CN114664508A - Soft magnetic composite material, preparation method thereof and integrally-formed inductor - Google Patents
Soft magnetic composite material, preparation method thereof and integrally-formed inductor Download PDFInfo
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- CN114664508A CN114664508A CN202210117455.6A CN202210117455A CN114664508A CN 114664508 A CN114664508 A CN 114664508A CN 202210117455 A CN202210117455 A CN 202210117455A CN 114664508 A CN114664508 A CN 114664508A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- 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
- H01F1/14—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 metals or alloys
- H01F1/20—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 metals or alloys in the form of particles, e.g. powder
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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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
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Abstract
The invention relates to the technical field of soft magnetic materials, in particular to a soft magnetic composite material, a preparation method thereof and an integrally formed inductor. The soft magnetic composite material comprises the following components in parts by mass: 100 parts of soft magnetic powder, 6-10 parts of resin adhesive and 10-15 parts of organic solvent, wherein the organic solvent is any two or three of acetone, methyl acetate and cyclohexanone. The resin adhesive can form a complete and bubble-free film in the drying process through the collocation of the organic solvents, so that the problem that bubbles or holes are easy to appear in the film forming process of the resin adhesive is avoided, the soft magnetic powder can be completely wrapped, and the corrosion resistance and the insulativity of the soft magnetic composite material are improved.
Description
Technical Field
The invention relates to the technical field of soft magnetic materials, in particular to a soft magnetic composite material, a preparation method thereof and an integrally formed inductor.
Background
With the popularization of new energy automobiles and 5G technologies, the usage amount of the integrally formed inductor is increased in geometric multiples. The number of integrally formed inductor products is increased rapidly, and meanwhile, the requirements on various properties of the integrally formed inductor are higher and higher, and besides the basic magnetic property requirements, the corrosion resistance and the insulation impedance property of the product also become important attention characteristics in the industry.
The integrally formed inductor consists of soft magnetic powder, a coil and an adhesive, and aiming at the problem of how to improve the corrosion resistance and the insulation property of the soft magnetic powder, the universal mode adopted in the industry mainly comprises the following steps: 1) the content of chromium in the soft magnetic material is increased, so that a layer of firm and compact chromium oxide is formed on the surface of the soft magnetic powder, and the soft magnetic powder is protected, however, the electromagnetic characteristic of the integrally formed inductor is sacrificed in the mode, and the risk of short circuit of the integrally formed inductor product is increased; 2) the soft magnetic powder is coated by chemical passivation by using a passivation material, but the surface of the soft magnetic powder cannot be completely coated in such a way or the coating film is too thick, so that the magnetic performance of the integrally formed inductor is reduced. Furthermore, the passivation material is partially toxic and pollutes the environment, thereby resulting in limited selectivity of the passivation material.
Disclosure of Invention
Therefore, the invention provides the soft magnetic composite material capable of improving corrosion resistance and insulativity, the preparation method thereof and the integrally formed inductor.
The first purpose of the invention is to provide a soft magnetic composite material, which comprises the following components in parts by mass:
100 parts of soft magnetic powder,
6 to 10 parts of a resin binder, and
10-15 parts of an organic solvent;
the organic solvent is selected from any two of acetone, methyl acetate and cyclohexanone.
Optionally, as for the soft magnetic composite material, the soft magnetic powder is one or more of carbonyl iron powder, iron silicon chromium powder, iron silicon aluminum powder and iron silicon powder.
Optionally, in the soft magnetic composite material, the median particle size of the soft magnetic powder is 5 μm to 25 μm.
Optionally, as described above in the soft magnetic composite material, the resin adhesive is one or more of an epoxy resin adhesive, a phenolic resin adhesive, a cyanate ester adhesive, and a silicone resin adhesive.
Optionally, the soft magnetic composite material further comprises 5-10 parts by mass of a toughening agent.
Optionally, as in the soft magnetic composite material described above, the toughening agent is one or more of polysulfide rubber, liquid silicone rubber and polyimide.
A second object of the present invention is to provide a method for preparing the soft magnetic composite material, comprising: mixing the soft magnetic powder, the resin binder and the organic solvent, and granulating.
Optionally, in the preparation method of the soft magnetic composite material, after the granulation, the step of sieving the soft magnetic composite material by a sieve of 60-200 meshes is further included.
Optionally, the preparation method of the soft magnetic composite material further includes a drying step, wherein the drying temperature is 40-80 ℃.
A third object of the present invention is to provide an integrally formed inductor, which includes the soft magnetic composite material and a coil embedded in the soft magnetic composite material.
According to the invention, the organic solvents with different boiling points are added into the soft magnetic composite material, and the matching of the organic solvents can enable the resin adhesive to form a complete and bubble-free film in the drying process, so that the problem that bubbles or holes are easy to appear in the film forming process of the resin adhesive is avoided, the soft magnetic powder can be completely wrapped, and the corrosion resistance and the insulativity of the soft magnetic composite material are improved.
Moreover, the corrosion resistance and the insulating property of the soft magnetic composite material can be improved without using a passivation material, so that the selection of the passivation material is not limited. Meanwhile, when the soft magnetic composite material is used for preparing the integrally formed inductor, the magnetic performance of the integrally formed inductor is not reduced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a diagram showing a film-forming state of a mixed solution prepared in example 1 of the present invention;
FIG. 2 is a diagram of a magnetic ring after salt spray testing in example 1 of the present invention;
FIG. 3 is a diagram showing a film-forming state of the mixed solution prepared in example 2 of the present invention;
FIG. 4 is a diagram of a magnetic ring after salt spray testing in example 2 of the present invention;
FIG. 5 is a diagram showing a film-forming state of the mixed solution prepared in example 3 of the present invention;
FIG. 6 is a diagram of a magnetic ring after a salt spray test in accordance with embodiment 3 of the present invention;
FIG. 7 is a diagram showing a film formation state of the mixed solution prepared in example 4 of the present invention;
FIG. 8 is a pictorial view of a magnetic ring after salt spray testing made in embodiment 4 of the present invention;
FIG. 9 is a diagram showing a state in which a mixed solution prepared in comparative example 1 of the present invention is formed into a film;
FIG. 10 is a pictorial view of a magnetic ring after salt spray testing as prepared in comparative example 1 of the present invention;
FIG. 11 is a diagram showing a state in which a mixed solution prepared in comparative example 2 of the present invention is formed into a film;
FIG. 12 is a pictorial view of a magnetic ring after salt spray testing in comparative example 2 of the present invention;
FIG. 13 is a diagram showing a state in which a mixed solution prepared in comparative example 3 of the present invention is formed into a film;
FIG. 14 is a pictorial view of a magnetic ring after salt spray testing as prepared in comparative example 3 of the present invention;
FIG. 15 is a view showing a state in which a mixed solution obtained in comparative example 4 of the present invention was formed into a film;
FIG. 16 is a pictorial view of a magnetic ring after salt spray testing as prepared in comparative example 4 of the present invention;
FIG. 17 is a view showing a state that a mixed solution prepared in comparative example 5 of the present invention is formed into a film;
FIG. 18 is a pictorial view of a magnetic ring after salt spray testing as prepared in comparative example 5 of the present invention.
Detailed Description
Reference will now be made in detail to embodiments of the invention, one or more examples of which are described below. Each example is provided by way of explanation, not limitation, of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment.
It is therefore intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. Other objects, features and aspects of the present invention are disclosed in or are apparent from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
It can be understood that the resin adhesive can form a complete film in the curing process through the matching combination of the organic solvents with different boiling points, and no air bubbles or holes appear, so that the soft magnetic powder can be completely wrapped. On one hand, the electrical conductivity of the resin material is low, so that a thin film formed by the resin adhesive has good insulation, and the insulation of the soft magnetic powder is improved; on the other hand, after the soft magnetic powder is wrapped by the complete film, the soft magnetic powder can be prevented from being rusted due to the influence of the environment.
The first purpose of the invention is to provide a soft magnetic composite material, which comprises the following components in parts by mass:
100 parts of soft magnetic powder,
6 to 10 parts of a resin binder, and
10-15 parts of an organic solvent;
wherein the organic solvent is selected from any two or three of acetone, methyl acetate and cyclohexanone.
The corrosion resistance and the insulativity of the soft magnetic composite material can be improved without using a passivation material, so that the selection of the passivation material is not limited. Meanwhile, when the soft magnetic composite material is used for preparing the integrally formed inductor, the magnetic performance of the integrally formed inductor is not reduced.
In some embodiments, the soft magnetic powder is not limited too much, and any soft magnetic powder known in the art may be selected, and for example, the soft magnetic powder may be soft magnetic iron powder, such as one or more of carbonyl iron powder, iron silicon chromium powder, iron silicon aluminum powder, and iron silicon powder.
In some embodiments, the resin adhesive may also be any known resin adhesive in the art, and by way of example and not limitation, the resin adhesive may be one or more of an epoxy adhesive, a phenolic adhesive, a cyanate adhesive, and a silicone adhesive.
In some embodiments, the median particle diameter of the soft magnetic powder may be 5 μm to 25 μm, and may also be, for example, 10 μm, 12 μm, 15 μm, 20 μm, 22 μm, or the like.
In some embodiments, in order to further improve the integrity of a film formed when the resin adhesive is cured in the process of preparing the integrally formed inductor, the soft magnetic composite material may further include 5 to 10 parts by mass of a toughening agent.
In some embodiments, the toughening agent may be a toughening agent commonly used in the art, and by way of example, the toughening agent may be one or more of polysulfide rubber, liquid silicone rubber, and polyimide.
A second object of the present invention is to provide a method for preparing the above soft magnetic composite material, the method comprising: mixing soft magnetic powder, resin binder and organic solvent, and granulating.
In some embodiments, the specific step of mixing the soft magnetic powder, the resin binder, and the organic solvent includes: the resin adhesive and the organic solvent are mixed, and then the soft magnetic powder is added and mixed.
In some embodiments, it is within the ability of one skilled in the art to select a method of granulation, which may be, for example, extrusion granulation.
In some embodiments, after granulation, in order to improve the quality of the soft magnetic composite material, a sieving step may be further included to reject the rejected product. Illustratively, the soft magnetic composite material can be sieved by a sieve with 60-200 meshes.
In some embodiments, the preparation method further comprises a drying step, wherein the drying temperature and time can be any common values, and as an example, the drying temperature can be 40-80 ℃ and the drying time can be 50-70 min.
The third objective of the present invention is to provide an integrally formed inductor, which includes the soft magnetic composite material and a coil embedded in the soft magnetic composite material.
In some embodiments, the method of embedding the coil in the soft magnetic composite material may be any method known in the art, for example, a powder metallurgy process.
In some embodiments, the coil is made of a material and has a shape not limited to a copper coil, and the coil may have a circular shape, a square shape, a flat shape, a multi-strand combination shape, or the like.
The present invention will be described in further detail with reference to specific examples and comparative examples.
And (3) performance testing:
1)24h neutral salt spray test: the magnetic rings prepared in the examples and comparative examples were subjected to a salt spray test in accordance with GB/T10125-1997.
2) And (3) insulation resistance testing: the magnetic rings prepared in each example and comparative example were subjected to an insulation resistance test using a Chroma19073 withstand voltage test instrument. Wherein the test voltage is 100V, and the electrifying time is 2 s.
Example 1
Taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5And is ready for use;
and (3) uniformly mixing 7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of methyl acetate, pouring the mixture into the soft magnet powder, uniformly mixing, granulating and drying to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of methyl acetate uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in figure 1. As can be seen from FIG. 1, the mixed solution can form a complete and bubble-free film after being baked.
2g of the soft magnetic composite material prepared above is pressed under 300MPa to form an annular magnetic ring with the outer diameter of 1.4cm and the inner diameter of 0.8cm, the annular magnetic ring is cooled after being baked and solidified, and a salt spray test and an insulation resistance test are respectively carried out for 24h, wherein the salt spray test results are shown in (a) and (b) in fig. 2. As can be seen from (a) and (b) in fig. 2, the rusted area on the surface of the magnetic ring is less than 5% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Example 2
This example is prepared substantially identically to example 1, except that: the kind of the mixed solution is different. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5For standby;
7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of cyclohexanone are uniformly mixed and dissolved, poured into the soft magnet powder, uniformly mixed, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of cyclohexanone uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film-forming state of the dried solution, as shown in figure 3. As can be seen from FIG. 3, the mixed solution can form a complete and bubble-free film after being baked.
2g of the soft magnetic composite material prepared above is pressed under 300MPa to form an annular magnetic ring with the outer diameter of 1.4cm and the inner diameter of 0.8cm, the annular magnetic ring is cooled after being baked and solidified, and a salt spray test and an insulation resistance test are respectively carried out for 24h, wherein the salt spray test results are shown in (a) and (b) in fig. 4. As can be seen from (a) and (b) of fig. 4, the surface of the magnetic ring is not rusted. The insulation resistance test results are shown in table 1.
Example 3
This example is prepared substantially identically to example 1, except that: the kind and parts of the mixed solution are different. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic powder Fe92Si3.5Cr4.5 with the D50 particle size of 10 mu m for later use;
7.5 parts of epoxy resin adhesive, 5 parts of acetone and 7 parts of cyclohexanone are uniformly mixed and dissolved, poured into the soft magnet powder, uniformly mixed, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive, 5 parts of acetone and 7 parts of cyclohexanone uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in figure 5. As can be seen from FIG. 5, the mixed solution can form a complete and bubble-free film after baking.
2g of the soft magnetic composite material prepared in the above manner is pressed under 300MPa to form an annular magnetic ring with the outer diameter of 1.4cm and the inner diameter of 0.8cm, the annular magnetic ring is baked, solidified and cooled, and a salt spray test and an insulation resistance test are respectively carried out for 24 hours, wherein the salt spray test results are shown in (a) and (b) in FIG. 6. As can be seen from (a) and (b) in fig. 6, the rusted area on the surface of the magnetic ring is less than 5% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Example 4
This example is prepared substantially identically to example 1, except that: the kind and parts of the mixed solution are different. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5For standby;
and (3) uniformly mixing 7.5 parts of epoxy resin adhesive, 5 parts of methyl acetate and 7 parts of cyclohexanone, pouring the mixture into the soft magnet powder, uniformly mixing, granulating and drying to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive, 5 parts of methyl acetate and 7 parts of cyclohexanone uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in figure 7. As can be seen from FIG. 7, the mixed solution can form a complete and bubble-free film after baking.
2g of the soft magnetic composite material prepared above was pressed under 300MPa to form an annular magnetic ring with an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and curing, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the salt spray test results shown in (a) and (b) of FIG. 8. As can be seen from (a) and (b) of fig. 8, the surface of the magnetic ring is not rusted. The insulation resistance test results are shown in table 1.
Comparative example 1
This comparative example was prepared substantially the same as example 1, except that: the organic solvent is acetone. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5And is ready for use;
and 7.5 parts of epoxy resin adhesive and 13 parts of acetone are uniformly mixed and dissolved, poured into the soft magnet powder and uniformly mixed, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive and 13 parts of acetone uniformly to form a mixed solution, baking 10g of the mixed solution in a 60 ℃ oven for 1h, and observing the film forming state of the dried solution, wherein the film forming state is shown in figure 9. As can be seen from fig. 9, the mixed solution after baking forms a thin film, and more bubbles are generated, so that a complete thin film cannot be formed.
2g of the soft magnetic composite material prepared above was pressed under 300MPa to form an annular magnetic ring with an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and curing, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the results of the salt spray test shown in (a) and (b) of FIG. 10. As can be seen from (a) and (b) in fig. 10, the rusted area on the surface of the magnetic ring is large, reaching within 25% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Comparative example 2
This comparative example was prepared substantially the same as example 1, except that: the organic solvent is methyl acetate. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5And is ready for use;
7.5 parts of epoxy resin adhesive and 13 parts of methyl acetate are mixed and dissolved uniformly, poured into the soft magnet powder and mixed uniformly, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive and 13 parts of methyl acetate uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in FIG. 11. As can be seen from fig. 11, the mixed solution after baking forms a thin film, and more bubbles are generated, so that a complete thin film cannot be formed.
2g of the soft magnetic composite material prepared above was pressed under 300MPa to form an annular magnetic ring with an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and curing, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the results of the salt spray test shown in (a) and (b) of FIG. 12. As can be seen from fig. 12 (a) and (b), the rusted area on the surface of the magnetic ring is large, reaching within 20% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Comparative example 3
This comparative example was prepared substantially the same as example 1, except that: the organic solvent is cyclohexanone. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5For standby;
7.5 parts of epoxy resin adhesive and 13 parts of cyclohexanone are uniformly mixed and dissolved, poured into the soft magnet powder, uniformly mixed, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive and 13 parts of cyclohexanone uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in FIG. 13. As can be seen from fig. 13, the film formed by baking the mixed solution generates many bubbles, and a complete film cannot be formed.
2g of the soft magnetic composite material prepared above was pressed under 300MPa to form an annular magnetic ring with an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and solidification, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the results of the salt spray test shown in (a) and (b) of FIG. 14. As can be seen from (a) and (b) in fig. 14, the rusted area on the surface of the magnetic ring is large, reaching within 35% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Comparative example 4
This comparative example was prepared substantially the same as example 1, except that: the organic solvent is N, N-dimethylformamide. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5And is ready for use;
7.5 parts of epoxy resin adhesive and 13 parts of N, N-dimethylformamide are uniformly mixed and dissolved, then poured into the soft magnet powder and uniformly mixed, granulated and dried to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive and 13 parts of N, N-dimethylformamide uniformly to form a mixed solution, baking 10g of the mixed solution in a baking oven at 60 ℃ for 1 hour, and observing the film forming state of the dried solution, wherein the film forming state is shown in figure 15. As can be seen from fig. 15, the mixed solution after baking forms a thin film, and more bubbles are generated, so that a complete thin film cannot be formed.
2g of the soft magnetic composite material prepared above was pressed under 300MPa to form an annular magnetic ring with an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and curing, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the results of the salt spray test shown in (a) and (b) of FIG. 16. As can be seen from (a) and (b) in fig. 16, the rusted area on the surface of the magnetic ring is large, reaching within 30% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Comparative example 5
This comparative example was prepared substantially the same as example 1, except that: the organic solvent is acetone and N, N-dimethylformamide. The method comprises the following specific steps:
taking 100 parts by mass of soft magnetic iron powder Fe with the D50 particle size of 10 mu m92Si3.5Cr4.5And is ready for use;
and (3) uniformly mixing 7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of N, N-dimethylformamide, pouring the mixture into the soft magnet powder, uniformly mixing, granulating and drying to prepare the flowable soft magnetic composite material.
And mixing 7.5 parts of epoxy resin adhesive, 9 parts of acetone and 4 parts of N, N-dimethylformamide uniformly to form a mixed solution, baking 10g of the mixed solution in a 60-DEG C oven for 1h, and observing the film forming state of the dried solution, as shown in FIG. 17. As can be seen from fig. 17, the mixed solution after baking forms a thin film, and more bubbles are generated, so that a complete thin film cannot be formed.
2g of the soft magnetic composite material prepared above was pressed at 300MPa to form an annular magnetic ring having an outer diameter of 1.4cm and an inner diameter of 0.8cm, and after baking and curing, cooling was performed, and a salt spray test and an insulation resistance test were performed for 24 hours, respectively, with the results of the salt spray test being shown in (a) and (b) of FIG. 18. As can be seen from (a) and (b) in fig. 18, the rusted area on the surface of the magnetic ring is large, and reaches within 25% of the total surface area of the magnetic ring. The insulation resistance test results are shown in table 1.
Insulation resistance tests were performed on 3 magnetic rings prepared in examples 1 to 4 and comparative examples 1 to 5, and the test results are shown in table 1.
TABLE 1
As can be seen from table 1, the resin films coated on the iron powder surfaces in the soft magnetic composite materials prepared in examples 1 to 4 are relatively complete and have no bubbles, so that the soft magnetic composite materials have excellent insulation resistance. As can be seen from the comparison between example 1 and comparative example 5, the resin film coated on the surface of the iron powder is relatively complete and does not generate bubbles by selecting and combining appropriate solvents.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is specific and detailed, but not to be understood 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 inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. The soft magnetic composite material is characterized by comprising the following components in parts by mass:
100 parts of soft magnetic powder,
6 to 10 parts of a resin binder, and
10-15 parts of an organic solvent;
the organic solvent is selected from any two or three of acetone, methyl acetate and cyclohexanone.
2. The soft magnetic composite material according to claim 1, wherein the soft magnetic powder is one or more of carbonyl iron powder, iron silicon chromium powder, iron silicon aluminum powder and iron silicon powder.
3. A soft magnetic composite material according to claim 2, characterized in that the median particle size of the soft magnetic powder is 5 μm to 25 μm.
4. A soft magnetic composite material according to any one of claims 1 to 3, wherein the resin binder is one or more of an epoxy resin binder, a phenolic resin binder, a cyanate ester binder and a silicone resin binder.
5. A soft magnetic composite material according to any one of claims 1 to 3, further comprising 5 to 10 parts by mass of a toughening agent.
6. The soft magnetic composite material according to claim 5, wherein the toughening agent is one or more of polysulfide rubber, liquid silicone rubber and polyimide.
7. A method for preparing a soft magnetic composite material according to any of claims 1 to 6, characterized in that it comprises: mixing the soft magnetic powder, the resin binder and the organic solvent, and granulating.
8. The method for preparing the soft magnetic composite material according to claim 7, further comprising the step of sieving the soft magnetic composite material with a 60-200 mesh sieve after the granulation.
9. A method for preparing soft magnetic composite material according to claim 8, characterized in that it further comprises a step of drying, the temperature of drying being 40-80 ℃.
10. An integrally formed inductor comprising the soft magnetic composite material according to any one of claims 1 to 6 and a coil embedded in the soft magnetic composite material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210117455.6A CN114664508A (en) | 2022-02-08 | 2022-02-08 | Soft magnetic composite material, preparation method thereof and integrally-formed inductor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210117455.6A CN114664508A (en) | 2022-02-08 | 2022-02-08 | Soft magnetic composite material, preparation method thereof and integrally-formed inductor |
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| CN114927304A (en) * | 2022-07-25 | 2022-08-19 | 广东力王高新科技股份有限公司 | Powder for inductor, preparation method thereof and integrally-formed inductor |
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| CN114927304A (en) * | 2022-07-25 | 2022-08-19 | 广东力王高新科技股份有限公司 | Powder for inductor, preparation method thereof and integrally-formed inductor |
| CN114927304B (en) * | 2022-07-25 | 2022-10-18 | 广东力王高新科技股份有限公司 | Powder for inductor, preparation method thereof and integrally-formed inductor |
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