CN114974786A - Soft magnetic composite material and preparation method thereof, metal powder core and preparation method thereof, and molded inductor and preparation method thereof - Google Patents
Soft magnetic composite material and preparation method thereof, metal powder core and preparation method thereof, and molded inductor and preparation method thereof Download PDFInfo
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- CN114974786A CN114974786A CN202210703311.9A CN202210703311A CN114974786A CN 114974786 A CN114974786 A CN 114974786A CN 202210703311 A CN202210703311 A CN 202210703311A CN 114974786 A CN114974786 A CN 114974786A
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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
- H01F1/22—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 pressed, sintered, or bound together
- H01F1/24—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 pressed, sintered, or bound together the particles being insulated
- H01F1/26—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 pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
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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
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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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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- 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
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Abstract
The invention discloses a soft magnetic composite material, which comprises first soft magnetic metal powder, a first insulating coating material and airflow crushing granulation powder. The airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified. The first insulating coating material and/or the second insulating coating material in the soft magnetic composite material are/is uniformly dispersed, the soft magnetic composite material is used for preparing the metal powder core and the molded inductor, and the prepared molded inductor has high insulating resistance and initial permeability. Correspondingly, the invention also discloses a preparation method of the soft magnetic composite material, and the prepared soft magnetic composite material has the advantages of uniform dispersion of the first insulating coating material and/or the second insulating coating material, simple operation and lower cost. Correspondingly, the invention also discloses a metal powder core and a preparation method thereof, and a molded inductor and a preparation method thereof.
Description
Technical Field
The invention relates to the technical field of electrical elements, in particular to a soft magnetic composite material and a preparation method thereof, a metal powder core and a preparation method thereof, and a molded inductor and a preparation method thereof.
Background
The molded inductor is widely applied to various power electronic devices as one of key devices in the field of modern power electronics, and along with popularization and application of electric vehicles, internet of things, cloud servers, intelligent technologies and new-generation semiconductor materials, the molded inductor has higher and higher stability requirements, the use working condition of the molded inductor is more and more rigorous, and the thermal stability of the related molded inductor is required to be higher and higher, so that the improvement of the insulation resistance of the molded inductor is a core problem in the technical development of the products.
The molded inductor can be made directly from the soft magnetic composite material and the winding, or can be made by molding the metal powder core made of the soft magnetic composite material and the winding again. The soft magnetic composite material takes soft magnetic metal powder as a matrix and is coated with at least one insulating coating material, and has the advantages of low eddy current loss, high magnetic conductivity, low coercive force and high insulation resistance.
However, in actual production, the insulation resistance of the metal powder core and/or the die-pressed inductor may be lowered due to non-uniform dispersion of the insulating coating material in the soft magnetic material and poor coating of the soft magnetic metal powder. In order to solve the above problem, a conventional method is to increase the insulation resistance of the soft magnetic composite material by increasing the addition amount of the insulation coating material, however, this method may reduce the initial permeability of the soft magnetic composite material to some extent.
Disclosure of Invention
The technical problem to be solved by the embodiment of the invention is how to make the soft magnetic composite material have higher insulation resistance and initial permeability.
In order to solve the above technical problems, the present invention provides a soft magnetic composite material including a first soft magnetic metal powder, a first insulating clad material, and an air current crushing granulation powder.
The airflow crushing granulation powder comprises second soft magnetic metal powder and second insulating coating material, and the second insulating coating material is completely solidified.
In a possible implementation, the mean particle size of the gas stream breaking granulated powder is 1.1 times to 3.0 times the mean particle size of the first soft magnetic metal powder.
In a possible implementation, the mass ratio of the airflow breaking granulated powder to the first soft magnetic metal powder is 0.05-0.2.
In aIn a possible implementation, the first soft magnetic metal powder and the second soft magnetic metal powder are independently selected from carbonyl iron powder, reduced iron powder, atomized Fe (100-x-y) Si x Cr y At least one of powder (x ═ 3.5-6.5, y ═ 0.0-6.5), iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, Sandust powder, and HighFlux powder.
In a possible implementation, the first soft magnetic metal powder and the second soft magnetic metal powder are of the same composition.
In one possible implementation, the first insulating cladding material includes at least a first thermosetting resin, the second insulating cladding material includes at least a second thermosetting resin, and the first thermosetting resin and the second thermosetting resin are independently selected from at least one of an epoxy resin, a cyanate ester resin, and a novolac resin.
The soft magnetic composite material provided by the invention comprises airflow crushing granulation powder, the powder particle size of the airflow crushing granulation powder is small, the particle size is in normal distribution, and the particle sphericity is good, when the metal powder core and the die pressing inductor are prepared subsequently, the airflow crushing granulation powder can move along with pressure, so that the gaps among the first soft magnetic metal powder and/or the second soft magnetic metal powder are reduced, the problem that the first insulating coating material and/or the second insulating coating material are dispersed unevenly is solved, and the prepared metal powder core and the die pressing inductor have higher insulating resistance and initial magnetic conductivity. And because the second insulating coating material in the airflow crushing granulation powder used in the invention is completely cured, the crushing strength of the airflow crushing granulation powder can be improved, so that the airflow crushing granulation powder can uniformly bear temperature and pressure, and the uniform dispersion of the first insulating coating material and/or the second insulating coating material is further promoted.
Correspondingly, the invention also provides a preparation method of the soft magnetic composite material, which comprises the following steps:
and providing airflow crushing granulation powder, wherein the airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified.
And mixing the airflow crushing granulation powder, the first soft magnetic metal powder and the first insulating coating material to obtain the soft magnetic composite material.
In one possible implementation, a method for preparing airflow crushing granulated powder comprises the following steps:
and mixing the second insulating coating material and the second soft magnetic metal powder, and sequentially performing granulation treatment, complete solidification treatment and airflow crushing treatment to obtain airflow crushing granulation powder.
By the preparation method of the soft magnetic composite material, the first insulating coating material and/or the second insulating coating material in the prepared soft magnetic composite material are uniformly dispersed. The soft magnetic composite material prepared by the method is used for preparing the metal powder core and the die pressing inductor, and the prepared metal powder core and the die pressing inductor have higher insulation resistance and initial permeability.
In actual production, the preparation of the soft magnetic composite material may generate a tailing, which is equivalent to an intermediate product of the granulation process after the second insulating coating material and the second soft magnetic metal powder are mixed in the present invention. Therefore, the invention recycles the tailings and has lower cost.
Correspondingly, the invention also provides a metal powder core prepared from the soft magnetic composite material, which has higher insulation resistance and initial permeability.
Correspondingly, the invention also provides a preparation method of the metal powder core, which comprises the following steps:
and (3) sequentially performing granulation treatment and warm-pressing treatment on the soft magnetic composite material to obtain the metal powder core soft magnetic composite material.
The metal powder core prepared by the method has high insulation resistance and initial permeability.
Correspondingly, the invention also provides a molded inductor prepared from the soft magnetic composite material, which has higher insulation resistance and initial permeability.
Correspondingly, the invention also provides a preparation method of the molded inductor, which comprises the following steps:
and (3) granulating the soft magnetic composite material to obtain granulated powder of the soft magnetic composite material.
And placing the granulated powder of the soft magnetic composite material and the winding in a mould, and then carrying out warm pressing treatment to obtain the metal powder core.
The molded inductor prepared by the method has high insulation resistance and initial permeability.
Detailed Description
The present invention will be described in detail with reference to the following embodiments in order to make the above objects, features and advantages of the present invention more comprehensible. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein, as those skilled in the art will recognize without departing from the spirit and scope 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 should be noted that the term "complete curing" is a general term in the art, and complete curing refers to a certain degree of crosslinking reaction between polymer resins, and does not mean that all reactive groups of the polymer resins are reacted.
A soft magnetic composite material includes a first soft magnetic metal powder, a first insulating coating material, and an airflow-breaking granulated powder. The airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified.
The soft magnetic composite material provided by the invention comprises airflow crushing granulation powder, the powder particle size of the airflow crushing granulation powder is small, the particle size is in normal distribution, and the particle sphericity is good, when the metal powder core and the die pressing inductor are prepared subsequently, the airflow crushing granulation powder can move along with pressure, so that the gaps among the first soft magnetic metal powder and/or the second soft magnetic metal powder are reduced, the problem that the first insulating coating material and/or the second insulating coating material are dispersed unevenly is solved, and the prepared metal powder core and the die pressing inductor have higher insulating resistance and initial magnetic conductivity. And because the second insulating coating material in the airflow crushing granulation powder used in the invention is completely cured, the airflow crushing granulation powder has higher crushing strength, so that the airflow crushing granulation powder can uniformly bear temperature and pressure, and the first insulating coating material and/or the second insulating coating material are/is further promoted to be uniformly dispersed.
In a possible implementation, the mean particle size of the gas stream breaking granulated powder is 1.1 to 3.0 times the mean particle size of the first soft magnetic metal powder.
Under the proportion, the airflow crushing granulation powder can slow down the flow of the first insulating coating material and/or the second insulating coating material and uniformly bear the pressing force, so that the problem that when the traditional soft magnetic composite material is in warm pressing, the thickness of the first insulating coating material and/or the second insulating coating material between powder contact interfaces of the first soft magnetic metal powder and/or the second soft magnetic metal powder is thin, and the gap position between the first soft magnetic metal powder and/or the second soft magnetic metal powder is filled with the insulating coating material is solved, and the insulating coating material is uniformly dispersed in the soft magnetic composite material.
In a possible implementation, the mass ratio of the airflow breaking granulated powder to the first soft magnetic metal powder is 0.05-0.2. With the increase of the addition amount of airflow crushing granulation powder, the insulation resistance of a metal powder core and/or a die pressing inductor made of the soft magnetic composite material is increased, and the initial magnetic permeability is reduced. When the mass ratio of the airflow crushing granulation powder to the first soft magnetic metal powder is 0.05-0.2, the comprehensive performance of the metal powder core and/or the die pressing inductor prepared from the soft magnetic composite material is better.
In one possible implementation, the first soft magnetic metal powder and the second soft magnetic metal powder are each independently selected from carbonyl iron powder, reduced iron powder, atomized iron powder, and atomized Fe (100-x-y) Si x Cr y Powder (x ═ 3.5-6.5, y ═ 0.0-6.5), iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, Sandust powder, and HigAt least one of hFlux powder.
In a possible implementation, the first soft magnetic metal powder and the second soft magnetic metal powder are of the same composition. The first soft magnetic metal powder and the second soft magnetic metal powder are the same in composition, so that other property changes of the metal powder core and/or the die pressing inductor made of the soft magnetic composite material due to the addition of the airflow crushing granulation powder can be reduced.
In one possible implementation, the first insulating cladding material includes at least a first thermosetting resin. In addition, the first insulating coating material also comprises a curing agent matched with the first thermosetting resin, and the first thermosetting resin and the curing agent jointly form a first thermosetting resin system.
In one possible implementation, the second insulating coating material includes at least a second thermosetting resin. In addition, the second insulating coating material also comprises a curing agent matched with the second thermosetting resin, and the second thermosetting resin and the curing agent jointly form a second thermosetting resin system.
In one possible implementation, the first thermosetting resin and the second thermosetting resin are each independently selected from at least one of an epoxy resin, a cyanate ester resin, and a novolac resin.
In one possible implementation, the first thermosetting resin and the second thermosetting resin are the same in composition.
In one possible implementation, the first insulating cladding material is a first thermosetting resin system and the second insulating cladding material is a second thermosetting resin system. The first insulating coating material and/or the second insulating coating material may further include inorganic coating materials such as mineral powder, silicate, and phosphate. However, compared with organic/inorganic coating, when the insulation coating mode in the soft magnetic composite material is only organic coating, the metal powder core and/or the die pressing inductor prepared from the soft magnetic composite material have better magnetic characteristics.
The first insulating coating material and/or the second insulating coating material in the soft magnetic composite material provided by the invention are uniformly dispersed, and the metal powder core and/or the die pressing inductor prepared from the soft magnetic composite material have higher insulating resistance and initial permeability.
Correspondingly, the invention also provides a preparation method of the soft magnetic composite material, which comprises the following steps:
and providing airflow crushing granulation powder, wherein the airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified.
And mixing the airflow crushing granulation powder, the first soft magnetic metal powder and the first insulating coating material to obtain the soft magnetic composite material.
The first insulating coating material and/or the second insulating coating material in the soft magnetic composite material prepared by the method are uniformly dispersed. The soft magnetic composite material prepared by the method is used for preparing the metal powder core and the die pressing inductor, and the prepared metal powder core and the die pressing inductor have higher insulation resistance and initial permeability. In one possible implementation, a method for preparing airflow crushing granulated powder comprises the following steps: and mixing the second insulating coating material and the second soft magnetic metal powder, and sequentially performing granulation treatment, complete solidification treatment and airflow crushing treatment to obtain airflow crushing granulation powder.
The airflow crushing treatment and the complete curing treatment enable the prepared airflow crushing granulation powder to enable the soft magnetic composite material, the metal powder core prepared from the soft magnetic composite material and the die pressing inductor to have the advantages of good mechanical property, high density and surface gloss.
In one possible implementation, the second soft magnetic metal powder is subjected to a surface insulation treatment before the step of mixing the second insulation coating material and the second soft magnetic metal powder.
In one possible implementation, the first soft magnetic metal powder is subjected to a surface insulation treatment before the step of mixing the airflow-broken granulated powder, the first soft magnetic metal powder, and the first insulation coating material.
The current path can be further blocked by carrying out surface insulation treatment on the first soft magnetic metal powder and/or the second soft magnetic metal powder, so that the eddy current loss of the soft magnetic composite material is effectively reduced, and the initial magnetic conductivity of the soft magnetic composite material is improved.
The soft magnetic composite material prepared by the method is used for preparing the metal powder core and the die pressing inductor, and the prepared metal powder core and the die pressing inductor have higher insulation resistance and initial permeability. According to the test data, the insulation resistance of the prepared metal powder core is more than or equal to 10(M omega @100V,3s), and the initial magnetic permeability of the metal powder core is more than or equal to 33.0 (H/M).
Correspondingly, the invention also provides a metal powder core prepared from the soft magnetic composite material, which has higher insulation resistance and initial permeability.
Correspondingly, the invention also provides a preparation method of the metal powder core, which comprises the following steps:
and (3) sequentially performing granulation treatment and warm-pressing treatment on the soft magnetic composite material to obtain the metal powder core soft magnetic composite material. The temperature of the warm-pressing treatment is at least a temperature at which the first insulating coating material and the second insulating coating material can be set.
The metal powder core prepared by the method has high insulation resistance and initial permeability.
Correspondingly, the invention also provides a molded inductor prepared from the soft magnetic composite material, which has higher insulation resistance and initial permeability.
Correspondingly, the invention also provides a preparation method of the molded inductor, which comprises the following steps:
and granulating the soft magnetic composite material to obtain granulated powder of the soft magnetic composite material.
And placing the granulated powder of the soft magnetic composite material and the winding in a mould, and then carrying out warm pressing treatment to obtain the metal powder core.
The molded inductor prepared by the method has high insulation resistance and initial permeability.
With reference to the above implementation contents, in order to make the technical solution of the present invention more specific and clear and easy to understand, the technical solution of the present invention is exemplified, but it should be noted that the contents to be protected by the present invention are not limited to the following embodiments 1 to 8.
Example 1
150g of carbonyl iron powder having an average particle size of 6.2 μm was subjected to surface insulation treatment using 0.45g of phosphoric acid and 7.5g of acetone to obtain a first soft magnetic metal powder.
150g of carbonyl iron powder having an average particle size of 6.2 μm was subjected to surface insulation treatment using 0.45g of phosphoric acid and 7.5g of acetone to obtain a second soft magnetic metal powder. 3g of bisphenol A cyanate ester and 0.75g of bisphenol A epoxy resin were mixed to obtain a first insulating coating material. 3g of bisphenol A cyanate ester and 0.75g of bisphenol A epoxy resin were mixed to obtain a second insulating coating material.
30g of phosphated carbonyl iron powder, 0.75g of second insulating coating material and 3g of acetone are mixed and then are subjected to granulation treatment in sequence to obtain granulation powder with the granularity of-60 meshes to +300 meshes.
And drying the granulated powder, and then carrying out complete curing treatment at 180 ℃, wherein the time of the complete curing treatment is 60min, so as to obtain the dried granulated powder.
And carrying out airflow crushing treatment on the dried granulated powder to obtain airflow crushed granulated powder with the average particle size of 8 mu m.
100g of the first soft magnetic metal powder, 2.5g of the first insulating coating material, 5g of the airflow crushing granulation powder, and 10g of acetone were mixed to obtain a soft magnetic composite material.
And (4) granulating the soft magnetic composite material to obtain granulated powder of the soft magnetic composite material.
The granulated powder of the soft magnetic composite material was subjected to a drying treatment, and then subjected to a warm-pressing treatment (180 ℃, 150 seconds, warm-pressing force of 2T) to obtain a sample of a ring-shaped metal powder core having an outer diameter of 14mm by an inner diameter of 8mm by a height of 3 mm.
Example 2
Example 2 differs from example 1 in that 10g of air-stream broken granulated powder was added.
Example 3
Example 3 differs from example 1 in that 15g of air-stream broken granulated powder was added.
Example 4
Example 4 differs from example 1 in that 20g of air-stream broken granulated powder was added.
Example 5
Example 5 differs from example 3 in that the average particle size of the airflow disruption granulated powder was 7 μm.
Example 6
Example 6 differs from example 3 in that the average particle size of the airflow disruption granulated powder was 10.4 μm.
Example 7
Example 7 differs from example 3 in that the average particle size of the airflow disruption granulated powder was 12.2. mu.m.
Example 8
Example 8 differs from example 3 in that the average particle size of the airflow disruption granulated powder was 15 μm.
Comparative example 1
Comparative example 1 differs from example 1 in that 0g of air-stream broken granulated powder was added.
Comparative example 2
Comparative example 2 differs from example 1 in that 2g of air-stream broken granulated powder was added.
Comparative example 3
Comparative example 3 differs from example 1 in that 30g of air-stream broken granulated powder was added.
Comparative example 4
Comparative example 4 is different from example 3 in that the average particle diameter of the airflow disruption granulated powder was 20.2 μm.
And (3) performance testing:
the annular metal powder core samples in comparative examples 1 to 4 and examples 1 to 8 were subjected to a full curing treatment (180 ℃, 60min), after which insulation resistance and initial permeability tests were performed:
the insulation resistance test in the invention uses a voltage-withstanding tester chroma19053 to test, the voltage is set as 100V, and the test time is 3 s;
the initial permeability of the invention is tested by a soft magnetic direct current tester MATS-2010 SD.
The test results are shown in tables 1 and 2.
TABLE 1 Performance test of comparative examples 1 to 3 and examples 1 to 4
TABLE 2 Performance test of comparative example 4 and examples 3, 5-8
As can be seen from table 1, examples 1 to 4 have superior insulation resistance and initial permeability; compared with the comparative examples 1-2, the addition amount of airflow crushing granulation powder is less, and the insulation resistance is lower; in comparative example 3, the initial permeability was decreased more because the addition amount of the airflow-crushing granulated powder was larger. In summary, the optimum mass ratio of the airflow breaking granulated powder to the first soft magnetic metal powder is 0.05-0.2.
As can be seen from table 2, example 3 and examples 5 to 8 had superior insulation resistance and initial permeability; when the ratio of the average particle size of the airflow crushing granulation powder to the average particle size of the first soft magnetic metal powder is 3.2, the insulation resistance is significantly reduced, and the initial magnetic permeability is also reduced more.
The technical features of the above embodiments can be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the above embodiments are not described, but should be considered as the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above examples only show some embodiments of the present invention, and the description thereof is more specific and detailed, but not construed 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 should be subject to the appended claims.
Claims (12)
1. A soft magnetic composite material, comprising a first soft magnetic metal powder, a first insulating coating material and an air flow crushing granulation powder;
the airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified.
2. The soft magnetic composite material according to claim 1, wherein the mean particle size of the jet-broken granulated powder is 1.1 times to 3.0 times the mean particle size of the first soft magnetic metal powder.
3. A soft magnetic composite material according to claim 1, wherein the mass ratio of the airflow disruption granulated powder to the first metallic soft magnetic powder is 0.05-0.2.
4. The soft magnetic composite material according to claim 1, wherein the first soft magnetic metal powder and the second soft magnetic metal powder are independently selected from carbonyl iron powder, reduced iron powder, atomized Fe (100-x-y) Si x Cr y At least one of powder (x ═ 3.5-6.5, y ═ 0.0-6.5), iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, Sandust powder, and HighFlux powder.
5. Soft magnetic composite material according to claim 1 or 4, characterized in that the composition of the first and second soft magnetic metal powder is the same.
6. The soft magnetic composite material according to claim 1, wherein the first insulating clad material includes at least a first thermosetting resin;
the second insulating coating material at least comprises a second thermosetting resin;
the first thermosetting resin and the second thermosetting resin are independently selected from at least one of epoxy resin, cyanate ester resin and phenol novolac resin.
7. A method for the preparation of a soft magnetic composite material according to any of claims 1 to 6, characterized in that it comprises the following steps:
providing airflow crushing granulation powder, wherein the airflow crushing granulation powder comprises second soft magnetic metal powder and a second insulating coating material, and the second insulating coating material is completely solidified; and
and mixing the airflow crushing granulation powder, the first soft magnetic metal powder and the first insulating coating material to obtain the soft magnetic composite material.
8. A method for preparing soft magnetic composite material according to claim 7, characterized in that the method for preparing airflow crushing granulation powder comprises the following steps:
and mixing the second insulating coating material and the second soft magnetic metal powder, and sequentially performing granulation treatment, complete solidification treatment and airflow crushing treatment to obtain airflow crushing granulated powder.
9. A metal powder core, characterized in that it is made of a soft magnetic composite material according to any of claims 1-6.
10. A preparation method of a metal powder core is characterized by comprising the following steps:
the soft magnetic composite material according to any one of claims 1 to 6 is subjected to a granulation treatment and a warm-pressing treatment in this order to obtain a metal powder core.
11. An embossed inductor made from the soft magnetic composite material of any of claims 1-6.
12. A preparation method of a molded inductor is characterized by comprising the following steps:
granulating the soft magnetic composite material of any one of claims 1 to 6 to obtain granulated powder of the soft magnetic composite material; and
and placing the granulated powder of the soft magnetic composite material and the winding in a mould, and then carrying out warm pressing treatment to obtain the metal powder core.
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| CN115440499A (en) * | 2022-09-22 | 2022-12-06 | 昆山玛冀电子有限公司 | Inductor and manufacturing method thereof |
| WO2024087621A1 (en) | 2022-10-24 | 2024-05-02 | 横店集团东磁股份有限公司 | Rare earth soft magnetic powder and preparation method therefor, and soft magnetic composite material and preparation method therefor |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115440499A (en) * | 2022-09-22 | 2022-12-06 | 昆山玛冀电子有限公司 | Inductor and manufacturing method thereof |
| WO2024087621A1 (en) | 2022-10-24 | 2024-05-02 | 横店集团东磁股份有限公司 | Rare earth soft magnetic powder and preparation method therefor, and soft magnetic composite material and preparation method therefor |
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