CN113192716B - Soft magnetic alloy material and preparation method thereof - Google Patents
Soft magnetic alloy material and preparation method thereof Download PDFInfo
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- CN113192716B CN113192716B CN202110472088.7A CN202110472088A CN113192716B CN 113192716 B CN113192716 B CN 113192716B CN 202110472088 A CN202110472088 A CN 202110472088A CN 113192716 B CN113192716 B CN 113192716B
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Abstract
The application discloses a soft magnetic alloy material and a preparation method thereof, wherein the preparation method comprises the following steps: providing a first alloy material, a second alloy material and a carbonyl iron material, respectively smelting into a first metal liquid, a second metal liquid and a third metal liquid, and respectively cooling; respectively treating the cooled first alloy powder, second alloy powder and carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ in a protective atmosphere to obtain first alloy powder, second alloy powder and carbonyl iron powder; after the first alloy powder, the second alloy powder and carbonyl iron powder are mixed according to a preset proportion, the mixture can be mixed with o-cresol formaldehyde epoxy resin, methylnadic anhydride, benzyl triphenyl phosphonium bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a release agent to obtain a mixed material; and melting and mixing the mixed material at 100 ℃, and then cooling, crushing and sieving to obtain the soft magnetic alloy material.
Description
Technical Field
The application relates to the technical field of soft magnetic alloy materials, in particular to a soft magnetic alloy material and a preparation method thereof.
Background
With the development of informatization, the application of electronic components is becoming wider and wider, and with the improvement of product performance, the demand for magnetic materials used for electronic components is becoming higher and higher, and in recent years, the magnetic materials used for electronic components are gradually developing in the directions of higher frequency, higher magnetic permeability, higher superimposed current, higher insulation, lower loss, and the like.
At present, most of the magnetic materials are soft magnetic alloy materials, and more customers pursue the soft magnetic alloy materials to achieve the characteristics of high magnetic permeability, high magnetic flux density, excellent current superposition, low loss and the like, so as to ensure that the electronic components can work efficiently, stably and reliably under the conditions of high-temperature environment and superposition of larger current.
And the magnetic permeability is improved, the direct current superposition characteristic is reduced, and one of the performances is usually selected to be sacrificed for some special application occasions, or both of the performances are reduced as appropriate.
Therefore, it is highly desirable to develop a soft magnetic alloy material with high magnetic permeability and high superimposed current.
Disclosure of Invention
Based on the above, in order to solve or improve the problems in the prior art, the present application provides a soft magnetic alloy material and a method for preparing the soft magnetic alloy material, which have high magnetic permeability and high superposition current.
A first aspect of the present application provides a soft magnetic alloy material comprising: the first alloy powder, the second alloy powder and carbonyl iron powder; the first alloy powder includes: iron, silicon, chromium, phosphorus, boron, and carbon; the second alloy powder includes: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon.
The first alloy powder comprises the following components in percentage by weight: 85-95 wt% of iron, 1.5-5.0 wt% of silicon, 0.1-0.5 wt% of chromium, 0.10-0.5 wt% of phosphorus, 0.5-6.5 wt% of boron and 0.05-0.5 wt% of carbon; in the second alloy powder, the ratio of each component is as follows: 83-94 wt% of iron, 3-6 wt% of silicon, 0.5-4.5 wt% of aluminum, 0.25-2.0 wt% of chromium, 0.5-1.5 wt% of phosphorus, 0.20-1.5 wt% of boron, 0.05-0.4 wt% of cobalt, 0.05-0.4 wt% of copper and 0.05-0.4 wt% of carbon; the iron content of the carbonyl iron powder is 95-99 wt%.
Wherein the granularity of the first alloy powder is 20-40 um; the granularity of the second alloy powder is 5-15 um; the granularity of the carbonyl iron powder is 2-3 um.
Wherein the soft magnetic alloy material further comprises: o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
Wherein the o-cresol novolac epoxy resin accounts for 1-4.0 wt%, the methylnadic anhydride accounts for 0.5-3.0 wt%, the benzyltriphenylphosphonium bromide accounts for 0.3-1.5 wt%, the 2-methylimidazole accounts for 0.1-2.0 wt%, the antimonous oxide accounts for 0.1-1.0 wt%, the silica micropowder accounts for 0.25-3.0 wt%, the methacryloxypropyltrimethoxysilane accounts for 0.1-1.5 wt%, and the mold release agent accounts for 0.1-1.0 wt%.
In a second aspect, the present application provides a method for preparing a soft magnetic alloy material, comprising: providing a first alloy material, a second alloy material, and a carbonyl iron material, wherein the first alloy material comprises iron, silicon, chromium, phosphorus, boron, and carbon, and the second alloy material comprises iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon; respectively smelting a first alloy material, a second alloy material and a carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid; respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to obtain spherical or spheroidal first alloy powder, second alloy powder and carbonyl iron powder; respectively treating the first alloy powder, the second alloy powder and carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ in a protective atmosphere to obtain first alloy powder, second alloy powder and carbonyl iron powder; and mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset ratio to obtain the soft magnetic alloy material.
Wherein, the granularity of the powder in the soft magnetic alloy material is 2 um-40 um.
Wherein the protective atmosphere is nitrogen or/and hydrogen.
The preparation method of the soft magnetic alloy material further comprises the following steps: after the first alloy powder, the second alloy powder and carbonyl iron powder are mixed according to a predetermined ratio to obtain the soft magnetic alloy material, the manufacturing method of the soft magnetic alloy material further comprises the following steps: mixing the soft magnetic alloy material with provided o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silicon micropowder, methacryloxypropyl trimethoxysilane and a release agent to obtain a mixed material; and melting and mixing the mixed materials at 100 ℃, and cooling, crushing and sieving the melted and mixed materials to obtain the improved soft magnetic alloy material.
Wherein, the preparation method of the soft magnetic alloy material also comprises the following steps: after the improved soft magnetic alloy material is obtained, the improved soft magnetic alloy material is placed in a mold, a magnetic ring is pressed at the temperature of 100-250 ℃ under the pressure of less than or equal to 300MPa, the molded magnetic ring is treated at the temperature of 160-180 ℃ for 0.5-1 hour, and the performance of the magnetic ring is tested to test the performance of the improved soft magnetic alloy material.
After the soft magnetic alloy material is made into the magnetic ring, the forming pressure of the magnetic ring is less than or equal to 300MPa, and the forming pressure is low, so that the probability that the insulating layer on the surface of the metal powder particle is damaged due to overlarge pressure during forming is reduced by reducing the forming pressure, and the insulating property of the magnetic powder core prepared by using the soft magnetic alloy material is improved.
According to the soft magnetic alloy material and the preparation method of the soft magnetic alloy material, the soft magnetic alloy material has high magnetic conductivity and high superposed current, and the electronic component prepared from the soft magnetic alloy material also has high magnetic conductivity and high superposed current.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings used in the description of the embodiments will be briefly introduced below. It is to be understood that the drawings in the following description are illustrative only and are not restrictive of the invention.
Fig. 1 is a schematic flow chart of a preparation method of a soft magnetic alloy material according to an embodiment of the present application.
Detailed Description
The technical solutions in the embodiments of the present application are clearly and completely described below with reference to the accompanying drawings, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As described in the background art, more and more customers are pursuing soft magnetic alloy materials that can achieve the characteristics of high magnetic permeability, high magnetic flux density, excellent current superposition, low loss, and the like, thereby ensuring that electronic components can work efficiently, stably, and reliably in a high-temperature environment and under the condition of superposing a large current.
The inventor researches and discovers that after the magnetic permeability of the soft magnetic alloy material is improved, the direct current superposition characteristic is reduced, and for some special application occasions, one of the performances is generally selected to be sacrificed, or both of the performances are reduced as appropriate.
Example one
The embodiment of the application provides a soft magnetic alloy material and a preparation method thereof, wherein the soft magnetic alloy material has high magnetic conductivity and high superposed current.
The embodiment of the application provides a soft magnetic alloy material, which comprises: the first alloy powder, the second alloy powder and carbonyl iron powder.
Wherein the first alloy powder comprises: iron, silicon, chromium, phosphorus, boron, and carbon; the second alloy powder comprises: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon.
In this embodiment, in the first alloy powder, the ratio of each component may be: 85-95 wt% of iron, 1.5-5.0 wt% of silicon, 0.1-0.5 wt% of chromium, 0.10-0.5 wt% of phosphorus, 0.5-6.5 wt% of boron and 0.05-0.5 wt% of carbon.
In the second alloy powder, the proportion of each component can be as follows: 83-94 wt% of iron, 3-6 wt% of silicon, 0.5-4.5 wt% of aluminum, 0.25-2.0 wt% of chromium, 0.5-1.5 wt% of phosphorus, 0.20-1.5 wt% of boron, 0.05-0.4 wt% of cobalt, 0.05-0.4 wt% of copper and 0.05-0.4 wt% of carbon.
The proportion of iron in the carbonyl iron powder can be 95-99 wt%.
In the embodiment, the granularity of the first alloy powder is 20-40 um; the granularity of the second alloy powder is 5-15 um; the granularity of the carbonyl iron powder is 2-3 um.
The soft magnetic alloy material provided by the embodiment has high magnetic conductivity, high superposed current, high insulation and low loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In an embodiment, an embodiment of the present application further provides a method for preparing a soft magnetic alloy material, including:
s101, providing a first alloy material, a second alloy material and a carbonyl iron material;
s102, respectively smelting a first alloy material, a second alloy material and a carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid;
s103, respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to form spherical or quasi-spherical first alloy powder, second alloy powder and carbonyl iron powder;
s104, respectively treating the first alloy powder, the second alloy powder and carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ in a protective atmosphere to obtain first alloy powder, second alloy powder and carbonyl iron powder;
and S105, mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset ratio to obtain the soft magnetic alloy material.
In step S101, the first alloy material includes iron, silicon, chromium, phosphorus, boron, and carbon, and the second alloy material includes iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon;
in step S102, the first alloy material, the second alloy material, and the carbonyl iron powder are melted in a high-temperature melting furnace into a first metal liquid, a second metal liquid, and a third metal liquid, respectively.
In step S103, the first metal liquid, the second metal liquid, and the third metal liquid are respectively broken into fine metal droplets by using the high-speed airflow generated by the atomizing nozzle.
In step S104, when different metal droplets are cooled, the cooling time is shortened as much as possible, so as to prevent the metal droplets from being deformed too much during the cooling process and being unusable in the subsequent preparation process.
In step S104, the protective atmosphere is a closed gas environment with a protective gas, and may be nitrogen, and/or hydrogen, in this embodiment, the protective atmosphere may be nitrogen, and in other embodiments, the protective atmosphere may also be hydrogen or a mixture of hydrogen and nitrogen.
In step S105, the particle size of the powder in the soft magnetic alloy material is 2um to 40 um.
The soft magnetic alloy material prepared by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In one embodiment, the soft magnetic alloy material further comprises: o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
Wherein the proportion of the o-cresol formaldehyde epoxy resin is 1 to 4.0 weight percent, the proportion of the methylnadic anhydride is 0.5 to 3.0 weight percent, the proportion of the benzyl triphenyl phosphonium bromide is 0.3 to 1.5 weight percent, the proportion of the 2-methylimidazole is 0.1 to 2.0 weight percent, the proportion of the antimony trioxide is 0.1 to 1.0 weight percent, the proportion of the silicon micropowder is 0.5 to 3.0 weight percent, the proportion of the methacryloxypropyl trimethoxy silane is 0.1 to 1.5 weight percent, and the proportion of the mold release agent is 0.1 to 1.0 weight percent.
The soft magnetic alloy material provided by the embodiment can be made into electronic components, so that the made electronic components have high magnetic conductivity and high superposed current. The requirements of the existing components on high insulation, high frequency, high saturation and low power consumption can be met.
In one embodiment, in step S105, after the first alloy powder, the second alloy powder and the carbonyl iron powder are mixed according to a predetermined ratio to obtain the soft magnetic alloy material, the method for preparing the soft magnetic alloy material further includes:
s201, mixing a soft magnetic alloy material with provided o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphonium bromide, 2-methylimidazole, antimony trioxide, silica powder, methacryloxypropyl trimethoxysilane and a release agent to obtain a mixed material;
s202, melting and mixing the mixed material at 100 ℃, and cooling, crushing and sieving the melted and mixed material to obtain an improved soft magnetic alloy material;
in one embodiment, after step S202, the method for preparing the soft magnetic alloy material further includes:
s203, placing the improved soft magnetic alloy material in a mold, pressing the improved soft magnetic alloy material into a magnetic ring at the temperature of 100-250 ℃ under the pressure of less than or equal to 300MPa, and treating the formed magnetic ring at the temperature of 160-180 ℃ for 0.5-1 hour.
After making the magnetically soft alloy material into the magnetic ring, the molding pressure of the magnetic ring is 300MPa, and the molding pressure is small, so that the probability that the insulating layer on the surface of the metal powder particle is damaged due to overlarge pressure during molding is reduced by reducing the molding pressure, and the insulating property of the magnetic powder core prepared by using the magnetically soft alloy material is improved.
Example two
The embodiment of the application provides a soft magnetic alloy material, which comprises: the first alloy powder, the second alloy powder and carbonyl iron powder.
Wherein, the first alloy powder comprises: iron, silicon, chromium, phosphorus, boron, and carbon; the second alloy powder includes: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon.
In this embodiment, in the first alloy powder, the ratio of each component may be: 93 wt% of iron, 1.6 wt% of silicon, 0.1 wt% of chromium, 0.4 wt% of phosphorus, 4.5 wt% of boron and 0.4 wt% of carbon.
In the second alloy powder, the ratio of each component can be as follows: 92 wt% of iron, 4.5 wt% of silicon, 1.0 wt% of aluminum, 1.0 wt% of chromium, 0.5 wt% of phosphorus, 0.5 wt% of boron, 0.1 wt% of cobalt, 0.15 wt% of copper and 0.25 wt% of carbon.
The proportion of iron in the carbonyl iron powder may be 97 wt%.
In the embodiment, the granularity of the first alloy powder is 20-40 um; the granularity of the second alloy powder is 5-15 um; the granularity of the carbonyl iron powder is 2-3 um.
The soft magnetic alloy material provided by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In an embodiment, an embodiment of the present application further provides a method for preparing a soft magnetic alloy material, including:
s111, providing a first alloy material, a second alloy material and a carbonyl iron material, wherein the first alloy material comprises iron, silicon, chromium, phosphorus, boron and carbon, and the second alloy material comprises iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper and carbon;
s112, respectively smelting the first alloy material, the second alloy material and the carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid;
s113, respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to form spherical or quasi-spherical first alloy powder, second alloy powder and carbonyl iron powder;
s114, treating the first alloy powder, the second alloy powder and carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ respectively to obtain first alloy powder, second alloy powder and carbonyl iron powder;
s115, mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset ratio to obtain the soft magnetic alloy material.
In step S112, the raw materials of the first alloy material, the second alloy material, and the carbonyl iron powder are melted in a high-temperature melting furnace into the first metal liquid, the second metal liquid, and the third metal liquid, respectively.
In step S113, the first metal liquid, the second metal liquid, and the third metal liquid are respectively broken into fine metal droplets by using the high-speed gas flow generated by the atomizing nozzle.
In step S114, when different metal droplets are cooled, the cooling time is shortened as much as possible, so as to prevent the metal droplets from being deformed too much during the cooling process and being unusable in the subsequent preparation process.
In step S114, the protective atmosphere is a closed gas environment with a protective gas, and may be nitrogen, and/or hydrogen, in this embodiment, the protective atmosphere may be nitrogen, and in other embodiments, the protective atmosphere may also be hydrogen or a mixture of hydrogen and nitrogen.
In step S115, the particle size of the powder in the soft magnetic alloy material is 2um to 40um, and the predetermined ratio of the first alloy powder, the second alloy powder and the carbonyl iron powder is 60%, 35%, 5%.
The soft magnetic alloy material prepared by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In one embodiment, the soft magnetic alloy material further comprises: o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
Wherein the proportion of the o-cresol formaldehyde epoxy resin is 2.5 wt%, the proportion of the methylnadic anhydride is 0.5 wt%, the proportion of the benzyl triphenyl phosphonium bromide is 0.5 wt%, the proportion of the 2-methylimidazole is 0.35 wt%, the proportion of the antimony trioxide is 0.15 wt%, the proportion of the silicon micropowder is 0.25 wt%, the proportion of the methacryloxypropyl trimethoxy silane is 0.15 wt%, and the proportion of the release agent is 0.1 wt%.
The soft magnetic alloy material provided by the embodiment can be made into electronic components, so that the made electronic components have high magnetic conductivity and high superposed current, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In one embodiment, after the step S115 of mixing the first alloy powder, the second alloy powder and the carbonyl iron powder according to a predetermined ratio to obtain the soft magnetic alloy material, the method for preparing the soft magnetic alloy material further includes:
s211, mixing the soft magnetic alloy material with the provided o-cresol formaldehyde epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silicon micropowder, methacryloxypropyl trimethoxy silane and a release agent to obtain a mixed material;
s212, melting and mixing the mixed material at 100 ℃, and cooling, crushing and sieving the melted and mixed material to obtain an improved soft magnetic alloy material;
in one embodiment, after step S212, the method for preparing the soft magnetic alloy material further includes:
s213, placing the improved soft magnetic alloy material in a mold, pressing the improved soft magnetic alloy material into a magnetic ring at the temperature of 100-250 ℃ under the pressure of less than or equal to 250MPa, and treating the molded magnetic ring at the temperature of 160-180 ℃ for 1 hour.
In the magnetic ring in this embodiment, the size of the magnetic ring is 20.0mm 12.0mm 2.0mm in terms of Outer Diameter (OD) Inner Diameter (ID) Thickness (TH).
In step S212, a 60-325 mesh screen is used for sieving.
After the soft magnetic alloy material is made into the magnetic ring, the forming pressure of the magnetic ring is 250MPa, and the forming pressure is low, so that the probability that the insulating layer on the surface of the metal powder particles is damaged due to overlarge pressure during forming is reduced by reducing the forming pressure, and the insulating property of the magnetic powder core prepared by using the soft magnetic alloy material is improved. EXAMPLE III
The embodiment of the application provides a soft magnetic alloy material, which comprises: the powder material comprises first alloy powder, second alloy powder and carbonyl iron powder.
Wherein the first alloy powder comprises: iron, silicon, chromium, phosphorus, boron, and carbon; the second alloy powder includes: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon.
In this embodiment, in the first alloy powder, the ratio of each component may be: 92 wt% of iron, 2.0 wt% of silicon, 0.1 wt% of chromium, 0.1 wt% of phosphorus, 5.5 wt% of boron and 0.3 wt% of carbon.
In the second alloy powder, the proportion of each component can be as follows: 91 wt% of iron, 5.5 wt% of silicon, 1.0 wt% of aluminum, 0.5 wt% of chromium, 0.5 wt% of phosphorus, 0.65 wt% of boron, 0.15 wt% of cobalt, 0.35 wt% of copper and 0.35 wt% of carbon.
The proportion of iron in the carbonyl iron powder may be 97 wt%.
In the embodiment, the granularity of the first alloy powder is 20-40 um; the granularity of the second alloy powder is 5-15 um; the granularity of the carbonyl iron powder is 2-3 um.
The soft magnetic alloy material provided by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In an embodiment, an embodiment of the present application further provides a method for preparing a soft magnetic alloy material, including:
s121, providing a first alloy material, a second alloy material and a carbonyl iron material, wherein the first alloy material comprises iron, silicon, chromium, phosphorus, boron and carbon, and the second alloy material comprises iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper and carbon;
s122, respectively smelting the first alloy material, the second alloy material and the carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid;
s123, respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to form spherical or quasi-spherical first alloy powder, second alloy powder and carbonyl iron powder;
s124, respectively treating the first alloy powder, the second alloy powder and carbonyl iron powder for 1-2 hours at the temperature of 350 ℃, 450-600 ℃ and 300 ℃ in a protective atmosphere to obtain first alloy powder, second alloy powder and carbonyl iron powder;
s125, mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset ratio to obtain the soft magnetic alloy material.
In step S122, the first alloy material, the second alloy material, and the carbonyl iron powder are melted into the first metal liquid, the second metal liquid, and the third metal liquid, respectively, in the high-temperature melting furnace.
In step S123, the first metal liquid, the second metal liquid, and the third metal liquid are respectively broken into fine metal droplets by using the high-speed gas flow generated by the atomizing nozzle.
In step S124, when different metal droplets are cooled, the cooling time is shortened as much as possible, so as to prevent the metal droplets from being deformed too much during the cooling process and being unusable in the subsequent preparation process.
In step S124, the protective atmosphere is nitrogen or/and hydrogen, in this embodiment, the protective atmosphere may be nitrogen, and in other embodiments, the protective atmosphere may also be hydrogen or a mixture of hydrogen and nitrogen.
In step S125, the grain size of the soft magnetic alloy material is 2um to 40um, and the predetermined ratio of the first alloy powder, the second alloy powder and the carbonyl iron powder is 50%, 42% or 8%.
The soft magnetic alloy material prepared by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In one embodiment, the soft magnetic alloy material further comprises: epoxy novolaks, methylnadic anhydride, benzyl triphenyl phosphonium bromide, 2-methylimidazole, antimony trioxide, silicon micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
Wherein the proportion of the o-cresol formaldehyde epoxy resin is 2.7 wt%, the proportion of the methylnadic anhydride is 0.5 wt%, the proportion of the benzyl triphenyl phosphonium bromide is 0.35 wt%, the proportion of the 2-methylimidazole is 0.25 wt%, the proportion of the antimony trioxide is 0.15 wt%, the proportion of the silicon micropowder is 0.25 wt%, the proportion of the methacryloxypropyl trimethoxy silane is 0.15 wt%, and the proportion of the release agent is 0.15 wt%.
The soft magnetic alloy material provided by the embodiment can be made into electronic components, so that the made electronic components have high magnetic conductivity and high superposed current. The requirements of the existing components on high insulation, high frequency, high saturation and low power consumption can be met.
In one embodiment, in step S125, after the first alloy powder, the second alloy powder and the carbonyl iron powder are mixed according to a predetermined ratio to obtain the soft magnetic alloy material, the method for preparing the soft magnetic alloy material further includes:
s221, mixing the soft magnetic alloy material with provided o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphonium bromide, 2-methylimidazole, antimony trioxide, silica powder, methacryloxypropyl trimethoxysilane and a release agent to obtain a mixed material;
and S222, melting and mixing the mixed materials at 100 ℃, and cooling, crushing and sieving the melted and mixed materials to obtain the improved soft magnetic alloy material.
In one embodiment, after step S222, the method for preparing the soft magnetic alloy material further includes:
s223, placing the improved soft magnetic alloy material into a mold, pressing the improved soft magnetic alloy material into a magnetic ring at the temperature of 100-250 ℃ under the pressure of less than or equal to 250MPa, and treating the formed magnetic ring at the temperature of 160-180 ℃ for 1 hour.
The magnetic ring in this embodiment is a magnetic ring, and the size of the magnetic ring is 20.0mm 12.0mm 2.0mm in terms of Outer Diameter (OD) Inner Diameter (ID) Thickness (TH).
In step S222, a screen of 60-325 mesh is used for the sieving.
After the soft magnetic alloy material is made into the magnetic ring, the molding pressure of the magnetic ring is 250MPa, so that the probability that the insulating layer on the surface of the metal powder particle is damaged due to overlarge pressure during molding is reduced by reducing the molding pressure, and the insulating property of the magnetic powder core prepared by using the soft magnetic alloy material is improved.
Example four
The embodiment of the application provides a soft magnetic alloy material, which comprises: the first alloy powder, the second alloy powder and carbonyl iron powder.
Wherein the first alloy powder comprises: iron, silicon, chromium, phosphorus, boron, and carbon; the second alloy powder includes: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon.
In this embodiment, in the first alloy powder, the ratio of each component may be: 91.5 wt% of iron, 2.5 wt% of silicon, 0.1 wt% of chromium, 0.2 wt% of phosphorus, 5.5 wt% of boron and 0.2 wt% of carbon.
In the second alloy powder, the proportion of each component can be as follows: 93 wt% of iron, 4.5 wt% of silicon, 0.5 wt% of aluminum, 1.0 wt% of chromium, 0.2 wt% of phosphorus, 0.25 wt% of boron, 0.15 wt% of cobalt, 0.2 wt% of copper, and 0.2 wt% of carbon.
The proportion of iron in the carbonyl iron powder may be 97 wt%.
In the embodiment, the granularity of the first alloy powder is 20-40 um; the granularity of the second alloy powder is 5-15 um; the granularity of the carbonyl iron powder is 2-3 um.
The soft magnetic alloy material provided by the embodiment has high magnetic conductivity, high superposed current, high insulation and low loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In an embodiment, an embodiment of the present application further provides a method for preparing a soft magnetic alloy material, including:
s131, providing a first alloy material, a second alloy material and a carbonyl iron material, wherein the first alloy material comprises iron, silicon, chromium, phosphorus, boron and carbon, and the second alloy material comprises iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper and carbon;
s132, respectively smelting the first alloy material, the second alloy material and the carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid;
s133, respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to form spherical or quasi-spherical first alloy powder, second alloy powder and carbonyl iron powder;
s134, treating the first alloy powder, the second alloy powder and the carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ respectively to obtain first alloy powder, second alloy powder and carbonyl iron powder;
and S135, mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset proportion to obtain the soft magnetic alloy material.
In step S132, the first alloy material, the second alloy material, and the carbonyl iron powder are melted into the first metal liquid, the second metal liquid, and the third metal liquid, respectively, in the high-temperature melting furnace.
In step S133, the first metal liquid, the second metal liquid, and the third metal liquid are respectively broken into fine metal droplets by using the high-speed gas flow generated by the atomizing nozzle.
In step S134, when different metal droplets are cooled, the cooling time is shortened as much as possible, so as to prevent the metal droplets from being deformed too much during the cooling process and being unusable in the subsequent preparation process.
In step S134, the protective atmosphere is a closed gas environment with a protective gas, and may be nitrogen, and/or hydrogen, in this embodiment, the protective atmosphere may be nitrogen, and in other embodiments, the protective atmosphere may also be hydrogen or a mixture of hydrogen and nitrogen.
In step S135, the particle size of the powder in the soft magnetic alloy material is 2um to 40um, and the predetermined ratio of the first alloy powder, the second alloy powder and the carbonyl iron powder is 55%, 40%, 5%.
The soft magnetic alloy material prepared by the embodiment has higher magnetic conductivity, high superposed current, high insulation and lower loss, and can meet the requirements of the existing components on high insulation, high frequency, high saturation and low power consumption.
In one embodiment, the soft magnetic alloy material further comprises: o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
Wherein the proportion of the o-cresol formaldehyde epoxy resin is 2.7 wt%, the proportion of the methylnadic anhydride is 0.5 wt%, the proportion of the benzyl triphenyl phosphonium bromide is 0.30 wt%, the proportion of the 2-methylimidazole is 0.35 wt%, the proportion of the antimony trioxide is 0.15 wt%, the proportion of the silicon micropowder is 0.25 wt%, the proportion of the methacryloxypropyl trimethoxy silane is 0.15 wt%, and the proportion of the release agent is 0.10 wt%.
The soft magnetic alloy material provided by the embodiment can be made into electronic components, so that the made electronic components have high magnetic conductivity and high superposed current. The requirements of the existing components on high insulation, high frequency, high saturation and low power consumption can be met.
In an embodiment, after the step S135 of mixing the first alloy powder, the second alloy powder and the carbonyl iron powder according to a predetermined ratio to obtain the soft magnetic alloy material, the method for preparing the soft magnetic alloy material further includes:
s231, mixing the soft magnetic alloy material with the provided o-cresol formaldehyde epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silicon micropowder, methacryloxypropyl trimethoxy silane and a release agent to obtain a mixed material;
s232, melting and mixing the mixed material at 100 ℃, and cooling, crushing and sieving the melted and mixed material to obtain an improved soft magnetic alloy material;
s233, placing the improved soft magnetic alloy material in a mold, pressing the improved soft magnetic alloy material into a magnetic ring at the temperature of 100-250 ℃ under the pressure of less than or equal to 250MPa, and treating the formed magnetic ring at the temperature of 160-180 ℃ for 1 hour.
In the magnetic ring in this embodiment, the size of the magnetic ring is 20.0mm 12.0mm 2.0mm in terms of Outer Diameter (OD) Inner Diameter (ID) Thickness (TH). In step S233, a 60-325 mesh screen is used for sieving.
After making the magnetically soft alloy material into the magnetic ring, the molding pressure of the magnetic ring is 250MPa, and the molding pressure is small, so that the probability that the insulating layer on the surface of the metal powder particle is damaged due to overlarge pressure during molding is reduced by reducing the molding pressure, and the insulating property of the magnetic powder core prepared by using the magnetically soft alloy material is improved.
EXAMPLE five
The embodiment also provides two comparative examples, namely a method for respectively using magnetic rings made of different existing soft magnetic alloy materials, and performance tests are carried out on the magnetic rings made by the two methods.
In a comparative example, a method of a magnet ring made of a conventional soft magnetic alloy material includes: selecting 200g of FeSiCr gas atomized powder with the granularity of 15 mu m, wherein the mass percentage of Fe is 94.5%, the mass percentage of Si is 4.5%, the mass percentage of Cr is 1.0%, fully mixing the FeSiCr gas atomized powder with epoxy resin glue with the solid content of 5%, uniformly stirring the mixture for 10min, placing the slurry in air for air drying, placing the slurry in an oven for further drying after drying, and selecting the temperature of 80 ℃; crushing the powder after the powder is completely dried, sieving the powder by using a 60-325-mesh sieve, and performing compression molding on the sieved powder by using a powder molding press, wherein the pressure is 1500MPa, and the size of a compression magnetic ring is that the Outer Diameter (OD) is the Inner Diameter (ID) is the Thickness (TH) is 20.0mm is 12.0mm is 2.0 mm; and (3) putting the pressed magnetic ring into an oven at 180 ℃ for baking for 1 hour.
In a comparative example, a method of forming a magnet ring of a conventional soft magnetic alloy material includes: 200g of FeSiB amorphous powder with the particle size of 24 mu m D50, wherein the mass percent of Fe is 93.6%, the mass percent of Si is 3.3%, the mass percent of B is 3.1%, and the mass percent of D50 is 5 mu m carbonyl iron powder are selected, the two powder materials are graded according to the proportion of 8:2, then fully mixed with epoxy resin glue with the solid content of 5% and uniformly stirred for 10min, the slurry is placed in air for air drying, and is placed in an oven for further drying after being dried, and the temperature is selected to be 80 ℃; crushing the powder after the powder is completely dried, sieving the powder by using a 60-325-mesh sieve, and performing compression molding on the sieved powder by using a powder molding press, wherein the pressure is 1500MPa, and the size of a compression magnetic ring is that the Outer Diameter (OD) is the Inner Diameter (ID) is the Thickness (TH) is 20.0mm is 12.0mm is 2.0 mm; and (3) putting the pressed magnetic ring into an oven at 180 ℃ for baking for 1 hour.
EXAMPLE six
In this embodiment, performance tests and evaluations of the magnetic ring were also performed on the comparative example one and the comparative example two in the second embodiment, the third embodiment, the fourth embodiment and the fifth embodiment, and the specific method includes:
the magnetic rings in the comparative examples I and II in the second, third, fourth and fifth examples were used
Winding 20Ts by using a copper wire and adopting WK3260The tester B tests the initial permeability mu i (1V/100KHz) of the magnetic ring sample and the inductance value under the superposed current; testing the insulation resistance of the magnetic ring by using a CH-333 tester; testing power consumption (100 mT) of magnetic ring by IWATSU-SY-8218 type hysteresis loop instrument&100KHz), the performance results of the specific tests are shown in table 1:
TABLE 1 comparison of magnetic ring Performance
Compared with the performance of the magnetic ring in the comparative example I and the comparative example II in the second embodiment, the third embodiment, the fourth embodiment and the fifth embodiment, when the 18A current is applied, the inductance reduction rate of the magnetic ring in the second embodiment, the third embodiment and the fourth embodiment is obviously lower than that of the comparative example I and the comparative example II in the fifth embodiment, the forming pressure and the power consumption are obviously lower than those of the comparative example I and the comparative example II, and the insulation resistance is obviously higher than that of the comparative example I and the comparative example II, which shows that the control of material components, granularity design, proportion and process is very important for high insulation, low power consumption and high saturation current High frequency, high saturation, and low power consumption.
The above-mentioned embodiments only express several embodiments of the present application, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the scope of protection of the present application. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (9)
1. A soft magnetic alloy material, comprising:
the first alloy powder, the second alloy powder and carbonyl iron powder;
the first alloy powder includes: iron, silicon, chromium, phosphorus, boron, and carbon;
the second alloy powder includes: iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon;
in the first alloy powder, the ratio of each component is as follows:
85-95 wt% of iron, 1.5-5.0 wt% of silicon, 0.1-0.5 wt% of chromium, 0.10-0.5 wt% of phosphorus, 0.5-6.5 wt% of boron and 0.05-0.5 wt% of carbon;
in the second alloy powder, the ratio of each component is as follows:
83-94 wt% of iron, 3-6 wt% of silicon, 0.5-4.5 wt% of aluminum, 0.25-2.0 wt% of chromium, 0.5-1.5 wt% of phosphorus, 0.20-1.5 wt% of boron, 0.05-0.4 wt% of cobalt, 0.05-0.4 wt% of copper and 0.05-0.4 wt% of carbon;
the iron content of the carbonyl iron powder is 95-99 wt%.
2. Soft magnetic alloy material according to claim 1,
the granularity of the first alloy powder is 20-40 um;
the granularity of the second alloy powder is 5-15 um;
the granularity of the carbonyl iron powder is 2-3 um.
3. Soft magnetic alloy material according to claim 1,
the soft magnetic alloy material further includes:
o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silica micropowder, methacryloxypropyl trimethoxysilane and a mold release agent.
4. Soft magnetic alloy material according to claim 3,
the o-cresol novolac epoxy resin accounts for 1-4.0 wt%, the methylnadic anhydride accounts for 0.5-3.0 wt%, the benzyl triphenyl phosphorus bromide accounts for 0.3-1.5 wt%, the 2-methylimidazole accounts for 0.1-2.0 wt%, the antimony trioxide accounts for 0.1-1.0 wt%, the silica powder accounts for 0.25-3.0 wt%, the methacryloxypropyl trimethoxy silane accounts for 0.1-1.5 wt%, and the release agent accounts for 0.1-1.0 wt%.
5. A method for preparing a soft magnetic alloy material is characterized by comprising the following steps:
providing a first alloy material, a second alloy material, and a carbonyl iron material, wherein the first alloy material comprises iron, silicon, chromium, phosphorus, boron, and carbon, and the second alloy material comprises iron, silicon, aluminum, chromium, phosphorus, boron, cobalt, copper, and carbon; respectively smelting a first alloy material, a second alloy material and a carbonyl iron material into a first metal liquid, a second metal liquid and a third metal liquid;
respectively crushing the first metal liquid, the second metal liquid and the third metal liquid into metal liquid drops, and respectively cooling to form spherical or quasi-spherical first alloy powder, second alloy powder and carbonyl iron powder;
respectively treating the first alloy powder, the second alloy powder and the carbonyl iron powder for 1-2 hours at 350 ℃, 450-600 ℃ and 300 ℃ under a protective atmosphere to obtain first alloy powder, second alloy powder and carbonyl iron powder;
wherein the first alloy powder comprises the following components in percentage by weight: 85-95 wt% of iron, 1.5-5.0 wt% of silicon, 0.1-0.5 wt% of chromium, 0.10-0.5 wt% of phosphorus, 0.5-6.5 wt% of boron and 0.05-0.5 wt% of carbon; the second alloy powder comprises the following components in percentage by weight: 83-94 wt% of iron, 3-6 wt% of silicon, 0.5-4.5 wt% of aluminum, 0.25-2.0 wt% of chromium, 0.5-1.5 wt% of phosphorus, 0.20-1.5 wt% of boron, 0.05-0.4 wt% of cobalt, 0.05-0.4 wt% of copper, and 0.05-0.4 wt% of carbon; wherein the iron content in the carbonyl iron powder is 95-99 wt%;
and mixing the first alloy powder, the second alloy powder and carbonyl iron powder according to a preset ratio to obtain the soft magnetic alloy material.
6. The method for producing a soft magnetic alloy material according to claim 5,
the granularity of the powder in the soft magnetic alloy material is 2 um-40 um.
7. The method for producing a soft magnetic alloy material according to claim 5,
the protective atmosphere is nitrogen or/and hydrogen.
8. A method for producing a soft magnetic alloy material according to any of claims 5 to 7, characterized in that the method for producing a soft magnetic alloy material further comprises:
after the first alloy powder, the second alloy powder and the carbonyl iron powder are mixed according to a predetermined ratio to obtain the soft magnetic alloy material, the preparation method of the soft magnetic alloy material further comprises the following steps:
mixing the soft magnetic alloy material with provided o-cresol novolac epoxy resin, methylnadic anhydride, benzyl triphenyl phosphorus bromide, 2-methylimidazole, antimony trioxide, silicon micropowder, methacryloxypropyl trimethoxysilane and a release agent to obtain a mixed material;
and melting and mixing the mixed materials at 100 ℃, and cooling, crushing and sieving the melted and mixed materials to obtain the improved soft magnetic alloy material.
9. The method for producing a soft magnetic alloy material according to claim 8,
the preparation method of the soft magnetic alloy material further comprises the following steps:
after the improved soft magnetic alloy material is obtained, the improved soft magnetic alloy material is placed in a mold, a magnetic ring is pressed at the temperature of 100-250 ℃ under the pressure of less than or equal to 300MPa, the molded magnetic ring is treated at the temperature of 160-180 ℃ for 0.5-1 hour, and a performance test is carried out on the magnetic ring to test the performance of the improved soft magnetic alloy material.
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