CN113223844B - Powder coating method - Google Patents
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- CN113223844B CN113223844B CN202110450103.8A CN202110450103A CN113223844B CN 113223844 B CN113223844 B CN 113223844B CN 202110450103 A CN202110450103 A CN 202110450103A CN 113223844 B CN113223844 B CN 113223844B
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- H—ELECTRICITY
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- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
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- H—ELECTRICITY
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/026—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets protecting methods against environmental influences, e.g. oxygen, by surface treatment
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Abstract
The invention discloses a powder coating method, which comprises the following steps: s1, screening soft magnetic alloy powder; s2, uniformly dispersing the soft magnetic ferrite micro-fine powder into an ethanol solution of polyvinylpyrrolidone to obtain a first dispersion liquid; s3, adding soft magnetic alloy powder into the first dispersion liquid for pretreatment; s4, adding tetrabutyl titanate into the composite powder dispersion liquid, and carrying out heat preservation water bath to generate a composite coating layer; s5, dissolving the binder and the lubricant in acetone, and uniformly dispersing the ferrite fine powder into the solution to obtain a second dispersion liquid; and S6, uniformly mixing the coated soft magnetic alloy powder to a second dispersion liquid, granulating and drying. The invention has the beneficial effects that: the titanium dioxide coating layer and the binder are doped with a proper amount of soft magnetic ferrite fine powder, so that the magnetic conductivity of the magnetic part formed by pressing is improved, and the high-frequency loss is low.
Description
Technical Field
The invention relates to the field of magnetic materials, in particular to a powder coating method.
Background
In the preparation process of the amorphous nanocrystalline magnetic powder core, the performance of the insulating coating layer is an important factor influencing the high-frequency loss of the magnetic powder core. The insulation coating is mainly used for reducing the phenomenon that electric charges are concentrated on the surfaces of the magnetic powder particles so as to avoid eddy current generated inside the magnetic powder particles under a high-frequency magnetic field, so that the magnetic powder particles are conducted (regarded as short circuit), eddy current loss among the magnetic powder particles is increased rapidly, power loss of an inductor is large, and even the inductor generates heat to burn out a circuit.
The existing insulation coating technology is mainly divided into organic insulation coating and inorganic insulation coating. In the organic insulation coating, an organic insulation coating agent such as epoxy resin, phenolic resin, organic silicon resin and the like is used as an adhesive, so that the inductor device after powder pressing has required shape, size and strength, the adhesive performance of the organic coating agent is good, but the organic insulation coating agent has poor heat resistance, is difficult to eliminate the internal stress of a magnetic core, and limits the heat treatment temperature of the magnetic powder core. In the process of inorganic insulation coating, mineral powder, silicate and various oxides with high resistivity are mainly used as inorganic coating agents, and the inorganic coating agents are widely used for insulating and coating magnetic powder cores due to the advantages of high heat treatment temperature, high resistivity, low cost and the like.
Among the prior art applications of inorganic insulation coating, the simplest and most used method is phosphating, for example, patent documents such as prior applications CN110181036A and CN104078180B disclose dissolving phosphoric acid in a volatile organic solvent (e.g., acetone, alcohol, etc.), mixing soft magnetic powder with a phosphoric acid solution to generate a phosphating reaction, forming a phosphate film on the surface of the soft magnetic powder, passivating the soft magnetic powder, and then adding an insulating agent and a binder to perform powder insulation coating. Because the phosphoric acid solution is a strong acid solution, if the adding amount of phosphoric acid is too small, the phosphating reaction is insufficient, the coating layer is incomplete and uneven, and the resistivity of the inductor is reduced; if the adding amount of the phosphoric acid is too much, the adverse effects of reduction of inductance permeability, increase of loss and the like can be caused. Therefore, in order to solve the above problems, it is urgently needed to design a powder coating method to meet the needs of practical use.
Disclosure of Invention
In view of the above problems in the prior art, a powder coating method is provided to prepare a powder material with high magnetic permeability and low eddy current loss.
The specific technical scheme is as follows:
a powder coating method utilizes a chemical reaction method to form a compact and uniform titanium dioxide and soft magnetic ferrite fine particle composite coating layer outside the particle shape of soft magnetic alloy powder, and uniformly mixes ferrite fine particles into a binder. The method comprises the following steps:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size, and weighing according to a preset mass;
step S2, preparing a first dispersion of ferrite fine powder: mixing polyvinylpyrrolidone, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the polyvinylpyrrolidone, the absolute ethyl alcohol and the deionized water, then adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder into the solution, and obtaining a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding tetrabutyl titanate with a certain mass into the composite powder dispersion liquid prepared in the step S3, then carrying out water bath, keeping the temperature for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain soft magnetic alloy powder with a titanium dioxide and soft magnetic ferrite fine particle composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: completely dissolving a binder and a lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite fine powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite fine powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite fine powder;
step S6, insulating and coating: and (5) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, stirring, kneading and granulating the composite soft magnetic slurry on granulating equipment, and drying in an oven to obtain the soft magnetic alloy powder with good insulation coating.
Preferably, in step S1, the soft magnetic alloy powder is at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, iron-silicon-aluminum alloy powder, iron-silicon-chromium alloy powder, iron-silicon-nickel alloy powder, iron-silicon-aluminum-nickel alloy powder, iron-nickel-aluminum alloy powder, and carbonyl iron powder.
Preferably, in the step S1, the grain size of the soft magnetic alloy powder is less than 100 μm.
Preferably, in the step S2, the mass of the soft magnetic ferrite fine powder is 0.5 to 3% of the preset mass of the soft magnetic alloy powder;
the content of the polyvinylpyrrolidone is 0.5% -5% of the preset mass of the soft magnetic alloy powder.
Preferably, the particle diameters of the soft magnetic ferrite fine powder in both the step S2 and the step S5 are less than 1 μm.
Preferably, in the step S4, the content of the tetrabutyl titanate is 10% to 30% of the predetermined mass of the soft magnetic alloy powder.
Preferably, in the step S5, the mass of the soft magnetic ferrite fine powder is 0.5% to 5% of the preset mass of the soft magnetic alloy powder.
Preferably, in the step S5, the content of the binder is 1% to 5% of the total mass of the soft magnetic alloy powder with the composite coating layer obtained in the step S4;
the content of the lubricant is 0.5-1% of the total mass of the soft magnetic alloy powder with the composite coating layer.
Preferably, in the step S4, a water bath is performed by using a water bath kettle;
the temperature of the water bath is 30-70 ℃, and the stirring is carried out for 1-12h at a preset speed.
Preferably, in the step S6, drying is performed in a vacuum oven;
the temperature is set to be 50-100 ℃, and the drying time is more than 1 h.
The invention utilizes a chemical reaction method to form a compact and uniform titanium dioxide and soft magnetic ferrite fine particle composite coating layer outside the soft magnetic alloy powder particles, and uniformly mixes ferrite fine particles into a binder. The beneficial effects of this technical scheme lie in:
firstly, the soft magnetic ferrite has higher resistivity, can effectively reduce eddy current loss, thereby reducing iron loss, and has higher high-frequency magnetic conductivity, compared with the existing soft magnetic alloy powder insulation coating technology, the technical scheme obviously improves the high-frequency magnetic conductivity of the magnetic part pressed and molded by the soft magnetic alloy powder, simultaneously keeps lower high-frequency loss, and ensures that the rear-end magnetic part, the inductor and other devices have more excellent comprehensive performance;
secondly, because the technical scheme avoids the corrosion to the powder particles, the prepared insulating coating has better uniformity and compactness, and the composite coating is made of stable titanium dioxide and ferrite materials, so that the prepared magnetic component, inductor and other devices have higher electric breakdown resistance and better stability.
Drawings
FIG. 1 is a schematic flow diagram of a powder coating process of the present invention.
Fig. 2 is a schematic diagram of a powder microstructure of a magnetic ring component press-molded using soft magnetic powder in the present invention.
The figures are numbered: 1. soft magnetic alloy powder particles; 2. fine particles of soft magnetic ferrite; 3. a composite coating layer; 4. and (3) a binder.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive efforts based on the embodiments of the present invention, shall fall within the scope of protection of the present invention.
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The invention is further described with reference to the following drawings and specific examples, which are not intended to be limiting.
The invention provides a powder coating method, which belongs to the field of magnetic materials and comprises the following steps as shown in figure 1:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size by using an ultrasonic vibration screen, and weighing according to a preset mass, wherein preferably, the particle size of the soft magnetic alloy powder is less than 100 mu m;
step S2, preparing a first dispersion of ferrite fine powder: weighing polyvinylpyrrolidone which is 0.5-5% of the preset mass of the soft magnetic alloy powder, weighing soft magnetic ferrite micro powder which is 0.5-3% of the preset mass of the soft magnetic alloy powder, mixing the polyvinylpyrrolidone, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the soft magnetic ferrite micro powder, adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder in the solution to obtain a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding tetrabutyl titanate with a certain mass into the composite powder dispersion liquid prepared in the step S3, then carrying out water bath through a water bath kettle, wherein the water bath temperature is 30-70 ℃, stirring at a preset constant speed for 1-12h, preserving heat for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain soft magnetic alloy powder with a titanium dioxide and soft magnetic ferrite micro-fine powder composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: weighing a binder and a lubricant, wherein the binder is 1% -5% of the total mass of the soft magnetic alloy powder with the composite coating layer obtained in the step S4, the lubricant is 0.5% -1% of the total mass of the soft magnetic alloy powder with the composite coating layer, weighing soft magnetic ferrite micro powder again, the soft magnetic ferrite micro powder is 0.5% -5% of the preset mass of the soft magnetic alloy powder, completely dissolving the binder and the lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite micro powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite micro powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite micro powder;
step S6, insulating and coating: and (4) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (5), stirring to obtain composite soft magnetic slurry, then stirring, kneading and granulating the composite soft magnetic slurry on a granulating device, and drying in a vacuum oven at the set temperature of 50-100 ℃ for more than 1h to obtain the insulated and coated soft magnetic alloy powder.
The invention abandons the general phosphating treatment mode in the prior art, but utilizes a chemical reaction method to form a compact and uniform titanium dioxide and soft magnetic ferrite fine particle composite coating layer outside the soft magnetic alloy powder particles, and uniformly mixes the ferrite fine particles into the binder so as to improve the magnetic conductivity of the magnetic part after the soft magnetic alloy powder is pressed and molded.
The first embodiment is as follows:
the soft magnetic alloy powder in the embodiment is Fe-Si-B-C-Cr amorphous soft magnetic alloy powder with the grain diameter of 5-15 mu m, wherein the median grain diameter D50 is about 10 mu m; the ferrite fine powder is Mn-Zn soft magnetic ferrite powder, and the median particle size D50 is about 750nm; the insulation coating method comprises the following steps:
step S1, powder screening: screening soft magnetic alloy powder with proper particle size by an ultrasonic vibration screen, and weighing according to preset mass;
step S2, preparing a first dispersion of ferrite fine powder: respectively weighing polyvinylpyrrolidone according to 2% of the preset mass of the soft magnetic alloy powder in the step S1, weighing Mn-Zn soft magnetic ferrite fine powder according to 2% of the preset mass of the soft magnetic alloy powder in the step S1, fully stirring and mixing the polyvinylpyrrolidone, absolute ethyl alcohol and deionized water, then adding the Mn-Zn soft magnetic ferrite fine powder into the solution, fully stirring for 1h at room temperature, and uniformly dispersing the Mn-Zn soft magnetic ferrite fine powder into the solution to obtain a first dispersion liquid of the Mn-Zn soft magnetic ferrite fine powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: weighing tetrabutyl titanate according to 25% of the preset mass of the soft magnetic alloy powder, adding tetrabutyl titanate into the mixed solution, then putting the mixed solution into a water bath kettle, stirring the mixed solution at a constant speed for 3 hours at the water bath temperature of 40 ℃, preserving heat for 0.5 hour, and finally repeatedly cleaning and drying the composite powder to obtain the soft magnetic alloy powder with the titanium dioxide and Mn-Zn soft magnetic ferrite micro-powder composite coating layer;
step S5, preparing a second dispersion liquid of the ferrite micro powder: respectively weighing a binder and a lubricant according to 3% and 0.8% of the total mass of the soft magnetic alloy powder with the composite coating layer prepared in the step S4, completely dissolving the binder and the lubricant in acetone to form an acetone solution, weighing Mn-Zn soft magnetic ferrite micro powder again according to 2% of the preset mass of the soft magnetic alloy powder in the step S1, doping the Mn-Zn soft magnetic ferrite micro powder into the acetone solution, fully stirring for 1h at room temperature, and uniformly dispersing the Mn-Zn soft magnetic ferrite micro powder into the acetone solution to obtain a second dispersion liquid of the Mn-Zn soft magnetic ferrite micro powder;
s6, insulating and coating: and (5) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the Mn-Zn soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, then stirring, kneading and granulating the composite soft magnetic slurry on granulation equipment, drying in a vacuum oven at the set temperature of 80 ℃ for more than 1h, screening the powder with the particle size of-80 meshes to +200 meshes by using an ultrasonic vibration sieve, and thus obtaining the Fe-Si-B-C-Cr soft magnetic alloy powder material with good insulation coating.
The Fe-Si-B-C-Cr soft magnetic alloy powder coated with insulation in the embodiment is used for preparing a magnetic component, and then a performance test is carried out, and the specific steps are as follows:
step A1, weighing the prepared soft magnetic alloy powder material, wherein the mass of the soft magnetic alloy powder material is 3g, placing the weighed soft magnetic alloy powder material in an annular die, and performing cold pressing to form a magnetic ring blank, preferably, the outer diameter of the annular die is 20mm, and the inner diameter of the annular die is 12mm; ultrasonic vibration is applied in the cold pressing process, the vibration frequency is 20KHz, and the pressure maintaining pressure is 6t/cm 2 Maintaining the pressure for 60s, and demolding to obtain a magnetic ring blank;
and step A2, placing the magnetic ring blank in a vacuum oven at 180 ℃, keeping the temperature for 2 hours, and taking out the magnetic ring blank after the magnetic ring blank is cooled to normal temperature to obtain a solidified magnetic ring component. As shown in fig. 2, fig. 2 is a schematic view of a microstructure of the powder inside the magnetic ring component, a compact and uniform composite coating layer 3 of titanium dioxide and soft magnetic ferrite fine particles 2 is formed outside the soft magnetic alloy powder particles 1 by using a chemical reaction method, and the soft magnetic ferrite fine particles 2 are uniformly doped in a binder 4, so as to achieve the purpose of improving the magnetic permeability of the magnetic ring component.
Step A3, testing the main magnetic property: winding 15 turns of enameled copper wires on the cured magnetic ring component prepared in the step A2, testing the inductance value of the cured magnetic ring component through an impedance analyzer under the test condition of 1MHz, and calculating to obtain the magnetic permeability mu' according to the inductance value; the loss value is tested by a B-H analyzer under the test condition of 1MHz/20mT.
Table 1 performance parameters of magnetic ring parts obtained in example one and comparative examples one and two
In the above table 1, 1 indicates that the Mn — Zn ferrite is added in the corresponding step, and the addition amount is 2% of the predetermined mass of the soft magnetic alloy powder in step S1; 0 means that no Mn-Zn ferrite was added in the corresponding step.
When the magnetic component is prepared from the Fe-Si-B-C-Cr soft magnetic alloy powder which is prepared by the embodiment and is well coated in an insulating way, the magnetic permeability mu' of the magnetic component is 29 under the condition of 1MHz measured by an impedance analyzer; the loss Pcv under the condition of 1MHz/20mT measured by a B-H analyzer was 798kW/m 3 。
The first comparative example adopts the same preparation process and parameters as the first example, and is only different in that fine powder of the Mn-Zn soft magnetic ferrite is not added in the step S5, and the magnetic permeability mu' of the magnetic ring component finally prepared in the first comparative example is 25; the loss Pcv is 811kW/m 3 。
Comparative exampleIn the second step, the same preparation process and parameters as those in the first step are adopted, and the difference is that fine Mn-Zn soft magnetic ferrite powder is not added in the whole preparation process, and the magnetic permeability mu' of the magnetic ring component finally prepared in the second step is 22; the loss Pcv is 835kW/m 3 。
The second embodiment:
the magnetically soft alloy powder in the embodiment is Fe-Si-B-Cu-Nb nanocrystalline magnetically soft alloy powder, the particle size is 3-20 μm, and the median particle size D50 is about 12 μm; the ferrite fine powder is Mn-Zn soft magnetic ferrite powder, and the median grain diameter D50 is about 750nm.
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the embodiment are the same as those of the embodiment one, and the differences are that the composition of the nanocrystalline soft magnetic alloy powder is different, the particle size is different, and the parameters of the magnetic ring part are shown in table 2.
Table 2 performance parameters of magnetic ring parts obtained in example two, comparative example three, and comparative example four
When the magnetic component is prepared from the Fe-Si-B-Cu-Nb soft magnetic alloy powder with good insulation coating prepared in the embodiment, the magnetic permeability mu' under the condition of 1MHz is measured to be 36 by an impedance analyzer; the loss Pcv under the condition of 1MHz/20mT measured by a B-H analyzer is 455kW/m 3 。
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the third comparative example are the same as those of the second example, except that the fine powder of the Mn-Zn soft magnetic ferrite is removed only in the step S4, and the magnetic permeability mu' of the finally prepared magnetic ring component under the same test condition is 32; the loss Pcv measured by a B-H analyzer was 464kW/m under the condition of 1MHz/20mT 3 。
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the fourth comparative example are the same as those of the second example, and the difference is that Mn-Zn soft magnetic ferrite micro-fine powder is not added in the whole preparation process, and the final preparation is carried outThe magnetic conductivity mu' of the obtained magnetic ring component is 28; the loss Pcv measured by a B-H analyzer under the condition of 1MHz/20mT is 480kW/m 3 。
As can be seen from tables 1 and 2: compact and uniform titanium dioxide and soft magnetic ferrite fine particle composite coating layers are formed outside the soft magnetic alloy powder particles, and the ferrite fine particles are uniformly mixed into the binder, so that on one hand, eddy current paths among the ferromagnetic particles can be effectively blocked, magnetic fields among the ferromagnetic particles can be well coupled, eddy current loss is effectively reduced, and iron loss is reduced; on the other hand, the ferrite has higher high-frequency magnetic conductivity, the magnetic conductivity of the magnetic part formed by pressing soft magnetic powder is improved to more than 30%, and meanwhile, lower high-frequency loss is kept, thereby being very beneficial to high-frequency miniaturization and miniaturization of inductance devices.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
Claims (10)
1. A powder coating method, comprising:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size, and weighing according to a preset mass;
step S2, preparing a first dispersion liquid of ferrite micro powder: mixing polyvinylpyrrolidone, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the polyvinylpyrrolidone, the absolute ethyl alcohol and the deionized water, then adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder into the solution, and obtaining a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding tetrabutyl titanate with a certain mass into the composite powder dispersion liquid prepared in the step S3, then carrying out water bath, keeping the temperature for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain the soft magnetic alloy powder with the titanium dioxide and soft magnetic ferrite fine particle composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: completely dissolving a binder and a lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite fine powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite fine powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite fine powder;
step S6, insulating and coating: and (4) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, then stirring, kneading and granulating the composite soft magnetic slurry on granulating equipment, and drying in an oven to obtain the insulated coated soft magnetic alloy powder.
2. The powder coating method according to claim 1, wherein in step S1, the soft magnetic alloy powder is at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, iron-silicon-aluminum alloy powder, iron-silicon-chromium alloy powder, iron-silicon-nickel alloy powder, iron-silicon-aluminum-nickel alloy powder, iron-nickel-aluminum alloy powder, and carbonyl iron powder.
3. The powder coating method according to claim 1, wherein in step S1, the grain size of the soft magnetic alloy powder is less than 100 μm.
4. The powder coating method according to claim 1, wherein in the step S2, the mass of the soft magnetic ferrite fine powder is 0.5 to 3% of the predetermined mass of the soft magnetic alloy powder;
the content of the polyvinylpyrrolidone is 0.5-5% of the preset mass of the soft magnetic alloy powder.
5. A powder coating method as claimed in claim 1, wherein the particle size of the soft magnetic ferrite fine powder is less than 1 μm in both the step S2 and the step S5.
6. The powder coating method according to claim 1, wherein in the step S4, the content of the tetrabutyl titanate is 10-30% of the preset mass of the soft magnetic alloy powder.
7. The powder coating method as claimed in claim 1, wherein in the step S5, the mass of the soft magnetic ferrite fine powder is 0.5 to 5% of the predetermined mass of the soft magnetic alloy powder.
8. The powder coating method according to claim 1, wherein in the step S5, the content of the binder is 1-5% of the total mass of the soft magnetic alloy powder with the composite coating layer obtained in the step S4;
the content of the lubricant is 0.5-1% of the total mass of the soft magnetic alloy powder with the composite coating layer.
9. The powder coating method according to claim 1, wherein in step S4, a water bath is performed in a water bath kettle;
the temperature of the water bath is 30-70 ℃, and the stirring is carried out for 1-12h at a preset speed.
10. The powder coating method according to claim 1, wherein in step S6, drying is performed in a vacuum oven;
the temperature is set to be 50-100 ℃, and the drying time is more than 1 h.
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| CN103959405A (en) * | 2011-12-28 | 2014-07-30 | 大冶美有限公司 | Composite soft magnetic material and production method therefor |
| CN103151134A (en) * | 2013-03-25 | 2013-06-12 | 北京科技大学 | Composite silicone rein-ferrite-coating soft magnetic powder core and preparation method thereof |
| CN103426580A (en) * | 2013-09-11 | 2013-12-04 | 彭晓领 | Composite magnetic powder core and preparation method thereof |
| CN108101114A (en) * | 2017-12-21 | 2018-06-01 | 湖南大学 | A kind of nanometer ferrite composite material of bivalve layer structure and preparation method thereof |
| CN109786100A (en) * | 2019-03-29 | 2019-05-21 | 中国科学院宁波材料技术与工程研究所 | A kind of preparation method of soft magnetic-powder core |
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