CN112700941B - 一种铁基非晶软磁合金磁芯材料及其制备方法 - Google Patents

一种铁基非晶软磁合金磁芯材料及其制备方法 Download PDF

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CN112700941B
CN112700941B CN202011514435.XA CN202011514435A CN112700941B CN 112700941 B CN112700941 B CN 112700941B CN 202011514435 A CN202011514435 A CN 202011514435A CN 112700941 B CN112700941 B CN 112700941B
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邓毕力
罗顶飞
王玉川
徐敏义
潘振海
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Anhui Zhimagnetic New Material Technology Co Ltd
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Abstract

本发明提供一种铁基非晶软磁合金磁芯材料及其制备方法，所述磁芯材料具有以下分子式：FeaSibMcBdPeCf，a+b+c+d+f＝100，所述M元素为Co、Zr、Nb、Cu中的一种或几种，所述磁芯材料外还具有NiCo2O4纳米线层，所述纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为5μm～10μm的聚苯胺薄膜，NiCo2O4纳米线层中的NiCo2O4纳米线的直径为50nm～100nm，厚度为3mm～8mm。本发明提供的制备方法制备得到的具有分子式FeaSibMcBdPeCf的铁基非晶软磁合金磁芯材料具有饱和磁化强度高、介电损耗较小且具有一定绝缘的能力的同时不影响其磁导率的优异性能。

Description

一种铁基非晶软磁合金磁芯材料及其制备方法
技术领域
本发明属于磁性材料技术领域，具体涉及一种铁基非晶软磁合金磁芯材料及其制备方法。
背景技术
与传统软磁材料相比，铁基非晶纳米晶合金具有更加优异的软磁性能而被广泛应用于电力、电子、信息和能源等高新技术领域。随着高新技术领域的进步以及时代的发展，对软磁材料提出了高频、微型、集成、低成本、节能和环保等新的需求。为满足这些需求，本文旨在研究成分及制备工艺相对简单，价格低廉且性能优异的铁基非晶合金，以及通过简单的热处理工艺提高商用铁基非晶纳米晶合金的磁性能，并用热处理后的商用非晶带材来设计和制备磁源。但是现有技术中缺乏一种饱和磁感应强度高的同时，介电损耗较小的基非晶软磁合金磁芯材料。
发明内容
本发明针对上述缺陷，提供一种饱和磁感应强度高、介电损耗较小且具有一定绝缘的能力的同时不影响其磁导率的铁基非晶软磁合金磁芯材料及其制备方法。
本发明提供如下技术方案：一种铁基非晶软磁合金磁芯材料，所述磁芯材料具有以下分子式：FeaSibMcBdPeCf，a+b+c+d+f＝100，所述M元素为Co、Zr、Nb、Cu中的一种或几种，所述磁芯材料外还具有NiCo2O4纳米线层，所述纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为5μm～10μm的聚苯胺薄膜。
进一步地，所述NiCo2O4纳米线层中的NiCo2O4纳米线的直径为50nm～100nm。
进一步地，所述NiCo2O4纳米线层的厚度为3mm～8mm。
进一步地，所述的Fe原子百分含量为70≤a≤80。
进一步地，所述的Si原子百分含量为10≤a≤15。
进一步地，所述的M原子百分含量为5≤a≤10。
进一步地，所述的B原子百分含量为3≤a≤7。
进一步地，所述的P原子百分含量为0.5≤a≤2。
进一步地，所述C的原子百分含量为1≤e≤3。
本发明还提供上述铁镍基非晶软磁合金磁粉芯材料的制备方法，包括以下步骤：
1)按照所述分子式FeaSibMcBdPeCf的铁基非晶软磁合金磁芯成分进行配料，将配料后的混合物熔炼成钢液，调整所述钢液的温度至160℃～320℃，使所述钢液的液位高度在600mm～700mm；
2)采用单铜辊于30m/s～45m/s的速率进行喷涂快淬法使所述步骤1)得到的钢液冷却得到铁基非晶合金薄带，喷涂所用的喷嘴与所述单铜辊的距离为250μm～280μm；
3)将所述步骤2)得到的铁基非晶合金薄带加热至250℃～350℃后，与所述NiCo2O4纳米线包裹至加热后的铁基非晶合金薄带表面，采用模具限制所述NiCo2O4纳米线层层的厚度，得到具有NiCo2O4纳米线层的磁芯材料；
4)将所述步骤3)得到的具有NiCo2O4纳米线层的磁芯材料采用正硅酸乙酯偶联剂进行偶联处理，然后采用化学气相沉积法沉积一层厚度为5μm～10μm的聚苯胺薄膜，形成所述带有聚苯胺导电绝缘薄膜包覆的具有NiCo2O4纳米线层的铁基非晶软磁合金磁粉芯材料。
本发明的有益效果为：
1、本发明提供的分子式为FeaSibMcBdPeCf的铁基非晶软磁合金磁粉芯材料，保证铁的原子百分含量为70～80，Si的的原子百分含量为10～15，增加了铁和硅的含量进而使最终获得的软磁合金磁粉芯材料具有1.54T～1.65T的饱和磁感强度以及较低的电阻率，进而磁导率高，介电损耗小。
2、本申请通过在磁粉芯材料外包裹的NiCo2O4纳米线层中的纳米NiCo2O4是一种强介电化合物材料，其含有Ni和Co两种磁性元素啊，而且其磁性与Ni和Co的价态及位点密切相关，四面体位由磁性的Co2+和非磁的Co3+占据，八面体位则由磁性的Ni3+和非磁的Ni2+占据，因此，在具有良好的磁学性能的同时，能够起到一定的磁能储存性能，进而使其具有更小的磁损率和介电损耗。
3、本发明通过在最外层包裹一层聚苯胺导电绝缘层，聚苯胺作为一种导电聚合物生成成本低、密度小、加工性能更好、机械柔韧性更高，因此，提高了最终形成的磁芯材料的机械能力并降低了其电阻率。
具体实施例方式
下面将结合本发明实施例，对本发明实施例中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。
实施例1
本实施例提供的一种铁基非晶软磁合金磁芯材料，磁芯材料具有以下分子式：Fe80Si10Co5B3PC，所述磁芯材料外还具有一层厚度为3mm的NiCo2O4纳米线层，NiCo2O4纳米线层中的NiCo2O4纳米线的直径为50nm，纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为5μm的聚苯胺薄膜。
本发明还提供上述铁镍基非晶软磁合金磁粉芯材料的制备方法，包括以下步骤：
1)按照所述分子式Fe80Si10Co5B3PC的铁基非晶软磁合金磁芯成分进行配料，将配料后的混合物熔炼成钢液，调整所述钢液的温度至160℃，使所述钢液的液位高度在600mm；
2)采用单铜辊于30m/s的速率进行喷涂快淬法使步骤1)得到的钢液冷却得到铁基非晶合金薄带，喷涂所用的喷嘴与所述单铜辊的距离为250μm；
3)将所述步骤2)得到的铁基非晶合金薄带加热至250℃后，与NiCo2O4纳米线包裹至加热后的铁基非晶合金薄带表面，采用模具限制所述NiCo2O4纳米线层层的厚度为3mm，得到具有NiCo2O4纳米线层的磁芯材料；
4)将步骤3)得到的具有NiCo2O4纳米线层的磁芯材料采用正硅酸乙酯偶联剂进行偶联处理，然后采用化学气相沉积法沉积一层厚度为5μm的聚苯胺薄膜，形成所述带有聚苯胺导电绝缘薄膜包覆的具有NiCo2O4纳米线层的铁基非晶软磁合金磁粉芯材料。
经试验，本实施例提供的磁粉芯材料具有1.54T的饱和磁感应强度，电阻率为1105×10-8Ω·m，磁导率损失率为3.88％，介电损耗为0.3487％。
实施例2
一种铁基非晶软磁合金磁芯材料，所述磁芯材料具有以下分子式：Fe75Si12(Zr0.5Cu0.5)5B5P2C，磁芯材料外还具有一层厚度为8mm的NiCo2O4纳米线层，NiCo2O4纳米线层中的NiCo2O4纳米线的直径为100nm，纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为10μm的聚苯胺薄膜。
本发明还提供上述铁镍基非晶软磁合金磁粉芯材料的制备方法，包括以下步骤：
1)按照所述分子式Fe75Si12(Zr0.5Cu0.5)5B5P2C的铁基非晶软磁合金磁芯成分进行配料，将配料后的混合物熔炼成钢液，调整所述钢液的温度至320℃，使所述钢液的液位高度在700mm；
2)采用单铜辊于45m/s的速率进行喷涂快淬法使所述步骤1)得到的钢液冷却得到铁基非晶合金薄带，喷涂所用的喷嘴与所述单铜辊的距离为280μm；
3)将所述步骤2)得到的铁基非晶合金薄带加热至350℃后，与NiCo2O4纳米线包裹至加热后的铁基非晶合金薄带表面，采用模具限制所述NiCo2O4纳米线层层的厚度为8mm，得到具有NiCo2O4纳米线层的磁芯材料；
4)将所述步骤3)得到的具有NiCo2O4纳米线层的磁芯材料采用正硅酸乙酯偶联剂进行偶联处理，然后采用化学气相沉积法沉积一层厚度为10μm的聚苯胺薄膜，形成带有聚苯胺导电绝缘薄膜包覆的具有NiCo2O4纳米线层的铁基非晶软磁合金磁粉芯材料。
经试验，本实施例提供的磁粉芯材料具有1.62T的饱和磁感应强度，电阻率为115×10-8Ω·m，磁导率损失率为2.9％，介电损耗为0.2956％。
实施例3
本实施例提供的一种铁基非晶软磁合金磁芯材料，磁芯材料具有以下分子式：Fe70Si15Nb6B4P2C3，磁芯材料外还具有一层厚度为5.5mm的NiCo2O4纳米线层，NiCo2O4纳米线层中的NiCo2O4纳米线的直径为75nm所述纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为7.5μm的聚苯胺薄膜。
本发明还提供上述铁镍基非晶软磁合金磁粉芯材料的制备方法，包括以下步骤：
1)按照所述分子式FeaSibMcBdPeCf的铁基非晶软磁合金磁芯成分进行配料，将配料后的混合物熔炼成钢液，调整所述钢液的温度至240℃，使所述钢液的液位高度在650mm；
2)采用单铜辊于32.5m/s的速率进行喷涂快淬法使所述步骤1)得到的钢液冷却得到铁基非晶合金薄带，喷涂所用的喷嘴与所述单铜辊的距离为360μm；
3)将步骤2)得到的铁基非晶合金薄带加热至300℃后，与所述NiCo2O4纳米线包裹至加热后的铁基非晶合金薄带表面，采用模具限制所述NiCo2O4纳米线层的厚度为5.5mm，得到具有NiCo2O4纳米线层的磁芯材料；
4)将所述步骤3)得到的具有NiCo2O4纳米线层的磁芯材料采用正硅酸乙酯偶联剂进行偶联处理，然后采用化学气相沉积法沉积一层厚度为7.5μm的聚苯胺薄膜，形成所述带有聚苯胺导电绝缘薄膜包覆的具有NiCo2O4纳米线层的铁基非晶软磁合金磁粉芯材料。
经试验，本实施例提供的磁粉芯材料具有1.65T的饱和磁感应强度，电阻率为107×10-8Ω·m，磁导率损失率为3.0％，介电损耗为0.3015％。
以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。
此外，本领域的技术人员能够理解，尽管在此的一些实施例包括其它实施例中所包括的某些特征而不是其它特征，但是不同实施例的特征的组合意味着处于本发明的范围之内并且形成不同的实施例。例如，在上面的权利要求书中，所要求保护的实施例的任意之一都可以以任意的组合方式来使用。公开于该背景技术部分的信息仅仅旨在加深对本发明的总体背景技术的理解，而不应当被视为承认或以任何形式暗示该信息构成已为本领域技术人员所公知的现有技术。

Claims (2)

1.一种铁基非晶软磁合金磁芯材料，其特征在于，所述磁芯材料具有以下分子式：FeaSibMcBdPeCf，a+b+c+d+e+f=100，所述M元素为Co、Zr、Nb、Cu中的一种或几种，所述磁芯材料外还具有NiCo2O4纳米线层，所述纳米NiCo2O4纳米线层外采用化学气象沉积一层厚度为5μm～10μm的聚苯胺薄膜；所述NiCo2O4纳米线层中的NiCo2O4纳米线的直径为50nm～100 nm；所述NiCo2O4纳米线层的厚度为3mm～8mm；所述的Fe原子百分含量为70≤a≤80；所述的Si原子百分含量为10≤b≤15；所述的M原子百分含量为5≤c≤10；所述的B原子百分含量为3≤d≤7；所述的P原子百分含量为0.5≤e≤2；所述C的原子百分含量为1≤f≤3。
2.根据权利要求1所述的一种铁镍基非晶软磁合金磁粉芯材料的制备方法，其特征在于，包括以下步骤：
1）按照所述分子式FeaSibMcBdPeCf的铁基非晶软磁合金磁芯成分进行配料，将配料后的混合物熔炼成钢液，调整所述钢液的温度至160℃～320℃，使所述钢液的液位高度在600mm～700mm；
2）采用单铜辊于30m/s～45m/s的速率进行喷涂快淬法使所述步骤1）得到的钢液冷却得到铁基非晶合金薄带，喷涂所用的喷嘴与所述单铜辊的距离为250μm～280μm；
3）将所述步骤2）得到的铁基非晶合金薄带加热至250℃～350℃后，与所述NiCo2O4纳米线包裹至加热后的铁基非晶合金薄带表面，采用模具限制所述NiCo2O4纳米线层的厚度，得到具有NiCo2O4纳米线层的磁芯材料；
4）将所述步骤3）得到的具有NiCo2O4纳米线层的磁芯材料采用正硅酸乙酯偶联剂进行偶联处理，然后采用化学气相沉积法沉积一层厚度为5μm～10μm的聚苯胺薄膜，形成所述带有聚苯胺导电绝缘薄膜包覆的具有NiCo2O4纳米线层的铁基非晶软磁合金磁粉芯材料。
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