CN106830916B - 一种锰锌功率铁氧体材料及其元件制备方法 - Google Patents

一种锰锌功率铁氧体材料及其元件制备方法 Download PDF

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CN106830916B
CN106830916B CN201611174772.2A CN201611174772A CN106830916B CN 106830916 B CN106830916 B CN 106830916B CN 201611174772 A CN201611174772 A CN 201611174772A CN 106830916 B CN106830916 B CN 106830916B
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王宏
曾伟鑫
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Jiangxi Sunshine Electronic Technology Co Ltd
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Abstract

本发明公开了一种锰锌功率铁氧体材料及其元件制备方法，一种锰锌软磁铁氧体材料，该材料包括主料和辅料，所述主料按摩尔百分比包括：51.5～53.5mol%的Fe2O3、6.5～8.5mol%的ZnO以及余量的Mn3O4，所述辅料为助熔剂、改性剂或增韧剂，其按照所述软磁铁氧体材料的重量计包括：0.03～0.05wt% V2O5、0.01～0.03wt% Nb2O3、0.02～0.04wt% CaCO3、0.05～0.10wt% ZrO2、0.10～0.20wt% Y2O3，其有效提高了磁芯元件的机械强度和韧性。改善了软磁铁氧体磁芯元件的脆性，减少运输时的破损及器件自动化装配中的应用断裂问题。

Description

一种锰锌功率铁氧体材料及其元件制备方法
技术领域
本发明涉及属于氧化物磁性材料技术领域，尤其涉及一种锰锌功率铁氧体材料及其元件制备方法。
背景技术
软磁铁氧体材料作为电子信息产业的基础功能材料自二十世纪60年代研发成功以来，已经走过了材料创新、性能开发、工艺完善三个阶段，现已步入全面应用、提高阶段。近年来由于开关电源、射频通讯、抗电磁干扰、高清晰度电视、新型节能照明及环保等新兴产业的发展，加上家电产业及计算机、程控交换机等工业长盛不衰，世界软磁材料的应用范围及市场需求量一直保持高速增长，其中锰锌功率软磁铁氧体材料及其元件的用量最大，应用最广。
但是作为基础功能材料，铁氧体材料的元件脆性问题一直是行业难题。随着电子产品的小型化、扁平化和国内运输行业暴力作业问题，铁氧体磁芯元件破损客诉非常突出。同时，由于近几年人工成本大幅上升，很多电子企业都开始采用自动化磁芯元件装配设备。这都对铁氧体磁芯元件的机械强度和韧性提出了更高的要求。
发明内容
针对现有技术中存在的不足，本发明的目的是在于提供一种锰锌功率铁氧体材料及其元件制备方法，其有效提高了磁芯元件的机械强度和韧性。改善了软磁铁氧体磁芯元件的脆性，减少运输时的破损及器件自动化装配中的应用断裂问题。
为实现上述目的，本发明通过以下技术方案予以实现：
一种锰锌软磁铁氧体材料，该材料包括主料和辅料，所述主料按摩尔百分比包括：51.5～53.5mol%的Fe2O3、6.5～8.5mol%的ZnO以及余量的Mn3O4，所述辅料为助熔剂、改性剂或增韧剂，其按照所述软磁铁氧体材料的重量计包括：0.03～0.05wt%V2O5、0.01～0.03wt%Nb2O3、0.02～0.04wt% CaCO3、0.05～0.10wt% ZrO2、0.10～0.20wt%Y2O3。
一种锰锌软磁铁氧体材料的制备方法，该方法步骤如下：
（1）粉体制造：
A、配料：将主成分按比例分别加入球磨机，用氧化物湿法工艺进行均匀混合;
B、一次喷雾造粒：将球磨后搅拌均匀的混合料，加入喷雾塔内，进行喷雾造粒;
C、预烧：将喷雾好的一次料用回转窑在780℃～920℃的温度条件下预烧，预烧时间45～60min。预烧时用富氧环境，采用鼓风机向窑内通入空气，使主成分预合成并提高磁化度;
D、掺杂：将预烧料放入砂磨机中，并添加改性剂，进行砂磨，注意控制浆料粒度为1.2～1.6μm;
E、二次喷雾造粒：用喷雾干燥塔进行造粒，使颗粒目数分布在80～160目之间；
（2）冲压成型：
A、在坯件的上下压制方向边角设计倒角，角度范围可以在30度～45度，其目的在于提高坯件的成型密度和强度；
B、在坯件的侧面内外拐角设计工艺圆角，范围在R0.2～R0.65。其目的在于分散应力，改善磁芯元件强度，减少坯件及成品边角碰撞破损；
（3）低温烧结：
A、生坯烧结前，先在露天放置24～72小时，使坯件在空气中膨胀，释放其内部应力，并使坯件内部的颗粒自由舒展；
B、烧结时，采用1320～1350度，保温4～6小时；还原气氛O2含量3～5%，阻止ZnO挥发，使磁芯元件尽可能达到细晶、高密度的内部结构。
综上所述，本发明与现有技术相比，（1）有效提高锰锌功率软磁铁氧体材料及其磁芯元件的机械强度，增强韧性。（2）改善软磁铁氧体磁芯元件的脆性，减少运输时的破损及器件自动化装配中的应用断裂问题。（3）在提高磁芯元件高机械强度的同时，使锰锌功率软磁铁氧体材料具有良好的电磁性能，并保证磁芯元件的尺寸、外观。
具体实施方式
下面结合具体实施方式对发明作进一步的说明：
一种锰锌软磁铁氧体材料，该材料包括主料和辅料，所述主料按摩尔百分比包括：51.5～53.5mol%的Fe2O3、6.5～8.5mol%的ZnO以及余量的Mn3O4，所述辅料为助熔剂、改性剂或增韧剂，其按照所述软磁铁氧体材料的重量计包括：0.03～0.05wt%V2O5、0.01～0.03wt%Nb2O3、0.02～0.04wt% CaCO3、0.05～0.10wt% ZrO2、0.10～0.20wt%Y2O3。
一种如权利要求1所述的锰锌软磁铁氧体材料的制备方法，该方法步骤如下：
（1）粉体制造：
A、配料：将主成分按比例分别加入球磨机，用氧化物湿法工艺进行均匀混合;
B、一次喷雾造粒：将球磨后搅拌均匀的混合料，加入喷雾塔内，进行喷雾造粒;
C、预烧：将喷雾好的一次料用回转窑在780℃～920℃的温度条件下预烧，预烧时间45～60min。预烧时用富氧环境，采用鼓风机向窑内通入空气，使主成分预合成并提高磁化度;
D、掺杂：将预烧料放入砂磨机中，并添加改性剂，进行砂磨，注意控制浆料粒度为1.2～1.6μm;
E、二次喷雾造粒：用喷雾干燥塔进行造粒，使颗粒目数分布在80～160目之间；
（4）冲压成型：
A、在坯件的上下压制方向边角设计倒角，角度范围可以在30度～45度，其目的在于提高坯件的成型密度和强度；
B、在坯件的侧面内外拐角设计工艺圆角，范围在R0.2～R0.65。其目的在于分散应力，改善磁芯元件强度，减少坯件及成品边角碰撞破损；
（5）低温烧结：
A、生坯烧结前，先在露天放置24～72小时，使坯件在空气中膨胀，释放其内部应力，并使坯件内部的颗粒自由舒展；
B、烧结时，采用1320～1350度，保温4～6小时；还原气氛O2含量3～5%，阻止ZnO挥发，使磁芯元件尽可能达到细晶、高密度的内部结构。
实施例一：
一种锰锌软磁铁氧体材料的制备方法，该方法步骤如下：
（1）、粉体制造：
A、配料：将主成分分别加入球磨机用氧化物湿法工艺进行均匀混合，所述主成分由52.3%的Fe2O3、6.8mol%的ZnO以及余量的Mn3O4组成，主成分的含量为100mol%。
B、一次喷雾造粒：将球磨后搅拌均匀的混合料，加入喷雾塔内，进行喷雾造粒。
C、预烧：将喷雾好的一次料用回转窑在850℃的温度条件下预烧，预烧时间45min。预烧时用鼓风机向窑内通入空气，使主成分预合成，尽量提高磁化度。
D、掺杂：将预烧料放入砂磨机中，并添加改性剂，进行砂磨，注意控制浆料粒度为1.3μm。掺杂为0.05wt%V2O5、0.03wt% Nb2O3、0.03wt% CaCO3、0.05wt% ZrO2、0.15wt%Y2O3。
E、二次喷雾造粒：用喷雾干燥塔进行造粒，使颗粒目数分布在80～160目之间。
（2）、冲压成型：
以常规的EE16磁芯元件为例。
A、在坯件的上下压制方向边角设计倒角，角度范围30度。
B、在坯件的侧面内外拐角设计工艺圆角，范围在R0.35。
（3）、低温烧结：
A、生坯烧结前，先在露天放置48小时，使坯件在空气中膨胀，释放其内部应力，并使坯件内部的颗粒自由舒展。
B、烧结时，采用1320度，保温6小时；还原气氛，O2含量4%。阻止ZnO挥发，使磁芯元件尽可能达到细晶、高密度的内部结构。
通过上述实施例制得的锰锌功率软磁铁氧体材料的特性如下：
序号 技术指标名称 测试条件 技术指标
1 初始磁导率μi 25℃ 2400±10%
2 功率损耗Pv（mw/cm3） 100KHz，200mT 350（100℃）
3 饱和磁通密度Bs(mT) 25℃；100℃ 520；400
4 居里温度Tc（℃） \ ≥230
5 磁芯密度d(g/cm3) \ 5.0
通过上述实施例制得的锰锌功率软磁铁氧体磁芯元件EE16的机械强度对比如下：
Figure DEST_PATH_IMAGE002
由此可见，本发明其不仅有效提高锰锌功率软磁铁氧体材料及其磁芯元件的机械强度，增强韧性。且改善软磁铁氧体磁芯元件的脆性，减少运输时的破损及器件自动化装配中的应用断裂问题。还在提高磁芯元件高机械强度的同时，使锰锌功率软磁铁氧体材料具有良好的电磁性能，并保证磁芯元件的尺寸、外观。
对于本领域的技术人员来说，可根据以上技术方案以及构思，做出其他各种相应的改变以及变形，而所有的这些改变和变形都应该属于本发明权利要求的保护范围之内。

Claims (1)

1.一种锰锌软磁铁氧体材料的制备方法，包括主料和辅料，其特征在于，所述主料按摩尔百分比包括： 52.3mol%的Fe2O3、6.8mol%的ZnO以及余量的Mn3O4，所述辅料按照所述软磁铁氧体材料的重量计为： 0.05wt%V2O5、0.03wt% Nb2O3、0.03wt% CaCO3、0.05wt% ZrO2、0.15wt%Y2O3；
具体的制备方法步骤如下：
（1）粉体制造：
A、配料：将主成分按比例分别加入球磨机，用氧化物湿法工艺进行均匀混合;
B、一次喷雾造粒：将球磨后搅拌均匀的混合料，加入喷雾塔内，进行喷雾造粒；
C、预烧：将喷雾好的一次料用回转窑在780℃～920℃的温度条件下预烧，预烧时间45～60min；
预烧时用富氧环境，采用鼓风机向窑内通入空气，使主成分预合成并提高磁化度；
D、掺杂：将预烧料放入砂磨机中，并添加改性剂，进行砂磨，注意控制浆料粒度为1.2～1.6μm；
E、二次喷雾造粒：用喷雾干燥塔进行造粒，使颗粒目数分布在80～160目之间；
（2）冲压成型：
A、在坯件的上下压制方向边角设计倒角，角度范围为30度～45度，其目的在于提高坯件的成型密度和强度；
B、在坯件的侧面内外拐角设计工艺圆角，范围在R0.2～R0.65；
其目的在于分散应力，改善磁芯元件强度，减少坯件及成品边角碰撞破损；
（3）低温烧结：
A、生坯烧结前，先在露天放置24～72小时，使坯件在空气中膨胀，释放其内部应力，并使坯件内部的颗粒自由舒展；
B、烧结时，采用1320～1350度，保温4～6小时；还原气氛O2含量3～5%，阻止ZnO挥发，使磁芯元件尽可能达到细晶、高密度的内部结构。
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