CN114156075A - Preparation method of integrally-formed inductor - Google Patents

Preparation method of integrally-formed inductor Download PDF

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CN114156075A
CN114156075A CN202111448644.3A CN202111448644A CN114156075A CN 114156075 A CN114156075 A CN 114156075A CN 202111448644 A CN202111448644 A CN 202111448644A CN 114156075 A CN114156075 A CN 114156075A
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powder
amorphous nanocrystalline
equal
amorphous
temperature
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王策
陈卫红
宗伟
胡丽红
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Foshan Zhongyan Amorphous Technology Co ltd
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Foshan Zhongyan Amorphous Technology Co ltd
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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
    • 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
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder

Abstract

The invention provides a preparation method of an integrally formed inductor, which comprises the following steps: s1, preparing amorphous nanocrystalline powder; s2, carrying out insulation coating treatment on the obtained amorphous nanocrystalline powder to obtain coated powder; s3, molding the obtained coated powder to obtain amorphous nanocrystalline insulating finished product powder; s4, heating the obtained amorphous nanocrystalline insulating finished product powder; and S5, placing the prefabricated coil and the amorphous nanocrystalline insulating finished product powder obtained by heating into a molding die cavity, and pressing by cold pressing equipment to obtain the integrally molded inductor. The integrally formed inductor prepared by the preparation method has the beneficial effects of simple and efficient processing and stable performance.

Description

Preparation method of integrally-formed inductor
Technical Field
The invention relates to the technical field of soft magnetic alloy metallurgy, in particular to a preparation method of an integrally formed inductor.
Background
The amorphous material has high saturation magnetic induction, high magnetic conductivity, low coercive force, low high-frequency loss, good strong hardness, wear resistance, corrosion resistance, good temperature and environmental stability and the like, has excellent comprehensive performance, replaces permalloy, silicon steel and ferrite, is applied to power electronic technology, shows the characteristics of small volume, high efficiency, energy conservation and the like, and has the optimal cost performance ratio in all metal soft magnetic materials.
In the prior art, carbonyl iron powder and iron-silicon-chromium powder are mainly used as raw materials for preparing an integrally formed inductor, but the two kinds of powder have larger hysteresis loss, and the powder body resistivity is lower, so that the product application process has larger eddy current loss, and the product application has the problems of higher loss, product heating, energy efficiency reduction and the like.
The term "amorphous nanocrystal" refers to a concept of juxtaposition of amorphous and nanocrystal, and the term "amorphous nanocrystal" refers to a generic concept of alloy morphology of amorphous, nanocrystal and nanocrystal, which is defined and described in the art based on different alloy processing stages, in the conversion process from amorphous to nanocrystal, or in the presence of three forms of amorphous, amorphous and nanocrystal, and nanocrystal.
Disclosure of Invention
The invention aims to provide a preparation method of an integrally formed inductor for overcoming the defects of the prior art.
A method of making an integrally formed inductor, comprising the steps of:
s1, preparing amorphous nanocrystalline powder;
s2, carrying out insulation coating treatment on the obtained amorphous nanocrystalline powder to obtain coated powder;
s3, molding the obtained coated powder to obtain amorphous nanocrystalline insulating finished product powder;
s4, heating the obtained amorphous nanocrystalline insulating finished product powder;
and S5, placing the prefabricated coil and the amorphous nanocrystalline insulating finished product powder obtained by heating into a molding die cavity, and pressing by cold pressing equipment to obtain the integrally molded inductor.
Further, in the step S3, before the cold pressing process, the obtained coating powder is pre-annealed to promote the insulation passivation reaction of the coating powder.
Further, the annealing temperature range of the pre-annealing treatment is Tx-100 to Tx +80 ℃, and Tx is the crystallization temperature of the amorphous nanocrystal.
Further, in step S1, the amorphous nanocrystal powder is prepared by the following steps:
s1-1, based on a preset composition formula, selecting a metal raw material with corresponding element components, and putting the metal raw material into a smelting furnace for smelting;
s1-2, after the metal raw materials are completely melted, selecting alloy raw materials or non-metal raw materials in corresponding element components for secondary smelting;
s1-3, after the materials are completely melted in the secondary smelting process, pouring the obtained alloy melt into a mold, and then cooling and forming; to obtain an amorphous nanocrystalline master alloy;
s1-4, carrying out powder preparation on the obtained master alloy by a strip-making crushing method and/or an atomization powder-making method to obtain the amorphous nanocrystalline powder.
Further, in step S1, the process of the insulation coating process includes the following steps:
s1-1, mixing the obtained amorphous nanocrystalline powder with a nitric acid solution and an acetone solution, placing the obtained mixture in a closed container, heating in a water bath at constant temperature, and performing heat preservation treatment;
s1-2, after the mixture fully reacts, opening the closed container to volatilize acetone therein and obtain the coated powder;
after the pre-annealing treatment is carried out on the coating powder, the stress generated in each working procedure at the early stage is released, and the formation of a compact and stable insulating coating layer is promoted.
Further, in step S4, the heating temperature of the heating process is 100 to 250 ℃.
Further, the amorphous nanocrystalline powder component includes Fe100-a-b-c-x-y-zSiaBbCcMnxCryXZWherein X is any one of P, Cu, Mo and Ni, wherein a is more than or equal to 8 and less than or equal to 15, b is more than or equal to 6 and less than or equal to 12, c is more than or equal to 0.2 and less than or equal to 3.0, X is more than or equal to 0.1 and less than or equal to 3.5, y is more than or equal to 0.5 and less than or equal to 2.5, and Z is more than or equal to 0 and less than or equal to 4.0.
Furthermore, b is more than or equal to 6 and less than or equal to 9, and y is more than or equal to 0.3 and less than or equal to 2.5.
Further, the amorphous nanocrystalline powder component includes Fe74.8Si11B9C1.5Cr2.5Mn0.2P1Or Fe74.8Si11B9C0.5Cr1.5Mn0.2P2Or Fe73.8Si11B9C1.5Cr1.5Mn0.2P2Or Fe79Si11B7C0.5Cr0.3Mn0.2P2Or Fe79Si9B6.2C0.5Cr0.3Mn1P4(ii) a In step S2, the temperature of the pre-annealing treatment is controlled to be 400-480 ℃.
Further, the amorphous nanocrystalline powder component includes Fe74.8Si11B9C1.5Cr2.5Mn0.2Mo1Or Fe76.8Si11B9C0.5Cr1.5Mn0.2Mo1Or Fe73.8Si11B9C1.5Cr1.5Mn1.2Mo1Or Fe78Si11B7C0.5Cr0.5Mn1Mo2(ii) a In step S2, the temperature of the pre-annealing process is controlled to be 420-520 ℃.
Further, the amorphous nanocrystalline powder component includes Fe74.8Si11B9C1.5Cr2.5Mn0.2Ni1Or Fe74.8Si11B9C0.5Cr1.5Mn0.2Ni2Or Fe74.8Si11B7C1.5Cr1.5Mn0.2Ni3Or Fe76.8Si11B7C0.5Cr0.5Mn0.2Ni4(ii) a In step S2, the temperature of the pre-annealing process is controlled to 380-480 ℃.
The invention has the beneficial effects that:
the integrally formed inductor prepared by the preparation method has the beneficial effects of simple and efficient processing and stable performance.
Detailed Description
In order to make the technical solution, objects and advantages of the present invention more apparent, the following examples further illustrate the present invention.
The preparation method of the inductor specifically comprises the following steps:
s1, blending and smelting the raw materials according to a preset component formula to prepare a master alloy;
s2, preparing powder of the obtained master alloy by a conventional belt-making crushing powder-making method or an atomization powder-making method in the prior art to obtain amorphous nanocrystalline powder, wherein the powder obtained by the belt-making crushing powder-making method is irregular and flaky; the powder prepared by the atomization powder preparation method is in a sphere-like shape;
s3, carrying out insulation coating treatment on the obtained amorphous nanocrystalline powder to obtain coated powder;
s4, molding the obtained coated powder to enable the corresponding powder to be granular so as to obtain amorphous nanocrystalline insulating finished product powder;
wherein the molding treatment process comprises adding binder into the coated powder for secondary coating treatment to obtain semi-finished powder; then, adding a lubricant into the semi-finished product powder, stirring and mixing to enable the corresponding powder to be granular, and obtaining the insulated finished product powder;
and S5, carrying out compression molding and baking solidification on the obtained insulating finished product powder, and carrying out subsequent treatment to obtain the inductor.
Example 1:
in the application based on step S1, the alloy composition prepared according to the predetermined composition formula of the present invention includes Fe100-a-b-c-x-y-zSiaBbCcMnxCryXZWherein X is any one of P, Cu, Mo and Ni, wherein a is more than or equal to 8 and less than or equal to 15, b is more than or equal to 6 and less than or equal to 12, c is more than or equal to 0.2 and less than or equal to 3.0, X is more than or equal to 0.1 and less than or equal to 3.5, y is more than or equal to 0.5 and less than or equal to 2.5, and Z is more than or equal to 0 and less than or equal to 4.0. Preferably, 6. ltoreq. b.ltoreq.9, 0.3. ltoreq. y.ltoreq.2.5.
The alloy components of the master alloy are arranged, so that the powder prepared subsequently has high amorphous forming capability, strong corrosion resistance, high saturation magnetic induction intensity and low coercive force, and the application of the master alloy has good application prospect.
The preferable application of the alloy composition scheme is Fe74.8Si11B9C1.5Cr2.5Mn0.2P1Or Fe74.8Si11B9C0.5Cr1.5Mn0.2P2Or Fe73.8Si11B9C1.5Cr1.5Mn0.2P2Or Fe79Si11B7C0.5Cr0.3Mn0.2P2Or Fe79Si9B6.2C0.5Cr0.3Mn1P4。
Specifically, the smelting process of the master alloy is as follows:
s1-1, selecting metal raw materials including industrial pure iron, nodular iron, electrolytic chromium, metal manganese and the like, and putting the metal raw materials into a smelting furnace for smelting, wherein the smelting temperature is 1350-1550 ℃, and the smelting time is 1.5-3.5 h;
s1-2, after the materials are completely melted, sequentially adding alloy raw materials such as ferroboron, ferrophosphorus, industrial silicon and the like and non-metal raw materials for secondary smelting;
s1-3, after the materials are completely melted in the secondary smelting, keeping the temperature for 10 min;
s1-4, after the molten metal is cooled to 1350 ℃, starting the smelting furnace, and performing surface impurity removal treatment on the molten alloy;
and S1-5, pouring the alloy melt with the surface impurities removed into a steel ingot mold, and then cooling and molding to obtain the master alloy.
Wherein the adopted smelting furnace is preferably a vacuum smelting furnace, and the charging amount of the smelting furnace is 15-35 kg.
In the application based on step S2, the master alloy with specific alloy components can be used to prepare corresponding amorphous nanocrystalline strip products, flaky amorphous nanocrystalline crushed powder products and spheroidal amorphous nanocrystalline atomized powder products.
The strip made from the master alloy will have the following performance characteristics, as shown in attached table 1.
Attached table 1 (different component amorphous nanocrystalline strip test performance)
Figure BDA0003385225290000041
As shown in the attached Table 2, the strip made of the master alloy is crushed into powder, and the magnetic powder core prepared by the method has the following performance characteristics through the preparation method of the magnetic powder core in the prior art.
Attached table 2 (magnetic powder core test performance prepared from amorphous nanocrystalline crushing powder with different components)
Figure BDA0003385225290000042
As shown in the attached table 3, the performance of the atomized powder made of the master alloy is evaluated by a pressing ring method based on the gas atomization or water-gas atomization combined method in the prior art, and the performance evaluation result has the following performance characteristics.
Attached table 3 (comparison of performance of amorphous nanocrystalline atomized powder and conventional powder compression ring test)
Figure BDA0003385225290000043
Figure BDA0003385225290000051
As shown in the attached Table 4, the performance evaluation results of the atomized powders prepared from different components based on the application of the alloy components have the following performance characteristics.
Attached table 4 (comparison of performance of different components amorphous nanocrystalline atomized powder compression ring test)
Figure BDA0003385225290000052
Example 2:
this example differs from example 1 above in that the alloy composition scheme is preferably applied as Fe74.8Si11B9C1.5Cr2.5Mn0.2Mo1Or Fe76.8Si11B9C0.5Cr1.5Mn0.2Mo1Or Fe73.8Si11B9C1.5Cr1.5Mn1.2Mo1Or Fe78Si11B7C0.5Cr0.5Mn1Mo2。
Specifically, the smelting process of the master alloy is as follows:
s1-1, selecting metal raw materials such as industrial pure iron, nodular iron, electrolytic chromium, metal manganese, electrolytic molybdenum and the like, and putting the metal raw materials into a smelting furnace for smelting, wherein the smelting temperature is 1350-1550 ℃, and the smelting time is 1.5-3.5 hours;
s1-2, after the materials are completely melted, sequentially adding alloy raw materials such as ferroboron, industrial silicon and the like and non-metal raw materials for secondary smelting;
s1-3, after the materials are completely melted in the secondary smelting, keeping the temperature for 10 min;
s1-4, after the molten metal is cooled to 1350 ℃, starting the smelting furnace, and performing surface impurity removal treatment on the molten alloy;
and S1-5, pouring the alloy melt with the surface impurities removed into a steel ingot mold, and then cooling and molding to obtain the master alloy.
Wherein the adopted smelting furnace is preferably a vacuum smelting furnace, and the charging amount of the smelting furnace is 15-35 kg.
In the application based on step S2, the master alloy with specific alloy components can be used to prepare corresponding amorphous nanocrystalline strip products, flaky amorphous nanocrystalline crushed powder products and spheroidal amorphous nanocrystalline atomized powder products.
Then strips made from the master alloy will have the following performance characteristics, as shown in attached table 5.
Attached table 5 (different components amorphous nanocrystalline strip test performance)
Figure BDA0003385225290000061
As shown in the attached Table 6, the strip made of the master alloy is crushed into powder, and the magnetic powder core made of the strip by the method for preparing the magnetic powder core in the prior art has the following performance characteristics.
Attached table 6 (magnetic powder core test performance prepared by amorphous nanocrystalline crushing powder with different components)
Figure BDA0003385225290000062
As shown in the attached Table 7, the performance of the atomized powder made of the master alloy is evaluated by a pressure ring method based on the gas atomization or water-gas atomization combined method in the prior art, and the performance evaluation result has the following performance characteristics.
Attached table 7 (comparison of performance of amorphous nanocrystalline atomized powder and conventional powder compression ring test)
Figure BDA0003385225290000063
As shown in the attached Table 8, based on the application of the alloy components, the performance evaluation results of the atomized powders prepared from different components are evaluated according to an integrally formed inductance evaluation mode, and the atomized powders have the following performance characteristics.
Attached table 8 (Performance comparison of amorphous nanocrystalline powders of different compositions according to the Integrated inductance evaluation mode)
Figure BDA0003385225290000071
Example 3:
this example differs from example 1 above in that the alloy composition scheme is preferably applied as follows: fe74.8Si11B9C1.5Cr2.5Mn0.2Ni1Or Fe75.8Si11B9C0.5Cr1.5Mn0.2Ni2Or Fe75.8Si11B7C1.5Cr1.5Mn0.2Ni3Or Fe76.8Si11B7C0.5Cr0.5Mn0.2Ni4。
Specifically, the smelting process of the master alloy is as follows:
s1-1, selecting metal raw materials such as industrial pure iron, nodular iron, electrolytic chromium, metal manganese, electrolytic nickel and the like, and smelting in a smelting furnace at 1350-1550 ℃ for 1.5-3.5 h;
s1-2, after the materials are completely melted, sequentially adding alloy raw materials such as ferroboron, industrial silicon and the like and non-metal raw materials for secondary smelting;
s1-3, after the materials are completely melted in the secondary smelting, keeping the temperature for 10 min;
s1-4, after the molten metal is cooled to 1350 ℃, starting the smelting furnace, and performing surface impurity removal treatment on the molten alloy;
and S1-5, pouring the alloy melt with the surface impurities removed into a steel ingot mold, and then cooling and molding to obtain the master alloy.
Wherein the adopted smelting furnace is preferably a vacuum smelting furnace, and the charging amount of the smelting furnace is 15-35 kg.
In the application based on step S2, the master alloy with specific alloy components can be used to prepare corresponding amorphous nanocrystalline strip products, flaky amorphous nanocrystalline crushed powder products and spheroidal amorphous nanocrystalline atomized powder products.
Then strips made from the master alloy will have the following performance characteristics, as shown in attached table 9.
Attached table 9 (different components amorphous nanocrystalline strip test performance)
Figure BDA0003385225290000072
Figure BDA0003385225290000081
As shown in the attached Table 10, the strip made of the master alloy is crushed into powder, and the magnetic powder core made by the method has the following performance characteristics.
Attached table 10 (magnetic powder core test performance prepared by amorphous nanocrystalline crushing powder with different components)
Figure BDA0003385225290000082
As shown in the attached table 11, based on the gas atomization or water atomization combination method in the prior art, the performance of the atomized powder made of the master alloy is evaluated by a compression ring method, and the performance evaluation result has the following performance characteristics.
Attached table 11 (comparison of performance of amorphous nanocrystalline atomized powder and conventional powder compression ring test)
Figure BDA0003385225290000083
As shown in the attached Table 12, based on the application of the alloy components, the performance evaluation results of the atomized powders prepared from different components are evaluated in an integrated molding inductance evaluation mode, and the performance evaluation results have the following performance characteristics.
Attached table 12 (Performance comparison of amorphous nanocrystalline powders of different compositions according to the Integrated inductance evaluation mode)
Figure BDA0003385225290000084
Example 4:
based on the application cases of the above examples 1 to 3, in order to optimize the powder flowability and the bulk density, the atomized powder prepared in the step S2 can be dried and classified to be applied in different mesh levels. In a preferred embodiment, the atomized powder is classified into three grades of-800 mesh, -500 mesh and-325 mesh; the proportion of the adopted powder is preferably-800: -500: -325 ═ 1:3: 6; the powder is mixed and prepared in a mixing mode of preferably ultrasonic dispersion; the loose density of the powder is 3.2-4.5 g/cm 3.
In the following attached table 13, evaluation was performed in the integrated molding inductance evaluation manner, and the effect of distinguishing the properties of different powder ratios will be shown.
Attached table 13 (comparison of different powder ratio compression test performance)
Figure BDA0003385225290000091
However, in the case of the atomized powder preparation application of the present invention, since the shape of the atomized powder is in the form of a sphere, there will be many gaps between the powder or the powder; then the inductor product is directly produced, and the product performance still has limitation.
In this embodiment, in step S3, before the atomized amorphous nanocrystalline powder is subjected to insulation coating, filler powder is added to fully stir and mix; the filling powder is selected from iron-silicon-chromium and/or carbonyl iron powder, and gaps among the atomized amorphous nanocrystalline powder are filled to form amorphous nanocrystalline mixed powder through mixing, so that the bonding strength among the powder particles is effectively increased, the density of subsequent products is effectively improved, and the effect of improving the product performance is achieved.
In the case of application of the amorphous nanocrystalline mixed powder, the particle size range of the atomized powder used is-325 to +500 mesh, the particle size range of the filler powder is-600 to 800 mesh, and the addition ratio of the filler powder to the entire amorphous nanocrystalline mixed powder is 2 to 15%.
In the following attached tables 14 and 15, the results of comparing the performance of the compression ring test under different proportions of the amorphous nanocrystalline powder, iron silicon chromium powder, carbonyl iron powder and the like are shown.
Attached table 14 (amorphous nanocrystalline powder and iron silicon chromium powder matching compression ring test performance comparison)
Figure BDA0003385225290000101
Attached table 15 (amorphous nanocrystalline powder and carbonyl iron powder ratio compression test performance contrast)
Figure BDA0003385225290000102
Example 5:
in the application based on step S3, the present invention further provides an insulation coating processing method to meet the preparation requirement of the coating powder, wherein the specific process steps are as follows:
a1, mixing the obtained amorphous nanocrystalline powder with a nitric acid solution and an acetone solution, placing the obtained mixture in a closed container, heating in a water bath at constant temperature, and performing heat preservation treatment; the heating temperature of the constant-temperature heating of the water bath is preferably 45 ℃; the heat preservation treatment time is preferably 30 min.
A2, stirring the mixture in the closed container to make the mixture fully react; the stirring treatment mode can be selected to fully stir the mixture in the closed container by a magnetic stirrer or output the mixture in the closed container by ultrasonic waves so as to make the mixture subjected to ultrasonic dispersion mixing; a uniform oxide film is generated on the surface of the amorphous nanocrystalline powder based on the application of nitric acid solution as a passivating agent, and a coating powder is formed.
A3, after full reaction, opening the closed container to volatilize the acetone; and taking out the coated powder.
Wherein, as a preferred embodiment, the mass ratio of the nitric acid solution to the amorphous nanocrystalline powder is 1.2-2.4 wt% based on the mass of the amorphous nanocrystalline powder, and the nitric acid solution can be concentrated nitric acid with a concentration of 68%; the acetone solution accounts for 30-40 wt% of the amorphous nanocrystalline powder. No corresponding nitric acid reaction waste liquid is generated in the process, and no environmental pollution is caused.
In the above process, the binder material used in the process is formed by mixing organic silicon resin, epoxy resin and curing agent, and the mixture ratio is, in parts by mass, organic silicon resin: epoxy resin: the curing agent was 14.5:3: 1. The mass ratio of the binder material to the amorphous nanocrystalline powder is 1.0-5 wt%.
In the above process, the lubricant selected is zinc stearate.
In the above process, the pressure of the press molding is controlled at 500-800 MPa.
Example 6:
after the coating powder is obtained, the invention is applied in a pre-annealing treatment mode to effectively promote the insulating coating effect of the powder, effectively remove the stress generated in the powder preparation process, the insulating stirring process and other processes, and volatilize harmful substances introduced in the insulating coating process.
The obtained coating powder is subjected to pre-annealing treatment, so that the annealing temperature of the pre-annealing treatment ranges from Tx-100 to Tx +80 ℃, and Tx is the crystallization temperature of the amorphous nanocrystal.
For the nanocrystalline powder, the formation of ultrafine crystals of the powder can be realized, the crystallization treatment is realized, the selected pre-annealing temperature is 420-570 ℃, and the annealing time is 30-80 min.
As shown in the attached tables 16 to 18, the evaluation results of the properties of the coated powders obtained from the respective compositions by pre-annealing at different temperatures based on the applications of the respective alloy compositions will have the following properties.
Note: the sample had wear test conditions of 100kHz, 100mT and the test results were in kw/m 3.
Attached table 16 (different components coating powder different pre-annealing temperature compression ring test performance comparison)
Figure BDA0003385225290000111
Figure BDA0003385225290000121
Attached table 17 (different components coating powder different pre-annealing temperature compression ring test performance comparison)
Figure BDA0003385225290000122
Attached table 18 (different components coating powder different pre-annealing temperature compression ring test performance comparison)
Figure BDA0003385225290000123
The pre-annealed coating powder is subjected to forming treatment to obtain insulating finished product powder; specifically, in the secondary coating treatment process, the adopted binder is epoxy resin, silicon resin, inorganic silicon and the like, and the diluent can be selected from acetone, ethanol, purified water and the like; the proportion of the binder is 0.5-5.0%, the proportion of the diluent is 0.5-10%, preferably the proportion of the binder is 1.2-3.0%, and the proportion of the diluent is 3-10%. The uniform mixing process can adopt normal temperature and heating state mixing, and the heating temperature is preferably 50-120 ℃.
The lubricant can be selected from paraffin, zinc stearate, magnesium stearate and the like, the adding proportion is 0.2-1.5%, and the insulating finished product powder is obtained after uniform mixing.
Example 7:
in the application process of step S5, in order to simplify the press forming process of the inductor, the present invention is directed to a structural form of integrally formed inductor to make an improvement of the press forming process therein.
Specifically, the obtained amorphous nanocrystalline insulating finished product powder is heated and further stirred and mixed, so that the obtained amorphous nanocrystalline insulating finished product powder is separated and uniformly heated; the amorphous nanocrystalline insulating finished product powder is heated to 100-250 ℃ integrally and then is kept warm for later use.
Preparing a corresponding molding die cavity, designing a prefabricated coil for the inductor, putting the prefabricated coil into the molding die cavity, filling the amorphous nanocrystalline insulating finished product powder subjected to heating treatment into the molding die cavity, and performing compression molding on the inductor by conventional cold pressing equipment to obtain an integrated inductor blank. In the compression molding process, the pressure range is 400-800 Mpa.
The following additional table 19 shows the performance differences of the amorphous nanocrystalline insulating finished product powder subjected to cold pressing by cold pressing equipment under different heating temperatures.
Attached meter 19 (different powder temperature compression ring test performance comparison)
Figure BDA0003385225290000131
Then, baking the obtained integrated inductor blank at the temperature of 150-220 ℃ for 1-2.5 h; and bending the pin part of the inductor according to the design requirement of a specific product to obtain the inductor.
Furthermore, in order to improve the magnetic permeability of the product and reduce the deformation of the coil, a step-by-step molding combination mode can be selected for preparing the inductor.
For example, for an inductor product which is formed by combining a T-shaped prefabricated magnet and a U-shaped prefabricated magnet, a corresponding T-shaped molding die cavity and a corresponding U-shaped molding die cavity can be arranged according to the structural characteristics; filling the heated amorphous nanocrystalline insulating finished product powder into the corresponding forming die cavity so as to prepare the T-shaped prefabricated magnet and the U-shaped prefabricated magnet firstly. Then, a coil is placed in the gap between the T-shaped prefabricated magnet and the U-shaped prefabricated magnet, and further, powder is filled for secondary pressing, so that a corresponding inductor product is obtained.
And on the other hand, after the coil is placed in the gap between the T-shaped prefabricated magnet and the U-shaped prefabricated magnet, or the contact boundary between the T-shaped prefabricated magnet and the U-shaped prefabricated magnet can be bonded by adopting magnetic glue, and the gap in the product can be filled by adopting the bonding, so that the required inductor product is obtained.
Based on the concept definition of "amorphous nanocrystalline", the above-mentioned related amorphous nanocrystalline alloy product may be considered as an application for selecting a corresponding amorphous alloy product, amorphous and nanocrystalline alloy product, or nanocrystalline alloy product.
The above description is only a preferred embodiment of the present invention, and those skilled in the art may still modify the described embodiment without departing from the implementation principle of the present invention, and the corresponding modifications should also be regarded as the protection scope of the present invention.

Claims (10)

1. The preparation method of the integrally formed inductor is characterized by comprising the following steps of:
s1, preparing amorphous nanocrystalline powder;
s2, carrying out insulation coating treatment on the obtained amorphous nanocrystalline powder to obtain coated powder;
s3, molding the obtained coated powder to obtain amorphous nanocrystalline insulating finished product powder;
s4, heating the obtained amorphous nanocrystalline insulating finished product powder;
and S5, placing the prefabricated coil and the amorphous nanocrystalline insulating finished product powder obtained by heating into a molding die cavity, and pressing by cold pressing equipment to obtain the integrally molded inductor.
2. The method of claim 1, wherein in step S3, the obtained coated powder is pre-annealed to promote insulation passivation reaction of the coated powder before cold pressing process.
3. The method of claim 2, wherein the pre-annealing process has an annealing temperature ranging from Tx-100 to Tx +80 degrees celsius, Tx being a crystallization temperature of the amorphous nanocrystal.
4. The manufacturing method of claim 1, wherein in step S1, the process steps of the insulation coating treatment are as follows:
s1-1, mixing the obtained amorphous nanocrystalline powder with a nitric acid solution and an acetone solution, placing the obtained mixture in a closed container, heating in a water bath at constant temperature, and performing heat preservation treatment;
s1-2, after the mixture fully reacts, opening the closed container to volatilize acetone therein and obtain the coated powder;
after the pre-annealing treatment is carried out on the coating powder, the stress generated in each working procedure at the early stage is released, and the formation of a compact and stable insulating coating layer is promoted.
5. The method according to claim 1, wherein in step S4, the heating temperature of the heating treatment is 100 to 250 ℃.
6. The method according to any one of claims 1 to 5, wherein the amorphous nanocrystalline powder component comprises Fe100-a-b-c-x-y-zSiaBbCcMnxCryXZWherein X is any one of P, Cu, Mo and Ni, wherein a is more than or equal to 8 and less than or equal to 15, b is more than or equal to 6 and less than or equal to 12, c is more than or equal to 0.2 and less than or equal to 3.0, X is more than or equal to 0.1 and less than or equal to 3.5, y is more than or equal to 0.5 and less than or equal to 2.5, and Z is more than or equal to 0 and less than or equal to 4.0.
7. The method according to claim 6, wherein 6. ltoreq. b.ltoreq.9 and 0.3. ltoreq. y.ltoreq.2.5.
8. The method of claim 7, wherein the amorphous nanocrystalline powder component comprises Fe74.8Si11B9C1.5Cr2.5Mn0.2P1Or Fe74.8Si11B9C0.5Cr1.5Mn0.2P2Or Fe73.8Si11B9C1.5Cr1.5Mn0.2P2Or Fe79Si11B7C0.5Cr0.3Mn0.2P2Or Fe79Si9B6.2C0.5Cr0.3Mn1P4(ii) a In step S2, the temperature of the pre-annealing treatment is controlled to be 400-480 ℃.
9. The method of claim 7, wherein the amorphous nanocrystalline powder component comprises Fe74.8Si11B9C1.5Cr2.5Mn0.2Mo1Or Fe76.8Si11B9C0.5Cr1.5Mn0.2Mo1Or Fe73.8Si11B9C1.5Cr1.5Mn1.2Mo1Or Fe78Si11B7C0.5Cr0.5Mn1Mo2(ii) a In step S2, the temperature of the pre-annealing process is controlled to be 420-520 ℃.
10. The method of claim 7, wherein the amorphous nanocrystalline powder component comprises Fe74.8Si11B9C1.5Cr2.5Mn0.2Ni1Or Fe74.8Si11B9C0.5Cr1.5Mn0.2Ni2Or Fe74.8Si11B7C1.5Cr1.5Mn0.2Ni3Or Fe76.8Si11B7C0.5Cr0.5Mn0.2Ni4(ii) a In step S2, the temperature of the pre-annealing process is controlled to 380-480 ℃.
CN202111448644.3A 2020-11-30 2021-11-30 Preparation method of integrally-formed inductor Pending CN114156075A (en)

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