CN105801100A - 多功能开关电源变压器磁芯及其制备方法 - Google Patents

多功能开关电源变压器磁芯及其制备方法 Download PDF

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CN105801100A
CN105801100A CN201610151892.4A CN201610151892A CN105801100A CN 105801100 A CN105801100 A CN 105801100A CN 201610151892 A CN201610151892 A CN 201610151892A CN 105801100 A CN105801100 A CN 105801100A
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magnetic core
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multifunction switch
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常国青
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CHANGSHU ZHONGYING ELECTRONIC Co Ltd
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Abstract

本发明公开了一种多功能开关电源变压器磁芯及其制备方法，所述磁芯包括第一组分和第二组分；第一组分的成分及其摩尔百分比为：Fe3O4、Mn3O4和ZnO；所述第二组分的成分包括CaCO3、V2O5、Bi2O3、Nb2O5、BaCO3、Al2O3和CuO。所述制备方法包括如下步骤：（1）称料；（2）一次研磨混合；（3）预烧；（4）二次研磨混合；（5）干燥；（6）造粒、制坯；（7）烧结成型；（8）后处理。本发明通过合理的配方设计和科学的预烧及烧结温度的控制，赋予磁芯优异的高磁导率、低功耗特性和低失真性能。所制备的磁芯表面光洁，综合性能优异，完全适用于大功率开关电源变压器对磁芯的要求，应用前景广阔。

Description

多功能开关电源变压器磁芯及其制备方法
技术领域
本发明涉及锰锌软磁铁氧体材料领域，特别是涉及一种多功能开关电源变压器磁芯及其制备方法。
背景技术
软磁铁氧体磁芯作为一种重要的基础功能材料,具有高饱和磁通密度、高频率特性和超低功耗等特点，被广泛用于各类视听设备、电光源、通讯和其他各种控制电路中作为、开关电源等电子工业中作为开关电源变压器磁芯，为软磁铁氧体的应用打开了广阔的市场。
随着电子元件的日趋小型化，整机设备向高频、高速、高组装密度发展，客户对软磁铁氧体材料的要求，已经从单纯的高饱和磁通密度要求向综合性能方面转移，不但要求材料具有高磁导率、低失真特性，还要求材料具有高频、低损耗特性、抗开裂、表面光滑无毛刺等功能要求和质量要求。因此，多用或多功能材料已经成为当前高磁导率铁氧体的市场发展趋势，也是企业向产业化发展的要求。
发明内容
本发明主要解决的技术问题是提供一种多功能开关电源变压器磁芯及其制备方法，制备的磁芯材料具有高磁导率、低功耗、低失真和高的表面光滑特性，密度高、抗开裂。
为解决上述技术问题，本发明采用的一个技术方案是：提供一种多功能开关电源变压器磁芯，包括第一组分和第二组分；所述第一组分的成分及其摩尔百分比为：Fe3O458～66%、Mn3O422～28%，其余为ZnO，Fe3O4、Mn3O4和ZnO的总量为100%；所述第二组分的成分包括CaCO3、V2O5、Bi2O3、Nb2O5、BaCO3、Al2O3和CuO；以所述第一组分的总质量为基础，按质量百分比，以氧化物计算，所述第二组分中各成分的量为：CaCO30.015～0.15%、V2O50.025～0.085%、Bi2O30.03～0.3%、Nb2O50.005～0.05%、BaCO30.01～0.1%、Al2O30.008～0.08%、CuO0.04～0.09%。
为解决上述技术问题，本发明采用的另一个技术方案是：提供一种多功能开关电源变压器磁芯的制备方法，包括如下步骤：
（1）称料：按配方量准确称取所述第一组分和第二组分中的各原料备用；
（2）一次研磨混合：将步骤（1）中称取的第一组分置于行星研磨机内，以120～150转/min的速率混合研磨10～20min，得到平均粒径为0.8～1.0μm的混合物料；
（3）预烧：将步骤（2）中得到的混合物料置入预烧炉中，在680～1050℃下预烧1～4h，然后随炉降温至温度低于180℃，出炉，得到预烧料；
（4）二次研磨混合：将步骤（1）中称取的第二组分和步骤（3）中得到的预烧料加入球磨罐中，按照物料：球：水的质量比为1～2：3～5：2的比例加入蒸馏水，混合湿磨，得到混合物料；
（5）干燥：将步骤（4）中研磨后的混合物料压滤去水，将得到的滤饼用微波干燥箱干燥至含水率小于10%；
（6）造粒、制坯：向步骤（5）中干燥后的混合物料中加入粘结胶水，搅拌混合均匀后用喷雾造粒机喷雾造粒，再将所得粒料放入磁芯模具中压制成磁芯坯料；
（7）烧结成型：将步骤（6）中得到的磁芯配料连通模具放入带程序升温功能的惰性气体气氛的窑炉中烧结，得到粗品多功能开关电源变压器磁芯；
（8）后处理：将步骤（7）中得到的粗品多功能开关电源变压器磁芯放入光整机中进行光整研磨30～40min，得到成品多功能开关电源变压器磁芯。
在本发明一个较佳实施例中，所述步骤（4）中，所述混合湿磨时间为5～6h，湿磨后物料的平均粒径为0.5～0.7μm。
在本发明一个较佳实施例中，所述步骤（6）中，所述粘结胶水为质量浓度为8～10%的PVA水溶液。
在本发明一个较佳实施例中，所述步骤（7）中，所述烧结工艺为：以100℃/h的升温速率从室温加热到500～600℃，再以300℃/h的速率继续升温至在1000～1100℃，保温烧结1～2h，最后以500℃/h的速率继续升温至1400～1450℃，恒温烧结3～4h，随后在惰性气氛下自然降温冷却至200℃，出炉冷至室温。
在本发明一个较佳实施例中，所述惰性气体为氮气、氢气、氦气或氩气中的至少一种。
本发明的有益效果是：本发明一种多功能开关电源变压器磁芯及其制备方法，通过合理的配方设计和科学的预烧及烧结温度的控制，赋予磁芯优异的高磁导率、低功耗特性和低失真性能。所制备的磁芯表面光洁，无开裂现象，综合性能优异，完全适用于大功率开关电源变压器对磁芯的要求，应用前景广阔。
具体实施方式
下面对本发明的较佳实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解，从而对本发明的保护范围做出更为清楚明确的界定。
本发明实施例包括：
实施例1
一种多功能开关电源变压器磁芯，包括第一组分和第二组分；所述第一组分的成分及其摩尔百分比为：Fe3O458%、Mn3O428%，ZnO20%；所述第二组分的成分包括CaCO3、V2O5、Bi2O3、Nb2O5、BaCO3、Al2O3和CuO；以所述第一组分的总质量为基础，按质量百分比，以氧化物计算，所述第二组分中各成分的量为：CaCO30.015%、V2O50.025%、Bi2O30.03%、Nb2O50.05%、BaCO30.1%、Al2O30.08%、CuO0.04%。
上述多功能开关电源变压器磁芯的制备方法，包括如下步骤：
（1）称料：按配方量准确称取所述第一组分和第二组分中的各原料备用；
（2）一次研磨混合：将步骤（1）中称取的第一组分置于行星研磨机内，以120转/min的速率混合研磨20min，得到平均粒径为0.8～1.0μm的混合物料；
（3）预烧：将步骤（2）中得到的混合物料置入预烧炉中，在680～800℃下预烧1～2，再在800～1050℃下预烧1～2h，然后随炉降温至温度低于180℃，出炉，得到预烧料；适当的预烧温度和低的出炉温度可以有效预防烧结开裂；
（4）二次研磨混合：将步骤（1）中称取的第二组分和步骤（3）中得到的预烧料加入球磨罐中，按照物料：球：水的质量比为1：3：2的比例加入蒸馏水，混合湿磨，得到混合物料；所述混合湿磨时间为5h，湿磨后物料的平均粒径为0.5～0.7μm。
（5）干燥：将步骤（4）中研磨后的混合物料压滤去水，将得到的滤饼用微波干燥箱干燥至含水率小于10%；
（6）造粒、制坯：向步骤（5）中干燥后的混合物料中加入粘结胶水，搅拌混合均匀后用喷雾造粒机喷雾造粒，再将所得粒料放入磁芯模具中压制成磁芯坯料；所述粘结胶水为质量浓度为8%的PVA水溶液。
（7）烧结成型：将步骤（6）中得到的磁芯配料连通模具放入带程序升温功能的惰性气体气氛的窑炉中烧结，得到粗品多功能开关电源变压器磁芯；所述烧结工艺为：以100℃/h的升温速率从室温加热到500℃，再以300℃/h的速率继续升温至在1000℃，保温烧结2h，最后以500℃/h的速率继续升温至1400～1450℃，恒温烧结4h，随后在惰性气氛下自然降温冷却至200℃，出炉冷至室温；其中，所述惰性气体为氮气和氦气以任意比例混合的混合气体；
（8）后处理：将步骤（7）中得到的粗品多功能开关电源变压器磁芯放入光整机中进行光整研磨30～40min，以去除表面的毛刺，得到成品多功能开关电源变压器磁芯。
实施例2
一种多功能开关电源变压器磁芯，包括第一组分和第二组分；所述第一组分的成分及其摩尔百分比为：Fe3O466%、Mn3O422%，ZnO12%；所述第二组分的成分包括CaCO3、V2O5、Bi2O3、Nb2O5、BaCO3、Al2O3和CuO；以所述第一组分的总质量为基础，按质量百分比，以氧化物计算，所述第二组分中各成分的量为：CaCO30.15%、V2O50.085%、Bi2O30.3%、Nb2O50.005%、BaCO30.01%、Al2O30.008%、CuO0.09%。
上述多功能开关电源变压器磁芯的制备方法，包括如下步骤：
（1）称料：按配方量准确称取所述第一组分和第二组分中的各原料备用；
（2）一次研磨混合：将步骤（1）中称取的第一组分置于行星研磨机内，以150转/min的速率混合研磨10min，得到平均粒径为0.8～1.0μm的混合物料；
（3）预烧：将步骤（2）中得到的混合物料置入预烧炉中，在680～800℃下预烧1～3h，再在800～1050℃下预烧1h，然后随炉降温至温度低于180℃，出炉，得到预烧料；
（4）二次研磨混合：将步骤（1）中称取的第二组分和步骤（3）中得到的预烧料加入球磨罐中，按照物料：球：水的质量比为2：5：2的比例加入蒸馏水，混合湿磨，得到混合物料；所述混合湿磨时间为6h，湿磨后物料的平均粒径为0.5～0.7μm。
（5）干燥：将步骤（4）中研磨后的混合物料压滤去水，将得到的滤饼用微波干燥箱干燥至含水率小于10%；
（6）造粒、制坯：向步骤（5）中干燥后的混合物料中加入粘结胶水，搅拌混合均匀后用喷雾造粒机喷雾造粒，再将所得粒料放入磁芯模具中压制成磁芯坯料；所述粘结胶水为质量浓度为10%的PVA水溶液。
（7）烧结成型：将步骤（6）中得到的磁芯配料连通模具放入带程序升温功能的惰性气体气氛的窑炉中烧结，得到粗品多功能开关电源变压器磁芯；所述烧结工艺为：以100℃/h的升温速率从室温加热到600℃，再以300℃/h的速率继续升温至在1100℃，保温烧结1h，最后以500℃/h的速率继续升温至1400～1450℃，恒温烧结3h，随后在惰性气氛下自然降温冷却至200℃，出炉冷至室温；所述惰性气体为氢气和氩气以任意比例混合的混合气体；
（8）后处理：将步骤（7）中得到的粗品多功能开关电源变压器磁芯放入光整机中进行光整研磨30～40min，得到成品多功能开关电源变压器磁芯。
上述方法所制备的多功能开关电源变压器磁芯，其表面光滑，经测试，其磁通密度为600～800mT，100℃，50KHz下的功率损耗为37～45kw/m3。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (6)

1.一种多功能开关电源变压器磁芯，其特征在于，包括第一组分和第二组分；所述第一组分的成分及其摩尔百分比为：Fe3O458～66%、Mn3O422～28%，其余为ZnO，Fe3O4、Mn3O4和ZnO的总量为100%；所述第二组分的成分包括CaCO3、V2O5、Bi2O3、Nb2O5、BaCO3、Al2O3和CuO；以所述第一组分的总质量为基础，按质量百分比，以氧化物计算，所述第二组分中各成分的量为：CaCO30.015～0.15%、V2O50.025～0.085%、Bi2O30.03～0.3%、Nb2O50.005～0.05%、BaCO30.01～0.1%、Al2O30.008～0.08%、CuO0.04～0.09%。
2.一种如权利要求1所述的多功能开关电源变压器磁芯的制备方法，其特征在于，包括如下步骤：
（1）称料：按配方量准确称取所述第一组分和第二组分中的各原料备用；
（2）一次研磨混合：将步骤（1）中称取的第一组分置于行星研磨机内，以120～150转/min的速率混合研磨10～20min，得到平均粒径为0.8～1.0μm的混合物料；
（3）预烧：将步骤（2）中得到的混合物料置入预烧炉中，在680～1050℃下预烧1～4h，然后随炉降温至温度低于180℃，出炉，得到预烧料；
（4）二次研磨混合：将步骤（1）中称取的第二组分和步骤（3）中得到的预烧料加入球磨罐中，按照物料：球：水的质量比为1～2：3～5：2的比例加入蒸馏水，混合湿磨，得到混合物料；
（5）干燥：将步骤（4）中研磨后的混合物料压滤去水，将得到的滤饼用微波干燥箱干燥至含水率小于10%；
（6）造粒、制坯：向步骤（5）中干燥后的混合物料中加入粘结胶水，搅拌混合均匀后用喷雾造粒机喷雾造粒，再将所得粒料放入磁芯模具中压制成磁芯坯料；
（7）烧结成型：将步骤（6）中得到的磁芯配料连通模具放入带程序升温功能的惰性气体气氛的窑炉中烧结，得到粗品多功能开关电源变压器磁芯；
（8）后处理：将步骤（7）中得到的粗品多功能开关电源变压器磁芯放入光整机中进行光整研磨30～40min，得到成品多功能开关电源变压器磁芯。
3.根据权利要求2所述的多功能开关电源变压器磁芯的制备方法，其特征在于，所述步骤（4）中，所述混合湿磨时间为5～6h，湿磨后物料的平均粒径为0.5～0.7μm。
4.根据权利要求2所述的多功能开关电源变压器磁芯的制备方法，其特征在于，所述步骤（6）中，所述粘结胶水为质量浓度为8～10%的PVA水溶液。
5.根据权利要求2所述的多功能开关电源变压器磁芯的制备方法，其特征在于，所述步骤（7）中，所述烧结工艺为：以100℃/h的升温速率从室温加热到500～600℃，再以300℃/h的速率继续升温至在1000～1100℃，保温烧结1～2h，最后以500℃/h的速率继续升温至1400～1450℃，恒温烧结3～4h，随后在惰性气氛下自然降温冷却至200℃，出炉冷至室温。
6.根据权利要求2或5所述的多功能开关电源变压器磁芯的制备方法，其特征在于，所述惰性气体为氮气、氢气、氦气或氩气中的至少一种。
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