CN107892563A - 一种高摆折强度镍锌软磁磁芯的制造方法 - Google Patents
一种高摆折强度镍锌软磁磁芯的制造方法 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 24
- QELJHCBNGDEXLD-UHFFFAOYSA-N nickel zinc Chemical compound [Ni].[Zn] QELJHCBNGDEXLD-UHFFFAOYSA-N 0.000 title claims abstract description 21
- 238000005245 sintering Methods 0.000 claims abstract description 17
- 238000000227 grinding Methods 0.000 claims abstract description 16
- 239000003292 glue Substances 0.000 claims abstract description 13
- 238000005453 pelletization Methods 0.000 claims abstract description 11
- 239000000047 product Substances 0.000 claims abstract description 11
- 239000011265 semifinished product Substances 0.000 claims abstract description 11
- 239000004372 Polyvinyl alcohol Substances 0.000 claims abstract description 8
- 229920002451 polyvinyl alcohol Polymers 0.000 claims abstract description 8
- 238000007747 plating Methods 0.000 claims abstract description 7
- 239000002994 raw material Substances 0.000 claims abstract description 5
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims abstract description 4
- 238000005520 cutting process Methods 0.000 claims abstract description 4
- 239000003595 mist Substances 0.000 claims abstract description 4
- 229910052709 silver Inorganic materials 0.000 claims abstract description 4
- 239000004332 silver Substances 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 21
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 239000007921 spray Substances 0.000 claims description 9
- 238000003756 stirring Methods 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 239000002002 slurry Substances 0.000 claims description 8
- 239000011236 particulate material Substances 0.000 claims description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 6
- 229910000416 bismuth oxide Inorganic materials 0.000 claims description 6
- 229960004643 cupric oxide Drugs 0.000 claims description 6
- TYIXMATWDRGMPF-UHFFFAOYSA-N dibismuth;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Bi+3].[Bi+3] TYIXMATWDRGMPF-UHFFFAOYSA-N 0.000 claims description 6
- 238000005469 granulation Methods 0.000 claims description 6
- 230000003179 granulation Effects 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- 239000004576 sand Substances 0.000 claims description 6
- 239000013530 defoamer Substances 0.000 claims description 5
- 238000010792 warming Methods 0.000 claims description 5
- 239000002270 dispersing agent Substances 0.000 claims description 4
- DQMUQFUTDWISTM-UHFFFAOYSA-N O.[O-2].[Fe+2].[Fe+2].[O-2] Chemical compound O.[O-2].[Fe+2].[Fe+2].[O-2] DQMUQFUTDWISTM-UHFFFAOYSA-N 0.000 claims description 3
- 238000000498 ball milling Methods 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 3
- 239000008187 granular material Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- QGLKJKCYBOYXKC-UHFFFAOYSA-N nonaoxidotritungsten Chemical compound O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1 QGLKJKCYBOYXKC-UHFFFAOYSA-N 0.000 claims description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 238000007493 shaping process Methods 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 229910001930 tungsten oxide Inorganic materials 0.000 claims description 3
- 239000011787 zinc oxide Substances 0.000 claims description 3
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 3
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 claims description 2
- 239000012752 auxiliary agent Substances 0.000 claims description 2
- 239000008188 pellet Substances 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000007812 deficiency Effects 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000009833 condensation Methods 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 238000011900 installation process Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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Abstract
本发明公开了一种高摆折强度镍锌软磁磁芯的制造方法，其步骤包括：将原料混合后振磨并造球、转移到回转窑中预烧、配置聚乙烯醇胶水、将前两步产物混合助剂一并超细研磨、喷雾造粒、压制成型、方形切削半成品、高温烧结、端银电镀，由该方法制得的镍锌软磁磁芯质地均匀，摆折强度高，在烧结后的后续加工过程中不易发生破损，提高了生产效率，降低了生产成本，在运输和安装使用时也不易发生摆面折断。
Description
技术领域
本发明涉及一种镍锌软磁磁芯，特别涉及一种高摆折强度镍锌软磁磁芯的制造方法。
背景技术
现有技术中的镍锌软磁磁芯，由于工艺原因，造成产品质地不均匀，应力集中，因而摆面强度不足，在烧结后镀银、绕线工序中容易造成摆面破损，产品报废，同时，破损的磁芯会造成卡机，增加了修机的工作量，极大地降低了生产效率，有的产品完好经过镀银、绕线工序也可能在运输、安装过程中出现摆面折断。
发明内容
为了克服现有技术的不足，本发明提供一种高摆折强度镍锌软磁磁芯的制造方法。
本发明解决其技术问题所采用的技术方案是：
一种高摆折强度镍锌软磁磁芯的制造方法，包括以下步骤：
A、配料及混合振动：按质量分数将原料三氧化二铁65%-70%、氧化锌15%-19%、氧化铜3%-5%、氧化亚镍10%-15%、氧化铋0.1%-0.3%、氧化钨0.05%-0.1%、氧化锆0.005%-0.01%、二氧化硅0.05-0.1%均匀倒入球磨机料槽中进行混合振动60分钟，再转移到造球机中进行造球作业，得到造球料，所述造球料的球径要求在1-8mm之间；
B、预烧：将步骤A得到的所述造球料从料斗中均匀加入到回转窑中进行预烧，回转窑中四个区域，温度在820-860℃之间，以3-5r/min的转速旋转炉管30-50分钟，再用球磨机进行球磨50分钟，得到预烧振磨料；
C、煮胶：按重量份将92份纯水升温至50-55℃，然后加入8份聚乙烯醇颗粒搅拌升温至95℃，继续边加热边搅拌5小时后停止加热继续搅拌，待温度降到45℃以下后过滤，得到聚乙烯醇胶水，用胶桶密封保存备用；
D、超细研磨：按重量份将纯水20-25份和步骤B得到的所述振磨料58-65份加入立式砂磨机研磨20分钟，再往所述立式砂磨机中加入分散剂0.2-0.5份、消泡剂0.1-0.35份、烧结助剂0.6-1.8份和步骤C得到的所述聚乙烯醇胶水16-20份，研磨60分钟后泵入卧式砂磨机进行超细研磨60分钟，得到料浆；
E、喷雾造粒: 将步骤D得到的所述料浆进行喷雾造粒法造粒，喷雾条件设定为喷雾入口温度300±20℃，喷雾出口温度110±10℃，送料频率为10-13Hz，甩片频率设定60Hz，喷雾出来的颗粒料需要进行加湿处理，要求松装密度为1.25-1.45g/cm3，含水量≤0.4%，得到颗粒料进仓备用；
F、成型压制: 将步骤E得到的所述颗粒料通过专用模具在粉末成型机上压制成型出所需形状和尺寸的半成品。
G、方形切削：将压制成型出来的半成品轻轻倒入NR方形加工机的振动盘中，加入生粉，以覆盖半成品表面为度，按图纸尺寸进行切削。
H、烧结：将已切削好的半成品送入隧道窖炉中，设定台板速度为24mm/min-28mm/min，所述隧道窖炉分为十一个区域，每个区域又分为上下温区，烧结温度在230-1080℃递增，烧结时间为14-18小时；
I、端银电镀：自然冷却后对合格产品进行端银电镀，得到镍锌软磁磁芯。
步骤B中回转窑所述四个区域的温度具体为860℃、845℃、845℃、820℃。
步骤D中所述烧结助剂由以下质量分数的物质组成：氧化铜62%-94%、氧化铋6%-38%。
步骤H中各个温区的温度具体为：第一区域上温区230℃、第一区域下温区300℃、第二区域上温区330℃、第二区域下温区380℃、第三区域上温区430℃、第三区域下温区480℃、第四区域上温区530℃、第四区域下温区580℃、第五区域上温区660℃、第五区域下温区730℃、第六区域上温区750℃、第六区域下温区795℃、第七区域上温区800℃、第七区域下温区840℃、第八区域上温区860℃、第八区域下温区900℃、第九区域上温区980℃、第九区域下温区1025℃、第十区域上温区1060℃、第十区域下温区1080℃、第十一区域上温区1060℃、第十一区域下温区1080℃。
本发明的有益效果是：以本发明制造方法制得的镍锌软磁磁芯质地均匀，摆折强度高，在烧结后的后续加工过程中不易发生破损，提高了生产效率，降低了生产成本，在运输和安装使用时也不易发生摆面折断。
具体实施方式
一种高摆折强度镍锌软磁磁芯的制造方法，包括以下步骤：
A、配料及混合振动：按质量分数将原料三氧化二铁65%-70%、氧化锌15%-19%、氧化铜3%-5%、氧化亚镍10%-15%及辅助材料氧化铋0.1%-0.3%、氧化钨0.05%-0.1%、氧化锆0.005%-0.01%、二氧化硅0.05-0.1%均匀倒入球磨机料槽中进行混合振动60分钟，使各种原料混合均匀并磨细，再转移到造球机中进行造球作业，得到造球料，所述造球料的球径要求在1-8mm之间。
B、预烧：将步骤A得到的所述造球料从料斗中均匀加入到回转窑中进行预烧，使混合材料在后续烧结步骤中减少收缩率，以防产品变型。回转窑中四个区域，温度在820-860℃之间，具体设定为860℃、845℃、845℃、820℃，以3-5r/min的转速旋转炉管30-50分钟，再用球磨机进行球磨50分钟，得到预烧振磨料。
C、煮胶：按重量份将92份纯水升温至50-55℃，然后加入8份聚乙烯醇颗粒搅拌升温至95℃，继续边加热边搅拌5小时后停止加热继续搅拌，待温度降到45℃以下后过滤，得到聚乙烯醇胶水，用胶桶密封保存备用。
D、超细研磨：按重量份将纯水20-25份和步骤B得到的所述振磨料58-65份加入立式砂磨机研磨20分钟，再往所述立式砂磨机中加入分散剂0.2-0.5份、消泡剂0.1-0.35份、烧结助剂0.6-1.8份和步骤C得到的所述聚乙烯醇胶水16-20份，研磨60分钟后泵入卧式砂磨机进行超细研磨60分钟，得到料浆。要求浆料平均粒径D50低于0.5微米。所述烧结助剂具体由以下质量分数的物质组成：氧化铜62%-94%、氧化铋6%-38%。所述消泡剂使用ND44DEfoamer，所述分散剂使用罗门哈斯731D。
E、喷雾造粒: 将步骤D得到的所述料浆进行喷雾造粒法造粒，使材料具有一定的流动性以便成型。喷雾条件设定为喷雾入口温度300±20℃，喷雾出口温度110±10℃，送料频率为10-13Hz，甩片频率设定60Hz，喷雾出来的颗粒料需要进行加湿处理，要求松装密度为1.25-1.45g/cm3，含水量≤0.4%，得到颗粒料进仓备用。
F、成型压制: 根据实际需求，将步骤E得到的所述颗粒料通过专用模具在粉末成型机上压制成型出所需形状和尺寸的半成品。
G、方形切削：将压制成型出来的半成品轻轻倒入NR方形加工机的振动盘中，加入生粉，以覆盖半成品表面为度，防止半成品在切削过程中损坏，然后按图纸尺寸进行切削。所述生粉可以是食用淀粉或玉米粉。
H、烧结：将已切削好的半成品送入隧道窖炉中，设定台板速度为24mm/min-28mm/
min，所述隧道窖炉分为十一个区域，每个区域又分为上下温区，烧结温度在230-1080℃递
增，烧结时间为14-18小时。十一个区域共22个温区具体温度设置如下：
| 区域 | 上温区温度（℃） | 下温区温度（℃） |
| 第一区域 | 230 | 300 |
| 第二区域 | 330 | 380 |
| 第三区域 | 430 | 480 |
| 第四区域 | 530 | 580 |
| 第五区域 | 660 | 730 |
| 第六区域 | 750 | 795 |
| 第七区域 | 800 | 840 |
| 第八区域 | 860 | 900 |
| 第九区域 | 980 | 1025 |
| 第十区域 | 1060 | 1080 |
| 第十一区域 | 1060 | 1080 |
I、端银电镀：自然冷却后对合格产品进行端银电镀，得到镍锌软磁磁芯。
测试所述摆折强度依行内常用方法，测试仪器为温州山度仪器有限公司生产的SJY-500电动机台（配有推拉力计）。将产品下摆面固定在SJY-500电动机台的铁板上，将SJY-500电动机台的头换成阶梯型，与上摆面相接，开启SJY-500电动机台，记录上摆面破碎时受到的力的大小。测试得本发明方法制造的镍锌软磁磁芯上摆面破碎时受到的力的大小为36-40N，高于现有技术产品的26-28N。对比现有技术中的镍锌软磁磁芯，本发明方法制造的产品质地均匀，摆折强度高，在烧结后的后续加工过程中不易发生破损，有利于提高生产效率，降低生产成本，在运输和安装使用时也不易发生摆面折断。
Claims (5)
1.一种高摆折强度镍锌软磁磁芯的制造方法，其特征在于包括以下步骤：
A、配料及混合振动：按质量分数将原料三氧化二铁65%-70%、氧化锌15%-19%、氧化铜3%-5%、氧化亚镍10%-15%、氧化铋0.1%-0.3%、氧化钨0.05%-0.1%、氧化锆0.005%-0.01%、二氧化硅0.05-0.1%均匀倒入球磨机料槽中进行混合振动60分钟，再转移到造球机中进行造球作业，得到造球料，所述造球料的球径要求在1-8mm之间；
B、预烧：将步骤A得到的所述造球料从料斗中均匀加入到回转窑中进行预烧，回转窑中四个区域，温度在820-860℃之间，以3-5r/min的转速旋转炉管30-50分钟，再用球磨机进行球磨50分钟，得到预烧振磨料；
C、煮胶：按重量份将92份纯水升温至50-55℃，然后加入8份聚乙烯醇颗粒搅拌升温至95℃，继续边加热边搅拌5小时后停止加热继续搅拌，待温度降到45℃以下后过滤，得到聚乙烯醇胶水，用胶桶密封保存备用；
D、超细研磨：按重量份将纯水20-25份和步骤B得到的所述振磨料58-65份加入立式砂磨机研磨20分钟，再往所述立式砂磨机中加入分散剂0.2-0.5份、消泡剂0.1-0.35份、烧结助剂0.6-1.8份和步骤C得到的所述聚乙烯醇胶水16-20份，研磨60分钟后泵入卧式砂磨机进行超细研磨60分钟，得到料浆；
E、喷雾造粒: 将步骤D得到的所述料浆进行喷雾造粒法造粒，喷雾条件设定为喷雾入口温度300±20℃，喷雾出口温度110±10℃，送料频率为10-13Hz，甩片频率设定60Hz，喷雾出来的颗粒料需要进行加湿处理，要求松装密度为1.25-1.45g/cm3，含水量≤0.4%，得到颗粒料进仓备用；
F、成型压制: 将步骤E得到的所述颗粒料通过专用模具在粉末成型机上压制成型出所需形状和尺寸的半成品；
G、方形切削：将压制成型出来的半成品轻轻倒入NR方形加工机的振动盘中，加入生粉，以覆盖半成品表面为度，按图纸尺寸进行切削；
H、烧结：将已切削好的半成品送入隧道窖炉中，设定台板速度为24mm/min-28mm/min，所述隧道窖炉分为十一个区域，每个区域又分为上下温区，烧结温度在230-1080℃递增，烧结时间为14-18小时；
I、端银电镀：自然冷却后对合格产品进行端银电镀，得到镍锌软磁磁芯。
2.根据权利要求1所述的高摆折强度镍锌软磁磁芯的制造方法，其特征在于步骤B中回转窑所述四个区域的温度具体为860℃、845℃、845℃、820℃。
3.根据权利要求1所述的高摆折强度镍锌软磁磁芯的制造方法，其特征在于步骤D中所述烧结助剂由以下质量分数的物质组成：氧化铜62%-94%、氧化铋6%-38%。
4.根据权利要求1所述的高摆折强度镍锌软磁磁芯的制造方法，其特征在于步骤D中所述料浆平均粒径D50要求在0.5μm以下。
5.根据权利要求1所述的高摆折强度镍锌软磁磁芯的制造方法，其特征在于步骤H中各个温区的温度具体为：第一区域上温区230℃、第一区域下温区300℃、第二区域上温区330℃、第二区域下温区380℃、第三区域上温区430℃、第三区域下温区480℃、第四区域上温区530℃、第四区域下温区580℃、第五区域上温区660℃、第五区域下温区730℃、第六区域上温区750℃、第六区域下温区795℃、第七区域上温区800℃、第七区域下温区840℃、第八区域上温区860℃、第八区域下温区900℃、第九区域上温区980℃、第九区域下温区1025℃、第十区域上温区1060℃、第十区域下温区1080℃、第十一区域上温区1060℃、第十一区域下温区1080℃。
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