CN111018510A - 一种多极磁环的制造方法 - Google Patents

一种多极磁环的制造方法 Download PDF

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CN111018510A
CN111018510A CN201911363952.9A CN201911363952A CN111018510A CN 111018510 A CN111018510 A CN 111018510A CN 201911363952 A CN201911363952 A CN 201911363952A CN 111018510 A CN111018510 A CN 111018510A
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following
steps
sintering
carrying
pressing
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俞晚霞
俞小娟
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Nanjing Dacheng Material Technology Co Ltd
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Nanjing Dacheng Material Technology Co Ltd
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Abstract

本发明公开了一种多极磁环的制造方法，具体步骤包括：对预烧料中添加添加剂并进行湿法粉碎；向经烘干后的粉体中添加粘合剂和润滑剂，然后进行预压预磁化工艺，再采用高速粉碎机进行混合的混合工序；对前述粉体在磁场进行压制成型工序；对成型后的样品进行烧结的烧结工序。本发明制备的多极磁环性能好，产品两端的密度一致，从而根本上解决该产品的开裂问题，多极磁环的表磁大于1800Gs，Br大于3850Gs，Hcb大于3000Oe。

Description

一种多极磁环的制造方法
技术领域
本发明涉及磁性材料技术领域，具体是指一种多极磁环的制造方法。
背景技术
各向异性永磁铁氧体多极磁环在变频空调电机、麻将机、洗衣机、油泵电机、伺服电机以及步进电机等领域有着广泛使用，图1所示为外圆多极各向异性永磁铁氧体多极磁环，图2为内圆多极各项异性永磁铁氧体多极磁环。目前各向异性永磁铁氧体多极磁环的制造工艺主要有两种方法，其一是采用传统的湿法成型工艺，即采用轴向取向成型工艺，该工艺采用的是压制方形铁氧体磁块，然后再切割、套孔的工艺，该工艺虽然性能和成品率都很高，由于是轴向取向成型，上下面的表磁差本来就很大，其极面间的表磁差达到200Gs或更大，在永磁电机中根本不可以用，以后即使解决了极面表磁差的问题，由于其增加切割、套孔等工艺，无形中就增加了生产成本，产品缺乏市场竞争力，这种方案具体应用目前并不是很多。其二是采用干压径向磁场成型，由于干粉料中的粒子之间缺少必要的分散介质，干压成型在磁场成型过程中的取向性较差，为提高取向度采用向粉体中添加适量的有机粘合剂。如中国专利申请(02803279.9)公开了一种涉及干压成型永磁铁氧体的制造方法，其核心是干压成型时添加了一种分子量在400-600的脂肪酸系蜡的粘合剂，从而有效的改善了粉体粒子的流动性，获得较高的磁性能。但是由于一般的径向多极磁环的高度与直径比大很多，在压制时存在上下端面在烧结时收缩不一致，从而产生开裂，成品率极低。
发明内容
本发明要解决的技术问题是克服以上技术缺陷，提供一种多极磁环的制造方法，目的是在优良的预烧料配方的基础上，通过工艺改进，选择合适的有机粘合剂和适当的添加量，有效改进干压粉体的取向性，采用预压预磁化、双向等压径向取向成型工艺，制备出性能高的径向多极永磁铁氧体磁环。
为了达到上述发明目的，本发明采用的技术方案为：一种多极磁环的制造方法，具体包括以下步骤：
(1)在预烧料中添加添加剂并进行湿法粉碎；
(2)向经烘干后的粉体中添加粘合剂和润滑剂，然后进行预压预磁化，再采用高速粉碎机进行混合；
(3)将混合后的粉体在径向磁场中进行压制成型；
(4)将成型后的样品进行烧结。
进一步的，步骤(1)中所述预烧料包括含有A、R、B和Fe的六角型铁氧体主相，并具有以下特征的分子式：A1-xRx[(Fe3+ a Fe2+ b)12-yBy]zO19，其中，A代表Sr、Ba中的一种或两种元素；R代表选自稀土元素和Bi中的至少一种元素，且必须含有La；B代表Co、Ti、Mn、Zn中的至少一种元素，其中必须含有Co，其中，a+b等于1；z优选为0.9～1.1；a优选为0.97～0.999，b优选为0.001～0.03；所述的x和y优选范围为：0≤x≤0.54，0.≤y≤0.45。
进一步的，步骤(2)中所述粘合剂包括聚乙烯醇、聚乙二醇(PEG)、脂肪酸系蜡、樟脑、甲基纤维素中的一种或一种以上，添加量为0～1.5wt％，优选为1.0-1.2wt％，粘合剂用有机溶剂进行溶解之后使用。
进一步的，步骤(2)中预压预磁化工艺处理，预压压力为10-25Mpa，预磁化磁场为8000-10000Oe。
进一步的，步骤(2)中预压预磁化后的毛坯进行高速粉碎机的再次混合工艺，过40-60目筛。
进一步的，步骤(3)中在磁场成型工序中，成型前的干压磁粉的含水量控制在0.2～0.5wt％，成型径向磁场不低于10000Oe。
进一步的，步骤(4)中对成型后的样品进行烧结，采用45m辊道窑快速烧结工艺，在300-500℃进行脱胶处理，在1240-1260℃进行烧结。
本发明的有益效果为：
(1)SiO2、CaCO3等添加剂的加入，有助于烧结过程中形成晶界，阻碍铁氧体晶粒的长大，从而有效提高产品的矫顽力；
(2)有机分散剂的加入，一方面在粉碎过程中起到助磨剂的作用，使得研磨后的磁体粉末粒径更为均匀；另一方面对干压产品的性能也有所提高；
(3)有机粘合剂的加入，一方面有效的改善了磁性粉体粒子的流动性，减少了粉体颗粒转动时的阻力，提高了干压成型时磁性粉体粒子的取向度，从而对提高产品的剩磁有贡献，另一方面基于上述同样的原因，有机物的加入也会造成产品密度的下降，从而降低的产品的剩磁；
(4)本发明在制造径向永磁铁氧体多极磁环的工艺中采用预压预磁化工序，经一次或多次预压预磁化后，经高速粉碎机粉碎后的粉料的粒度相对更粗，从而便于成型，减少开裂，而粉料经多次预磁化后便于在最终的径向成型中提高取向度，而获得好的性能；
(5)采用双向压制成型工序可以解决上下表面的密度差尽量一致，采用双面同时加压的方式就可以确保产品两端的密度一致，从而根本上解决该产品的开裂问题。
(6)本发明制备的多极磁环的表磁大于1800Gs，Br大于3850Gs，Hcb大于3000Oe。
附图说明
图1为外圆多极各向异性永磁铁氧体多极磁环；
图2为内圆多极各项异性永磁铁氧体多极磁环。
具体实施方式
下面将结合本发明实施例，对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅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做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。
一种多极磁环的制造方法，具体包括以下步骤：
(1)在预烧料中添加添加剂并进行湿法粉碎；
(2)向经烘干后的粉体中添加粘合剂和润滑剂，然后进行预压预磁化，再采用高速粉碎机进行混合；
(3)将混合后的粉体在径向磁场中进行压制成型；
(4)将成型后的样品进行烧结。
本发明所选用的预烧料磁体粉末包括含有A、R、B和Fe的六角型铁氧体主相，并具有以下特征的分子式：A1-xRx[(Fe3+ a Fe2+ b)12-yBy]zO19，其中，A代表Sr、Ba中的一种或两种元素；R代表选自稀土元素和Bi中的至少一种元素，且必须含有La；B代表Co、Ti、Mn、Zn中的至少一种元素，其中必须含有Co，Co元素的化合价为正三价；其中，a+b等于1；z优选为0.9～1.1；a优选为0.97～0.999，b优选为0.001～0.03；所述的x和y优选范围为：0≤x≤0.54，0≤y≤0.45，优选x、y、z的最佳取值为；1.0≤x/y≤1.5，z为1。
在二次湿磨粉碎工序中，除了向预烧料中添加常规的SiO2、CaCO3等添加剂外，还添加聚乙二醇(PEG)、硬脂酸钙中的至少一种有机分散剂，添加量为0～1.0wt％。SiO2、CaCO3等添加剂的加入，有助于烧结过程中形成晶界，阻碍铁氧体晶粒的长大，从而有效提高产品的矫顽力。有机分散剂的加入，一方面在粉碎过程中起到助磨剂的作用，使得研磨后的磁体粉末粒径更为均匀；另一方面对干压产品的性能也有所提高，尤其是分子量为800左右的聚乙二醇(PEG)加入能在不降低剩磁的基础上，提高产品的内禀矫顽力300-500Oe。
在上述混合工序中，可加入的粘合剂包括聚乙烯醇、聚乙二醇(PEG)、脂肪酸系蜡、樟脑和硬脂酸盐中的一种或一种以上，添加量为0～1.5wt％。为了便于粘合剂与干粉的充分接触，上述粘合剂可用酒精、丙酮等有机溶剂进行溶解后加入，效果更佳。有机粘合剂的加入，一方面有效的改善了磁性粉体粒子的流动性，减少了粉体颗粒转动时的阻力，提高了干压成型时磁性粉体粒子的取向度，从而对提高产品的剩磁有贡献，另一方面基于上述同样的原因，有机物的加入也会造成产品密度的下降，从而降低的产品的剩磁。所以有机粘合剂的加入量非常重要，添加量应控制在0～1.5wt％，优选为1.0-1.2wt％。
本发明在制造径向永磁铁氧体多极磁环的工艺中采用预压预磁化工序，经一次或多次预压预磁化后，经高速粉碎机粉碎后的粉料的粒度相对更粗，从而便于成型，减少开裂，而粉料经多次预磁化后便于在最终的径向成型中提高取向度，而获得好的性能。
本发明在制造径向永磁铁氧体多极磁环的工艺中采用双向压制成型工序，采用该工艺的目的是为了解决产品高度较厚而造成开裂，在成型过程中上下两个端面的密度不一致，所以在烧结过程中就导致收缩率的不一样，从而产生开裂。采用双向压制成型工序可以解决上下表面的密度差尽量一致，采用双面同时加压的方式就可以确保产品两端的密度一致，从而根本上解决该产品的开裂问题。
对经一次或多次预压预磁化后的干式粉料在上述径向磁场成型工序中，成型前的干压磁粉的含水量控制在0.2～0.5wt％，成型磁场不低于12000Oe。
对成型后的样品进行烧结的烧结工序采用45m辊道窑快速烧结工艺，在300-500℃进行脱胶处理，在1240-1260℃进行0.5-2小时烧结。
实施例1：
基料采用常规高性能永磁铁氧体的配方，其具体工艺如下：
(1)球磨工艺：先将永磁铁氧体预烧料进行二次湿磨，同时添加二次小料，其工艺如同传统永磁铁氧体生产中的二次球磨工艺。
(2)烘干工艺：然后将二次砂磨后的料浆进行烘干，实验室是在干燥箱120℃进行10-12小时干燥，或者将该料浆放在电窑随窑干燥，一般要求烘干后的粉料的含水率要求0.3％以内。
(3)预磁化造粒工艺：首先将烘干后的粉料与粘接剂甲基纤维素溶液混合，其比例约为40％，然后在磁场中磁化，然后再烘干，最后将粉料进行高速粉碎机粉碎，并过60目筛，制得干压永磁铁氧体径向成型用粉料。
(4)径向成型工艺：在45T实验压机上进行永磁铁氧体径向多极磁环的成型，压力3MPa，磁场12000～13000Oe左右。
(5)烧结、研磨、测试：烧结工艺如同目前的湿压产品的烧结工艺相同，在300-500℃进行脱胶处理，然后进行烧结温度1250℃保温2小时烧结，其注意点是防止烧结过程中的有机物的挥发产生开裂以及冷却过程中降温过快产生开裂。实验室采用箱式炉烧结，工厂则随电窑烧结，性能测试主要测试磁性能和表磁。
Figure BDA0002337918120000041
以上对本发明及其实施方式进行了描述，这种描述没有限制性，只是本发明的实施方式之一，实际的实施方式并不局限于此。总而言之如果本领域的普通技术人员受其启示，在不脱离本发明创造宗旨的情况下，不经创造性的设计出与该技术方案相似的结构方式及实施例，均应属于本发明的保护范围。

Claims (7)

1.一种多极磁环的制造方法，其特征在于：具体包括以下步骤：
(1)在预烧料中添加添加剂并进行湿法粉碎；
(2)向经烘干后的粉体中添加粘合剂和润滑剂，然后进行预压预磁化，再采用高速粉碎机进行混合；
(3)将混合后的粉体在径向磁场中进行压制成型；
(4)将成型后的样品进行烧结。
2.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(1)中所述预烧料包括含有A、R、B和Fe的六角型铁氧体主相，并具有以下特征的分子式：A1-xRx[(Fe3+ a Fe2 + b)12-yBy]zO19，其中，A代表Sr、Ba中的一种或两种元素；R代表选自稀土元素和Bi中的至少一种元素，且必须含有La；B代表Co、Ti、Mn、Zn中的至少一种元素，其中必须含有Co，其中，a+b等于1；z优选为0.9～1.1；a优选为0.97～0.999，b优选为0.001～0.03；所述的x和y优选范围为：0≤x≤0.54，0.≤y≤0.45。
3.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(2)中所述粘合剂包括聚乙烯醇、聚乙二醇(PEG)、脂肪酸系蜡、樟脑、甲基纤维素中的一种或一种以上，添加量为0～1.5wt％，优选为1.0-1.2wt％，粘合剂用有机溶剂进行溶解之后使用。
4.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(2)中预压预磁化工艺处理，预压压力为10-25Mpa，预磁化磁场为8000-10000Oe。
5.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(2)中预压预磁化后的毛坯进行高速粉碎机的再次混合工艺，过40-60目筛。
6.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(3)中在磁场成型工序中，成型前的干压磁粉的含水量控制在0.2～0.5wt％，成型径向磁场不低于10000Oe。
7.根据权利要求1所述的一种多极磁环的制造方法，其特征在于：步骤(4)中对成型后的样品进行烧结，采用45m辊道窑快速烧结工艺，在300-500℃进行脱胶处理，在1240-1260℃进行烧结。
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Application publication date: 20200417