CN113421731B - 一种磁粉芯的制备方法 - Google Patents

一种磁粉芯的制备方法 Download PDF

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CN113421731B
CN113421731B CN202110977892.0A CN202110977892A CN113421731B CN 113421731 B CN113421731 B CN 113421731B CN 202110977892 A CN202110977892 A CN 202110977892A CN 113421731 B CN113421731 B CN 113421731B
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Abstract

一种磁粉芯的制备方法，包括混合均匀的质量份为50‑100份的粉末X和1‑10份的粉末Y；其中，粉末X为铁基纳米晶粉，粉末Y为稀土基纳米粉。制备方法为将粘合剂和复合粉末，投入球磨机中，抽真空，充入液氮，球磨混合后；置于氮气氛中熔融、模压、冷却处理后，制得磁粉芯。通过在FeNbB磁铁中掺杂Nd、Si、Tb、Dy，制备成具备永磁特性的磁粉芯，通过Tb、Dy提高磁体的矫顽力。通过低温冷脆酚醛树脂，经球磨细化粒径与纳米级的复合粉末均匀混合，使熔融后的复合粉末均匀分散且被均匀的融合再模压成磁粉芯，保证了各组分的均匀分散性，均衡颗粒间的间隙，强化其稳定性、提高磁导、降低磁损耗，有效提升了磁粉芯的各项性能。

Description

一种磁粉芯的制备方法
技术领域
本发明涉及一种磁粉芯用复合粉末，具体涉及一种磁粉芯用复合粉末及其磁粉芯制备方法。
背景技术
磁粉芯是一种铁磁粉末经绝缘包覆后通过粉末冶金压制成的复合性材料。由于铁磁性颗粒很小（高频下使用的为0.5-5 微米），又被非磁性电绝缘膜物质隔开，因此，一方面可以隔绝涡流，材料适用于较高频率；另一方面由于颗粒之间的间隙效应，导致材料具有低导磁率及恒导磁特性；又由于颗粒尺寸小，基本上不发生集肤现象，磁导率随频率的变化也就较为稳定。主要用于高频电感。
磁粉芯的磁电性能主要取决于粉粒材料的导磁率、粉粒的大小和形状、它们的填充系数、绝缘介质的含量、成型压力及热处理工艺等。 常用的磁粉芯有铁粉芯、坡莫合金粉芯及铁硅铝粉芯三种。
纳米晶软磁粉芯是一种以纳米晶体金属材料（铁基）为基体材料，与其他纳米粉体复合后，严格按照一定的尺寸和结构要求成型的一种纳米复合材料磁芯。该产品具有高饱和磁感、低铁损、高起始导磁率、低矫顽力的特性，可取代硅钢、坡莫合金、铁氧体等传统软磁材料铁芯，实现高频信号转换、控制、保护、滤波、抗干扰、稳压、多路输出、电压调节等功能。
发明内容
为解决现有技术的不足，本发明的目的在于提供一种磁粉芯用复合粉末及其磁粉芯制备方法。
为了实现上述目标，本发明采用如下的技术方案：
磁粉芯用复合粉末，包括混合均匀的质量份为50-100份的粉末X和1-10份的粉末Y；
其中，粉末X为铁基纳米晶粉，粉末Y为稀土基纳米粉。
上述铁基纳米晶粉含Fe，及Nb、Si、B中的至少2种。
上述稀土基纳米粉含Nd、Fe，或及B。
进一步的，上述稀土纳米粉还含Tb、Dy，其质量份分别为1-3份、1-3份。
上述复合粉末的组合为FeaNdbNbcBdSieTbfDyg；
其中，a=60-70，b=10-15，c=6-10，d=4-8，e=4-8，f=0-3，g=0-3。
进一步的，上述复合粉末的组合为Fe60Nd15Nb10B5Si4Tb3Dy3；或Fe70Nd10Nb9B5Si6；或Fe67Nd12Nb9B4Si4Tb2Dy2。
磁粉芯制备方法，包括以下步骤：
S1、将原料：粘合剂和磁粉芯用复合粉末，投入球磨机中，抽真空，充入液氮，球磨混合；
S2、球磨后的复合物，于氮气氛中熔融、模压、冷却处理后，制得磁粉芯。
上述步骤S1中的磨球的直径为0.5-20mm；原料与磨球的质量比为1:（10-1000），优选1:50-1:300；球磨的时间为0.5-120h，优选1-50h。
上述粘合剂包括环氧树脂和/或酚醛树脂，粘合剂的质量占磁粉芯质量的0.5-3.5％。
上述液氮的温度为-（160-180）℃，模压温度为150-175℃之间，模压力为1500-2000MPa。
本发明的有益之处在于：
本发明的磁粉芯用复合粉末，在常规的Fe、Nb、B磁铁中掺杂含有一定量的Nd、Si、Tb、Dy，以软磁铁的制备方式构成具备一定永磁特性的磁粉芯，再通过Tb、Dy提高磁体的矫顽力。本发明通过低温冷脆化酚醛树脂，再经球磨细化粒径与纳米级的复合粉末均匀混合，使得熔融后的复合粉末均匀分散且被均匀的融合再经模压成磁粉芯，保证了磁粉芯内各组分的均匀分散，均衡颗粒间的间隙，强化其稳定性、提高磁导、降低磁损耗，通过更均匀的混合方式，增加了模压后的相对密度，进而提高了热稳定性；其制备方法简单，成本低，效果好，有效提升了磁粉芯的各项性能，具有很强的实用性和广泛的适用性。
具体实施方式
以下结合具体实施例对本发明作具体的介绍。
磁粉芯用复合粉末，由粉末X和粉末Y混合均匀组成；其中，粉末X为铁基纳米晶粉，其质量份为50-100份；粉末Y为稀土基纳米粉，其质量份为1-10份。
铁基纳米晶粉含Fe，及Nb、Si、B中的至少2种。稀土基纳米粉含Nd、Fe，或Nd、Fe、Tb，或Nd、Fe、Dy，或Nd、Fe、Tb、Dy，或含Nd、Fe、B，或Nd、Fe、Tb、B，或Nd、Fe、Dy、B，或Nd、Fe、Tb、Dy、B；
优选的，复合粉末的成分组合为FeaNdbNbcBdSieTbfDyg，其中，a=60-70,b=10-15,c=6-10,d=4-8,e=4-8,f=0-3,g=0-3。
更优选的，复合粉末的成分组合为Fe60Nd15Nb10B5Si4Tb3Dy3；或Fe70Nd10Nb9B5Si6；或Fe67Nd12Nb9B4Si4Tb2Dy2。
磁粉芯的制备方法，包括以下步骤：
S0、原料选用：
粘合剂：酚醛树脂；
复合粉末的目标成分选用Fe67Nd12Nb9B4Si4Tb2Dy2。选用原子组分为Fe70Nb10B4。 5Si4.5铁基纳米晶粉90份，选用原子组分为Nd12Fe4Tb2Dy2为稀土基纳米粉10份。
S1、将原料：35g酚醛树脂和965g复合粉末，投入球磨机中，磨球直径为1mm，磨球的质量为50kg，抽真空，充入-160℃的液氮，球磨48h混合；
S2、将球磨后的复合物导入模具中，在氮气气氛下，加热至250℃熔融，再以10℃/10min的速度降至150℃后，以1500MPa的压力模压成型后，再在300MPa的压力80-90℃下保温1h后，以5℃/min的速度冷却至室温后，制得磁粉芯。
经测试各项性能指标如下：
1）使用频率范围f：0.1MHz-300MHz；
2）饱和磁通密度Bs：1.22T；
3）温度稳定性：92PPM/℃；
4）密度ρ：5.88g/cm3；
5）磁导率/(H/m)(50kHz，0.05T)：143；
6）磁芯损耗/(W/cm3)(50kHz，0.05mT)：47。
实际制备时，可根据使用需求，选用合适的复合粉末的组份配比，以获取所需求的具备对应性能的磁粉芯。
以上显示和描述了本发明的基本原理、主要特征和优点。本行业的技术人员应该了解，上述实施例不以任何形式限制本发明，凡采用等同替换或等效变换的方式所获得的技术方案，均落在本发明的保护范围内。

Claims (5)

1.一种磁粉芯的制备方法，其特征在于，制备包括以下步骤：
S1、将原料：粘合剂和磁粉芯用复合粉末，投入球磨机中，抽真空，充入-（160-180）℃的液氮，球磨混合；
S2、球磨后的复合物，于氮气氛中熔融、模压、冷却处理后，制得磁粉芯；
所述步骤S1中的粘合剂包括环氧树脂和/或酚醛树脂，粘合剂的质量占磁粉芯质量的0.5-3.5％；
所述步骤S1中的磁粉芯用复合粉末，包括混合均匀的粉末X和粉末Y；
粉末X为含Fe，及Nb、Si、B中的至少2种的铁基纳米晶粉，
粉末Y为含Nd、Fe，或及B的稀土基纳米粉；
复合粉末的组合为FeaNdbNbcBdSieTbfDyg；
其中，a=60-70，b=10-15，c=6-10，d=4-8，e=4-8，f=0-3，g=0-3。
2.根据权利要求1所述的一种磁粉芯的制备方法，其特征在于，所述复合粉末的组合为Fe60Nd15Nb10B5Si4Tb3Dy3；或Fe70Nd10Nb9B5Si6；或Fe67Nd12Nb9B4Si4Tb2Dy2。
3.根据权利要求1所述的一种磁粉芯的制备方法，其特征在于，所述粉末X的质量份为50-100份，粉末Y的质量份为1-10份。
4.根据权利要求1所述的一种磁粉芯的制备方法，其特征在于，所述步骤S1中的磨球的直径为0.5-20mm；原料与磨球的质量比为1:（10-1000）；球磨的时间为0.5-120h。
5.根据权利要求1所述的一种磁粉芯的制备方法，其特征在于，所述模压温度为150-175℃之间，模压力为1500-2000MPa。
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