CN105742030B - 一种变压器及其变压器的e型磁芯的制造方法 - Google Patents
一种变压器及其变压器的e型磁芯的制造方法 Download PDFInfo
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Abstract
本发明属于变压器领域,具体公开一种变压器及其变压器的E型磁芯的制造方法,包括增材制造的E型磁芯,所述磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为30.0‑35.0:6.0‑7.0:3.0‑4.0:3.0‑6.0:8.4‑9.2:6.7‑8.9,其余为Fe和辅助材料。本发明设置中间层中的居里点较低,能够根据变压器绕组温升来设定,防止过热,当绕组过热,超过中间层的居里点,使得中间层失磁,变压器停止工作,能够防止变压器过热,同时E型磁芯的性能远超常规磁芯。
Description
发明领域
本发明属于变压器领域,具体地说是涉及一种变压器及其变压器的E型磁芯的制造方法。
背景技术
变压器在使用的过程中温度会升高,长时间工作后,变压器的高温甚至会引燃变压器的电路或者其他设备,造成安全事故。
发明内容
为解决上述技术问题,本发明提供一种变压器及其变压器的E型磁芯的制造方法。
为达到上述目的,本发明所采取的技术方案为:
一种变压器的E型磁芯的制造方法,包括增材制造的E型磁芯,所述磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为30.0-35.0:6.0-7.0:3.0-4.0:3.0-6.0:8.4-9.2:6.7-8.9,其余为Fe和辅助材料,所述辅助材料包括成分按重量百分比计的以下组分:Ce:0.2-0.8%,Pr:0.4-0.9%,Sm:1.2-3.4%,Dy:5.4-11.2%,Pm:0.6-0.8%,其余为La。
进一步地,所述硬磁性相由R2Fe14B型化合物构成。
进一步地,所述软磁性相主要含有α-Fe相和居里点为790℃以上1130℃以下的结晶相。
上述磁芯的软磁性相的制备方法如下,
(1)熔铸合金
将纯度大于99.9%的原料Fe、Co、Si、Mn、La、B,Hf按合金成分以原子百分比称量并配料,将称好的Fe、Co、Hf放入感应加热熔炉中,抽真空至10-5Pa以上,充入高纯氩气至炉内气压为1.0×105Pa,之后再通电加热,将Fe、Co、Hf融化后,依次加入Mn、La、Si和B,反复熔炼6-10次以获得母合金熔液,在氩气保护下铸坯,得到母合金铸锭;
(2)制备非合金带
将母合金锭熔炼到1120-1350℃,并采用单辊法以60-75m/s的辊速制备出的宽10-15mm、厚度在10-25μm的非晶薄带;
(3)热处理
将非晶薄带装入热处理炉中,在真空低于1.0×10-3Pa或惰性气体氛围中,在450-550℃保温20-35分钟,最后淬火冷却;
(4)制备软磁材料成品
将热处理后的非晶薄带氢破后球磨至粒径为10-15μm的软磁颗粒,然后置于搅拌机中,将质量比为3-4:1-3:24-36的三羟甲基丙烷、硬脂酸、氧化钕混合,共同在46-75℃下搅拌混合1.5-2.0小时,加入浓度为15-30%的乙酸,220-303转/分搅拌分散40-55分钟,加入氟化铵,搅拌混合12-23分钟,加入预混液,400-500转/分搅拌分散0.5-0.9小时,60-70℃下干燥30-40分钟,进行研磨,研磨到800-1200目,得到预烧料,用压机将颗粒料压制为生坯,以20-35℃/min的速度升温至1350-1400℃,在15-25%的氧分压下保温烧结6-7h,将得到的产品放入真空环境下,急冷保压2-3h。
进一步地,在所述急冷保压中,冷却速度调节为1.5×105K/s以上3.2×105K/s以下。
本发明的有益效果:本发明提供的变压器及E型磁芯在保证了磁性能力不降低的情况下,设置中间层中的居里点较低,能够根据变压器绕组温升来设定,防止过热,当绕组过热,超过中间层的居里点,使得中间层失磁,变压器停止工作,能够防止变压器过热,同时E型磁芯的性能远超常规磁芯。
具体实施方式
下面结合具体实施例对本发明所述技术方案作进一步的说明。
实施例1:
一种变压器的E型磁芯的制造方法,包括增材制造的E型磁芯,所述磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为30.0:6.0:3.0:3.0:8.4:6.7,其余为Fe和辅助材料,所述辅助材料包括成分按重量百分比计的以下组分:Ce:0.2%,Pr:0.4%,Sm:1.2%,Dy:5.4%,Pm:0.6%,其余为La。
进一步地,所述硬磁性相由R2Fe14B型化合物构成。
进一步地,所述软磁性相主要含有α-Fe相和居里点为790℃以上1130℃以下的结晶相。
上述磁芯的软磁性相的制备方法如下,
(1)熔铸合金
将纯度大于99.9%的原料Fe、Co、Si、Mn、La、B,Hf按合金成分以原子百分比称量并配料,将称好的Fe、Co、Hf放入感应加热熔炉中,抽真空至10-5Pa以上,充入高纯氩气至炉内气压为1.0×105Pa,之后再通电加热,将Fe、Co、Hf融化后,依次加入Mn、La、Si和B,反复熔炼6次以获得母合金熔液,在氩气保护下铸坯,得到母合金铸锭;
(2)制备非合金带
将母合金锭熔炼到1120℃,并采用单辊法以60m/s的辊速制备出的宽10mm、厚度在10μm的非晶薄带;
(3)热处理
将非晶薄带装入热处理炉中,在真空低于1.0×10-3Pa或惰性气体氛围中,在450℃保温20分钟,最后淬火冷却;
(4)制备软磁材料成品
将热处理后的非晶薄带氢破后球磨至粒径为10μm的软磁颗粒,然后置于搅拌机中,将质量比为3:1:24的三羟甲基丙烷、硬脂酸、氧化钕混合,共同在46℃下搅拌混合1.5小时,加入浓度为15%的乙酸,220转/分搅拌分散40分钟,加入氟化铵,搅拌混合12分钟,加入预混液,400转/分搅拌分散0.5小时,60℃下干燥30分钟,进行研磨,研磨到800目,得到预烧料,用压机将颗粒料压制为生坯,以20℃/min的速度升温至1350℃,在15%的氧分压下保温烧结6h,将得到的产品放入真空环境下,急冷保压2h。
进一步地,在所述急冷保压中,冷却速度调节为1.5×105K/s以上3.2×105K/s以下。
实施例2:
一种变压器的E型磁芯的制造方法,包括增材制造的E型磁芯,所述磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为32.5:6.5:3.5:4.0:8.9:7.2,其余为Fe和辅助材料,所述辅助材料包括成分按重量百分比计的以下组分:Ce:0.5%,Pr:0.8%,Sm:2.6%,Dy:6.7%,Pm:0.7%,其余为La。
进一步地,所述硬磁性相由R2Fe14B型化合物构成。
进一步地,所述软磁性相主要含有α-Fe相和居里点为790℃以上1130℃以下的结晶相。
上述磁芯的软磁性相的制备方法如下,
(1)熔铸合金
将纯度大于99.9%的原料Fe、Co、Si、Mn、La、B,Hf按合金成分以原子百分比称量并配料,将称好的Fe、Co、Hf放入感应加热熔炉中,抽真空至10-5Pa以上,充入高纯氩气至炉内气压为1.0×105Pa,之后再通电加热,将Fe、Co、Hf融化后,依次加入Mn、La、Si和B,反复熔炼6-10次以获得母合金熔液,在氩气保护下铸坯,得到母合金铸锭;
(2)制备非合金带
将母合金锭熔炼到1230℃,并采用单辊法以65m/s的辊速制备出的宽12mm、厚度在20μm的非晶薄带;
(3)热处理
将非晶薄带装入热处理炉中,在真空低于1.0×10-3Pa或惰性气体氛围中,在500℃保温25分钟,最后淬火冷却;
(4)制备软磁材料成品
将热处理后的非晶薄带氢破后球磨至粒径为13μm的软磁颗粒,然后置于搅拌机中,将质量比为3.5:2.5:29的三羟甲基丙烷、硬脂酸、氧化钕混合,共同在54℃下搅拌混合1.9小时,加入浓度为20%的乙酸,289转/分搅拌分散49分钟,加入氟化铵,搅拌混合16分钟,加入预混液,450转/分搅拌分散0.7小时,65℃下干燥35分钟,进行研磨,研磨到1100目,得到预烧料,用压机将颗粒料压制为生坯,以25℃/min的速度升温至1383℃,在20%的氧分压下保温烧结6.5h,将得到的产品放入真空环境下,急冷保压2.5h。
进一步地,在所述急冷保压中,冷却速度调节为1.5×105K/s以上3.2×105K/s以下。
实施例3:
一种变压器的E型磁芯的制造方法,包括增材制造的E型磁芯,所述磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为35.0:7.0:4.0:6.0:9.2:8.9,其余为Fe和辅助材料,所述辅助材料包括成分按重量百分比计的以下组分:Ce:0.8%,Pr:0.9%,Sm:3.4%,Dy:11.2%,Pm:0.8%,其余为La。
进一步地,所述硬磁性相由R2Fe14B型化合物构成。
进一步地,所述软磁性相主要含有α-Fe相和居里点为790℃以上1130℃以下的结晶相。
上述磁芯的软磁性相的制备方法如下,
(1)熔铸合金
将纯度大于99.9%的原料Fe、Co、Si、Mn、La、B,Hf按合金成分以原子百分比称量并配料,将称好的Fe、Co、Hf放入感应加热熔炉中,抽真空至10-5Pa以上,充入高纯氩气至炉内气压为1.0×105Pa,之后再通电加热,将Fe、Co、Hf融化后,依次加入Mn、La、Si和B,反复熔炼10次以获得母合金熔液,在氩气保护下铸坯,得到母合金铸锭;
(2)制备非合金带
将母合金锭熔炼到1350℃,并采用单辊法以75m/s的辊速制备出的宽15mm、厚度在25μm的非晶薄带;
(3)热处理
将非晶薄带装入热处理炉中,在真空低于1.0×10-3Pa或惰性气体氛围中,在550℃保温35分钟,最后淬火冷却;
(4)制备软磁材料成品
将热处理后的非晶薄带氢破后球磨至粒径为15μm的软磁颗粒,然后置于搅拌机中,将质量比为4:3:36的三羟甲基丙烷、硬脂酸、氧化钕混合,共同在75℃下搅拌混合2.0小时,加入浓度为30%的乙酸,303转/分搅拌分散55分钟,加入氟化铵,搅拌混合23分钟,加入预混液,500转/分搅拌分散0.9小时,70℃下干燥40分钟,进行研磨,研磨到1200目,得到预烧料,用压机将颗粒料压制为生坯,以35℃/min的速度升温至1400℃,在25%的氧分压下保温烧结7h,将得到的产品放入真空环境下,急冷保压3h。
进一步地,在所述急冷保压中,冷却速度调节为1.5×105K/s以上3.2×105K/s以下。
对实施例1-3所准备的材料的分散性以及最终制品的质量进行了检测,发现实施例2所准备的材料磁性最强,在产品制造过程中,同时中间层中的居里点较低,能够根据变压器绕组温升来设定,防止过热,当绕组过热,超过中间层的居里点,使得中间层失磁,变压器停止工作,能够防止变压器过热,同时E型磁芯的性能检测如下,远超常规磁芯。
Claims (1)
1.一种变压器的E型磁芯的制造方法,其特征在于:该E型磁芯为增材制造的E型磁芯,磁芯结构为堆叠层,所述堆叠层为夹心层,所述夹心层中心为中间层,所述中间层为软磁性相,所述软磁性相外包裹硬磁性相,所述软磁性相包含如下金属,分子数量比为Co:Si:Mn:La:B:Hf为30.0-35.0:6.0-7.0:3.0-4.0:3.0-6.0:8.4-9.2:6.7-8.9,其余为Fe和辅助材料,所述辅助材料包括成分按重量百分比计的以下组分:Ce:0.2-0.8%,Pr:0.4-0.9%,Sm:1.2-3.4%,Dy:5.4-11.2%,Pm:0.6-0.8%,其余为La;
所述硬磁性相由R2Fe14B型化合物构成;
所述软磁性相主要含有α-Fe相和居里点为790℃以上1130℃以下的结晶相;
上述磁芯的软磁性相的制备方法如下:
(1)熔铸合金
将纯度大于99.9%的原料Fe、Co、Si、Mn、La、B,Hf按合金成分以原子百分比称量并配料,将称好的Fe、Co、Hf放入感应加热熔炉中,抽真空至10-5Pa以上,充入高纯氩气至炉内气压为1.0×105Pa,之后再通电加热,将Fe、Co、Hf融化后,依次加入Mn、La、Si和B,反复熔炼6-10次以获得母合金熔液,在氩气保护下铸坯,得到母合金铸锭;
(2)制备非合金带
将母合金锭熔炼到1120-1350℃,并采用单辊法以60-75m/s的辊速制备出的宽10-15mm、厚度在10-25μm的非晶薄带;
(3)热处理
将非晶薄带装入热处理炉中,在真空低于1.0×10-3Pa或惰性气体氛围中,在450-550℃保温20-35分钟,最后淬火冷却;
(4)制备软磁材料成品
将热处理后的非晶薄带氢破后球磨至粒径为10-15μm的软磁颗粒,然后置于搅拌机中,将质量比为3-4:1-3:24-36的三羟甲基丙烷、硬脂酸、氧化钕混合,共同在46-75℃下搅拌混合1.5-2.0小时,加入浓度为15-30%的乙酸,220-303转/分搅拌分散40-55分钟,加入氟化铵,搅拌混合12-23分钟,加入预混液,400-500转/分搅拌分散0.5-0.9小时,60-70℃下干燥30-40分钟,进行研磨,研磨到800-1200目,得到预烧料,用压机将颗粒料压制为生坯,以20-35℃/min的速度升温至1350-1400℃,在15-25%的氧分压下保温烧结6-7h,将得到的产品放入真空环境下,急冷保压2-3h;以上所述急冷保压中,冷却速度调节为1.5×105K/s以上3.2×105K/s以下。
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