CN106348740A - 一种网络变压器用高磁导率高q值铁氧体磁芯及制备方法 - Google Patents

一种网络变压器用高磁导率高q值铁氧体磁芯及制备方法 Download PDF

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CN106348740A
CN106348740A CN201610654616.XA CN201610654616A CN106348740A CN 106348740 A CN106348740 A CN 106348740A CN 201610654616 A CN201610654616 A CN 201610654616A CN 106348740 A CN106348740 A CN 106348740A
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ferrite core
value
permeability
ball
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刘丹莉
李常青
胡庚
赖敏敏
贾璐
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SHENZHEN MICROGATE TECHNOLOGY Co Ltd
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Abstract

一种网络变压器用高磁导率高Q值铁氧体磁芯及制备方法，包括主成分和辅助成分，主成分包括按照摩尔比为：(48‑50)％Fe2O3、(15‑20)％NiO、(25‑30)％ZnO、(3.5‑6)％CuO，辅助成分包括(0.1‑0.35)wt％V2O5、(0.05‑0.15)wt％Co2O3和(0.01‑0.05)wt％CaCO3。本发明的铁氧体材料在保持较高初始磁导率上，具有高Q值、超低的相对损耗因子，较高的饱和磁感应强度和居里温度，能够满足网络变压器对铁氧体磁芯的性能要求。本发明的铁氧体磁芯的初始磁导率为2000‑4500，饱和磁感应强度为300+/‑5％，居里温度100℃，Q值大于150。

Description

一种网络变压器用高磁导率高Q值铁氧体磁芯及制备方法
技术领域
本发明公开一种铁氧体磁芯及制备方法，特别是一种网络变压器用高磁导率高Q值铁氧体磁芯及制备方法。
背景技术
随着通信技术的不断发展，网络变压器在人们生活中的应用也越来越多，网络变压器是一种新兴的电子产品，具体有T1/E1隔离变压器；ISDN/ADSL接口变压器；VDSL高通/低通滤波器模块、接口变压器；T3/E3、SDH、64KBPS接口变压器；10/100BASE、1000BASE-TX网络滤波器；RJ45集成变压器；还可根据客户需要设计专用变压器。网络变压器主要应用于：高性能数字交换机；SDH/ATM传输设备；ISDN、ADSL、VDSL、POE受电设备综合业务数字设备；FILT光纤环路设备；以太网交换机等等。由于网络变压器的特殊用途，使其要求网络变压器的磁芯应具有较高初始磁导率上，具有高Q值以及超低的相对损耗因子等优越的性能，常规的磁性铁氧体往往无法满足网络变压器的性能要求。
发明内容
针对上述提到的现有技术中的磁性铁氧体性能无法满足网络变压器需要的缺点，本发明提供一种网络变压器用高磁导率高Q值铁氧体磁芯及制备方法，其采用特殊的物料配比，使生产的铁氧体磁芯具有高磁导率、高Q值的特性。
本发明解决其技术问题采用的技术方案是：一种网络变压器用高磁导率高Q值铁氧体磁芯，铁氧体磁芯包括主成分和辅助成分，主成分包括按照摩尔比为：(48-50)％Fe2O3、(15-20)％NiO、(25-30)％ZnO、(3.5-6)％CuO，辅助成分包括加入量为其与主成分相比的重量比为(0.1-0.35)wt％V2O5、(0.05-0.15)wt％Co2O3和(0.01-0.05)wt％CaCO3。
一种用于网络变压器用高磁导率高Q值软磁铁氧体磁芯的制备方法，制备方法包括下述步骤：
(1)配料：按照摩尔百分比称取主成分的配料：(48-50)％Fe2O3、(25-30)％NiO、(20-25)％ZnO、(3.5-6)％CuO，进行配料；
(2)湿法球磨：将所得的配料与弥散剂加入到球磨罐中，以250-280转/min的转速在球磨罐中混合湿磨4-6h，得到混合浆料，将混合浆料用压滤机脱水，再放入150℃～200℃烘箱内干燥至含水量为2-5％，去除球体；
(3)预烧：将混合粉料进行预烧，预烧温度控制在850～920℃，预烧时间2.5-4.5h，得预烧料；
(4)二次球磨：称取预烧料重量百分比的辅助成分：(0.1-0.35)wt％V2O5、(0.05-0.15)wt％Co2O3和(0.01-0.05)wt％CaCO3，与预烧料一起加入球磨罐中，加入等质量去离子水进行二次球磨，按照料：水：球的重量比为1:1:3的配比进行二次球磨，转速250-280转/min球磨时间4-6h；
(5)造粒成型：在二次球磨中加入一定比例的PVA溶液，混合均匀后进行压力式喷雾造粒，颗粒粒径60-220μm，最后压制成型；
(6)烧结：在空气气氛中烧结处理，梯度升温制度，采用4-5℃/min的升温速度由室温升至450℃，并保温2h；采用4-5℃/min的升温速度升至800℃，并保温1.5h；然后采用4-5℃/min的升温速度升至1080-1200℃，并保温2-4h。
本发明解决其技术问题采用的技术方案进一步还包括：
所述的弥散剂为去离子水。
所述的步骤(2)中，湿法球磨时按照主成分配料：水：球的重量比为1：1：3的配比。
所述的步骤(3)中，预烧时将混合粉料置于马弗炉中进行预烧。
所述的步骤(5)中，造粒成型时颗粒中PVA质量百分比为0.73％。
本发明的有益效果是：本发明的铁氧体材料在保持较高初始磁导率上，具有高Q值、超低的相对损耗因子，较高的饱和磁感应强度和居里温度，能够满足网络变压器对铁氧体磁芯的性能要求。本发明的铁氧体磁芯的初始磁导率为2000-4500，饱和磁感应强度为300+/-5％，居里温度100℃，Q值大于150。
具体实施方式
本实施例为本发明优选实施方式，其他凡其原理和基本结构与本实施例相同或近似的，均在本发明保护范围之内。
本发明主要保护一种用于网络变压器用高磁导率高Q值软磁铁氧体磁芯，其成分包括有主成分和辅助成分，其中，主成分为Fe2O3、NiO、ZnO和CuO，主成分为本发明中的铁氧体磁芯的主要组成基材，本实施例中，主成分中Fe2O3、NiO、ZnO和CuO按照摩尔比为：(48-50)％Fe2O3、(15-20)％NiO、(25-30)％ZnO、(3.5-6)％CuO，主成分中的各物料的比值为其在主成分中物料配比；辅助成分包括V2O5、Co2O3和CaCO3，辅助成分主要起到调节性能的目的，辅助成分加入量为其与主成分相比的重量比为(0.1-0.35)wt％V2O5(即其占主成分总重量的0.1％-0.35％)、(0.05-0.15)wt％Co2O3、(0.01-0.05)wt％CaCO3。
本发明同时保护一种用于网络变压器用高磁导率高Q值软磁铁氧体磁芯的制备方法，其主要包括配料、湿法球磨、预烧、二次球磨、造粒成型以及烧结等步骤，具体如下：
(1)配料：按照摩尔百分比称取主成分的配料：(48-50)％Fe2O3、(25-30)％NiO、(20-25)％ZnO、(3.5-6)％CuO，进行配料；
(2)湿法球磨：将所得的配料与弥散剂加入到球磨罐中，本实施例中，采用的弥散剂为去离子水，按照主成分配料：水：球的重量比为1：1：3的配比，以250-280转/min的转速在球磨罐中混合湿磨4-6h，得到混合浆料，将混合浆料用压滤机脱水，再放入150℃～200℃烘箱内干燥至含水量(重量百分比)为2-5％，然后去除球体；
(3)预烧：将混合粉料置于马弗炉中进行预烧，预烧温度控制在850～920℃，预烧时间2.5-4.5h，得预烧料。
(4)二次球磨：称取预烧料重量百分比的辅助成分(即其占预烧料的重量百分比)：(0.1-0.35)wt％V2O5、(0.05-0.15)wt％Co2O3和(0.01-0.05)wt％CaCO3，与预烧料一起加入球磨罐中，加入等质量(与预烧料和辅助成分的总质量相等)去离子水，按照料：水：球的重量比为1：1：3的配比进行二次球磨，转速250-280转/min球磨时间4-6h。
(5)造粒成型：在二次球磨中加入一定比例的PVA溶液(溶液中PVA质量百分比为0.73％左右)，混合均匀后进行压力式喷雾造粒，颗粒粒径60-220μm，最后压制成型。
(6)烧结：在空气气氛中烧结处理，梯度升温制度，采用4-5℃/min的升温速度由室温升至450℃，并保温2h；采用4-5℃/min的升温速度升至800℃，并保温1.5h；然后采用4-5℃/min的升温速度升至1080-1200℃，并保温2-4h。
本发明中的添加剂为V2O5与Co2O3组合和CaCO3，能同时达到在低温下烧结降低损耗，提高使用频率，又能保持磁导率下降幅度小。采用本发明生产的铁氧体磁芯的初始磁导率为2000-4500，饱和磁感应强度为300+/-5％，居里温度100℃，Q值大于150。

Claims (6)

1.一种网络变压器用高磁导率高Q值铁氧体磁芯，其特征是：所述的铁氧体磁芯包括主成分和辅助成分，主成分包括按照摩尔比为：(48-50)％Fe2O3、(15-20)％NiO、(25-30)％ZnO、(3.5-6)％CuO，辅助成分包括加入量为其与主成分相比的重量比为(0.1-0.35)wt％V2O5、(0.05-0.15)wt％Co2O3和(0.01-0.05)wt％CaCO3。
2.一种用于网络变压器用高磁导率高Q值软磁铁氧体磁芯的制备方法，其特征是：所述的制备方法包括下述步骤：
(1)配料：按照摩尔百分比称取主成分的配料：(48-50)％Fe2O3、(25-30)％NiO、(20-25)％ZnO、(3.5-6)％CuO，进行配料；
(2)湿法球磨：将所得的配料与弥散剂加入到球磨罐中，以280转/min的转速在球磨罐中混合湿磨6h，得到混合浆料，将混合浆料用压滤机脱水，再放入150℃～200℃烘箱内干燥至含水量为2-5％；
(3)预烧：将混合粉料进行预烧，预烧温度控制在850～920℃，预烧时间2.5-4.5h，得预烧料；
(4)二次球磨：称取预烧料重量百分比的辅助成分：(0.1-0.35)wt％V2O5、(0.05-0.15)wt％Co2O3和(0.01-0.05)wt％CaCO3，与预烧料一起加入球磨罐中，加入等质量去离子水进行二次球磨，球磨时间6h；
(5)造粒成型：在二次球磨中加入一定比例的PVA溶液，混合均匀后进行压力式喷雾造粒，颗粒粒径60-220μm，最后压制成型；
(6)烧结：在空气气氛中烧结处理，梯度升温制度，采用4-5℃/min的升温速度由室温升至450℃，并保温2h；采用4-5℃/min的升温速度升至800℃，并保温1.5h；然后采用4-5℃/min的升温速度升至1080-1200℃，并保温2-4h。
3.根据权利要求2所述的制备方法，其特征是：所述的弥散剂为去离子水。
4.根据权利要求2所述的制备方法，其特征是：所述的步骤(2)中，湿法球磨时按照主成分配料：水：球的重量比为1：1：3的配比。
5.根据权利要求2所述的制备方法，其特征是：所述的步骤(3)中，预烧时将混合粉料置于马弗炉中进行预烧。
6.根据权利要求2所述的制备方法，其特征是：所述的步骤(5)中，造粒成型时颗粒中PVA质量百分比为0.73％。
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