CN114974785A - Powder coating method, finished product powder and finished product magnetic powder core preparation method - Google Patents
Powder coating method, finished product powder and finished product magnetic powder core preparation method Download PDFInfo
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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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
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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
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15358—Making agglomerates therefrom, e.g. by pressing
- H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
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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
- H01F41/0266—Moulding; Pressing
Abstract
The invention provides a powder coating method, finished product powder and a finished product magnetic powder core preparation method, wherein the powder coating method comprises the following steps: s1, preparing amorphous powder; s2, mixing and attaching inorganic powder to the amorphous powder by ultrasonic waves to obtain attached powder; s3, mixing and fully reacting the alkaline solution with the attached powder, and drying to form an insulating coating layer on the surface of the attached powder to obtain coated powder; the invention also provides a finished product powder preparation method and a finished product magnetic powder core preparation method by applying the powder coating method; the method disclosed by the invention is applied, a non-corrosive treatment method is adopted for corresponding insulating coating application, so that the cost problem and the environmental pollution problem are effectively improved, an acid solution is not needed for corresponding corrosive reaction, the change of the amorphous structure on the surface of the powder particles caused by nonuniform coating and excessive local heat release of the powder particles can be effectively avoided, and the phenomena of reduced magnetic conductivity and other magnetic performance deterioration of the amorphous powder are avoided.
Description
Technical Field
The invention relates to the technical field of magnetically soft alloy metallurgy, in particular to a powder coating method, finished powder and a finished magnetic powder core preparation method.
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.
The insulating coating is a key technology in the preparation process of the amorphous magnetic powder core, the performance of the insulating coating layer is an important factor influencing the high-frequency loss of the magnetic powder core, and if the insulating coating layer is not completely coated or damaged, the eddy current loss among magnetic powder particles is increased sharply, so that the high-frequency loss of the magnetic powder core is increased.
In the application of the prior art, an acidic solution is usually adopted for corrosive insulating coating treatment in the insulating coating process, and the acidic solution is usually diluted by volatile organic matters, so that the cost is increased and the environment is damaged; and the reaction control difficulty in the corrosion process is higher, and the change of the amorphous structure on the surface of the powder particles caused by nonuniform coating and excessive local heat release of the powder particles is easy to occur. Meanwhile, erosion of the powder particles causes undesirable effects of a decrease in powder permeability and an increase in hysteresis loss.
Disclosure of Invention
The invention provides a powder coating method for overcoming the defects of the prior art.
A powder coating method comprising the steps of: s1, preparing amorphous alloy powder, wherein the alloy component of the alloy powder comprises FeSiBCMN amorphous alloy, M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; s2, mixing and attaching inorganic powder to the alloy powder by ultrasonic waves to obtain attached powder; and S3, mixing the alkaline solution with the attached powder, fully reacting, and drying to form an insulating coating layer on the surface of the attached powder, thereby obtaining the coated powder.
Further, in step S1, the alloy powder is prepared by the following mesh ratio: 10-40% of-100 meshes to +150 meshes, 20-70% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +400 meshes; the mesh number of the inorganic powder is set to be more than 8000 meshes.
Further, the inorganic powder includes SiO 2 The alkali solution is a NaOH solution, and in step S3, the reaction formula of the inorganic powder and the alkali solution is: SiO 2 2 +2NaOH＝Na 2 SiO 3 +H 2 O。
Further, in step S3, a binder is added to the adhering powder that has been sufficiently reacted with the alkali solution, and the adhering powder is stirred until it is uniformly dried.
Further, the binder is an inorganic binder or an organic binder.
Furthermore, the adhesive is silicon resin, water glass or epoxy resin, and the addition amount of the adhesive is 0.2-2.5%.
Further, in step S1, the alloy powder has Fe as an alloy component (100-x-y-z-a-b) Si x B y C z M a N b Wherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
Further, the alloy component of the alloy powder comprises Fe 76 Si 7.5 B 7 C 4 Ni 1.5 Cr 3 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.54T, Hc is 1.7A/m, mu i @1k and 0.5V is 21400;
or a component thereof including Fe 75 Si 8 B 7 C 4 Mo 1 Cr 5 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.33T, Hc is 1.2A/m, mu i @1k and 0.5V is 38600;
or a component thereof including Fe 78 Si 6 B 8 C 3 Ni 3 Mn 2 The performances of the amorphous strip are shown in that Bs of the amorphous strip prepared by the components is 1.71T, and Hc is 3.6A/m,. mu.i @1k,0.5V at 8400;
or a component thereof including Fe 76 Si 9 B 7 C 5 Cr 3 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.42T, Hc is 1.5A/m, mu i @1k and 0.5V is 28500;
or a component thereof including Fe 78 Si 6 B 9 C 4 Cr 3 The performances of the amorphous strip prepared by the component are that Bs is 1.51T, Hc is 2.2A/m, mui @1k and 0.5V is 13600.
The preparation method of the finished product powder applies the powder coating method; wherein also include the following steps:
and S4, adding the lubricant into the obtained coating powder, and stirring and mixing the coating powder by a stirrer to obtain finished product powder.
The preparation method of the finished magnetic powder core applies the preparation method of the finished powder; wherein also include the following steps:
s5, processing, sintering, annealing and curing the obtained finished product powder to obtain a magnetic powder core base block;
and S6, performing surface coating treatment on the magnetic powder core base block to obtain the finished magnetic powder core.
The invention has the beneficial effects that:
the method aims at adopting a non-corrosive treatment method to carry out corresponding powder insulation coating application so as to effectively improve the problem of cost and the problem of environmental pollution, does not need an acid solution to carry out corresponding corrosive reaction, can effectively avoid the change of the amorphous structure on the surface of the powder particles caused by uneven coating and excessive local heat release of the powder particles, and avoids the phenomena of magnetic permeability reduction and other magnetic property deterioration of the amorphous powder.
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.
A method for preparing amorphous magnetic powder core, which comprises the following steps:
s1, smelting the alloy raw materials in a smelting furnace to prepare a master alloy;
s2, preparing corresponding amorphous powder from the master alloy;
s3, mixing the amorphous powder according to a ratio to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;
s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;
and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.
In step S1, the present invention provides a master alloy for Fe-based amorphous alloy, the composition expression of which is Fe (100-x-y-z-a-b) Si x B y C z M a N b Wherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
The mother alloy for the iron-based amorphous alloy may be based on Fe 78 Si 9 B 13 The amorphous alloy is manufactured by adding elements to change the internal atomic arrangement of the amorphous alloy.
Specifically, the Fe is added to the mixture according to the preparation requirement 78 Si 9 B 13 On the basis of the components of the alloy, the alloy is designed by adding and replacing elements such as C, Ni, Mo, Cr, Mn and the like; calculating the weight ratio of each required element according to the designed component atomic ratio, and further calculating the weight of each raw material required by each element added; and calculating the weight of each required raw material and smelting to prepare the master alloy for the iron-based amorphous alloy.
Example 1:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe 76 Si 7.5 B 7 C 4 Ni 1.5 Cr 3 The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic permeability of 60, the direct current magnetic biasing capacity of 55%, the loss of 310mw/cm3@50k, and 100 mT.
Example 2:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe 75 Si 8 B 7 C 4 Mo 1 Cr 5 The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic conductivity of 60 and the direct current magnetic biasing capacity of 51%; the loss is 186mw/cm3@50k,100 mT.
Example 3:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe 78 Si 6 B 8 C 3 Ni 3 Mn 2 The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 10% of 100-150 meshes, 50% of 150-200 meshes, 30% of 200-270 meshes and 10% of 270-400 meshes, the magnetic permeability of the prepared magnetic powder core is 60, and the direct-current magnetic biasing capacity is 64%; the loss was 362mw/cm3@50k,100 mT.
Example 4:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe 76 Si 9 B 7 C 5 Cr 3 The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic permeability of 60, the direct current magnetic biasing capacity of 54%, the loss of 280mw/cm3@50k, and 100 mT.
Example 5:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe 78 Si 6 B 9 C 4 Cr 3 The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, and the magnetic powder core prepared by the method has the magnetic conductivity of 60, the direct current magnetic biasing capacity of 56%, the loss of 275mw/cm3@50k, and 100 mT.
Conventionally, the performance of the amorphous alloy is usually embodied by the performance of the amorphous strip, and the corresponding amorphous strip prepared by the corresponding iron-based amorphous alloy master alloy is embodied as follows:
| alloy composition | Bs(T) | Hc(A/m) | μi@1k,0.5V |
| Fe 76 Si 7.5 B 7 C 4 Ni 1.5 Cr 3 | 1.54 | 1.7 | 21400 |
| Fe 75 Si 8 B 7 C 4 Mo 1 Cr 5 | 1.33 | 1.2 | 38600 |
| Fe 78 Si 6 B 8 C 3 Ni 3 Mn 2 | 1.71 | 3.6 | 8400 |
| Fe 76 Si 9 B 7 C 5 Cr 3 | 1.42 | 1.5 | 28500 |
| Fe 78 Si 6 B 9 C 4 Cr 3 | 1.51 | 2.2 | 13600 |
Example 6:
in step S2, the master alloy is further rapidly cooled to perform the corresponding amorphous powder preparation, wherein the rapid cooling method may include: the rapid cooling amorphous preparation method in the prior art comprises a single-roller rapid quenching method, a double-roller rapid quenching method, a water atomization method, an air atomization method, a water-air atomization combination method and the like.
By the single-roller rapid quenching method or the double-roller rapid quenching method, the mother alloy can be prepared into corresponding amorphous strips, and the prepared amorphous strips are mechanically crushed to prepare corresponding flaky first amorphous powder.
By means of the water atomization method, the gas atomization method, the water-gas atomization combination method and the like, the second amorphous powder with the corresponding similar spherical shape can be prepared from the master alloy.
In the step S2, the method includes the following steps:
s2-1, preparing first amorphous powder in a flaky state by using the mother alloy for the iron-based amorphous alloy;
s2-2, preparing a second amorphous powder in a spheroidal state by using the mother alloy for the iron-based amorphous alloy.
In step S3, the present invention mixes the first amorphous powder and the second amorphous powder to obtain an amorphous mixed powder, and the mixing method of the amorphous mixed powder is selected as follows:
the mesh range of the first amorphous powder is-100 to +270 meshes, and the mesh range of the second amorphous powder is-200 to +400 meshes. 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%. The amorphous mixed powder with good flowability is obtained by adjusting the proportion of the first amorphous powder and the second amorphous powder which are arranged in different mesh numbers, and the main parameters of good powder flowability are as follows: bulk density, tap density, angle of repose, degree of dispersion, etc.; the comprehensive index is a fluidity index which can be tested by using a Dandongbaote powder characteristic analyzer; the fluidity index is above 70, the good level is, and the larger the fluidity index is, the better the fluidity is; the powder with good fluidity has smaller resistance among powder particles in the molding process, thereby being beneficial to molding; under the same pressure condition, the magnetic powder core prepared by the method has higher density and better product performance.
The first amorphous powder and the second amorphous powder with different types of appearances are mixed and applied, so that the flowability and the forming density of the powder are effectively improved, and the direct current bias capability of the amorphous magnetic powder core prepared by applying the amorphous magnetic powder core is further improved.
The same production conditions were used to prepare the following products: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 7:
in step S4, a first insulation coating method is applied to perform insulation coating processing on the amorphous mixed powder, the first insulation coating method including the steps of:
s4-01, mixing inorganic powder by ultrasonic waves and attaching the inorganic powder to the amorphous mixed powder to obtain amorphous attached powder;
and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.
The inorganic powder is SiO 2 Or Fe 2 O 3 And the like inorganic oxides; the mesh number of the inorganic powder is more than 8000 meshes, so that the ultrafine effect is achieved, and the particles of the inorganic powder approach to the nano level.
Specifically, the amorphous mixed powder of each mesh is mixed and uniformly mixed by a V-shaped mixer, and the V-shaped mixer is used for outputting ultrasonic waves by an ultrasonic vibrator during the mixing and stirring process of the amorphous mixed powder, so that the ultrafine inorganic powder has a certain adsorption capacity to uniformly adhere the inorganic powder to the amorphous mixed powder, thereby obtaining the amorphous adhered powder.
Mixing an alkali solution with the amorphous attached powder and fully reacting, wherein the alkali solution can be selected from a NaOH solution, and the reaction process comprises the following steps: SiO 2 2 +2NaOH＝Na 2 SiO 3 +H 2 O, stirring uniformly and fully reacting under the condition of normal temperature; adding a binder into the amorphous attaching powder which is fully reacted with the alkali solution to stir until the amorphous attaching powder is uniformly dried, so that the surface of the amorphous attaching powder is provided with Na 2 SiO 3 To obtain an amorphous coated powder.
The binder is a cohesive inorganic or organic binder; the adhesive is silicon resin, water glass or epoxy resin, and the addition amount of the adhesive is 0.2-2.5%.
The addition amount of the inorganic powder can be increased according to the performance requirement according to the content required by forming a single-layer insulating coating layer; the thickness of the attached insulating coating layer approaches to a single layer and approaches to complete attachment.
The first insulation coating method is applied by adopting a non-corrosive treatment method to carry out corresponding insulation coating application so as to effectively improve the problems of cost and environmental pollution, does not need acid solution to carry out corresponding corrosive reaction, can effectively avoid the change of the amorphous structure on the surface of the powder particles caused by nonuniform coating and excessive local heat release of the powder particles, and avoids the phenomena of magnetic permeability reduction and other magnetic property deterioration of amorphous finished powder.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 8:
preparing a master alloy for the Fe-based amorphous alloy containing Fe and Si based on the first and/or second amorphous powder; in step S4, a second insulation coating method is applied to perform insulation coating treatment, the second insulation coating method includes the following steps:
s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;
and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.
Specifically, the obtained amorphous mixed powder is subjected to a baking treatment in a rotary kiln to perform stress relief annealing; the rotary furnace is provided with a corresponding oxygen introducing mechanism and a corresponding turnover mechanism, oxygen-containing air is continuously introduced into the rotary furnace through the oxygen introducing mechanism, the amorphous mixed powder in the furnace is turned over through the turnover mechanism, the surface of the amorphous mixed powder is fully reacted with the oxygen-containing air, and the chemical reaction formula of the amorphous mixed powder relates to the formula; fe + O 2 ＝Fe 2 O 3 And Si + O 2 ＝SiO 2 Turning and stirring evenly for full reaction; so that an insulating coating layer with corresponding oxide is formed on the surface of the amorphous mixed powder to obtain coated powder.
According to the second insulation coating method, the insulation coating layer is generated in the insulation coating step by adopting hot air, so that the problems of production cost and environmental pollution are effectively solved; meanwhile, the quality of the insulating coating layer can be effectively improved; the influence of foreign substances introduced in the insulating and coating process on the magnetic performance of the prepared amorphous magnetic powder core is reduced.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of products.
Example 9:
in step S4, a third insulation coating method is applied to perform the insulation coating process, the third insulation coating method including the steps of:
and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix and form an insulating coating layer on the surface of the amorphous mixed powder to obtain the amorphous coated powder.
Adding the obtained amorphous mixed powder into a double-shaft stirrer, and adding a cohesive inorganic substance to stir until the mixture is uniform, so that an insulating coating layer is formed on the surface of the amorphous mixed powder, and amorphous coated powder is obtained; the adopted cohesive inorganic matter is a sodium silicate solution or inorganic silicon resin, preferably the sodium silicate solution, the modulus of the sodium silicate solution is preferably 2.5-3.5, the Baume degree is preferably 0.35-0.48, the ratio of the sodium silicate solution is 0.5-3.2%, the sodium silicate solution is diluted by a diluent, the ratio of the diluent is 1.2-6.5%, and the diluent can be selected from water, acetone and ethanol.
According to the third insulation coating method, the amorphous mixed powder is coated by the cohesive inorganic substance, and the amorphous mixed powder is used as the adhesive and the insulation coating agent, so that the production efficiency is effectively improved, the introduction of non-magnetic substances is reduced, the magnetic conductivity of the product is improved, and the magnetic performance of the product is optimized.
In step S5, the lubricant used in the above embodiments includes, but is not limited to, zinc stearate, paraffin wax, and barium stearate.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 10:
in the invention, a surface coating treatment method of an amorphous product is applied, which comprises the following steps:
(1) carrying out surface pretreatment on the amorphous product to form a pretreatment insulating layer on the surface of the amorphous product;
(2) carrying out preheating treatment on the amorphous product subjected to surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by the preheated amorphous product with self heat so as to form a roll coating on the pretreated insulating layer.
The second insulating material is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.
The thickness range of the pre-treatment insulating layer is 20-150 mu m, and preferably 30-80 mu m; the thickness range of the roller coating is 100-400 mu m, and preferably 150-250 mu m.
Wherein, in the step (1), the method comprises the following steps:
(1-01) heating the amorphous product to raise the temperature, wherein the heating temperature is 150-250 ℃;
(1-02) carrying out electrostatic spraying treatment on the heated and heated amorphous product by using first insulating powder through electrostatic spraying equipment so as to form the pretreated insulating layer on the surface of the amorphous product; the first insulating powder is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.
Example 11:
the present embodiment is different from the above embodiment 10 in that, in the step (1), it includes the following steps:
(1-11) spraying the amorphous product with a first insulating varnish by using a liquid spray gun; the first insulating paint is acetal insulating paint or phenolic insulating paint or epoxy insulating paint;
(1-21) baking and heating the sprayed amorphous product, wherein the baking and heating temperature is 100-150 ℃; so that the surface of the amorphous product is formed with the pretreatment insulating layer.
Specifically, the application principle of the amorphous product surface coating treatment method is as follows:
firstly, performing surface pretreatment on the amorphous product by using first insulating powder or first insulating paint to prepare a thin insulating pretreatment insulating layer on the surface of a rough amorphous product, so that the insulating property of the amorphous product is improved and the surface defects (such as residual holes) of the amorphous product are compensated to a certain extent; and then the amorphous product is subjected to roller coating treatment by using a second insulating material. Based on the premise that the amorphous product is preheated, the second insulating material in the material box can be adsorbed by the heated amorphous product in a roll coating mode to form a roll coating.
In the roll coating process, the amorphous product is in a rolling state in the material box, and the rolling speed of the amorphous product is controlled through the parameter and process adjustment of roll coating equipment, so that the uniformity of the roll coating formed by the amorphous product can be effectively controlled; the second insulating materials are intensively placed in a material box, so that the second insulating materials in the roll coating process are intensively arranged without scattering, the roll coating process basically does not consume the second insulating materials additionally, and raw materials are saved.
Compared with the prior art that the insulating coating treatment on the surface of the amorphous product is carried out by directly applying a spraying mode or directly applying a rolling coating mode, the scheme is based on the step-by-step processing application of the double-layer insulating coating, and the thickness and the uniformity of the insulating coating are controlled by adjusting the matching of the parameters of rolling coating equipment, and the surface quality of the insulating coating is improved.
Based on the application of the amorphous product surface coating treatment method, the spraying qualification rate of the amorphous product is effectively improved, and the surface quality of the insulating coating of the amorphous product is improved; meanwhile, the uniformity of the thickness of the insulating coating can be ensured, and the coating material is saved.
Then, in step S7, the surface coating treatment method for the amorphous product described above can be applied to perform the surface coating treatment on the magnetic powder core substrate.
Example 12:
based on the application of the prior art, the mother alloy for the iron-based amorphous alloy can also be processed and prepared into a corresponding magnetic core, and the processing steps are as follows:
【1】 Preparing a corresponding amorphous strip from the master alloy for the iron-based amorphous alloy;
【2】 Winding or superposing the amorphous strip, and annealing to obtain a magnetic core matrix;
【3】 And carrying out surface coating treatment on the magnetic core substrate.
Example 13:
the magnetic core substrate prepared by the step [ 2 ] of example 12 may be subjected to a surface coating treatment by the surface coating treatment method of the amorphous product described in the above example 10 or 11.
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. A powder coating method, comprising the steps of:
s1, preparing amorphous alloy powder, wherein the alloy component of the alloy powder comprises FeSiBCMN amorphous alloy, M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements;
s2, mixing and attaching inorganic powder to the alloy powder by ultrasonic waves to obtain attached powder;
and S3, mixing the alkaline solution with the attached powder, fully reacting, and drying to form an insulating coating layer on the surface of the attached powder, thereby obtaining the coated powder.
2. The powder coating method according to claim 1, wherein in step S1, the alloy powder is prepared by the following mesh ratio: 10-40% of-100 meshes to +150 meshes, 20-70% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +400 meshes; the mesh number of the inorganic powder is set to be more than 8000 meshes.
3. The powder coating method of claim 1, wherein the inorganic powder comprises SiO 2 In step S3, the reaction formula of the inorganic powder and the alkali solution is as follows: SiO 2 2 +2NaOH＝Na 2 SiO 3 +H 2 O。
4. The powder coating method according to claim 1, wherein in step S3, a binder is added to the adhered powder after sufficiently reacting with the alkali solution, and the mixture is stirred until uniform drying.
5. The powder coating method of claim 4, wherein the binder is an inorganic binder or an organic binder.
6. The powder coating method according to claim 4, wherein the binder is a silicone resin, a water glass, or an epoxy resin, and the amount of the binder added is 0.2 to 2.5%.
7. The powder coating method of any one of claims 1 to 6, wherein in step S1, the alloy component of the alloy powder comprises Fe (100-x-y-z-a-b) Si x B y C z M a N b Wherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
8. The powder cladding method of claim 7, wherein said alloy powder has an alloy composition comprising Fe 76 Si 7.5 B 7 C 4 Ni 1.5 Cr 3 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.54T, Hc is 1.7A/m, mu i @1k and 0.5V is 21400;
or a composition comprising Fe 75 Si 8 B 7 C 4 Mo 1 Cr 5 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.33T, Hc is 1.2A/m, mu i @1k and 0.5V is 38600;
or a component thereof including Fe 78 Si 6 B 8 C 3 Ni 3 Mn 2 The performances of the amorphous strip are represented as that Bs of the amorphous strip prepared by the component is 1.71T, Hc is 3.6A/m, mu i @1k and 0.5V is 8400;
or a component thereof including Fe 76 Si 9 B 7 C 5 Cr 3 The performance of the amorphous strip is represented by that Bs of the amorphous strip prepared by the component is 1.42T, Hc is 1.5A/m, mu i @1k and 0.5V is 28500;
or a component thereof including Fe 78 Si 6 B 9 C 4 Cr 3 The performances of the amorphous strip prepared by the component are that Bs is 1.51T, Hc is 2.2A/m, mui @1k and 0.5V is 13600.
9. A method of manufacturing a finished powder using the powder coating method of any one of claims 1 to 8; the method is characterized by further comprising the following steps:
and S4, adding the lubricant into the obtained coating powder, and stirring and mixing the coating powder by a stirrer to obtain finished product powder.
10. A method for preparing a magnetic powder core finished product, which applies the method for preparing the powder finished product as claimed in claim 9; the method is characterized by further comprising the following steps:
s5, carrying out treatment, sintering treatment, annealing treatment and curing treatment on the obtained finished product powder to obtain a magnetic powder core base block;
and S6, performing surface coating treatment on the magnetic powder core base block to obtain the finished magnetic powder core.
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