CN109727763A - 宽频高导磁环的生产工艺 - Google Patents

宽频高导磁环的生产工艺 Download PDF

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CN109727763A
CN109727763A CN201910093696.XA CN201910093696A CN109727763A CN 109727763 A CN109727763 A CN 109727763A CN 201910093696 A CN201910093696 A CN 201910093696A CN 109727763 A CN109727763 A CN 109727763A
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magnet ring
broad
production technology
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crawler belt
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CN109727763B (zh
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燕杰
陈志华
谢文革
赵武奇
吴斌
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Zhejiang Chunhui Magnetoelectric Technology Co Ltd
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Zhejiang Chunhui Magnetoelectric Technology Co Ltd
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Abstract

本发明公开了一种宽频高导磁环的生产工艺，包括主料和辅料，其制备步骤包括：S1、混合处理，取用Fe2O3 45.0‑65.0mol％、Mn3O425.0‑44.0mol％、ZnO 5‑15.0mol％混合处理，然后在800‑1500℃下进行预烧；S2、粉碎处理，将经预烧处理后原料震荡粉碎45‑65min；S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，超声波震荡60‑120min;S4、向物料中中分别加入TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO作为添加剂，改善材料的频率特性和损耗特性；S4、喷雾造粒;S5、成型处理。本发明满足了轻薄小型化、高性能化和高密度化的电子元器件的日益增长的需求，具有更高的磁导率，初始磁导率达5K。

Description

宽频高导磁环的生产工艺
技术领域
本发明属于软磁抗EMI（Electromagnetic Interference，简称 EMI）技术领域，尤其是涉及一种宽频高导磁环的生产工艺。
背景技术
高磁导率铁氧体磁粉、磁芯是实现程控通讯、数字技术、网络通讯彩电等电子设备中用作电感器、滤波器、脉冲变压器等产品使其小型化、轻量化必不可少的电子材料，不断提高磁性材料中的初始磁导率，一直是从事该专业的工程技术人员和生产厂商的追求；到目前为止，用氧化物法生产的高磁导率材料只能达到10000左右，且材料的性能指标，如损耗、频率特性、居里温度等都不尽人意。
发明内容
本发明为了克服现有技术的不足，提供一种损耗低 频率高的宽频高导磁环的生产工艺。
为了实现上述目的，本发明采用以下技术方案：一种宽频高导磁环的生产工艺，包括主料和辅料，其制备步骤包括
S1、混合处理，取用Fe2O3 45.0-65.0mol％、Mn3O4 25.0-44.0mol％、ZnO 5-15.0mol％混合处理，然后在800-1150℃下进行预烧；
S2、粉碎处理，将经预烧处理后原料震荡粉碎45-65min；
S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，超声波震荡60-120min;
S4、向物料中中分别加入 TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO 作为添加剂，改善材料的频率特性和损耗特性；
S4、喷雾造粒;
S5、成型处理；
S6、烧结处理，成型后所得的毛坯置于氮气燃烧窑当中，在氧含量0.50%-35.00%的气氛中烧结处理。
优选的，所述醇溶液为PVA 溶液。
优选的，步骤S4中添加剂的各组分量为TiO2 45-65ppm、MoO3 60-78ppm、V2O5 20-42ppm、Bi2O3 58-65ppm、CaCO3 32-42ppm、SiO2 55-61ppm、Nb2O5 50-66ppm、SnO2 48-68ppm、Co2O3 33-42ppm、CuO 45-65ppm。
优选的，步骤S2粉碎后颗粒粒径为90-150μm。
优选的，所述氮气燃烧窑包括窑体、用于向推动磁环进入至窑体内的进料装置及出料装置，所述窑体内设有用于将磁环由所述窑体一端输送至另一端的输送部件、用于加热窑体内部空气的多个加热部件、用于向窑体内输入气体的送气部件及用于降低所述窑体一端温度以冷却磁环的冷却部件，所述冷却部件设于所述窑体一端。
优选的，所述输送部件包括设于所述窑体内的支架、设于所述支架上的履带、用于驱动所述履带转动的驱动结构及支撑所述履带的轨道，所述轨道设于所述支架上；通过设置履带，其在窑体内的时候，其具有耐高温特性，其可在一千多度的条件下稳定的运行而不会发生形变，并且因为设置的是履带，其在转动的过程中还会形成平整的平面，从而在该过程中可实现支撑件进行支撑，保障支撑件的支撑效果。
优选的，所述履带包括多个第一横杆和多个与所述第一横杆间隔设置的第二横杆，所述第一横杆与所述第二横杆活动连接；将履带设为第一横杆和第二横杆，其可便于在使用过程中履带发生形变，从而实现履带进行往复转动，并且第一、第二横杆会形成平整的平面，可对支撑板进行良好的支撑。
优选的，所述输送部件还包括用于供磁环放置的支撑板，所述支撑板上设有圆盘形设置齿块，所述支架上设有与所述齿块相配合的齿条；通过设置齿条可与齿块之间相互啮合，因此支撑板可旋转，实现边加热边旋转的过程，使得在加热的过程中磁环可尽可能的受热均匀，保持磁环加热后的成型效果。
优选的，所述履带上端面向下凹陷形成有环形的旋转凹轨，所述凹轨内设有多个第一滚珠，所述履带上设有直径大于所述第一滚珠的第二滚珠，所述齿块中部设有与所述第二滚珠相配合的凹陷部；通过设置第二滚珠与所述凹陷部相接触，可将整个齿块进行支撑；而第一就滚珠则可对齿块的边缘进行支撑，因此在齿块和齿条相接触的时候，因此整个支撑板可发生转动，其能带动磁环履带上进行旋转；而在支撑板上设置凹陷部，其可便于第二滚珠位于所述凹陷部内，从而限制支撑板发生移动，保持支撑板在运动的过程中随着履带同步运动，保障履带和支撑板之间运动的同步性，使得支撑板能稳定的转动，提高支撑板运动的稳定性。
综上所述，本发明满足了轻薄小型化、高性能化和高密度化的电子元器件的日益增长的需求，具有更高的磁导率，初始磁导率达5K；更高的直流叠加特性；提高磁芯对复杂环境的适应能力，具备相对较宽的温度特性。
附图说明
图1为本发明的结构示意图。
图2为本发明的局部结构示意图一。
图3为本发明的局部结构示意图二。
图4为本发明的局部结构示意图三。
图5为图4中A的放大图。
图6为本发明的局部结构示意图四。
图7为本发明的局部结构示意图五。
图8为本发明履带的局部结构示意图一。
图9为本发明履带的局部结构示意图二。
图10为本发明支撑板的结构示意图。
图11为本发明支撑板的剖视图。
图12为本发明限高部件的结构示意图。
具体实施方式
为了使本技术领域的人员更好的理解本发明方案，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整的描述。
实施例一
一种宽频高导磁环的生产工艺，包括主料和辅料，其制备步骤包括：
S1、混合处理，取用Fe2O3 45.0mol％、Mn3O4 25.0mol％、ZnO 5mol％混合处理，然后在800℃下进行预烧；
S2、粉碎处理，将经预烧处理后原料震荡粉碎45min，并且粉碎后颗粒粒径为90μm；
S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，该醇溶液为PVA 溶液超声波震荡60-120min;
S4、向物料中中分别加入 TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO 作为添加剂，改善材料的频率特性和损耗特性；
S4、喷雾造粒;
S5、成型处理；
S6、烧结处理，成型后所得的毛坯置于氮气燃烧窑当中，在氧含量0.50%-35.00%的气氛中烧结处理。
具体的，添加剂的各组分量为TiO2 45ppm、MoO3 60ppm、V2O5 20ppm、Bi2O358ppm、CaCO3 32ppm、SiO2 55ppm、Nb2O5 50ppm、SnO2 48ppm、Co2O3 33ppm、CuO 45ppm。
实施例二
一种宽频高导磁环的生产工艺，包括主料和辅料，其制备步骤包括：
S1、混合处理，取用Fe2O3 45.0-65.0mol％、Mn3O4 25.0-44.0mol％、ZnO 5-15.0mol％混合处理，然后在950℃下进行预烧；
S2、粉碎处理，将经预烧处理后原料震荡粉碎45-65min，并且粉碎后颗粒粒径为90-150μm；
S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，该醇溶液为PVA 溶液超声波震荡60-120min;
S4、向物料中中分别加入 TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO 作为添加剂，改善材料的频率特性和损耗特性；
S4、喷雾造粒;
S5、成型处理；
S6、烧结处理，成型后所得的毛坯置于氮气燃烧窑当中，在氧含量0.50%-35.00%的气氛中烧结处理。
具体的，添加剂的各组分量为TiO2 45-65ppm、MoO3 69ppm、V2O5 22ppm、Bi2O360ppm、CaCO3 38ppm、SiO2 58ppm、Nb2O5 56ppm、SnO2 60ppm、Co2O3 38ppm、CuO 55ppm。
实施例三
一种宽频高导磁环的生产工艺，包括主料和辅料，其制备步骤包括：
S1、混合处理，取用Fe2O3 65.0mol％、Mn3O4 44.0mol％、ZnO 15.0mol％混合处理，然后在1150℃下进行预烧；
S2、粉碎处理，将经预烧处理后原料震荡粉碎65min，并且粉碎后颗粒粒径为150μm；
S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，该醇溶液为PVA 溶液超声波震荡120min;
S4、向物料中中分别加入 TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO 作为添加剂，改善材料的频率特性和损耗特性；
S4、喷雾造粒;
S5、成型处理；
S6、烧结处理，成型后所得的毛坯置于氮气燃烧窑当中，在氧含量0.50%-35.00%的气氛中烧结处理。
具体的，添加剂的各组分量为TiO2 65ppm、MoO3 78ppm、V2O5 42ppm、Bi2O365ppm、CaCO3 42ppm、SiO2 61ppm、Nb2O5 66ppm、SnO2 68ppm、Co2O3 42ppm、CuO 65ppm。
如图1-12所示，实施例1-3中步骤S6所述氮气燃烧窑包括窑体1、进料装置及出料装置，其中磁环通过进料装置输送到窑体1内进行加热，然后再经过出料装置输出；具体的，所述窑体1内设有输送部件2、加热部件3、送气部件4及冷却部件5，所述窑体1为一方形的窑体，该窑体1上设有两块由上至下倾斜设置的导热板11，该导热板11为的弧形设置，该导热板11有两块，并且两块导热板11为对称设置；因此所述加热部件3上散出的热量会与所述导热板11相接触，然后被反向弹回，形成循环流动的热量，该方式可保障在对磁环进行加热时候，对位于下部的多个磁环进行加热；所述加热部件3为设于所述窑体1内的电阻丝，其通过导电发出热量；所述送气部件4包括氮气管道41和氧气管道42，所述氮气管道41用于输送氮气，使得窑体1内部处于氮气氛围状态下；所述氧气管道42用于输送氧气；并且所述氮气管道41的端部向上弯折，使得氮气管道41为朝上设置，所述氧气管道42也为朝上设置，因此在氮气管道41和氧气管道42向着窑体1内输入气体时，气体撞击到窑体1的顶部和导热板11上，然后氮气和氧气均会循环流动；该设置方式避免局部氧气和氮气的浓度过高而造成对磁环进行加热的时候，造成构成磁环的铁氧材料反应不完全，其能提高磁环在经过加热后的效果。
进一步的，所述输送部件2包括设于所述窑体1内的支架21、履带22、驱动结构23及轨道24，所述支架21为金属架，该支架21设于所述窑体1内；所述驱动结构23为由主动辊231、从动辊232及电机构成，所述主动辊231设于所述支架21上，并且该主动辊231在所述电机驱动下发生转动，并且在所述主动辊231的两端设有一多个咬齿234，所述咬齿234为金属齿，该咬齿234凸于所述主动辊231的表面；所述咬齿234与所述履带22相啮合，从而带动所述履带22转动；所述从动辊232设在所述支架21的另一端，所述从动辊232的两端与所述支架21活动连接。
具体的，所述履带22为套在所述主动辊231和从动辊232上的金属履带；该履带22包括多个第一横杆221和多个第二横杆222，所述第一横杆221为一金属方条，所述第二横杆222同样为金属方条；在所述第一横杆221的一侧设有第一凸出部291，另一侧设有深度与所述第一凸出部291厚度相同的第一凹部292，第二横杆222的一侧设有厚度与所述第一第一凸出部291深度一致的第二凸出部293，第二横杆222的另一侧设有深度与所述第一凸出部291厚度一致的第二凹部294，因此在所述履带22转动的时候，所述第一凸出部291可嵌入到所述第二凹部294内，同样的第二凸部293可嵌入到所述第一凹部291内，从而履带22能形成平板状。
具体的，所述第一横杆221和第二横杆222的端部通过铰链实现活动连接；在所述第一横杆221的两侧设有第一缺口229，所述第二横杆222的两侧设有第二缺口228，所述第一缺口229和第二缺口22形成一凹槽，所述咬齿234插入到所述第一缺口229和第二缺口228之间；从而带动所述履带22转动，该设置方式可有效提高履带22运动的稳定性，该设置还能避免在履带22上焊接凸部，其减小履带22的重量。
进一步的，所述第一横杆221和第二横杆222的端部通过的铰链活动连接，在所述履带22上设有圆形佘设置的旋转凹轨223，所述旋转凹轨223为圆形设置凹轨，该旋转凹轨223为履带上端面向下凹陷形成，在所述旋转凹轨223内设有多个第一滚珠224，所述第一滚珠224为金属钢珠，并且所述第一滚珠224为设在第一或第二横杆上；在所述旋转凹轨223所圈起来的圆形正中间设有第二滚珠225，所述第二滚珠225为金属滚珠，所述第二滚珠225的直径大于所述第一滚珠224；因此所述第二滚珠225高出所述履带22上端面。
在所述支架上设有轨道28，所述轨道28为的金属梁，在所述轨道28上为一中间向下凹陷的轨道，所述第一、第二横杆上均设有的第三滚珠281，所述第三滚珠281位于所述轨道28内；该轨道28的设置可对履带22进行支撑，保持履带22在支撑磁环的时候，第三滚珠281位于所述轨道28内。
具体的，所述输送部件2还包括用于支撑磁环的支撑板27，所述支撑板27为的金属板，磁环直接放置到支撑板27上；所述支撑板27上连接有齿块271，所述齿块271为的圆盘形的金属块，并且齿块271的侧壁具有金属齿；所述齿块271上具有凹陷部272，所述凹陷部272为锥形设置，同时在所述齿块271上设有与所述凹陷部272相连通的防滑凹部273，该防滑凹部273为近似于半球形的凹部，该防滑凹部273位于所述防滑凹部273的顶端；在所述支撑板27放置到履带22上的时候，第二滚珠225会与凹陷部272的内壁相接触，从而在履带22的震动和磁环的重力作用下，凹陷部272的内壁与所述第二滚珠225相接触，然后整个支撑板27会发生活动，进而防滑凹部273会套入到所述第二滚珠225上，从而支撑板27会发生转动。
进一步的，在所述支架21的上设有两个齿条211，所述齿条211为具有咬齿的金属条；在防脱凹部233套入第二滚珠225之后，支撑板27随着履带22运动的时候，支撑板27会与齿条211相接触，从而支撑板27转动；在所述支架21上设有推动部件24，所述推动部件24包括推杆241和推动板242，所述推杆241为金属杆，该推杆241通过气缸进行活动，所述推杆241为倾斜设置；所述推板242为金属板，该推板242与所述推杆241相连，从而推杆241通过推板242可将支撑板27推出所述窑体1。
具体的，所述冷却部件5包括布设于所述窑体1一端处的循环管道51和进水管道52，所循环管道51位于所述窑体1内的上部，该循环管道51连接有出水管道53和所述进水管道52，进水管道52通过水泵泵送到所循环管道51内进行流动，然后再经由所述出水管道53排出所述窑体1外，并且所述窑体1外具有散热槽54，所述散热槽54设于所述窑体1侧壁上，所述出水管道53上的水会进入到散热槽54当中进行散热处理，然后再集中流到清水池当中，进而被泵送后再次流动；通过该设置方式可有效的降低窑体1一端的温度，进而也吸收磁环上的热量。
具体的，所述进料装置包括架体61、传送部件、限高部件及推送部件，所述架体61为金属架，所述传送部件设于所述架体61上，该传送部件包括第一辊体、第二辊体、电机613及传送带614，所述第一辊体和第二辊体均设于所述架体61上，然后所述电机613通过轴与所述第一辊体相连以带动所述第一辊体转动，所述传送带614套在所述第一辊体和第二辊体上，因此放置有磁环的支撑板27上时，该传送带614运输支撑板27到所述窑体1一端；所述限高部件包括支杆621和限高杆622，所述支杆621为金属杆，所述限高杆622的端部连接有弹簧623，所述弹簧623下端与所述限高杆622相连，所述弹簧623的上端连接有连接杆624，所述连接杆624插入到所述支杆621当中，并且所述支杆621上设有锁定螺栓625，通过锁定螺栓625对所述连接杆624进行固定。
进一步的，在所述架体61上设有多个限位块63，该限位块63上设有弹性件631，所述弹性件631为金属弹簧，该弹性件631的一端与所述限位块63相连，另一端与所述架体61相连；因此在传送带输送到架体61上的时候，限位块63会对所述支撑板27进行限位；所述推送部件包括推送气缸641和推送块642，所述推送气缸642可推动所述推送块运动，从通过推送块推动所述支撑板27向前运动，进而支撑板27会落到所述履带22上；同时需要特别指出的是，所述支架的高度高于履带3-6厘米。
进一步的，所述出料装置包括金属架和输送带，所述输送带的高度低于所述履带上端面3-6厘米。
显然，所描述的实施例仅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他实施例，都应当属于本发明保护的范围。

Claims (9)

1.一种宽频高导磁环的生产工艺，包括主料和辅料，其特征在于：其制备步骤包括：
S1、混合处理，取用Fe2O3 45.0-65.0mol％、Mn3O4 25.0-44.0mol％、ZnO 5-15.0mol％混合处理，然后在800-1150℃下进行预烧；
S2、粉碎处理，将经预烧处理后原料震荡粉碎45-65min；
S3、加醇搅拌，向经过粉碎后物料当中加入醇溶液，超声波震荡60-120min;
S4、向物料中中分别加入 TiO2、MoO3、V2O5、Bi2O3、CaCO3、SiO2、Nb2O5、SnO2、Co2O3、CuO 作为添加剂，改善材料的频率特性和损耗特性；
S4、喷雾造粒;
S5、成型处理；
S6、烧结处理，成型后所得的毛坯置于氮气燃烧窑当中，在氧含量0.50%-35.00%的气氛中烧结处理。
2.根据权利要求1所述的宽频高导磁环的生产工艺，其特征在于：所述醇溶液为PVA 溶液。
3.根据权利要求1所述的宽频高导磁环的生产工艺，其特征在于：步骤S4中添加剂的各组分量为TiO2 45-65ppm、MoO3 60-78ppm、V2O5 20-42ppm、Bi2O3 58-65ppm、CaCO3 32-42ppm、SiO2 55-61ppm、Nb2O5 50-66ppm、SnO2 48-68ppm、Co2O3 33-42ppm、CuO 45-65ppm。
4.根据权利要求1所述的宽频高导磁环的生产工艺，其特征在于：步骤S2粉碎后颗粒粒径为90-150μm。
5.根据权利要求1所述的一种宽频高导磁环的生产工艺，其特征在于：所述氮气燃烧窑包括窑体（1）、用于推送磁环进入至窑体内的进料装置及出料装置，所述窑体（1）内设有用于将磁环由所述窑体（1）一端输送至另一端的输送部件（2）、设于所述窑体（1）内的多个加热部件（3）、用于向所述窑体（1）内输入气体的送气部件（4）及用于降低所述窑体（1）一端温度以冷却磁环的冷却部件（5），所述冷却部件（5）设于所述窑体（1）一端。
6.根据权利要求5所述的一种宽频高导磁环的生产工艺，其特征在于：所述输送部件（2）包括设于所述窑体（1）内的支架（21）、设于所述支架（21）上的履带（22）、用于驱动所述履带（22）转动的驱动结构（23）及支撑所述履带（22）的轨道（28），所述轨道（28）设于所述支架（21）上。
7.根据权利要求6所述的一种宽频高导磁环的生产工艺，其特征在于：所述履带（22）包括多个第一横杆（221）和多个与所述第一横杆（221）间隔设置的第二横杆（222），所述第一横杆（221）与所述第二横杆（222）活动连接。
8.根据权利要求7所述的一种宽频高导磁环的生产工艺，其特征在于：所述输送部件（2）还包括用于供磁环放置的支撑板（23），所述支撑板（23）上设有圆盘形设置齿块（231），所述支架（21）上设有与所述齿块（231）相配合的齿条（211）。
9.根据权利要求8所述的一种宽频高导磁环的生产工艺，其特征在于：所述履带（22）上端面向下凹陷形成有环形的旋转凹轨（223），所述凹轨（223）内设有多个第一滚珠（224），所述履带（22）上设有直径大于所述第一滚珠（224）的第二滚珠（225），所述齿块（231）中部设有与所述第二滚珠（225）相配合的凹陷部（232）。
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