CN108585820A - 一种特长圆柱形软磁铁氧体磁芯的制备方法 - Google Patents
一种特长圆柱形软磁铁氧体磁芯的制备方法 Download PDFInfo
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Abstract
本发明属于铁氧体磁芯技术领域。本发明公开了一种特长圆柱形软磁铁氧体磁芯的制备方法,其包括混料、粉料填充、等静压处理、修坯、烧结及后处理等步骤,其中等静压处理时采用等静压胶模,其由保护套、橡胶管、橡胶塞和开口插销组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上。通过本发明制备方法能够获得长径比不小于10的烧结软磁铁氧体磁芯;获得的烧结软磁铁氧体磁芯具有更高的致密度,相较于现有技术获得的烧结软磁铁氧体磁芯密度增加6~10%左右;烧结软磁铁氧体磁芯变形率更低,精度更高。
Description
技术领域
本发明涉及铁氧体磁芯技术领域,尤其是涉及一种特长圆柱形软磁铁氧体磁芯的制备方法。
背景技术
某些电磁应用场合需要使用圆管状和圆柱状软磁铁氧体磁芯,如焊接设备上用的电感器、车载wifi用天线棒等。众所周知,当圆棒或圆管的长度与直径比值大10时,就不适用钢模干粉压制成型方案,需采取湿式或半湿式的注浆成型或挤出成型工艺方法,但注浆成型或挤出成型的压坯因成型添加剂较多所致压坯密度低,使制品无法获得原材料所属标准特性要求;另一方面,特长磁芯高温烧时弯曲变形所带来的品质问题,也是制约特长磁棒广泛应用的障碍。
发明内容
为解决上述特长圆柱形软磁铁氧体磁芯的制备方法过程中存在的成型密度低、烧结易变形等问题,提供了一种能够增加成型密度,解决烧结变形问题的特长圆柱形软磁铁氧体磁芯的制备方法。
为实现上述目的,本发明采用的技术方案如下:
一种特长圆柱形软磁铁氧体磁芯的制备方法,包括以下步骤:
a)混料:向软磁磁粉中添加成型润滑剂并混合均匀制得粉料;
b)粉料填充:将粉料填充到等静压胶模中;
c)等静压处理:将填充粉料后的等静压胶模放入等静压缸内进行压制制得成型压坯;
d)修坯:将成型压坯修正至烧结前尺寸;
e)烧结:将修坯后的成型压坯放置在承烧板上进行烧结;
f)后处理。
步骤b)粉料填充后将粉料震实使密度至1.6g/cm3及以上,步骤c)等静压处理后成型压坯的密度为3.2~3.3g/cm3,并且模具尺寸与成型压坯的压缩比系数为1.26;粉料填充时以七根等静压胶模呈行星式捆扎在一起填充为宜,这样可以校正等静压胶模的直线度,提高填充效率。
填料采用自动填料器,自动填料器由容积式自动称量器、垂直振动器组成;称量器设有七组量杯,呈行星式分布;量杯可伸缩调节容积以改变粉料克重,旋转阀片交替动作实现自动称量和填料;填料过程中垂直振动器同时工作,将胶模内的粉料振实。
步骤d)修坯时将成型压坯修正至烧结前尺寸,烧结前尺寸为成品尺寸的1.165~1.17倍。
作为优选,软磁磁粉为锰锌铁氧体磁粉或镍锌铁氧体磁粉。
作为优选,步骤a)中,成型润滑剂的添加量为软磁磁粉重量的0.4~0.6wt%。
作为优选,成型润滑剂为硬脂酸锌、石墨或甘油中的至少一种。
作为优选,等静压胶模由保护套、橡胶管、橡胶塞和开口插销组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上。
作为优选,保护套均匀分布通油孔。
作为优选,通油孔的总面积大于保护套表面积的3/4。
等静压胶模由保护套、橡胶管、橡胶塞、开口插销组成;装配时,橡胶管两端塞入两橡胶塞子,使胶模形成密封的空间,铁氧体粉末被密封在胶模内;橡胶模的外周套有保持套,确保胶模圆柱形状精度;管的两端插入开口销,防止塞子脱落。胶管与塞子装入或取出借助真空吸嘴工具完成;保护套周面设有通油孔,通油圆孔呈梅花形阵列均匀分布,保护套的圆柱度精度需在0.05mm以内;通油孔面积所占圆周面积大于3/4,但是由于保护套还需要自支撑等原因,通油孔的总面积所占面积不超过保护套表面积的4/5。
作为优选,步骤c)等静压处理时,压强为200~240MPa,保压时间为50~70s;卸压时,先卸压至125~135MPa,保压15~25s,再卸压至55~65MPa,保压15~25s,最后完全卸压。
作为优选,承烧板的表面设有氧化锆涂层并设有V型槽。
作为优选,V型槽的夹角为85~95度。V型槽的夹角最优为90度。
防止磁棒在烧结过程发生变形,托烧的承烧板上设有若干条夹角约为90度的V形槽,在高温状态下将磁棒修正较直;在V槽的表面涂有氧化锆陶瓷层,以防止承烧托板与磁棒材发生反应,造成磁芯废品。
作为优选,后处理包括将烧好的坯品外径加工到标准尺寸并进行工艺倒角。加工时可以采用无心磨床进行加工。
因此,本发明具有以下有益效果:
(1)通过本发明制备方法能够获得长径比不小于10的烧结软磁铁氧体磁芯;
(2)通过本发明制备方法获得的烧结软磁铁氧体磁芯具有更高的致密度,相较于现有技术获得的烧结软磁铁氧体磁芯密度增加6~10%左右;
(3)通过本发明制备方法获得的烧结软磁铁氧体磁芯变形率更低,精度更高。
附图说明
图1为本发明中采用的等静压胶模的一种示意图;
图2为本发明中采用的承烧板的一种示意图;
图中:保护套1、橡胶管2、橡胶塞3、开口插销4、通油孔5、承烧板6、V型槽7。
具体实施方式
下面结合具体实施方式对本发明的技术方案作进一步的说明。
显然,所描述的实施例仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
在本发明中,若非特指,所有的设备和原料均可从市场上购得或是本行业常用的,下述实施例中的方法,如无特别说明,均为本领域常规方法。
实施例1
一种特长圆柱形软磁铁氧体磁芯的制备方法,包括以下步骤:
a)混料:向锰锌铁氧体磁粉中添加磁粉重量的0.4wt%的石墨并混合均匀制得粉料;
b)粉料填充:将粉料填充到等静压胶模中;
c)等静压处理:将填充粉料后的等静压胶模放入等静压缸内进行压制制得成型压坯;等静压处理时,压强为200MPa,保压时间为50s;卸压时,先卸压至125MPa,保压15s,再卸压至55MPa,保压15s,最后完全卸压;
d)修坯:将成型压坯修正至烧结前尺寸;烧结前尺寸为成品尺寸的1.165倍;
e)烧结:将修坯后的成型压坯放置在承烧板上进行烧结制得;承烧板6的表面设有氧化锆涂层并设有夹角为85度的V型槽7;
f)后处理:采用无心磨床将烧好的坯品外径加工到标准尺寸并进行工艺倒角制得特长圆柱形软磁铁氧体磁芯。
其中,等静压胶模由保护套1、橡胶管2、橡胶塞3和开口插销4组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上;保护套均匀分布通油孔5,通油孔的总面积为保护套表面积的3/4。
实施例2
一种特长圆柱形软磁铁氧体磁芯的制备方法,包括以下步骤:
a)混料:向锰锌铁氧体磁粉中添加磁粉重量的0.5wt%的硬脂酸锌并混合均匀制得粉料;
b)粉料填充:将粉料填充到等静压胶模中;
c)等静压处理:将填充粉料后的等静压胶模放入等静压缸内进行压制制得成型压坯;等静压处理时,压强为220MPa,保压时间为60s;卸压时,先卸压至130MPa,保压20s,再卸压至60MPa,保压20s,最后完全卸压;
d)修坯:将成型压坯修正至烧结前尺寸;烧结前尺寸为成品尺寸的1.165倍;
e)烧结:将修坯后的成型压坯放置在承烧板上进行烧结制得;承烧板6的表面设有氧化锆涂层并设有夹角为85~95度的V型槽7;
f)后处理:采用无心磨床将烧好的坯品外径加工到标准尺寸并进行工艺倒角制得特长圆柱形软磁铁氧体磁芯。
其中,等静压胶模由保护套1、橡胶管2、橡胶塞3和开口插销4组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上;保护套均匀分布通油孔5,通油孔的总面积为保护套表面积的77.5%。
实施例3
实施例3除了软磁磁粉为镍锌铁氧体磁粉外,其他制备过程及参数同实施例2。
实施例4
一种特长圆柱形软磁铁氧体磁芯的制备方法,包括以下步骤:
a)混料:向镍锌铁氧体磁粉中添加磁粉重量的0.6wt%的甘油并混合均匀制得粉料;
b)粉料填充:将粉料填充到等静压胶模中;
c)等静压处理:将填充粉料后的等静压胶模放入等静压缸内进行压制制得成型压坯;等静压处理时,压强为240MPa,保压时间为70s;卸压时,先卸压至135MPa,保压25s,再卸压至65MPa,保压25s,最后完全卸压;
d)修坯:将成型压坯修正至烧结前尺寸;烧结前尺寸为成品尺寸的1.17倍;
e)烧结:将修坯后的成型压坯放置在承烧板上进行烧结制得;承烧板6的表面设有氧化锆涂层并设有夹角为95度的V型槽7;
f)后处理:采用无心磨床将烧好的坯品外径加工到标准尺寸并进行工艺倒角制得特长圆柱形软磁铁氧体磁芯。
其中,等静压胶模由保护套1、橡胶管2、橡胶塞3和开口插销4组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上;保护套均匀分布通油孔5,通油孔的总面积为保护套表面积的4/5。
性能指标:
对由实施例1~3制得的特长圆柱形软磁铁氧体磁芯进行外观形貌及磁性能测试,性能指标如下:
1.形状精度:长度与直径比L/D≥10、直径公差±0.05、圆柱度公差小于0.1、表面粗糙度Ra1.6;本发明制备方法制得的磁芯精度更高,公差更小。
2.磁性能:以实施例2制备获得的锰锌铁氧体磁芯和实施例3制备获得的镍锌铁氧体磁芯为例;表1为实施例2制备获得的锰锌铁氧体磁芯的相关性能,表2为实施例3制备获得的镍锌铁氧体磁芯的相关性能。
表1
表2
由上述两份表格可见,由本发明制备获得的锰锌铁氧体磁芯和镍锌铁氧体磁芯具有优于现有技术制备而得的锰锌铁氧体磁芯和镍锌铁氧体磁芯的磁性能,这是由于通过本发明制备方法制得的磁芯具有更高的致密度所获得的,现有技术制得的锰锌铁氧体磁芯密度约为4.6g/cm3左右,镍锌铁氧体磁芯密度约为4.8g/cm3左右,由上述表1表2可知本发明制备方法获得的磁芯的密度都比现有技术至少增加6~10%,致密度增加效果明显。
应当理解的是,对于本领域普通技术人员来说,可以根据上述说明加以改进或变换,而所有这些改进和变换都应属于本发明所附权利要求的保护范围。
Claims (10)
1.一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于包括以下步骤:
a)混料:向软磁磁粉中添加成型润滑剂并混合均匀制得粉料;
b)粉料填充:将粉料填充到等静压胶模中;
c)等静压处理:将填充粉料后的等静压胶模放入等静压缸内进行压制制得成型压坯;
d)修坯:将成型压坯修正至烧结前尺寸;
e)烧结:将修坯后的成型压坯放置在承烧板上进行烧结;
f)后处理。
2.根据权利要求1所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述的软磁磁粉为锰锌铁氧体磁粉或镍锌铁氧体磁粉。
3.根据权利要求1所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述步骤a)中,成型润滑剂的添加量为软磁磁粉重量的0.4~0.6wt%。
4.根据权利要求1或3所述的一种一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述的成型润滑剂为硬脂酸锌、石墨或甘油中的至少一种。
5.根据权利要求1所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述的等静压胶模由保护套、橡胶管、橡胶塞和开口插销组成,保护套设置在橡胶管的外侧,橡胶塞塞入橡胶管的两端,开口销设置在保护套两端将橡胶塞固定在橡胶管上。
6.根据权利要求5所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述的保护套均匀分布通油孔。
7.根据权利要求6所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述通油孔的总面积大于保护套表面积的3/4。
8.根据权利要求1或5或6或7所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述步骤c)等静压处理时,压强为200~240MPa,保压时间为50~70s;卸压时,先卸压至125~135MPa,保压15~25s,再卸压至55~65MPa,保压15~25s,最后完全卸压。
9.根据权利要求1所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述的承烧板的表面设有氧化锆涂层并设有V型槽。
10.根据权利要求9所述的一种特长圆柱形软磁铁氧体磁芯的制备方法,其特征在于:
所述V型槽的夹角为85~95度。
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