CN111875368B - 一种低磁导率铁氧体磁性介质材料、其制备方法及应用 - Google Patents
一种低磁导率铁氧体磁性介质材料、其制备方法及应用 Download PDFInfo
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Abstract
本发明公开了一种低磁导率铁氧体磁性介质材料,属于铁氧体材料技术领域,其原料包括主成分和辅助成分,其中,所述主成分含量:NiO(0.45~0.65)mol%、ZnO(42~45)mol%、CuO(9~11)mol%、Fe2O3(45~47)mol%,所述辅助成分含量:Co2O3(0.15~0.25)wt%、MnCO3(0.2~0.4)wt%、Bi2O3(0.4~0.6)wt%;本发明所得的介质材料,磁导率μi≤3、收缩率12~20%、烧结温度850~910℃,具有高电阻率特性,与功率镍锌LTCF材料体系兼容,适于铁氧体磁性介质浆料研制,满足铁氧体磁性介质浆料高耐压(击穿电压>1500V/50μm)、高绝缘电阻(>1012Ω)、极低磁导率(μi≤3)及在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
Description
技术领域
本发明涉及铁氧体材料技术领域,尤其涉及一种低磁导率铁氧体磁性介质材料、其制备方法及应用。
背景技术
LTCF功率器件介质浆料是实现LTCF功率器件如LTCF微磁变压器、功率电感、功率变压器等结构和功能的关键材料,用于构建磁路和气隙,提高变压器耦合系数和增强抗饱和能力,对LTCF功率器件结构和功能的实现具有至关重要的作用。
而铁氧体磁性介质材料是研制LTCF功率器件介质浆料和实现浆料特性的关键材料,其与常规用于LTCC工艺的介质材料有本质上的区别,除需要满足铁氧体磁性介质浆料高耐压(击穿电压>1500V/50μm)、高绝缘电阻(>1012Ω)和极低的磁导率(μi≤3)要求外,更重要的是在900℃左右实现和功率镍锌LTCF材料、Ag导体浆料匹配共烧要求,因此必须开发出与功率镍锌LTCF材料体系兼容的铁氧体磁性介质材料,然后才能进行满足多异质材料匹配共烧要求的铁氧体磁性介质浆料研制。
LTCF功率器件用LTCF材料采用功率型低温烧结NiZn铁氧体(NiCuZn系列)材料,烧结温度在900℃左右。低磁导率是铁氧体磁性介质材料磁介质特性的基本要求,低磁导率铁氧体磁性介质材料可在高磁导率LTCF材料制作的多层叠片变压器层与层间形成气隙,阻断磁力线穿透,明显降低基板内部的磁通密度,从而减小漏磁。
因此,LTCF功率器件介质浆料用μi≤3铁氧体磁性介质材料的基本要求为磁导率μi≤3、收缩率12~20%、烧结温度850~910℃。
一般来说,铁氧体磁性介质材料采用NiZn铁氧体(NiCuZn系列)材料,以使其与功率镍锌LTCF材料体系兼容。提高和降低磁导率基于畴壁位移理论:
从式中可以看出,提高材料的磁导率除了提高材料的Ms外,更主要的是降低磁晶各向异性常数K1、磁致伸缩系数λS,力求使材料的K1→0、λS→0。而K1、λS来源于自旋—轨道耦合的机制,因此有两种方法可选择:一种是采用正负K1、λS进行补偿,另一种是加入非磁性金属离子冲淡磁性离子间的耦合作用。通过选择加入非磁性金属离子Cu2+、Zn2+冲淡磁性离子间的耦合作用,降低K1、λS以提高材料的磁导率;同时采用缺铁配方,使在烧结时出现较多的氧离子空位,促进离子扩散,利用单独或组合掺杂V2O5、Bi2O3等助熔剂降低烧结温度,在微量助熔剂和较低Cu含量的条件下,可在900℃左右烧成晶粒细小而且均匀,具有优异显微结构的铁氧体,选择最佳的工艺条件,以提高材料的磁导率等方法。根据畴壁位移理论,降低材料的磁导率可采用与提高磁导率相反的途径。
NiCuZn铁氧体最佳性能的主配方组成,如图1所示;
从图1中可以看出,要实现NiCuZn铁氧体磁导率最佳性能可调,主配方中NiO含量较高(35~40mol%),ZnO含量较低(17~40mol%),否则必须配合掺杂改性等其它方法;
通过上述方法调整控制NiCuZn系LTCF材料的磁导率,因低温烧结材料的高导磁率和低烧结温度是一对矛盾,兼顾综合性能,目前满足使用要求的低温烧结NiCuZn系铁氧体材料,其磁导率大多在15~400间可调,磁导率高于400、低于15就相当困难,尤其是要实现LTCF功率器件介质浆料用μi≤3铁氧体磁性介质材料的基本要求几乎不可能。本领域亟需一种满足LTCF功率器件介质浆料用μi≤3铁氧体磁性介质材料。
发明内容
本发明的目的之一,就在于提供一种LTCF功率器件介质浆料用μi≤3铁氧体磁性介质材料,以解决上述问题。
为了实现上述目的,本发明采用的技术方案是这样的:
主配方设计上,本发明以尖晶石NiCuZn系软磁铁氧体材料为μi≤3铁氧体磁性介质材料的配方基础,材料由主成分和辅助成分组成,所述主成分为粉末状氧化物NiO、ZnO、CuO、Fe2O3,采用摩尔百分含量标示,辅助成分为Co2O3、MnCO3、低熔点添加物Bi2O3等,采用质量百分含量标示;
材料性能设计上,为了降低磁导率μi,本发明采用NiCuZn欠铁(Fe2O3含量<50mol%)、高Cu含量(CuO含量8~12mol%)、高Zn含量(ZnO含量>40mol%)、适量Co配方,利用加入非磁性金属离子Cu2+、Zn2+冲淡磁性离子间的耦合作用,降低K1、λS,同时过多ZnO、CuO类似于掺杂沉积于铁氧体相中,高Cu含量有助于降低烧结温度并抑制Zn2+挥发的方法;提高电阻率采用添加辅助成分MnCO3以抑制Fe2+与Ni2+出现的方法;降低烧结温度、控制收缩率采用高Cu含量(CuO含量8~12mol%)配方;添加低熔点物Bi2O3并配合湿法磨料工艺细化粉料颗粒(粒度分布D90<2.5μm)的方法,使材料在900℃左右烧成后具有优异显微结构(晶粒细小、均匀、完整、内部气孔少而分散等)。
具体而言,从配方上,本发明采用NiCuZn欠铁(Fe2O3含量<50mol%)、高Cu含量配方,主成分为粉末状氧化物NiO、ZnO、CuO、Fe2O3,辅助成分为Co2O3、MnCO3、低熔点添加物Bi2O3(湿法磨料时添加),并控制铁氧体磁性介质材料主成分含量:NiO(0.45~0.65)mol%、ZnO(42~45)mol%、CuO(9~11)mol%、Fe2O3(45~47)mol%,辅助成分含量Co2O3(0.15~0.25)wt%、MnCO3(0.2~0.4)wt%、Bi2O3(0.4~0.6)wt%。
作为优选的技术方案:所述主成分含量:NiO 0.50mol%、ZnO 43.50mol%、CuO10.00mol%、Fe2O3 46.00mol%;
所述辅助成分含量:Co2O3 0.20wt%、MnCO3 0.30wt%、Bi2O3 0.50wt%。
本发明的目的之二,在于提供上述的介质材料的制备方法,在传统的介质浆料制备工艺基础上,首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为40~70分钟;
然后进一步采用烧结窑炉进行预烧结,控制预烧结温度为(860~890)℃;
更进一步采用大流量循环砂磨机湿法磨料,一级磨料3~5小时,二级精细磨料3.5~5.5小时,进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
即本发明除了在原料配方上进行改进外,还在制备工艺方面进行了改进,工艺上采用陶瓷氧化物干法和湿法并用方案来获得2.5μm超精细铁氧体颗粒。因为传统的干法(采用高频振混系统混料D90:20μm~50μm,粒度大、分布范围宽,均匀性差)或湿法工艺技术(采用一级砂磨或球磨磨料D90:3μm~15μm,粒度大、分布范围宽,均匀性差,不适于LTCF器件多层叠片工艺)不能达到D90<2.5μm的粒度分布要求,因此本发明采用了能达到更小粒度分布要求的陶瓷氧化物干法和湿法并用方案。具体而言,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速初步破碎效果,完成干法混料,控制混料时间为40~70分钟,更进一步采用大流量循环砂磨机湿法磨料(一级磨料3~5小时,二级精细磨料3.5~5.5小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,达到控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
本发明的目的之三,在于提供上述的介质材料的应用,具体而言,将其应用于LTCF功率器件介质浆料,因为其性能能够满足LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
与现有技术相比,本发明的优点在于:本发明所得的介质材料,磁导率μi≤3、收缩率12~20%、烧结温度850~910℃,具有高电阻率特性,与功率镍锌LTCF材料体系兼容,适于铁氧体磁性介质浆料研制,满足铁氧体磁性介质浆料高耐压(击穿电压>1500V/50μm)、高绝缘电阻(>1012Ω)、极低磁导率(μi≤3)及在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
附图说明
图1为NiCuZn铁氧体最佳性能的主配方组成;
图2为ZnO含量与铁氧体磁性介质浆料磁导率关系。
具体实施方式
下面将结合实施例对本发明作进一步说明。
实施例1:
一种低磁导率铁氧体磁性介质材料,具体成分百分比为:主成分含量:NiO 0.65mol%、ZnO 42.00mol%、CuO 11.00mol%、Fe2O3 46.35mol%;辅助成分含量:Co2O3 0.25wt%、MnCO3 0.20wt%、Bi2O3 0.60wt%。
制备方法如下:
首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为70分钟;
然后,进一步采用烧结窑炉进行预烧结,控制预烧结温度为890℃;
更进一步采用大流量循环砂磨机湿法磨料(一级磨料4小时,二级精细磨料5小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
实施例1铁氧体磁性介质材料性能为:磁导率μi:2.88、收缩率:15.50%、烧结温度900℃,制备的铁氧体磁性介质浆料性能为:耐压(击穿电压):1600V/50μm、绝缘电阻:1.48×1012Ω、磁导率μi:2.85,满足在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
实施例2:
一种低磁导率铁氧体磁性介质材料,具体成分百分比为:主成分含量:NiO0.60mol%、ZnO 43.00mol%、CuO 10.50mol%、Fe2O3 45.90mol%;辅助成分含量:Co2O30.21wt%、MnCO3 0.25wt%、Bi2O3 0.55wt%。
制备方法如下:
首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为65分钟;
然后,进一步采用烧结窑炉进行预烧结,控制预烧结温度为885℃;
更进一步采用大流量循环砂磨机湿法磨料(一级磨料4小时,二级精细磨料4.5小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
实施例2铁氧体磁性介质材料性能为:磁导率μi:2.65、收缩率:15.48%、烧结温度900℃,制备的铁氧体磁性介质浆料性能为:耐压(击穿电压):1680V/50μm、绝缘电阻:2.12×1012Ω、磁导率μi:2.60,满足在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
实施例3:
一种低磁导率铁氧体磁性介质材料,具体成分百分比为:主成分含量:NiO0.50mol%、ZnO 43.50mol%、CuO 10.00mol%、Fe2O3 46.00mol%;辅助成分含量:Co2O30.20wt%、MnCO3 0.30wt%、Bi2O3 0.50wt%。
制备方法如下:
首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为60分钟;
然后,进一步采用烧结窑炉进行预烧结,控制预烧结温度为880℃;
更进一步采用大流量循环砂磨机湿法磨料(一级磨料4小时,二级精细磨料4小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
实施例3铁氧体磁性介质材料性能为:磁导率μi:2.26、收缩率:15.43%、烧结温度900℃,制备的铁氧体磁性介质浆料性能为:耐压(击穿电压):1780V/50μm、绝缘电阻:2.36×1012Ω、磁导率μi:2.18,满足在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
实施例4:
一种低磁导率铁氧体磁性介质材料,具体成分百分比为:主成分含量:NiO0.50mol%、ZnO 44.00mol%、CuO 9.50mol%、Fe2O3 46.00mol%;辅助成分含量:Co2O3 0.17wt%、MnCO3 0.35wt%、Bi2O3 0.45wt%。
制备方法如下:
首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为50分钟;
然后,进一步采用烧结窑炉进行预烧结,控制预烧结温度为870℃;
更进一步采用大流量循环砂磨机湿法磨料(一级磨料3.5小时,二级精细磨料4.5小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
实施例4铁氧体磁性介质材料性能为:磁导率μi:2.20、收缩率:15.42%、烧结温度900℃,制备的铁氧体磁性介质浆料性能为:耐压(击穿电压):1750V/50μm、绝缘电阻:2.22×1012Ω、磁导率μi:2.15,满足在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
实施例5:
一种低磁导率铁氧体磁性介质材料,具体成分百分比为:主成分含量:NiO0.45mol%、ZnO 45.00mol%、CuO 9.00mol%、Fe2O3 45.55mol%;辅助成分含量:Co2O3 0.15wt%、MnCO3 0.40wt%、Bi2O3 0.40wt%;
制备方法如下:
首先,采用高频振混系统有效提高各原材料氧化物的混和均匀性,达到高速破碎效果,完成干法混料,控制混料时间为45分钟;
然后,进一步采用烧结窑炉进行预烧结,控制预烧结温度为860℃;
更进一步采用大流量循环砂磨机湿法磨料(一级磨料3.5小时,二级精细磨料4小时)进行粉料颗粒细化,以提高粉料活性、降低反应激活能并有效降低烧结温度,控制粉料颗粒粒度分布D90<2.5μm获得超精细铁氧体颗粒。
实施例5铁氧体磁性介质材料性能为:磁导率μi:2.17、收缩率:15.43%、烧结温度900℃,制备的铁氧体磁性介质浆料性能为:耐压(击穿电压):1710V/50μm、绝缘电阻:2.10×1012Ω、磁导率μi:2.14,满足在900℃左右实现LTCF功率器件功率镍锌LTCF材料、Ag导体浆料等多异质材料匹配共烧要求。
采用本发明实施例1、2、3、4、5低磁导率铁氧体磁性介质材料,ZnO含量与制备的铁氧体磁性介质浆料磁导率关系如图2。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的构思和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (4)
1.一种低磁导率铁氧体磁性介质材料,其特征在于:其原料包括主成分和辅助成分,其中,
所述主成分含量:NiO(0.45~0.65)mol%、ZnO(42~45)mol%、CuO(9~11)mol%、Fe2O3(45~47)mol%;
所述辅助成分含量:Co2O3(0.15~0.25)wt%、MnCO3(0.2~0.4)wt%、Bi2O3(0.4~0.6)wt%。
2.根据权利要求1所述的低磁导率铁氧体磁性介质材料,其特征在于:所述主成分含量:NiO 0.50mol%、ZnO 43.50mol%、CuO 10.00mol%、Fe2O3 46.00mol%;
所述辅助成分含量:Co2O3 0.20wt%、MnCO3 0.30wt%、Bi2O3 0.50wt%。
3.权利要求1或2的低磁导率铁氧体磁性介质材料的制备方法,其特征在于:采用高频振混系统对原料氧化物进行干法混料,混料时间为40~70min;
采用烧结窑炉进行预烧结,控制预烧结温度为860~890℃;
采用大流量循环砂磨机湿法磨料,一级磨料3~5小时,二级精细磨料3.5~5.5小时。
4.权利要求1或2的低磁导率铁氧体磁性介质材料的应用,其特征在于:应用于LTCF功率器件介质浆料。
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