder.Take Fe respectively
93.5si
6.5the phosphoric acid solution of 85% concentration of powder weight 5 ‰ and Fe
93.5si
6.5the alcohol of powder weight 7%, adds Fe after both being mixed
93.5si
6.5powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Take Fe respectively
85si
9.6al
5.4phosphoric acid solution, the Fe of 85% concentration of powder weight 16 ‰
85si
9.6al
5.4the boric acid of powder weight 3 ‰ and Fe
85si
9.6al
5.4the alcohol of powder weight 7%, adds Fe after three being mixed
85si
9.6al
5.4powder also stirs, and is then heated to about 100 DEG C insulations and constantly stirs until magnetic is dry.Dried Fe is got respectively according to the ratio of mass ratio 9:1
93.5si
6.5powder and Fe
85si
9.6al
5.4powder.By dried Fe
93.5si
6.5powder and Fe
93.5si
6.5the silicone of powder weight 6 ‰ and Fe
93.5si
6.5the zinc stearate of powder weight 5 ‰ mixes.By dried Fe
85si
9.6al
5.4powder and Fe
85si
9.6al
5.4the phenol resin of powder weight 6 ‰ and Fe
85si
9.6al
5.4the zinc stearate of powder weight 5 ‰ mixes.To be insulated mixed Fe
93.5si
6.5powder and the mixed Fe of insulation
85si
9.6al
5.4powder mixes, and adopts hydraulic forming machine at 21.7 tons/cm
2pressure under be pressed into OD26.92 × ID14.73 × H11.18(and external diameter be 26.92mm, internal diameter is 14.73mm, highly for 11.18mm) annular powder core.Powder core is put into tube furnace that nitrogen makes protective atmosphere and be heated to 780 DEG C and with stove cooling after being incubated 120min, obtained soft magnetic metal composite core.
The section EDS Element area profile of soft magnetic metal composite core as shown in Figure 3.Visible, powder core inner containing iron silica magnetic particle particle and Fe-Si-Al magnetic particle, the periphery of two kinds of magnetic powder particle is coated with the insulating barrier of one deck containing P element and O element all comparatively equably.Iron silicon metal soft magnetic powder core adopts wire diameter Φ 0.71mm, the enamelled wire coiling 25 circle inductance coil of line length 0.9m, measures the powder core magnetic electricity performance obtained as follows:
(1) under 100kHz/1V condition, inductance L=46.61 μ H;
(2) under 100kHz/1V condition, Q=121.43;
(3) DC stacked performance: when 100kHz, H=100Oe, L
h/ L
0=72.01%; During H=200Oe, L
h/ L
0=41.49%;
(4) powder core loss: during 50kHz/100mT, P
cv=590mW/cm
3.
Furtherly, be coated with phosphatic iron sial insulate the mass ratio of pre-feed by regulating in the mix insulation powder of iron silicon and iron sial, the inductance of this soft magnetic metal of linear regulation composite core, DC stacked performance and powder core loss:
When the mass percent being coated with phosphatic iron sial insulation pre-feed increases to 30% by 10%, the inductance value of soft magnetic metal composite core of the present invention rises to 49.25 μ H by 46.61 μ H, during superposition 100Oe D.C. magnetic field, and L
h/ L
062.57% is reduced to by 72.01%, during superposition 200Oe D.C. magnetic field, L
h/ L
0be reduced to 35.09% by 41.49%, powder core loss is by 590mW/cm
3be reduced to 445mW/cm
3.
Claims (8)
1. a soft magnetic metal composite core, is characterized in that: being annealed by the metal dust of iron silicon and the metal dust of iron sial forms; Wherein, the mass ratio of iron silicon and iron sial is 2.00 ~ 9.00:1; The metal dust of iron silicon and the metal dust of iron sial are the particulate through insulation processing; This soft magnetic metal composite core,
Under 100kHz/1V condition, inductance L is between 46.00 μ H ~ 50.00 μ H;
Under 100kHz/1V condition, quality factor q is between 121.00 ~ 125.00;
Under 100kHz condition: as DC stacked magnetic field H=100Oe, L
h/ L
0between 62.00% ~ 72.01%; As DC stacked magnetic field H=200Oe, L
h/ L
0between 35.00% ~ 41.49%;
Under 50kHz/100mT condition, powder core loss P
cvat 445mW/cm
3~ 590mW/cm
3between.
2. a kind of soft magnetic metal composite core as claimed in claim 1, is characterized in that: the Surface coating of iron silicon particle has had the phosphate particulate of insulating effect; The Surface coating of iron silicon aluminium particle has had the phosphate particulate of insulating effect.
3. the preparation method of soft magnetic metal composite core as claimed in claim 1, is characterized in that: carry out as follows:
Step 1: preparation is coated with phosphatic iron silicon insulation pre-feed;
1) to sieve process: the spherical iron Si powder of getting aerosolization crosses 200 object screen clothes, obtain the iron Si powder after sieving;
2) insulating wrapped process: the mixing material adding phosphoric acid and alcohol in the iron Si powder after sieving, and stir, obtain the iron silicon slurry containing phosphoric acid; Subsequently, the iron silicon slurry containing phosphoric acid be heated to 90-120 DEG C and constantly stir, until the iron silicon slurry drying of phosphoric acid should be contained, obtaining and be coated with phosphatic iron silicon insulation powder;
3) binding agent is added: add silicone, zinc stearate to being coated with in phosphatic iron silicon insulation powder, and stir, obtain and be coated with phosphatic iron silicon insulation pre-feed;
Step 2: preparation is coated with phosphatic iron sial insulation pre-feed;
1) to sieve process: get sheet iron sial powder and cross 200 object screen clothes, obtain the iron sial powder after sieving;
2) insulating wrapped process: the mixing material adding phosphoric acid, boric acid and alcohol in the iron sial powder after sieving, and stir, obtain the iron sial slurry containing phosphoric acid and boric acid; Subsequently, the iron sial slurry containing phosphoric acid and boric acid be heated to 90-120 DEG C and constantly stir, until the iron sial slurry drying of phosphoric acid and boric acid should be contained, obtaining and be coated with phosphatic iron sial insulation powder;
3) binding agent is added: add phenol resin, zinc stearate to being coated with in phosphatic iron sial insulation powder, and stir, obtain and be coated with phosphatic iron sial insulation pre-feed;
Step 3: the mix insulation powder of preparation iron silicon and iron sial; The phosphatic iron silicon insulation pre-feed that is coated with obtained by step 1 insulate pre-feed 2.00 ~ 9.00:1 Homogeneous phase mixing in mass ratio with the phosphatic iron sial that is coated with obtained by step 2, the mix insulation powder of acquisition iron silicon and iron sial;
Step 4: compressing; By hydraulic forming machine by shaping for the mix insulation stamping of powder of the iron silicon mixed that obtained by step 3 and iron sial, obtain the mix insulation blank of iron silicon and iron sial; Wherein, the compacting pressure of hydraulic forming machine is 18.6 ~ 21.7 tons/cm
2;
Step 5: heat treatment; Adopt nitrogen to make protective atmosphere, the anneal environment that the mix insulation blank being suppressed iron silicon and the iron sial obtained by step 4 is placed in 700 DEG C ~ 780 DEG C is incubated 30min ~ 120min, obtained soft magnetic metal composite core.
4. the preparation method of soft magnetic metal composite core as claimed in claim 3, it is characterized in that: in step 1, the mass ratio of iron Si powder, phosphoric acid and alcohol after sieving is 1:0.005 ~ 0.008:0.070.
5. the preparation method of soft magnetic metal composite core as claimed in claim 3, is characterized in that: in step 1, be coated with phosphatic iron silicon insulation powder, silicone, zinc stearate mass ratio be 1:0.004 ~ 0.006:0.003 ~ 0.005.
6. the preparation method of soft magnetic metal composite core as claimed in claim 3, it is characterized in that: in step 2, the mass ratio of iron sial powder, phosphoric acid, boric acid and alcohol after sieving is 1:0.015 ~ 0.018:0.001 ~ 0.003:0.070.
7. the preparation method of soft magnetic metal composite core as claimed in claim 3, is characterized in that: in step 2, be coated with phosphatic iron sial insulation powder, phenol resin, zinc stearate mass ratio be 1:0.006 ~ 0.008:0.003 ~ 0.005.
8. the preparation method of soft magnetic metal composite core as claimed in claim 3, it is characterized in that: be coated with phosphatic iron sial in the mix insulation powder by iron silicon and iron sial in regulating step 3 and insulate the mass ratio of pre-feed, the inductance of this soft magnetic metal of linear regulation composite core, DC stacked performance and powder core loss: when the mass percent being coated with phosphatic iron sial insulation pre-feed increases to 30% by 10%, the inductance value of soft magnetic metal composite core of the present invention rises to 49.25 μ H by 46.61 μ H, during superposition 100Oe D.C. magnetic field, L
h/ L
062.57% is reduced to by 72.01%, during superposition 200Oe D.C. magnetic field, L
h/ L
0be reduced to 35.09% by 41.49%, powder core loss is by 590mW/cm
3be reduced to 445mW/cm
3.
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