CN112517919A - 一种高饱和磁通密度铁硅磁粉芯的制备方法 - Google Patents

一种高饱和磁通密度铁硅磁粉芯的制备方法 Download PDF

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CN112517919A
CN112517919A CN202011525848.8A CN202011525848A CN112517919A CN 112517919 A CN112517919 A CN 112517919A CN 202011525848 A CN202011525848 A CN 202011525848A CN 112517919 A CN112517919 A CN 112517919A
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蒋庆林
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Huzhou Haotong Electronic Technology Co ltd
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Abstract

本发明公开了一种高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：合金熔炼、破碎、分筛、表面处理、绝缘包覆、加润滑剂、压制成型、热处理和表面涂层处理；其中，分筛过程中采用‑250目：‑120目：‑60目=4：2：1的质量比进行粉料配比；热处理完成后对磁粉芯表面进行涂层处理。本发明的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加0.12‑0.18%的铬和0.02‑0.04%的钡，硅7.2‑7.7%，余量为铁。本发明制备的高饱和磁通密度铁硅磁粉芯，饱和磁通密度可以达到1.8 T以上，而剩余磁化强度仅为0.12‑0.15T，故也可以使磁芯在通电流时不容易饱和，以达到提高磁芯输出功率的目的。

Description

一种高饱和磁通密度铁硅磁粉芯的制备方法
技术领域
本发明涉及电子元器件技术领域，尤其涉及一种高饱和磁通密度铁硅磁粉芯的制备方法。
背景技术
软磁合金磁粉芯是将软磁合金粉末与绝缘介质混合压制而成的一种复合软磁材料。由于在软磁合金粉末颗粒的表面均匀包覆着一层绝缘介质膜，磁粉芯的电阻率高，因而涡流损耗很低，适用于较高频率应用。此外，磁粉芯还具有较高的饱和磁感应强度、良好的频率特性和恒导磁等优点，使得磁粉芯作为电感滤波器、扼流线圈广泛应用于电子通讯、雷达、电源开关等领域，已经成为软磁材料重要的组成部分之一。
采用铁硅软磁合金制造成的磁粉芯，工作温度可以达到200℃，避免了磁芯在高温工作时的热老化问题，同时以高性价比和优良的直流叠加特性、高频低损耗特性等特点，使其性能特点正好填补与铁粉芯和其它三种合金磁粉芯（高磁通、铁硅铝、铁镍钼）之间。与铁粉芯相比，铁硅磁粉具有不老化，功率损耗低的优点；与铁硅铝磁粉芯相比，铁硅磁粉芯具有直流叠加特性，更低的价格；与铁镍磁粉芯相比，二者的直流叠加特性相当，损耗比铁镍磁粉芯略高，但由于镍是贵金属，价格昂贵，所以铁硅磁粉芯的成本要远低于铁镍磁粉芯。故采用铁硅合金材料作成的合金磁粉具有广阔的应用领域，引起了业界的广泛关注。专利CN102294476A公开了一种铁硅材料及铁硅磁粉芯的制造方法，其应用条件在50kHz，500Gs，-55℃—150℃，已经无法满足太阳能逆变器、风力发电逆变器、汽车ABS控制系统、汽车发电机、变频空调等客户的需要。
为了拓展应用范围，提高磁芯输出功率，本发明提供了一种高饱和磁通密度铁硅磁粉芯的制备方法。
发明内容
基于背景技术存在的技术问题，本发明提出了一种高饱和磁通密度铁硅磁粉芯的制备方法。
本发明的技术方案如下：
一种高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：
A、合金熔炼：合金熔炼在氧化镁坩埚开式中频感应炉中进行，熔炼温度为1400℃以上，合金熔化时间在50分钟以上；
B、破碎：合金熔炼好后进行氮气喷雾破碎制粉；
C、分筛：粉末过筛，所述铁硅磁粉芯的粒度分布为：按-250目：-120目：-60目=4：2：1的质量比进行粉料配比；
D、表面处理：铁硅粉末烘炒至温度100℃左右时加入0.2-0.3%磷酸溶液中，具体根据透磁率种类而定，进行表面钝化处理；
E、绝缘包覆：加入2-3%硅树脂粘结剂，继续烘炒至干燥，所述的硅树脂粘结剂为聚甲基苯基硅氧烷中加入少量的滑石粉，其加入量为甲基苯基硅氧烷重量的10-15%；
F、加润滑剂：铁硅粉末冷却后加入硬脂酸锌，硬脂酸锌的加入量为铁硅粉末重量的0.4-0.6%，制得铁硅混合物；
G、压制成型：在压强1500-1650MPa的条件下压制成型；
H、热处理：温度在600-700℃条件下通入氮气，热处理30-45分钟；
I、表面涂层处理：磁粉芯表面进行涂层处理，即可。
优选的，所述的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加一定的微量元素，硅7.2-7.7%，余量为铁。
优选的，所述的微量元素为铬元素和钡元素。
进一步优选的，所述的铬元素和钡元素的重量百分比含量分别为0.12-0.18%和0.02-0.04%。
本发明的有益之处在于：本发明的高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：合金熔炼、破碎、分筛、表面处理、绝缘包覆、加润滑剂、压制成型、热处理和表面涂层处理；其中，分筛过程中采用-250目：-120目：-60目=4：2：1的质量比进行粉料配比；热处理完成后对磁粉芯表面进行涂层处理。本发明的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加0.12-0.18%的铬和0.02-0.04%的钡，硅7.2-7.7%，余量为铁。本发明制备的高饱和磁通密度铁硅磁粉芯，饱和磁通密度可以达到1.8 Tesla以上，而剩余磁化强度仅为0.12-0.15Tesla，故也可以使磁芯在通电流时不容易饱和，以达到提高磁芯输出功率的目的。
具体实施方式
实施例1
一种高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：
A、合金熔炼：合金熔炼在氧化镁坩埚开式中频感应炉中进行，熔炼温度为1450℃，合金熔化时间为70分钟；
B、破碎：合金熔炼好后进行氮气喷雾破碎制粉；
C、分筛：粉末过筛，所述铁硅磁粉芯的粒度分布为：按-250目：-120目：-60目=4：2：1的质量比进行粉料配比；
D、表面处理：铁硅粉末烘炒至温度100℃左右时加入0.25%磷酸溶液中，具体根据透磁率种类而定，进行表面钝化处理；
E、绝缘包覆：加入2.7%硅树脂粘结剂，继续烘炒至干燥，所述的硅树脂粘结剂为聚甲基苯基硅氧烷中加入少量的滑石粉，其加入量为甲基苯基硅氧烷重量的12%；
F、加润滑剂：铁硅粉末冷却后加入硬脂酸锌，硬脂酸锌的加入量为铁硅粉末重量的0.55%，制得铁硅混合物；
G、压制成型：在压强1550MPa的条件下压制成型；
H、热处理：温度在620℃条件下通入氮气，热处理32分钟；
I、表面涂层处理：磁粉芯表面进行涂层处理，即可。
所述的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加一定的微量元素，硅7.57%，余量为铁。
所述的微量元素为铬元素和钡元素；所述的铬元素和钡元素的重量百分比含量分别为0.15%和0.03%。
实施例2
一种高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：
A、合金熔炼：合金熔炼在氧化镁坩埚开式中频感应炉中进行，熔炼温度为1420℃，合金熔化时间为90分钟；
B、破碎：合金熔炼好后进行氮气喷雾破碎制粉；
C、分筛：粉末过筛，所述铁硅磁粉芯的粒度分布为：按-250目：-120目：-60目=4：2：1的质量比进行粉料配比；
D、表面处理：铁硅粉末烘炒至温度100℃左右时加入0.3%磷酸溶液中，具体根据透磁率种类而定，进行表面钝化处理；
E、绝缘包覆：加入2%硅树脂粘结剂，继续烘炒至干燥，所述的硅树脂粘结剂为聚甲基苯基硅氧烷中加入少量的滑石粉，其加入量为甲基苯基硅氧烷重量的15%；
F、加润滑剂：铁硅粉末冷却后加入硬脂酸锌，硬脂酸锌的加入量为铁硅粉末重量的0.4%，制得铁硅混合物；
G、压制成型：在压强1650MPa的条件下压制成型；
H、热处理：温度在600℃条件下通入氮气，热处理45分钟；
I、表面涂层处理：磁粉芯表面进行涂层处理，即可。
所述的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加一定的微量元素，硅7.22%，余量为铁。
所述的微量元素为铬元素和钡元素；所述的铬元素和钡元素的重量百分比含量分别为0.18%和0.02%。
实施例3
一种高饱和磁通密度铁硅磁粉芯的制备方法，包括以下步骤：
A、合金熔炼：合金熔炼在氧化镁坩埚开式中频感应炉中进行，熔炼温度为1510℃，合金熔化时间为55分钟；
B、破碎：合金熔炼好后进行氮气喷雾破碎制粉；
C、分筛：粉末过筛，所述铁硅磁粉芯的粒度分布为：按-250目：-120目：-60目=4：2：1的质量比进行粉料配比；
D、表面处理：铁硅粉末烘炒至温度100℃左右时加入0.2%磷酸溶液中，具体根据透磁率种类而定，进行表面钝化处理；
E、绝缘包覆：加入3%硅树脂粘结剂，继续烘炒至干燥，所述的硅树脂粘结剂为聚甲基苯基硅氧烷中加入少量的滑石粉，其加入量为甲基苯基硅氧烷重量的10%；
F、加润滑剂：铁硅粉末冷却后加入硬脂酸锌，硬脂酸锌的加入量为铁硅粉末重量的0.6%，制得铁硅混合物；
G、压制成型：在压强1500MPa的条件下压制成型；
H、热处理：温度在700℃条件下通入氮气，热处理30分钟；
I、表面涂层处理：磁粉芯表面进行涂层处理，即可。
所述的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加一定的微量元素，硅7.68%，余量为铁。
所述的微量元素为铬元素和钡元素；所述的铬元素和钡元素的重量百分比含量分别为0.12%和0.04%。
测试例
将实施例1-3中所述铁硅磁粉芯进行性能测试，测试结果如表1所示：
表1：
测试项目 实施例1 实施例2 实施例3
饱和磁通密度Tesla 1.92 1.86 1.88
剩余磁化强度 Tesla 1.27 1.35 1.44
工作温度范围℃ -55—200 -55—200 -55—200
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。

Claims (4)

1.一种高饱和磁通密度铁硅磁粉芯的制备方法，其特征在于，包括以下步骤：
A、合金熔炼：合金熔炼在氧化镁坩埚开式中频感应炉中进行，熔炼温度为1400℃以上，合金熔化时间在50分钟以上；
B、破碎：合金熔炼好后进行氮气喷雾破碎制粉；
C、分筛：粉末过筛，所述铁硅磁粉芯的粒度分布为：按-250目：-120目：-60目=4：2：1的质量比进行粉料配比；
D、表面处理：铁硅粉末烘炒至温度100℃左右时加入0.2-0.3%磷酸溶液中，具体根据透磁率种类而定，进行表面钝化处理；
E、绝缘包覆：加入2-3%硅树脂粘结剂，继续烘炒至干燥，所述的硅树脂粘结剂为聚甲基苯基硅氧烷中加入少量的滑石粉，其加入量为甲基苯基硅氧烷重量的10-15%；
F、加润滑剂：铁硅粉末冷却后加入硬脂酸锌，硬脂酸锌的加入量为铁硅粉末重量的0.4-0.6%，制得铁硅混合物；
G、压制成型：在压强1500-1650MPa的条件下压制成型；
H、热处理：温度在600-700℃条件下通入氮气，热处理30-45分钟；
I、表面涂层处理：磁粉芯表面进行涂层处理，即可。
2.如权利要求1所述的高饱和磁通密度铁硅磁粉芯的制备方法，其特征在于，所述的高饱和磁通密度铁硅磁粉芯的主要成分为二元系铁硅合金并添加一定的微量元素，硅7.2-7.7%，余量为铁。
3.如权利要求1所述的高饱和磁通密度铁硅磁粉芯的制备方法，其特征在于，所述的微量元素为铬元素和钡元素。
4.如权利要求3所述的高饱和磁通密度铁硅磁粉芯的制备方法，其特征在于，所述的铬元素和钡元素的重量百分比含量分别为0.12-0.18%和0.02-0.04%。
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