CN108597713B - Preparation method of magnetic material - Google Patents

Preparation method of magnetic material Download PDF

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CN108597713B
CN108597713B CN201810595962.4A CN201810595962A CN108597713B CN 108597713 B CN108597713 B CN 108597713B CN 201810595962 A CN201810595962 A CN 201810595962A CN 108597713 B CN108597713 B CN 108597713B
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magnetic
soft magnetic
solvent
adhesive
slurry
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CN108597713A (en
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彭晓领
李静
杨艳婷
徐靖才
金红晓
金顶峰
洪波
王新庆
葛洪良
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China Jiliang University
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    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
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    • H01F1/14716—Fe-Ni based alloys in the form of sheets
    • H01F1/14725—Fe-Ni based alloys in the form of sheets with insulating coating
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    • H01F1/0036—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties showing low dimensional magnetism, i.e. spin rearrangements due to a restriction of dimensions, e.g. showing giant magnetoresistivity
    • H01F1/0045—Zero dimensional, e.g. nanoparticles, soft nanoparticles for medical/biological use
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    • H01F1/14733—Fe-Ni based alloys in the form of particles
    • H01F1/14741—Fe-Ni based alloys in the form of particles pressed, sintered or bonded together
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    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
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    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
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    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
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    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15358—Making agglomerates therefrom, e.g. by pressing
    • H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
    • H01F1/15375—Making agglomerates therefrom, e.g. by pressing using a binder using polymers
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    • 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
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder

Abstract

The invention relates to a preparation method of a soft magnetic composite material, which comprises the following specific steps: the raw materials consist of flaky soft magnetic alloy, insulating medium, solvent, dispersant and adhesive; mixing and ball-milling the soft magnetic alloy, the insulating medium, the solvent and the dispersing agent for 5-30 h; then adding an adhesive, continuing ball milling for 0.5-10 h, and performing vacuum degassing to obtain dispersed slurry; injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 10-500 mu m, and the speed of the casting machine is 0.5-5 cm/s; drying at the temperature of 20-30 ℃ and at the relative humidity of 30-60% to obtain a dry and flat casting belt; carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity. The invention has the advantages that: an oriented magnetic field is not needed, the orderly arranged sheet-shaped structure can be continuously and efficiently prepared by adopting a tape casting method, and the magnetic conductivity of the composite material is effectively improved.

Description

Preparation method of magnetic material
Technical Field
The invention relates to a preparation method of a soft magnetic composite material, belonging to the field of preparation of magnetic materials.
Background
The soft magnetic material is a magnetic material with low coercive force and high magnetic conductivity, is widely applied to the fields of electric power, information, energy, traffic, national defense and the like, and is an important functional material and a key basic material of national economy. With the increasing miniaturization, light weight, high frequency and integration of electric and electronic equipment, the demand of soft magnetic materials is larger and larger, and the soft magnetic materials are developed towards the directions of high magnetic conductivity, high frequency and low loss. The metal soft magnetic material has high saturation magnetic flux density and magnetic conductivity, can meet the requirement of miniaturization, but has low resistivity and large high-frequency eddy current loss, so the metal soft magnetic material is usually used at power frequency; ferrite is a ferrimagnetic material, has low saturation magnetic flux density and low energy conversion efficiency during operation, but has high resistivity and low high-frequency loss, and therefore, ferrite is generally used at high frequencies (MHz to GHz). The soft magnetic composite material combines the advantages of the metal soft magnetic material and the soft magnetic ferrite: the main phase is soft magnetic alloy, so that the saturation magnetic flux density is high and the energy conversion efficiency is high; the interface insulating layer has high resistance and low high-frequency loss. Therefore, the soft magnetic composite material has the characteristics of high magnetic flux and low loss, and can meet the requirements of high-frequency (kHz-MHz) use and volume miniaturization.
Research on soft magnetic composite materials is carried out in various colleges and universities, scientific research institutions and production enterprises in China, and the work is focused on three aspects of magnetic phase component design, interface insulation coating and magnet process optimization so as to improve the magnetic performance and improve the magnetic flux density, the magnetic conductivity and the magnetic loss characteristics. Firstly, the magnetic phase composition is designed mainly from the soft magnetic alloy itself, and the magnetic permeability, the coercive force, the resistivity and other properties of the alloy are improved by adding elements. Secondly, interface insulation coating is the research focus of the soft magnetic composite material, and the resistivity is improved and the eddy current loss is reduced by fully insulating and isolating soft magnetic particles; the good coating layer should be thin to ensure high magnetic conductivity and complete in structure to ensure sufficient insulation coating; the insulating coating material can be inorganic (glass powder, water glass, MgO, SiO)2And Al2O3Etc.), organic substances (epoxy resin, phenol resin, silicone, etc.), and may be organic-inorganic composite coatings. And thirdly, optimizing the microstructure of the material and improving the magnetic property by mainly adjusting preparation parameters in process optimization.
Although the magnetic performance of the soft magnetic composite material is continuously improved, the magnetic conductivity of the material is low due to the self structure. Based on two factors: firstly, alloy particles are separated by a non-magnetic insulating layer, a magnetic circuit is separated, and the magnetic resistance is high; secondly, a free magnetic pole appears in alloy particles in the magnetization process due to the non-magnetic interface, and the local demagnetization field is large. The combined action of the high magnetic resistance and the local demagnetization field effect causes the magnetic permeability to be reduced and the hysteresis loss to be increased. The magnetic resistance is directly related to the total thickness of the non-magnetic insulating layer in the magnetic circuit, while the demagnetizing field is determined by the shape of the alloy particles, so that the low permeability of the soft magnetic composite material is inevitably caused by the structure of the soft magnetic composite material. How to reduce the local demagnetizing field and the magnetic resistance by optimizing the organization structure is the key for improving the magnetic conductivity of the material and reducing the loss.
Chinese patent 2012104332238 discloses that magnetic particles form a chain cluster along the direction of a magnetic field by using the magnetic field, so as to obtain a unidirectional light transmission characteristic; chinese patents 2009101405358, 2016110014476, 2016110015356 and 2016110017173 adopt sheet-like soft magnetic alloy or ferrite to obtain the composite material in a polymer or paraffin matrix in a magnetic field orientation mode, and an oriented ordered structure has certain optimization on the magnetic permeability or loss of the material, but the defects of low magnetic permeability and high frequency loss of the matrix are still not essentially improved due to the fact that the content of a nonmagnetic phase in the matrix is still too high.
Aiming at the problem of low magnetic permeability common property of the soft magnetic composite material, the invention adopts the tape casting process to ensure that the flaky magnetic powder is orderly arranged in parallel along the plane of the magnetic ring (the direction of a working magnetic circuit), and finally the soft magnetic composite material with high magnetic permeability is obtained.
Disclosure of Invention
The invention aims to provide a preparation method of a soft magnetic composite material.
The invention designs a soft magnetic composite material with a novel structure: the soft magnetic alloy particles are of a sheet structure, and all the sheet particles are orderly arranged in parallel along the plane of the magnetic ring (the direction of a working magnetic circuit); the soft magnetic composite material with the structure is prepared by adopting a tape casting method, so that the magnetic conductivity of the composite material is improved.
The magnetic circuit of the soft magnetic composite material during working is a closed loop along the circumference of the magnetic ring. The demagnetization factor of the spherical particles in any direction is 1/3, while the demagnetization factor of the flaky particles in the plane direction is almost zero, so the local demagnetization field of the flaky particles magnetized in the plane is far lower than that of the spherical particles; if the flaky magnetic powder is distributed orderly and parallelly along the surface of the magnetic ring, the nonmagnetic gap in the magnetic circuit is far smaller than that of the magnetic ring formed by spherical particles with the same volume. Therefore, the sheet alloy can effectively reduce the local demagnetizing field and the magnetic resistance of the magnetic circuit and improve the magnetic conductivity. The magnetic loss of the soft magnetic composite material at the working frequency is mainly hysteresis loss and eddy current loss. The sheet alloy is easy to magnetize along the plane direction, and has high magnetic conductivity and low magnetic hysteresis loss; meanwhile, the sheet structure can effectively reduce the influence of skin effect and reduce eddy current loss. Therefore, the sheet structure can reduce magnetic loss in both hysteresis loss and eddy current loss. The non-magnetic insulating layer in the soft magnetic composite material improves the resistivity, but reduces the content of the soft magnetic alloy and sacrifices partial magnetic performance. The magnetic oxide is used as the insulating layer, so that the magnetic conductivity of the insulating layer can be improved, the magnetic resistance can be reduced, the magnetic conductivity of the composite material can be improved, and the hysteresis loss can be reduced.
The tape casting method is a forming method which adds solvent, dispersant, binder, plasticizer and other components into powder to obtain evenly dispersed stable slurry and then produces a film with required thickness on a tape casting machine. The method has the advantages of simple equipment, continuous operation, high production efficiency, high automation level, stable process, high repeatability of the performance of the formed blank and high consistency of the size, and the blank has uniform performance.
The preparation method of the soft magnetic composite material comprises the following steps:
1) raw material preparation
The magnetic main phase is flaky soft magnetic alloy powder;
other components include: insulating medium, solvent, dispersant and adhesive;
the flaky soft magnetic alloy powder comprises: fe. Fe-Si, Fe-Ni-Mo, Fe-Si-Al, amorphous nanocrystalline alloy;
the flaky soft magnetic alloy powder is preferably prepared by a ball milling method;
the thickness of the flaky soft magnetic alloy powder is 1-10 mu m;
the diameter of the flaky soft magnetic alloy powder is 40-500 mu m;
the insulating medium comprises: glass powder, water glass, MgO and SiO2And Al2O3；
The solvent comprises: water, ethanol, methyl ethyl ketone, trichloroethylene, toluene and xylene;
the dispersant comprises: polyacrylic acid, polymethacrylic acid, phosphoric acid esters, triolein, and herring oil;
the adhesive comprises: PVA, acrylic emulsion, ammonium polyacrylate, polyvinyl acetate, PVB, polymethyl acrylate, ethyl cellulose and polymethacrylic acid;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 5-30 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 0.5-10 h, and performing vacuum degassing to obtain dispersed slurry;
wherein the content of the insulating medium is 0.5-3 wt.% of the soft magnetic alloy;
the content of the dispersing agent is 0.1-5 wt% of the solvent;
the content of the adhesive is 0.3-3 wt% of the solvent;
the volume fraction of the solid phase in the slurry is 50-90 vol%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 10-500 mu m, and the speed of the casting machine is 0.5-5 cm/s; controlling the height of the scraper to be smaller than the diameter of the flaky soft magnetic alloy disc, so that the flaky soft magnetic alloy is distributed in the direction parallel to the flow casting direction under the combined action of the scraper and the slurry rheological force;
4) drying of green bodies
Drying at the temperature of 20-30 ℃ and at the relative humidity of 30-60% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
The invention has the advantages that:
1. the flaky particles are all arranged in parallel and orderly along the plane of the magnetic ring (the working magnetic circuit direction), so that the magnetic circuit reluctance and the demagnetizing field in the working direction of the magnetic ring are reduced, and the magnetic conductivity of the magnetic ring is improved;
2. the tape casting method can continuously and efficiently prepare the soft magnetic composite material with the flaky magnetic powder oriented in parallel along the tape casting direction, and the high orientation can be obtained without a magnetic field.
Detailed Description
The present invention will be described in detail with reference to the following examples in order to better understand the objects, features and advantages of the present invention. While the invention is described in conjunction with the specific embodiments, it is not intended that the invention be limited to the specific embodiments described. On the contrary, alternatives, modifications and equivalents may be made to the embodiments as may be included within the scope of the invention as defined by the appended claims. The process parameters not specifically mentioned can be carried out according to conventional techniques.
Example 1:
1) raw material preparation
The magnetic main phase is flaky Fe powder;
the powder is prepared by a ball milling method;
the powder thickness is 1 μm and the diameter is 40 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: glass powder;
the solvent is as follows: water;
the dispersing agent is: polyacrylic acid;
the adhesive is as follows: PVA;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 5 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 0.5h, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 0.5 wt.% of the soft magnetic alloy;
dispersant content 0.1 wt.% of solvent;
binder content 0.3 wt.% of solvent;
volume fraction of solid phase in slurry 50 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 10 mu m, and the speed of the casting machine is controlled to be 0.5 cm/s;
4) drying of green bodies
Drying at 20 ℃ and relative humidity of 30% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 2:
1) raw material preparation
The magnetic main phase is flaky Fe-Si powder;
the powder is prepared by a ball milling method;
the powder thickness is 2 μm and the diameter is 60 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: water glass;
the solvent is as follows: water;
the dispersing agent is: polymethacrylic acid;
the adhesive is as follows: an acrylic emulsion;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 8 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 1h, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 0.8 wt.% of the soft magnetic alloy;
dispersant content 0.5 wt.% of solvent;
binder content 0.5 wt.% of solvent;
volume fraction of solid phase in slurry 50 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 20 mu m, and the speed of the casting machine is controlled to be 0.8 cm/s;
4) drying of green bodies
Drying at 20 ℃ and relative humidity of 40% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 3:
1) raw material preparation
The magnetic main phase is flaky Fe-Ni powder;
the powder is prepared by a ball milling method;
the powder thickness was 4 μm and the diameter was 100 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: MgO;
the solvent is as follows: ethanol;
the dispersing agent is: herring oil;
the adhesive is as follows: polyvinyl acetate;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 10 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 2 hours, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 1.0 wt.% of the soft magnetic alloy;
dispersant content 1 wt.% of solvent;
binder content 0.8 wt.% of solvent;
the solid phase volume fraction in the slurry was 55 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 40 mu m, and the speed of the casting machine is controlled to be 1 cm/s;
4) drying of green bodies
Drying at 25 ℃ and with relative humidity of 50% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 4:
1) raw material preparation
The magnetic main phase is flaky Fe-Ni-Mo powder;
the powder is prepared by a ball milling method;
the powder thickness is 5 μm and the diameter is 200 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: SiO 22；
The solvent is as follows: methyl ethyl ketone;
the dispersing agent is: triolein;
the adhesive is as follows: PVB;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 15 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 4 hours, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 1.2 wt.% of the soft magnetic alloy;
dispersant content 1.5 wt.% of solvent;
binder content 1.2 wt.% of solvent;
the solid phase volume fraction in the slurry was 60 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 60 mu m, and the speed of the casting machine is controlled to be 2 cm/s;
4) drying of green bodies
Drying at 30 ℃ and relative humidity of 60% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 5:
1) raw material preparation
The magnetic main phase is flaky Fe-Si-Al powder;
the powder is prepared by a ball milling method;
the powder thickness is 6 μm and the diameter is 300 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: al (Al)2O3；
The solvent is as follows: trichloroethylene;
the dispersing agent is: a phosphate ester;
the adhesive is as follows: polymethyl acrylate;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 20 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 6 hours, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 1.5 wt.% of the soft magnetic alloy;
dispersant content was 2 wt.% of solvent;
binder content 1.5 wt.% of solvent;
the solid phase volume fraction in the slurry was 70 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 10 mu m, and the speed of the casting machine is controlled to be 3 cm/s;
4) drying of green bodies
Drying at 20 ℃ and relative humidity of 60% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 6:
1) raw material preparation
The magnetic main phase is flaky amorphous powder;
the powder is prepared by a ball milling method;
the powder thickness was 8 μm and the diameter was 400 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: SiO 22；
The solvent is as follows: toluene;
the dispersing agent is: triolein;
the adhesive is as follows: ethyl cellulose;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 25 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 8 hours, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 2 wt.% of the soft magnetic alloy;
dispersant content was 3 wt.% of solvent;
binder content was 2 wt.% of solvent;
the volume fraction of solid phase in the slurry was 80 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 200 mu m, and the speed of the casting machine is controlled to be 4 cm/s;
4) drying of green bodies
Drying at 30 ℃ and at a relative humidity of 50% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
Example 7:
1) raw material preparation
The magnetic main phase is flaky nanocrystalline powder;
the powder is prepared by a ball milling method;
the powder thickness is 10 μm and the diameter is 500 μm;
other components include: insulating medium, solvent, dispersant and adhesive;
the insulating medium is: SiO 22；
The solvent is as follows: xylene;
the dispersing agent is: herring oil;
the adhesive is as follows: polymethacrylic acid;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 30 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 10 hours, and performing vacuum degassing to obtain dispersed slurry;
wherein the insulating medium content is 3 wt.% of the soft magnetic alloy;
dispersant content was 5 wt.% of solvent;
binder content was 3 wt.% of solvent;
the solid phase volume fraction in the slurry was 90 vol.%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 500 mu m, and the speed of the casting machine is controlled to be 5 cm/s;
4) drying of green bodies
Drying at 25 ℃ and relative humidity of 60% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.

Claims (1)

1. A preparation method of a soft magnetic composite material is characterized by comprising the following specific steps:
1) raw material preparation
The magnetic main phase is flaky soft magnetic alloy powder;
other components include: insulating medium, solvent, dispersant and adhesive;
the flaky soft magnetic alloy powder comprises: fe. Fe-Si, Fe-Ni-Mo, Fe-Si-Al or amorphous nanocrystalline alloys;
the thickness of the flaky soft magnetic alloy powder is 1-10 mu m;
the diameter of the flaky soft magnetic alloy powder is 40-500 mu m;
the insulating medium comprises: glass powder, water glass, MgO and SiO2Or Al2O3；
The solvent comprises: water, ethanol, methyl ethyl ketone, trichloroethylene, toluene or xylene;
the dispersant comprises: polyacrylic acid, polymethacrylic acid, phosphate ester, triolein, or herring oil;
the adhesive comprises: PVA, acrylic emulsion, ammonium polyacrylate, polyvinyl acetate, PVB, polymethyl acrylate, ethyl cellulose or polymethacrylic acid;
2) preparation of the slurry
Mixing the flaky magnetically soft alloy powder with an insulating medium, a solvent, a dispersant and an adhesive, and performing ball milling for 5-30 hours to prepare slurry with low viscosity and high solid phase fraction; then adding an adhesive, continuing ball milling for 0.5-10 h, and performing vacuum degassing to obtain dispersed slurry;
wherein the content of the insulating medium is 0.5-3 wt.% of the soft magnetic alloy;
the content of the dispersing agent is 0.1-5 wt% of the solvent;
the content of the adhesive is 0.3-3 wt% of the solvent;
the volume fraction of the solid phase in the slurry is 50-90 vol%;
3) tape casting
Injecting the dispersion slurry into a casting machine, wherein the height of a scraper is 10-500 mu m, and the speed of the casting machine is 0.5-5 cm/s; controlling the height of the scraper to be smaller than the diameter of the flaky soft magnetic alloy, so that the flaky soft magnetic alloy is distributed in the parallel casting direction under the combined action of the scraper and the slurry rheological force;
4) drying of green bodies
Drying at the temperature of 20-30 ℃ and at the relative humidity of 30-60% to obtain a dry and flat casting belt;
5) pressing and cutting lamination
Carrying out composite lamination pressing on the dried tape casting, and then cutting the tape casting into soft magnetic composite magnetic rings with different sizes; the obtained magnetic powder in the magnetic ring is arranged in parallel along the ring surface and has high magnetic conductivity.
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