CN109534807A - 一种抗开裂铁氧体磁芯及其制备方法 - Google Patents

一种抗开裂铁氧体磁芯及其制备方法 Download PDF

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CN109534807A
CN109534807A CN201811487043.1A CN201811487043A CN109534807A CN 109534807 A CN109534807 A CN 109534807A CN 201811487043 A CN201811487043 A CN 201811487043A CN 109534807 A CN109534807 A CN 109534807A
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parts
oxide
mixed
ferrite core
magnetic core
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张辛萌
周景
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Anhui Jingmei Electronics Co Ltd
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Anhui Jingmei Electronics Co Ltd
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Abstract

本发明提供一种抗开裂铁氧体磁芯及其制备方法，涉及铁氧体磁芯生产技术领域。所述铁氧体磁芯由以下重量份的原料制成：氧化铁50‑54份、氧化铜20‑24份、氧化锌14‑18份、氧化镍8‑12份、四氧化三铁16‑20份、氧化锂12‑16份、硫酸镁12‑16份、二氧化锰8‑12份、氢氧化锌4‑8份、五氧化二钒16‑20份、氧化钨12‑16份、硫酸钡12‑16份、二氧化钒8‑12份、氢氧化锰4‑8份，碳纤维14‑18份、偶联剂2‑4份、增韧剂1‑3份、抗收缩剂1‑3份。本发明克服了现有技术的不足，有效提高了磁芯的抗裂、阻抗和磁导率等特性，使得各组分连接紧密，防止在外界挤压或低温状态下发生开裂的现象，从而大大延长了磁芯的使用寿命，使用效果好，同时有效消除了磁芯的内应力，磁芯性能优越，适宜推广。

Description

一种抗开裂铁氧体磁芯及其制备方法
技术领域
本发明涉及铁氧体磁芯生产技术领域，具体涉及一种抗开裂铁氧体磁芯及其制备方法。
背景技术
铁氧体磁芯是一种高频导磁材料，主要做高频变压器、高频磁环等等，增大导磁率、提高电感品质因素，变压器里面用。随着数字通信技术和光纤通信技术的快速发展，传统的模拟通信设备不断地更新淘汰。在电子电路宽带变压器，综合业务数据网、局域网、广域网、背景照明等领域的脉冲变压器和光伏逆变器中共模滤波电感用的高磁导率铁氧体磁芯，由于变压器等朝着小型化发展，因此对铁氧体磁芯的磁特性提出了更高要求。
目前的铁氧体磁芯的配方组成和生产工艺不合理，导致铁氧体磁芯的性能较差。特别是在外界挤压或者低温状态下，铁氧体磁芯内各组分联结不紧密，使制备的铁氧体磁芯容易发生开裂的现象，从而影响其正常使用，给工作人员带来了较大的麻烦。
发明内容
针对现有技术不足，本发明提供一种抗开裂铁氧体磁芯及其制备方法，本发明克服了现有技术的不足，有效提高了磁芯的抗裂、阻抗和磁导率等特性，使得各组分连接紧密，防止在外界挤压或低温状态下发生开裂的现象，从而大大延长了磁芯的使用寿命，使用效果好，同时有效消除了磁芯的内应力，磁芯性能优越，适宜推广。
为实现以上目的，本发明的技术方案通过以下技术方案予以实现：
一种抗开裂铁氧体磁芯，所述铁氧体磁芯由以下重量份的原料制成：氧化铁50-54份、氧化铜20-24份、氧化锌14-18份、氧化镍8-12份、四氧化三铁16-20份、氧化锂12-16份、硫酸镁12-16份、二氧化锰8-12份、氢氧化锌4-8份、五氧化二钒16-20份、氧化钨12-16份、硫酸钡12-16份、二氧化钒8-12份、氢氧化锰4-8份，碳纤维14-18份、偶联剂2-4份、增韧剂1-3份、抗收缩剂1-3份。
优选的，所述铁氧体磁芯由以下重量份的原料制成：氧化铁52份、氧化铜22份、氧化锌16份、氧化镍10份、四氧化三铁18份、氧化锂14份、硫酸镁14份、二氧化锰10份、氢氧化锌6份、五氧化二钒18份、氧化钨14份、硫酸钡14份、二氧化钒10份、氢氧化锰6份，碳纤维16份、偶联剂3份、增韧剂2份、抗收缩剂2份。
优选的，所述偶联剂由硅烷偶联剂和钛酸酯偶联剂以质量比为3:1混合而成。
优选的，所述增韧剂由聚酰胺、聚碳酸酯纤维和聚乙烯醇缩丁醛以质量比为5:4:1混合而成。
优选的，所述抗收缩剂为单甘脂。
一种抗开裂铁氧体磁芯的制备方法，所述铁氧体磁芯的制备方法包括以下步骤：
(1)将氧化铁、氧化铜、氧化锌和氧化镍混合后加入破碎机中，再加入碳纤维进行混合破碎，后将其混合物倒入混合机中，再加入配方1/2量的偶联剂和混合物4-8倍体积的聚乙烯醇溶液进行混合，混合20-30min得磁芯基料备用；
(2)将四氧化三铁、氧化锂、硫酸镁、二氧化锰和氢氧化锌混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(1)中的混合机内与磁芯基料混合，并加入剩余的偶联剂，继续混合20-30min得磁芯物料备用；
(3)将五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(2)中的混合机内与磁芯物料混合，继续混合20-30min得磁芯原料备用；
(4)向上述步骤(3)中的混合机中加入增韧剂和抗收缩剂，继续混合1-2h后将其混合物倒入砂磨机中进行混合研磨，再将其混合物通过压制成型得到磁芯坯料；
(5)将上述步骤(4)中的磁芯坯料倒入烧结炉中，先以5-8℃/min的速度升温至700-800℃，保温烧结1-2h后以2-5℃/min的速度升温至1150-1200℃，保温烧结2-4h后以8-10℃/min的速度降至500-600℃，后自然冷却至室温得到产品。
优选的，步骤(1)、(2)和(3)中各混合物均破碎至粒度为2-5mm，且步骤(4)中的混合物研磨至粒度为0.01-0.05mm。
优选的，步骤(1)中的聚乙烯醇溶液的浓度为1.2-1.6％，且步骤(1)、(2)、(3)和(4)中均以200-400r/min的速度进行搅拌。
本发明提供一种抗开裂铁氧体磁芯及其制备方法，与现有技术相比优点在于：
(1)本发明采用四氧化三铁、氧化锂、硫酸镁、二氧化锰、氢氧化锌、五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰等原料制成两种辅料，并将其依次添加混合到磁芯基料中，有效提高了磁芯的抗裂性能，使得各组分连接紧密，防止在外界挤压或低温状态下发生开裂的现象，从而大大延长了磁芯的使用寿命，使用效果好，同时有效提高了磁芯的阻抗和磁导率等特性，磁芯性能优越，适宜推广；
(2)本发明在磁芯基料中还添加有碳纤维，通过破碎、混合和研磨等工序使其分散为纤维单丝，纤维单丝纵横交错，从而利用其优异的抗拉强度和分散性等性能，碳纤维与多种辅料相互配合，有效提高了磁芯的抗裂性能，防止其在外界影响下发生开裂，性能优越；
(3)本发明采用偶联剂、增韧剂和抗收缩剂等添加剂，并将其混合到磁芯原料内，有效增强了各组分的联结性和磁芯的韧性、抗收缩性，最后依次通过中速和低速升温的方式使磁芯坯料得到有效烧结，再依次通过快速降温再自然冷却的方式有效降低了磁芯的内应力，磁芯品质优良，便于使用。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面结合本发明实施例对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，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作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1：
一种抗开裂铁氧体磁芯，所述铁氧体磁芯由以下重量份的原料制成：氧化铁50份、氧化铜20份、氧化锌14份、氧化镍8份、四氧化三铁16份、氧化锂12份、硫酸镁12份、二氧化锰8份、氢氧化锌4份、五氧化二钒16份、氧化钨12份、硫酸钡12份、二氧化钒8份、氢氧化锰4份，碳纤维14份、偶联剂2份、增韧剂1份、抗收缩剂1份。
其中，所述偶联剂由硅烷偶联剂和钛酸酯偶联剂以质量比为3:1混合而成；所述增韧剂由聚酰胺、聚碳酸酯纤维和聚乙烯醇缩丁醛以质量比为5:4:1混合而成；所述抗收缩剂为单甘脂。
一种抗开裂铁氧体磁芯的制备方法，所述铁氧体磁芯的制备方法包括以下步骤：
(1)将氧化铁、氧化铜、氧化锌和氧化镍混合后加入破碎机中，再加入碳纤维进行混合破碎，后将其混合物倒入混合机中，再加入配方1/2量的偶联剂和混合物4-8倍体积的聚乙烯醇溶液进行混合，混合20-30min得磁芯基料备用；
(2)将四氧化三铁、氧化锂、硫酸镁、二氧化锰和氢氧化锌混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(1)中的混合机内与磁芯基料混合，并加入剩余的偶联剂，继续混合20-30min得磁芯物料备用；
(3)将五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(2)中的混合机内与磁芯物料混合，继续混合20-30min得磁芯原料备用；
(4)向上述步骤(3)中的混合机中加入增韧剂和抗收缩剂，继续混合1-2h后将其混合物倒入砂磨机中进行混合研磨，再将其混合物通过压制成型得到磁芯坯料；
(5)将上述步骤(4)中的磁芯坯料倒入烧结炉中，先以5-8℃/min的速度升温至700-800℃，保温烧结1-2h后以2-5℃/min的速度升温至1150-1200℃，保温烧结2-4h后以8-10℃/min的速度降至500-600℃，后自然冷却至室温得到产品。
其中，步骤(1)、(2)和(3)中各混合物均破碎至粒度为2-5mm，且步骤(4)中的混合物研磨至粒度为0.01-0.05mm；步骤(1)中的聚乙烯醇溶液的浓度为1.2-1.6％，且步骤(1)、(2)、(3)和(4)中均以200-400r/min的速度进行搅拌。
实施例2：
一种抗开裂铁氧体磁芯，所述铁氧体磁芯由以下重量份的原料制成：氧化铁52份、氧化铜22份、氧化锌16份、氧化镍10份、四氧化三铁18份、氧化锂14份、硫酸镁14份、二氧化锰10份、氢氧化锌6份、五氧化二钒18份、氧化钨14份、硫酸钡14份、二氧化钒10份、氢氧化锰6份，碳纤维16份、偶联剂3份、增韧剂2份、抗收缩剂2份。
其中，所述偶联剂由硅烷偶联剂和钛酸酯偶联剂以质量比为3:1混合而成；所述增韧剂由聚酰胺、聚碳酸酯纤维和聚乙烯醇缩丁醛以质量比为5:4:1混合而成；所述抗收缩剂为单甘脂。
一种抗开裂铁氧体磁芯的制备方法，所述铁氧体磁芯的制备方法包括以下步骤：
(1)将氧化铁、氧化铜、氧化锌和氧化镍混合后加入破碎机中，再加入碳纤维进行混合破碎，后将其混合物倒入混合机中，再加入配方1/2量的偶联剂和混合物4-8倍体积的聚乙烯醇溶液进行混合，混合20-30min得磁芯基料备用；
(2)将四氧化三铁、氧化锂、硫酸镁、二氧化锰和氢氧化锌混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(1)中的混合机内与磁芯基料混合，并加入剩余的偶联剂，继续混合20-30min得磁芯物料备用；
(3)将五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(2)中的混合机内与磁芯物料混合，继续混合20-30min得磁芯原料备用；
(4)向上述步骤(3)中的混合机中加入增韧剂和抗收缩剂，继续混合1-2h后将其混合物倒入砂磨机中进行混合研磨，再将其混合物通过压制成型得到磁芯坯料；
(5)将上述步骤(4)中的磁芯坯料倒入烧结炉中，先以5-8℃/min的速度升温至700-800℃，保温烧结1-2h后以2-5℃/min的速度升温至1150-1200℃，保温烧结2-4h后以8-10℃/min的速度降至500-600℃，后自然冷却至室温得到产品。
其中，步骤(1)、(2)和(3)中各混合物均破碎至粒度为2-5mm，且步骤(4)中的混合物研磨至粒度为0.01-0.05mm；步骤(1)中的聚乙烯醇溶液的浓度为1.2-1.6％，且步骤(1)、(2)、(3)和(4)中均以200-400r/min的速度进行搅拌。
实施例3：
一种抗开裂铁氧体磁芯，所述铁氧体磁芯由以下重量份的原料制成：氧化铁54份、氧化铜24份、氧化锌18份、氧化镍12份、四氧化三铁20份、氧化锂6份、硫酸镁16份、二氧化锰12份、氢氧化锌8份、五氧化二钒20份、氧化钨16份、硫酸钡16份、二氧化钒12份、氢氧化锰8份，碳纤维18份、偶联剂4份、增韧剂3份、抗收缩剂3份。
其中，所述偶联剂由硅烷偶联剂和钛酸酯偶联剂以质量比为3:1混合而成；所述增韧剂由聚酰胺、聚碳酸酯纤维和聚乙烯醇缩丁醛以质量比为5:4:1混合而成；所述抗收缩剂为单甘脂。
一种抗开裂铁氧体磁芯的制备方法，所述铁氧体磁芯的制备方法包括以下步骤：
(1)将氧化铁、氧化铜、氧化锌和氧化镍混合后加入破碎机中，再加入碳纤维进行混合破碎，后将其混合物倒入混合机中，再加入配方1/2量的偶联剂和混合物4-8倍体积的聚乙烯醇溶液进行混合，混合20-30min得磁芯基料备用；
(2)将四氧化三铁、氧化锂、硫酸镁、二氧化锰和氢氧化锌混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(1)中的混合机内与磁芯基料混合，并加入剩余的偶联剂，继续混合20-30min得磁芯物料备用；
(3)将五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(2)中的混合机内与磁芯物料混合，继续混合20-30min得磁芯原料备用；
(4)向上述步骤(3)中的混合机中加入增韧剂和抗收缩剂，继续混合1-2h后将其混合物倒入砂磨机中进行混合研磨，再将其混合物通过压制成型得到磁芯坯料；
(5)将上述步骤(4)中的磁芯坯料倒入烧结炉中，先以5-8℃/min的速度升温至700-800℃，保温烧结1-2h后以2-5℃/min的速度升温至1150-1200℃，保温烧结2-4h后以8-10℃/min的速度降至500-600℃，后自然冷却至室温得到产品。
其中，步骤(1)、(2)和(3)中各混合物均破碎至粒度为2-5mm，且步骤(4)中的混合物研磨至粒度为0.01-0.05mm；步骤(1)中的聚乙烯醇溶液的浓度为1.2-1.6％，且步骤(1)、(2)、(3)和(4)中均以200-400r/min的速度进行搅拌。
实施例4：
检测本发明铁氧体磁芯的各项性能，选取上述实施例1-3所制得的铁氧体磁芯和市面上普通的铁氧体磁芯，以实施例1-3所得铁氧体磁芯为实验组1-3，普通铁氧体磁芯为对照组，结果如下表所示：
组别 实验组1 实验组2 实验组3 对照组
抗拉强度(kg/mm) 12.1 15.4 13.8 8.5
抗弯强度(kg/mm) 16.3 18.2 17.9 10.0
阻抗(D) 175 205 187 128
磁导率 4448 5243 4824 2375
由上表可知，本发明所制得铁氧体磁芯的各项性能远远优于普通铁氧体磁芯，且实施例2所制得的铁氧体磁芯的各项性能最佳。
需要说明的是，在本文中，诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下，由语句“包括一个……”限定的要素，并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。

Claims (8)

1.一种抗开裂铁氧体磁芯，其特征在于，所述铁氧体磁芯由以下重量份的原料制成：氧化铁50-54份、氧化铜20-24份、氧化锌14-18份、氧化镍8-12份、四氧化三铁16-20份、氧化锂12-16份、硫酸镁12-16份、二氧化锰8-12份、氢氧化锌4-8份、五氧化二钒16-20份、氧化钨12-16份、硫酸钡12-16份、二氧化钒8-12份、氢氧化锰4-8份，碳纤维14-18份、偶联剂2-4份、增韧剂1-3份、抗收缩剂1-3份。
2.根据权利要求1所述的一种抗开裂铁氧体磁芯，其特征在于，所述铁氧体磁芯由以下重量份的原料制成：氧化铁52份、氧化铜22份、氧化锌16份、氧化镍10份、四氧化三铁18份、氧化锂14份、硫酸镁14份、二氧化锰10份、氢氧化锌6份、五氧化二钒18份、氧化钨14份、硫酸钡14份、二氧化钒10份、氢氧化锰6份，碳纤维16份、偶联剂3份、增韧剂2份、抗收缩剂2份。
3.根据权利要求1-2所述的一种抗开裂铁氧体磁芯，其特征在于，所述偶联剂由硅烷偶联剂和钛酸酯偶联剂以质量比为3:1混合而成。
4.根据权利要求1-2所述的一种抗开裂铁氧体磁芯，其特征在于，所述增韧剂由聚酰胺、聚碳酸酯纤维和聚乙烯醇缩丁醛以质量比为5:4:1混合而成。
5.根据权利要求1-2所述的一种抗开裂铁氧体磁芯，其特征在于，所述抗收缩剂为单甘脂。
6.一种抗开裂铁氧体磁芯的制备方法，其特征在于，所述铁氧体磁芯的制备方法包括以下步骤：
(1)将氧化铁、氧化铜、氧化锌和氧化镍混合后加入破碎机中，再加入碳纤维进行混合破碎，后将其混合物倒入混合机中，再加入配方1/2量的偶联剂和混合物4-8倍体积的聚乙烯醇溶液进行混合，混合20-30min得磁芯基料备用；
(2)将四氧化三铁、氧化锂、硫酸镁、二氧化锰和氢氧化锌混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(1)中的混合机内与磁芯基料混合，并加入剩余的偶联剂，继续混合20-30min得磁芯物料备用；
(3)将五氧化二钒、氧化钨、硫酸钡、二氧化钒和氢氧化锰混合后加入破碎机中进行混合破碎，后将其混合物倒入上述步骤(2)中的混合机内与磁芯物料混合，继续混合20-30min得磁芯原料备用；
(4)向上述步骤(3)中的混合机中加入增韧剂和抗收缩剂，继续混合1-2h后将其混合物倒入砂磨机中进行混合研磨，再将其混合物通过压制成型得到磁芯坯料；
(5)将上述步骤(4)中的磁芯坯料倒入烧结炉中，先以5-8℃/min的速度升温至700-800℃，保温烧结1-2h后以2-5℃/min的速度升温至1150-1200℃，保温烧结2-4h后以8-10℃/min的速度降至500-600℃，后自然冷却至室温得到产品。
7.根据权利要求6所述的一种抗开裂铁氧体磁芯的制备方法，其特征在于：步骤(1)、(2)和(3)中各混合物均破碎至粒度为2-5mm，且步骤(4)中的混合物研磨至粒度为0.01-0.05mm。
8.根据权利要求6所述的一种抗开裂铁氧体磁芯的制备方法，其特征在于：步骤(1)中的聚乙烯醇溶液的浓度为1.2-1.6％，且步骤(1)、(2)、(3)和(4)中均以200-400r/min的速度进行搅拌。
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