CN112185640A - 一种硅酸钠包覆磁粉芯的方法 - Google Patents
一种硅酸钠包覆磁粉芯的方法 Download PDFInfo
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- 239000006247 magnetic powder Substances 0.000 title claims abstract description 83
- 239000004115 Sodium Silicate Substances 0.000 title claims abstract description 59
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 title claims abstract description 59
- 229910052911 sodium silicate Inorganic materials 0.000 title claims abstract description 59
- 238000000576 coating method Methods 0.000 title claims abstract description 58
- 239000011248 coating agent Substances 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims abstract description 25
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims abstract description 41
- 229910052751 metal Inorganic materials 0.000 claims abstract description 33
- 239000002184 metal Substances 0.000 claims abstract description 33
- 229910019142 PO4 Inorganic materials 0.000 claims abstract description 22
- 239000010452 phosphate Substances 0.000 claims abstract description 22
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims abstract description 19
- 238000002156 mixing Methods 0.000 claims abstract description 19
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims abstract description 19
- 229920001732 Lignosulfonate Polymers 0.000 claims abstract description 17
- 239000000853 adhesive Substances 0.000 claims abstract description 17
- 230000001070 adhesive effect Effects 0.000 claims abstract description 17
- 239000002245 particle Substances 0.000 claims abstract description 11
- 239000000314 lubricant Substances 0.000 claims abstract description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 8
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 8
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims abstract description 4
- 239000000292 calcium oxide Substances 0.000 claims abstract description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims abstract description 4
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- 239000007864 aqueous solution Substances 0.000 claims description 6
- 239000008367 deionised water Substances 0.000 claims description 6
- 229910021641 deionized water Inorganic materials 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 claims description 6
- 229910005347 FeSi Inorganic materials 0.000 claims description 4
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 claims description 4
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- 229910002555 FeNi Inorganic materials 0.000 claims description 2
- CEGOLXSVJUTHNZ-UHFFFAOYSA-K aluminium tristearate Chemical compound [Al+3].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CEGOLXSVJUTHNZ-UHFFFAOYSA-K 0.000 claims description 2
- 229940063655 aluminum stearate Drugs 0.000 claims description 2
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 claims description 2
- 238000007781 pre-processing Methods 0.000 claims description 2
- 230000035699 permeability Effects 0.000 abstract description 9
- 239000002270 dispersing agent Substances 0.000 abstract description 6
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- 239000000463 material Substances 0.000 abstract description 3
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- 229910010272 inorganic material Inorganic materials 0.000 abstract description 2
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- 238000001035 drying Methods 0.000 abstract 1
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- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 14
- 230000000052 comparative effect Effects 0.000 description 8
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 7
- 239000000696 magnetic material Substances 0.000 description 6
- 239000005416 organic matter Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 5
- 230000002265 prevention Effects 0.000 description 5
- 239000000126 substance Substances 0.000 description 4
- -1 alcohol ether phosphate ester Chemical class 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910000976 Electrical steel Inorganic materials 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011863 silicon-based powder Substances 0.000 description 2
- 230000032683 aging Effects 0.000 description 1
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Abstract
本发明公开了一种硅酸钠包覆磁粉芯的方法,是以醇醚磷酸酯作为硅酸钠的分散剂，以木质素磺酸盐作为金属磁性粉末的分散剂，将分散后的硅酸钠溶液与分散后的金属磁性粉末混合包覆，干燥后添加粘接剂和润滑剂后模压成型，最后高温退火处理得到硅酸钠包覆磁粉芯。本发明中硅酸钠使用醇醚磷酸酯分散，金属磁性粉末使用木质素磺酸盐分散，两种不同的分散剂在一起搅拌，可以起到协同分散作用，使硅酸钠更均匀的分散包覆在金属磁性粉末颗粒表面；包覆粘结材料为硅酸钠、二氧化硅、三氧化二铝、氧化钙等无机材料，提高了耐候性，降低了成本；本发明磁粉芯损耗可在传统工艺产品基础上降低15%以上（50kHz，100mT），100Oe直流偏置磁场下的磁导率与初始磁导率的比例可以在传统工艺产品基础上提高2个百分点以上。
Description
技术领域
本发明涉及磁粉芯制备技术领域，尤其涉及一种硅酸钠包覆磁粉芯的方法。
背景技术
磁性材料广泛的应用于电子，计算机和通信领域，现如今已经彻底的改变了我们的生活。目前磁粉芯因具有相对较高的磁通密度、较好的温度稳定性和机械冲击适应性，而广泛应用于航空、汽车、家用电器等领域中的微电机、电感器件、快速驱动及脉冲变压器。但传统的磁性材料如硅钢片在使用过程中也出现了一些弊端，硅钢片等传统的软磁材料在高频条件下由于涡流迅速上升造成能量损耗提高，使得电机的温度升高且效率降低。基于降低这种涡流现象提高软磁材料的能量效率，开发出一种新型绿色节能软磁材料作为电动设备的机芯迫在眉睫。同时，随着电子元器件和电子设备的发展，电器越来越往集成化和小型化的方向发展，这要求磁性材料有更高的磁导率和更小的损耗。
传统包覆工艺中，一般使用磷酸作为绝缘物质，添加有机物作为粘接剂，其粉末颗粒表面的包覆不均匀，损耗较大，非磁性物质比例大大降低，造成直流偏置性能差，添加的有机物粘接剂在温度或者湿度变化大的户外环境使用时容易老化，耐候性不好。
发明内容
为了解决上述传统采用磷酸包覆、有机物粘接剂制备磁粉芯时包覆不均匀，损耗较大，直流偏置性能差，有机物粘接剂容易老化，耐候性不好的问题，本发明提供了一种采用硅酸钠包覆磁粉芯的方法。
本发明的技术方案是这样实现的：
一种硅酸钠包覆磁粉芯的方法，其特征在于包括以下步骤：
S1、硅酸钠预处理：将硅酸钠和去离子水按1：1～5的比例混合，加入醇醚磷酸酯，混合均匀，得到硅酸钠溶液；
醇醚磷酸酯的作用是将硅酸钠更好的分散在水溶液里面，同时醇醚磷酸酯还能起防锈作用，防止金属磁粉生锈。
S2、金属磁性粉末预处理：将金属磁性粉末加入到包覆炉中，炉温设为60～80℃，达到设定温度后，加入木质素磺酸盐，搅拌10～30分钟；
木质素磺酸盐的作用是将金属磁性粉末更好的分散。
S3、包覆：将步骤S1中的硅酸钠溶液加入到步骤S2中的金属磁性粉末中去，硅酸钠溶液的加入量为金属磁性粉末的1～10wt％，搅拌10～30分钟；
S4、烘烤：将步骤S3所得粉末在120～150℃下烘烤60～120分钟，得到包覆粉末；
S5、添加绝缘粘接剂和润滑剂：向包覆粉末中添加0.1％～1％包覆粉末重量的绝缘粘接剂，和0.1％～1％包覆粉末重量的硬脂酸盐作为润滑剂，混合均匀；
S6、模压成型：将步骤S5混合均匀的磁粉在成型压力1500～2300MPa下模压成型；
S7、退火热处理：成型后的磁粉芯在600～800℃的N2或H2气氛保护下保温30～90分钟，得到硅酸钠包覆磁粉芯。
优选的，所述步骤S1中醇醚磷酸酯加入量为硅酸钠的0.1～3wt％。
优选的，所述步骤S2中木质素磺酸盐加入量为金属磁性粉末的0.1～1wt％。优选的，所述金属磁性粉末为纯Fe、FeSi、FeSiAl、FeSiNi、FeNi、FeNiMo或FeSiCr中的一种或多种组成，平均粒度为10-200μm。
优选的，所述步骤S5中添加的绝缘粘接剂为二氧化硅、三氧化二铝、氧化钙中的一种或几种混合，其粒径为10μm以下。
优选的，所述步骤S5中硬脂酸盐为硬脂酸锌、硬脂酸铝、硬脂酸锂中的一种或几种混合。
优选的，所述步骤S6在压力1500～2300MPa下压制成环形或E型或U型。与现有技术相比，本发明的有益效果为：
1)硅酸钠使用醇醚磷酸酯分散剂，使硅酸钠能更好的分散。金属磁性粉末使用木质素磺酸盐分散剂，两种不同的分散剂在一起搅拌，可以起到协同分散作用，使硅酸钠更均匀的分散包覆在金属磁性粉末颗粒表面；
2)使用的包覆粘结材料为硅酸钠、二氧化硅、三氧化二铝、氧化钙等无机材料，比传统的采用有机物作为粘结材料的耐候性有很大的提高，成本有很大的降低。
3)本发明做出来的磁粉芯，损耗可在传统工艺产品基础上降低15％以上(50kHz，100mT)，100Oe直流偏置磁场下的磁导率与初始磁导率的比例可以在传统工艺产品基础上提高2个百分点以上
4)本发明制备设备简单、易操作，成本低，特别适合于工业化大批量、大规模生产用。
附图说明
图1为本发明实施例包覆工艺流程图；
图2为本发明硅酸钠包覆磁粉芯退火处理后的SME照片；
图3为传统采用有机物粘接剂磷酸包覆工艺磁粉芯退火处理后的SME照片。
具体实施方式
下面结合附图及具体实施例对本发明进行进一步描述，但本发明的保护范围并不仅限于此：
实施例1：
取10g硅酸钠，10g去离子水，混合均匀，加入0.01g醇醚磷酸酯，混合均匀，得到硅酸钠溶液，醇醚磷酸酯的作用是将硅酸钠更好的分散在水溶液里面，同时醇醚磷酸酯还能起防锈作用，防止金属磁粉生锈；取颗粒平均粒径为30μm气雾化铁硅铝粉1000g，将包覆炉炉温升到60℃后，向包覆炉内加入1g木质素磺酸盐，搅拌20分钟，木质素磺酸盐的作用是将金属磁性粉末更好的分散；将硅酸钠溶液加入到金属磁性粉末中去，搅拌10～30分钟；将包覆炉炉温升至120℃下烘烤120分钟，得到包覆粉末；然后向包覆粉末中添加0.1％包覆粉末重量的三氧化二铝，和0.1％包覆粉末重量的硬脂酸锌润滑剂，混合均匀，将混合均匀的磁粉在成型压力1500MPa下模压成
环形磁粉芯，并且倒角；然后再将磁粉芯在600℃的N2气氛保护下保温30分钟，得到硅酸钠包覆磁粉芯。
实施例2：
取40g硅酸钠，40g去离子水，混合均匀，加入1.2g醇醚磷酸酯，混合均匀，得到硅酸钠溶液，醇醚磷酸酯的作用是将硅酸钠更好的分散在水溶液里面，同时醇醚磷酸酯还能起防锈作用，防止金属磁粉生锈；取颗粒平均粒径为32μm的气雾化铁硅铝粉1000g，将包覆炉炉温升到80℃后，向包覆炉内加入5g木质素磺酸盐，搅拌30分钟，木质素磺酸盐的作用是将金属磁性粉末更好的分散；将硅酸钠溶液加入到金属磁性粉末中去，搅拌30分钟；将包覆炉炉温升至120℃下烘烤120分钟，得到包覆粉末；然后向包覆粉末中添加0.5％包覆粉末重量的三氧化二铝，和0.8％包覆粉末重量的硬脂酸锌润滑剂，混合均匀，将混合均匀的磁粉在成型压力2000MPa下模压成
环形磁粉芯，并且倒角；然后再将磁粉芯在700℃的H2气氛保护下保温90分钟，得到硅酸钠包覆磁粉芯。
对比例1：传统采用有机物粘接剂磷酸包覆工艺制作的气雾化FeSiAl环形磁粉芯
磁导率为90的标准品。
对比例2：传统采用有机物粘接剂磷酸包覆工艺制作的气雾化FeSiAl环形磁粉芯
磁导率为75的标准品。
性能测试：对实施例1、2和对比例1、2所得环形磁粉芯绕线测试，使用
铜线，绕线35匝，其中感量测试仪器为TH2816B，损耗测试仪器为VR152，直流偏置性能测试仪器为CHROMA3302+1320。所得结果见表1。
表1：实施例1、2和对比例1、2的磁性测试结果
从表1中可以看出本发明实施例1、2与传统包覆工艺相比，磁芯损耗大幅下降，直流偏置性能都提高了2个百分点以上。
实施例3：
取100g硅酸钠，100g去离子水，混合均匀，加入3g醇醚磷酸酯，混合均匀，得到硅酸钠溶液，醇醚磷酸酯的作用是将硅酸钠更好的分散在水溶液里面，同时醇醚磷酸酯还能起防锈作用，防止金属磁粉生锈；取颗粒平均粒径为35μm的铁硅粉1000g，将包覆炉炉温升到80℃后，向包覆炉内加入10g木质素磺酸盐，搅拌30分钟，木质素磺酸盐的作用是将金属磁性粉末更好的分散；将硅酸钠溶液加入到金属磁性粉末中去，搅拌30分钟；将包覆炉炉温升至150℃下烘烤60分钟，得到包覆粉末；然后向包覆粉末中添加1％包覆粉末重量的三氧化二铝，和1％包覆粉末重量的硬脂酸锌润滑剂，混合均匀，将混合均匀的磁粉在成型压力2300MPa下模压成
环形磁粉芯，并且倒角；然后再将磁粉芯在800℃的H2气氛保护下保温90分钟，得到硅酸钠包覆磁粉芯。
实施例4：
取50g硅酸钠，50g去离子水，混合均匀，加入0.5g醇醚磷酸酯，混合均匀，得到硅酸钠溶液，醇醚磷酸酯的作用是将硅酸钠更好的分散在水溶液里面，同时醇醚磷酸酯还能起防锈作用，防止金属磁粉生锈；取颗粒平均粒径为38μm的铁硅粉1000g，将包覆炉炉温升到70℃后，向包覆炉内加入10g木质素磺酸盐，搅拌30分钟，木质素磺酸盐的作用是将金属磁性粉末更好的分散；将硅酸钠溶液加入到金属磁性粉末中去，搅拌30分钟；将包覆炉炉温升至150℃下烘烤60分钟，得到包覆粉末；然后向包覆粉末中添加1％包覆粉末重量的三氧化二铝，和0.5％包覆粉末重量的硬脂酸锌润滑剂，混合均匀，将混合均匀的磁粉在成型压力2000MPa下模压成
环形磁粉芯，并且倒角；然后再将磁粉芯在700℃的H2气氛保护下保温80分钟，得到硅酸钠包覆磁粉芯。
对比例3：传统采用有机物粘接剂磷酸包覆工艺制作的FeSi环形磁粉芯
磁导率为26的标准品。
对比例4：传统采用有机物粘接剂磷酸包覆工艺制作的FeSi环形磁粉芯
磁导率为60的标准品。
性能测试：对实施例3、4和对比例3、4所得环形磁粉芯绕线测试，使用
铜线，绕线35匝，其中感量测试仪器为TH2816B，损耗测试仪器为VR152，直流偏置性能测试仪器为CHROMA3302+1320。所得结果见表2。
表2：实施例3、4和对比例3、4的磁性测试结果
从表2中可以看出本发明实施例3、4与传统包覆工艺相比，磁芯损耗大幅下降，直流偏置性能都提高了2个百分点以上。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (7)
1.一种硅酸钠包覆磁粉芯的方法，其特征在于包括以下步骤：
S1、硅酸钠预处理：将硅酸钠和去离子水按1：1～5的比例混合，加入醇醚磷酸酯，混合均匀，得到硅酸钠溶液，醇醚磷酸酯用于将硅酸钠更好的分散在水溶液里面；
S2、金属磁性粉末预处理：将金属磁性粉末加入到包覆炉中，炉温设为60～80℃，达到设定温度后，加入木质素磺酸盐，搅拌10～30分钟，木质素磺酸盐用于将金属磁性粉末更好的分散；
S3、包覆：将步骤S1中的硅酸钠溶液加入到步骤S2中的金属磁性粉末中去，硅酸钠溶液的加入量为金属磁性粉末的1～10wt%，搅拌10～30分钟；
S4、烘烤：将步骤S3所得粉末在120～150℃下烘烤60～120分钟，得到包覆粉末；
S5、添加绝缘粘接剂和润滑剂：向包覆粉末中添加0.1%～1%包覆粉末重量的绝缘粘接剂，和0.1%～1%包覆粉末重量的硬脂酸盐作为润滑剂，混合均匀；
S6、模压成型：将步骤S5混合均匀的磁粉在成型压力1500～2300MPa下模压成型；
S7、热处理：成型后的磁粉芯在600～800℃的N2或H2气氛保护下保温30～90分钟，得到硅酸钠包覆磁粉芯。
2.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述步骤S1中醇醚磷酸酯加入量为硅酸钠的0.1-3wt%。
3.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述步骤S2中木质素磺酸盐加入量为金属磁性粉末的0.1～1wt%。
4.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述金属磁性粉末为纯Fe、FeSi、FeSiAl、FeSiNi、FeNi、FeNiMo或FeSiCr中的一种或多种组成,平均粒度为10-200μm。
5.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述步骤S5中添加的绝缘粘接剂为二氧化硅、三氧化二铝、氧化钙中的一种或几种混合，其粒径为10μm以下。
6.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述步骤S5中硬脂酸盐为硬脂酸锌、硬脂酸铝、硬脂酸锂中的一种或几种混合。
7.根据权利要求1所述的一种硅酸钠包覆磁粉芯的方法，其特征在于：所述步骤S6在压力1500～2300MPa下压制成环形或E型或U型。
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