CN108074701B - High-density bonded magnet and preparation method thereof - Google Patents
High-density bonded magnet and preparation method thereof Download PDFInfo
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- CN108074701B CN108074701B CN201610975935.0A CN201610975935A CN108074701B CN 108074701 B CN108074701 B CN 108074701B CN 201610975935 A CN201610975935 A CN 201610975935A CN 108074701 B CN108074701 B CN 108074701B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/02—Permanent magnets [PM]
- H01F7/0205—Magnetic circuits with PM in general
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
Abstract
The invention provides a high-density bonded magnet and a preparation method thereof, wherein the high-density bonded magnet consists of coarse particle powder, 1-25 wt% of fine particle powder, 0.5-5.0 wt% of organic binder and 0.05-1.2 wt% of high-temperature-resistant lubricant, and the balance is the coarse particle powder. The invention can prepare the sample density prepared under the conventional process of 1000MPa with the low forming pressure of about 100MPa, thereby effectively reducing the requirements on the material of the die and the tonnage of a forming press, prolonging the service life of the die, reducing the cost and equipment investment of the die, realizing one-step press forming on the anisotropic bonded magnet, improving the orientation degree of magnetic powder, the magnetic performance of the magnet and realizing cost optimization.
Description
Technical Field
The invention relates to a high-density bonded magnet and a preparation method thereof.
Background
The bonded magnet has the characteristics of high dimensional accuracy, good consistency of magnetic performance, large degree of freedom of shape, easiness in automation, easiness in batch production, high utilization rate of raw materials, high resistivity, low eddy current loss and the like, so that the bonded magnet is widely applied to the fields of computers, communication, consumer electronics, office automation, industrial automation, energy-saving household appliances, automobile industry and the like. The emergence of neodymium-iron-boron permanent magnet materials in the eighties of the last century has enabled bonded magnets to enter the rapid development period centered on bonded neodymium-iron-boron magnets, and as is known, neodymium-iron-boron permanent magnet materials have the characteristic of being hard and brittle, and when neodymium-iron-boron powder is subjected to press forming, high pressure is required to be applied to compact neodymium-iron-boron powder to form bonded magnets with practical value, for example, a raw material formula that 2.0 wt% of epoxy resin binder and 0.4 wt% of zinc stearate lubricant are added into neodymium-iron-boron powder is adopted, and the forming pressure of 1200MPa is used for pressing in a steel die, so that the density of the prepared magnets is only about 6.0g/cm3. And higher forming pressure has high requirements on the material of the forming die, and the method is suitable forThe service life of the forming die is greatly influenced, the die cost is high, and meanwhile, a large-tonnage forming press is needed for preparing small-size products, so that the investment is large.
For the anisotropic bonded magnet, especially for the anisotropic bonded multi-pole rare earth magnet ring, because the rare earth magnet powder has high coercive force, the magnetic field strength required by the sufficient orientation of the magnet powder is very high, so that a magnetic field source (whether an electromagnetic field or a permanent magnet field) is required to be close enough to the magnet powder, namely the thickness of a die wall of a forming die is very small, so that the forming and pressing pressure applied to the magnet powder in the magnetic field orientation in the prior art is very small, and in the prior art, the low forming and pressing pressure means that the density of the prepared formed compact is very low, therefore, the forming process of the existing anisotropic bonded magnet usually adopts the steps of transferring the low-density oriented formed compact to a die with thicker wall thickness and applying high-pressure pressing again to form the low-density oriented formed compact to the final required density under the condition of no magnetic field, thereby not only increasing the processing procedures and improving the cost, but also enabling the magnet powder to generate random displacement and plastic deformation by high-pressure pressing again, the degree of orientation of the magnetic powder is destroyed, and the magnetic properties of the magnet are deteriorated.
Chinese patent CN 100568410C proposes a method for preparing a bonded magnet by warm compaction, namely, heating raw material powder to 80-220 ℃ in a mold, and then carrying out press forming, but compared with room temperature forming, the method has the problem that the reduction range of forming pressure when obtaining a sample with the same density or the density improvement range of the sample prepared under the same forming pressure are still not large enough, according to the patent specification, the magnetic performance or density of the sample prepared under the same forming pressure is only improved by not more than 20%, and the problem of high forming pressure of neodymium iron boron powder still cannot be thoroughly solved.
Disclosure of Invention
In order to solve the problem of high forming and pressing pressure of powder, particularly rare earth powder, the invention organically combines the powder granularity, the forming temperature field and the forming vibration field to greatly reduce the forming and pressing pressure. The principle of the method is that the double lubrication action of the organic binder and the high-temperature lubricant which are softened in a temperature field is utilized to reduce the friction force between the powder when the powder moves and rotates, the powder particles are enabled to move rapidly, rotate and rearrange fully through a vibration field, the effect that the fine particle powder is effectively filled in the gaps between the coarse particle powder is achieved, and therefore the forming and pressing pressure intensity is greatly reduced, and therefore the matching of the powder particle sizes is very critical. The powder is prepared from coarse powder with good fluidity and mold cavity filling property and fine powder for gap filling according to a certain proportion. The coarse powder particle size distribution is to conform to the normal distribution, the particle size is controlled mainly to have a powder proportion of less than 38 μm and not more than 5 wt%, the maximum particle size is too large for the powder to have good flowability and small cavity filling property, the proportion of more than 180 μm is not more than 5 wt%, and the morphology of the coarse powder particle is not limited to spherical, nearly spherical, polygonal, needle-shaped and needle-shaped. Since the main role of the fine particle powder is to be gap-filling, the amount of addition of the fine particle powder and the selection of the particle size of the fine particle powder depend not only on the particle size distribution of the coarse particle powder but also on the morphology of the coarse particle powder. The porosity of the powder rearranged in the coarse powder can be estimated or calculated according to the particle size distribution and the morphology of the coarse powder by means of practical experience or related simulation software so as to determine the parameters of the fine powder. The optimum amount of fine powder added is the porosity between coarse powders, the fine powder should not be too large, not more than 15 μm at most, preferably not more than 5 μm, and the fine powder should not be too small in particle size in view of the production process, cost, and the like.
The invention provides a high-density bonded magnet prepared by using low pressing pressure, which consists of coarse particle powder, 1-25 wt% of fine particle powder, 0.5-5.0 wt% of organic binder and 0.05-1.2 wt% of high-temperature-resistant lubricant, wherein the coarse particle powder is the balance; the particle size of the coarse particle powder is 25-250 microns, the proportion of the particle size smaller than 38 microns is not higher than 5 wt%, the proportion of the particle size larger than 180 microns is not higher than 5 wt%, and the coarse particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite; the particle size of the fine particle powder is 0.1-15 microns, and the fine particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite; the organic binder is selected from at least one of epoxy resin, phenolic resin and acrylic resin; the high-temperature-resistant lubricant is at least one selected from molybdenum disulfide, zinc stearate, aluminum stearate, lithium stearate, calcium stearate, magnesium stearate, barium stearate, strontium stearate and sodium stearate.
As a further description of the high-density bonded magnet of the present invention, it is preferable that the fine particle powder is added in an amount of 5 to 15 wt% and the fine particle powder has a particle diameter of 0.2 to 5 μm.
As a further description of the high-density bonded magnet of the present invention, it is preferable that the organic binder is added in an amount of 2.0 to 3.0 wt%.
As a further description of the high-density bonded magnet of the present invention, it is preferable that the high-temperature-resistant lubricant is added in an amount of 0.2 to 0.6 wt%.
As a further explanation of the high-density bonded magnet of the present invention, it is preferable that the high-temperature-resistant lubricant has a temperature resistance temperature of not lower than 60 ℃.
According to another aspect of the present invention, there is also provided a method of manufacturing a high-density bonded magnet, the method including the steps of: 1) uniformly mixing fine powder into the coarse powder to obtain mixed powder; 2) weighing the organic binder according to a proportion, fully dissolving the organic binder in a proper amount of acetone, then adding the mixed powder according to a proportion, stirring and heating to completely volatilize the acetone, and obtaining dry magnetic powder uniformly coated by the organic binder; 3) then adding a high-temperature-resistant lubricant in proportion, and fully and uniformly mixing to obtain pre-compressed magnetic powder; 4) placing the pre-compressed magnetic powder into a die, heating to a preset temperature of 60-160 ℃, applying a preset forming pressure and a preset vibration pressure after the temperature is reached, and performing vibration pressing; and 5) demolding to obtain a high-density bonded magnet forming blank, and then carrying out subsequent conventional curing, finishing, surface coating, magnetizing and detecting to obtain a finished product. Here, the fine particle powder which is easily oxidized is subjected to an oxidation preventing treatment in advance.
As a further explanation of the preparation method of the present invention, it is preferable that the coarse particle powder is the rest, the fine particle powder is added in an amount of 1 to 25 wt%, the organic binder is added in an amount of 0.5 to 5.0 wt%, and the high temperature resistant lubricant is added in an amount of 0.05 to 1.2 wt%; the particle size of the coarse particle powder is 25-250 microns, wherein the proportion of the particle size smaller than 38 microns is not higher than 5 wt%, the proportion of the particle size larger than 180 microns is not higher than 5 wt%, and the coarse particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite; the particle size of the fine particle powder is 0.1-15 microns, and the fine particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite; the organic binder is selected from at least one of epoxy resin, phenolic resin and acrylic resin; the high-temperature-resistant lubricant is at least one selected from molybdenum disulfide, zinc stearate, aluminum stearate, lithium stearate, calcium stearate, magnesium stearate, barium stearate, strontium stearate and sodium stearate.
As a further explanation of the manufacturing method of the present invention, it is preferable that the pre-compressed magnetic powder is put into a die and heated to a predetermined temperature of 80 to 120 ℃.
As a further explanation of the preparation method of the present invention, it is preferable that a forming pressure of 50 to 200MPa is applied to the mold for pressing, and the mold is vibrated at the same time, the vibration pressure is 30 to 200% of the forming pressure, and the vibration time is 1 to 5 seconds.
As a further description of the preparation method of the present invention, it is preferable that the mold is pressed under a forming pressure of 80 to 130MPa, and the mold is vibrated at a vibration intensity of 40 to 100% of the forming pressure for a vibration time of 2 seconds.
In summary, the detailed implementation process of the technical scheme of the invention is as follows: a) in the conventional method, 1-25 wt% of fine powder with a particle size of 0.1-15 μm is uniformly mixed into coarse powder with a particle size of 25-250 μm and a particle size distribution of approximately normal distribution, wherein the addition ratio of the fine powder is preferably 5-15 wt%, the particle size of the fine powder is preferably 0.2-5 μm, and the fine powder easy to be oxidized is subjected to anti-oxidation treatment in advance. b) And (b) coating the mixed powder obtained from the step (a) by using an organic binder, wherein the coating method is preferably wet coating, the binder is one or a mixture of more of epoxy resin, phenolic resin and acrylic resin, and the addition amount is 0.5-5.0 wt%, and the preferred addition amount is 2.0-3.0 wt%. Adding a lubricant into the powder coated with the organic binder to obtain pre-compressed powder, wherein the lubricant is selected from at least one of high-temperature-resistant lubricants, such as molybdenum disulfide, zinc stearate, aluminum stearate, lithium stearate, calcium stearate, magnesium stearate, barium stearate, strontium stearate and sodium stearate, and the adding amount is 0.05-1.2%, preferably 0.2-0.6%. c) And (c) filling the pre-compressed powder obtained in step (b) into a die cavity, and heating the die cavity together with the die to a temperature higher than the softening point of the binder and lower than the curing point, wherein the heating temperature is 60-160 ℃, and the heating temperature is 80-120 ℃ according to the commonly used binder. d) After the temperature is reached, applying 50-200 MPa of pressing pressure on the die, and simultaneously applying vibration to the die, wherein the vibration force is 30-200% of the pressure, and the vibration time is 1-5 s. The pressing pressure is preferably 80-130 MPa, the vibration force is preferably 40-100% of the pressure, and the vibration time is preferably 2 s. e) D, demolding to obtain a high-density bonded magnet formed blank, and carrying out subsequent processes including curing, finishing, surface coating, magnetizing, detecting and the like to obtain a finished product.
Compared with the prior art, the invention has the main advantages that: 1) uniformly mixing 1-25 wt% of 0.1-15 μm fine particle powder into coarse particle powder with a particle size of 25-250 μm and a particle size distribution of approximately normal distribution; 2) applying vibration to the die while applying pressing pressure for forming, wherein the vibration force is 30-200% of the pressure, and before vibration pressing, heating the powder and the die, wherein the temperature is controlled to be above the softening point of the used binder and below the curing point; 3) the applied forming and pressing pressure is low pressure, and for the pressed powder, the powder can be densified by using the pressure of 50-200 MPa, and the density of the pressed powder is equivalent to that of a pressed powder formed by the conventional process with the pressure of about 1000 MPa. The technology similar or similar to the technical scheme of the invention has not been reported. The invention can prepare the sample density prepared under the conventional process of 1000MPa with the low forming pressure of about 100MPa, thereby effectively reducing the requirements on the material of the die and the tonnage of a forming press, prolonging the service life of the die, reducing the cost and equipment investment of the die, realizing one-step press forming on the anisotropic bonded magnet, improving the orientation degree of magnetic powder, the magnetic performance of the magnet and realizing cost optimization.
Detailed Description
In order to make the examiner understand the structure, characteristics and other objects of the present invention, the following detailed description is given with reference to the accompanying preferred embodiments, which are only for describing the technical aspects of the present invention and are not intended to limit the present invention.
Examples
The preparation method comprises the following steps of:
the preparation method comprises the following steps: 1) uniformly mixing fine particle powder into coarse particle powder according to the proportion in table 1 to obtain mixed powder; 2) weighing the organic binder according to the proportion in the table 1, fully dissolving the organic binder in a proper amount of acetone, then adding the mixed powder according to the proportion, stirring and heating to completely volatilize the acetone, and obtaining dry magnetic powder uniformly coated by the organic binder; 3) then adding a lubricant according to the proportion in the table 1, and fully and uniformly mixing to obtain pre-compressed magnetic powder; 4) placing the pre-compressed magnetic powder into a die according to the condition parameters in the table 1, heating to a preset temperature, applying a preset forming pressure and a preset vibration pressure after the temperature is reached, and performing vibration pressing; and 5) demolding to obtain a high-density bonded magnet forming blank, and then carrying out subsequent conventional curing, finishing, surface coating, magnetizing and detecting to obtain a finished product.
TABLE 1 test data for examples and comparative examples
In order to verify the effect of the technical scheme, a series of experiments are carried out, and the experimental conditions and the test data are shown in table 1. Wherein reference numerals 1, 2, 8, 9, 10, 11, 12, 18, 20, 22 and 24 are samples prepared by the technique of the present invention, 3, 4, 5, 6, 13, 14, 15 and 16 are samples partially prepared by the technique of the present invention, and 7, 17, 19, 21, 23 and 24 are samples prepared by the conventional technique. Under the same formula, the density of the sample prepared by adopting the technical scheme can be higher than or close to that of the sample prepared by adopting the conventional process under the forming and pressing pressure of 60-200 MPa, and the forming and pressing pressure can be obviously reduced; the density of part of samples prepared by adopting the technology of the invention is obviously lower than that of samples prepared by adopting the technical scheme of the invention completely, which proves that the proper particle size distribution, the temperature field and the vibration field are an inseparable system and have the defects of no choice.
Compared with the prior art, the technical scheme of the invention can obtain higher density of the formed blank under low forming and pressing pressure, effectively reduce the requirements on the material of the die and the tonnage of a forming press, prolong the service life of the die, realize one-step press forming on the anisotropic bonded magnet, avoid the damage of step-by-step forming on the orientation degree of magnetic powder and reduce the cost.
It should be noted that the above summary and the detailed description are intended to demonstrate the practical application of the technical solutions provided by the present invention, and should not be construed as limiting the scope of the present invention. Various modifications, equivalent substitutions, or improvements may be made by those skilled in the art within the spirit and principles of the invention. The scope of the invention is to be determined by the appended claims.
Claims (3)
1. A method for producing a high-density bonded magnet, characterized in that,
the high-density bonded magnet comprises coarse particle powder, 1-25 wt% of fine particle powder, 0.5-5.0 wt% of organic binder and 0.05-1.2 wt% of high-temperature-resistant lubricant, wherein the coarse particle powder is the balance; wherein the content of the first and second substances,
the particle size of the coarse particle powder is 25-250 microns, wherein the proportion of the particle size smaller than 38 microns is not higher than 5 wt%, the proportion of the particle size larger than 180 microns is not higher than 5 wt%, and the coarse particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite;
the particle size of the fine particle powder is 0.1-15 microns, and the fine particle powder is selected from at least one of isotropic or anisotropic neodymium iron boron, neodymium iron nitrogen, samarium cobalt and ferrite;
the organic binder is selected from at least one of epoxy resin, phenolic resin and acrylic resin;
the high-temperature-resistant lubricant is selected from at least one of molybdenum disulfide, zinc stearate, aluminum stearate, lithium stearate, calcium stearate, magnesium stearate, barium stearate, strontium stearate and sodium stearate;
the method comprises the following steps:
1) uniformly mixing fine powder into the coarse powder to obtain mixed powder;
2) weighing the organic binder according to a proportion, fully dissolving the organic binder in a proper amount of acetone, then adding the mixed powder according to a proportion, stirring and heating to completely volatilize the acetone, and obtaining dry magnetic powder uniformly coated by the organic binder;
3) then adding a high-temperature-resistant lubricant in proportion, and fully and uniformly mixing to obtain pre-compressed magnetic powder;
4) placing the pre-compressed magnetic powder into a die, heating to a preset forming temperature of 60-160 ℃, applying a preset forming pressure and a preset vibration pressure after the temperature is reached, and performing vibration pressing; applying 50-130 MPa of forming pressure on the die for pressing, and applying vibration to the die, wherein the vibration pressure is 30-200% of the forming pressure, and the vibration time is 1-5 s; and
5) demoulding to obtain a high-density bonded magnet forming blank, and then carrying out subsequent conventional curing, finishing, surface coating, magnetizing and detecting to obtain a finished product.
2. The method of claim 1, wherein the pre-compressed magnetic powder is placed in a die and heated to a predetermined temperature of 80-120 ℃.
3. The method according to claim 1, wherein the pressing is performed by applying a forming pressure of 80 to 130MPa to the mold, and the mold is vibrated at a vibration pressure of 40 to 100% of the forming pressure for a vibration time of 2 seconds.
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| CN109872856B (en) * | 2018-10-29 | 2022-04-05 | Neo新材料技术（新加坡）私人有限公司 | Mixed rubber magnetic powder and preparation method thereof |
| CN110783052B (en) * | 2019-11-06 | 2021-11-05 | 有研稀土新材料股份有限公司 | Composite rare earth anisotropic bonded magnet and preparation method thereof |
| WO2022077150A1 (en) * | 2020-10-12 | 2022-04-21 | 昆山磁通新材料科技有限公司 | Magnetic composite material and preparation method therefor, and inductor and manufacturing method therefor |
| CN113674921B (en) * | 2021-08-27 | 2023-08-22 | 广州新莱福磁材有限公司 | Preparation method of magnetic automatic crimping and free stretching data line |
| CN114188140A (en) * | 2021-11-18 | 2022-03-15 | 绵阳西磁科技有限公司 | Preparation method of bonded samarium cobalt magnet and vacuum stirring device thereof |
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