CN117577437A - Composite magnetic powder and inductor - Google Patents
Composite magnetic powder and inductor Download PDFInfo
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- CN117577437A CN117577437A CN202210450300.4A CN202210450300A CN117577437A CN 117577437 A CN117577437 A CN 117577437A CN 202210450300 A CN202210450300 A CN 202210450300A CN 117577437 A CN117577437 A CN 117577437A
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- 239000002131 composite material Substances 0.000 title claims abstract description 25
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- 238000000034 method Methods 0.000 claims abstract description 29
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- 229910000863 Ferronickel Inorganic materials 0.000 claims description 3
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- SNKMVYBWZDHJHE-UHFFFAOYSA-M lithium;dihydrogen phosphate Chemical compound [Li+].OP(O)([O-])=O SNKMVYBWZDHJHE-UHFFFAOYSA-M 0.000 description 1
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- 235000012239 silicon dioxide Nutrition 0.000 description 1
- AJPJDKMHJJGVTQ-UHFFFAOYSA-M sodium dihydrogen phosphate Chemical compound [Na+].OP(O)([O-])=O AJPJDKMHJJGVTQ-UHFFFAOYSA-M 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- 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
-
- 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
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
- H01F27/36—Electric or magnetic shields or screens
- H01F27/366—Electric or magnetic shields or screens made of ferromagnetic material
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Soft Magnetic Materials (AREA)
Abstract
The application discloses a preparation method of composite magnetic powder. The method comprises the following steps: acquiring first magnetic powder and second magnetic powder, wherein the particle size distribution of the first magnetic powder is different from the particle size distribution of the second magnetic powder; performing a first pre-treatment operation on the first magnetic powder to obtain a first target powder; performing a second pre-treatment operation on the second magnetic powder to obtain a second target powder; mixing the first target powder and the second target powder based on a preset mass ratio to obtain the composite magnetic powder.
Description
Technical Field
The application relates to the field of electronic information, in particular to composite magnetic powder and an inductor prepared based on the composite magnetic powder.
Background
With the gradual development and mutual fusion of network technology, computer technology, communication technology and artificial intelligence technology, humans began to enter the fourth industrial revolution. The main feature of this age is that people-to-people, object-to-object, and person-to-object establish tight connections and information interactions. The complex connection depends on the transmission, communication and processing of the information by the hardware system, and can be a transmitting end, a receiving end and a cloud end of the information, and the key of the intelligent hardware is a chip and related components.
The molded inductor is used as one of the main passive elements around the chip and is widely applied to various intelligent hardware systems, such as smart phones, smart televisions, intelligent home appliances, tablet computers, notebook computers, various communication terminals, servers and the like, and has the main functions of electromagnetic signal and energy conversion, storage and filtering. The molded inductor is composed of a coil winding and a magnetic core, wherein the coil is preset in a mold, the free space inside and around the winding is filled with magnetic powder and is molded by pressing, and then a molded block is completely solidified, so that the molded inductor has excellent EMI interference resistance and a completely closed magnetic structure.
The magnetic powder for manufacturing the molded inductor can be mixed powder of soft magnetic metal powder and resin, and the molded block can shrink in volume in the complete curing process after molding, so that cracking is caused, and the final product is affected.
Disclosure of Invention
The technical problem to be solved by the embodiment of the application is that the molded inductor is cracked during preparation.
In order to solve the technical problems, the application provides a preparation method of composite magnetic powder. The composite magnetic powder can be used for preparing inductors. The method comprises the following steps: acquiring first magnetic powder and second magnetic powder, wherein the particle size distribution of the first magnetic powder is different from that of the second magnetic powder; performing a first pre-treatment operation on the first magnetic powder to obtain a first target powder; performing a second pre-treatment operation on the second magnetic powder to obtain a second target powder; and mixing the first target powder and the second target powder based on a preset mass ratio to obtain the composite magnetic powder.
In one possible implementation, the first magnetic powder has a particle size distribution of-50 mesh to +x mesh and the second magnetic powder has a particle size distribution of-X mesh, wherein X is between 100 and 200.
In one possible implementation, the first preprocessing includes: heating the first magnetic powder to a first temperature and preserving heat for a first period of time.
In one possible implementation, the first temperature is 50-90 ℃ and the first period of time is 0.1-2h.
In one possible implementation, the second preprocessing includes: heating the second magnetic powder to a second temperature and maintaining the temperature for a second period of time.
In one possible implementation, the second temperature is between 100 ℃ and 190 ℃ and the second time period is between 0.5 and 2 hours.
In a possible implementation, the preset mass ratio is a first mass of the first target powder: the second mass of the second target powder is 20:1-4:1.
In one possible implementation, the obtaining the first magnetic powder and the second magnetic powder includes: providing a soft magnetic metal powder and a resin composition; uniformly mixing the soft magnetic metal powder and the resin composition to obtain an intermediate mixture; performing granulation operation on the intermediate mixture to obtain granulated powder; screening the granulated powder to obtain the first magnetic powder and the second magnetic powder.
In one possible implementation, the soft magnetic metal powder includes at least one of: carbonyl iron powder, reduced iron powder, atomized iron powder, ferrosilicon alloy powder, ferrosilicon aluminum alloy powder, ferrosilicon chromium alloy powder, ferronickel alloy powder, iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, and permalloy soft magnetic alloy powder; the resin composition includes a matrix resin and a curing agent for the matrix resin; the matrix resin comprises at least one of the following: epoxy resin and its modified product, polyester resin and its modified product, vinyl ester resin and its modified product, bismaleimide resin and its modified product, polyimide resin and its modified product, cyanate ester resin and its modified product, and silicone resin and its modified product.
The present application also provides an inductor prepared based on the composite magnetic powder prepared by the method as described above.
By implementing the application, the method has the following beneficial effects: the volume shrinkage rate of the molded inductor after curing is less than or equal to 0.1% by adjusting the curing state of the powder by utilizing the differential curing shrinkage rate of the composite powder with different curing states under the curing condition, so as to ensure that the appearance of the molded inductor after curing is consistent with that before curing.
Drawings
FIG. 1 is an exemplary flow chart of a method of preparing a composite magnetic powder according to some embodiments of the present application;
FIG. 2 is an exemplary flow chart of a method of preparing a first magnetic powder and a second magnetic powder according to some embodiments of the present application;
Detailed Description
In order to make the above objects, features and advantages of the present application more comprehensible, embodiments accompanied with figures are described in detail below. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. This application is, however, susceptible of embodiment in many other forms than those described herein and similar modifications can be made by those skilled in the art without departing from the spirit of the application, and therefore the application is not to be limited to the specific embodiments disclosed below.
It will be understood that when an element is referred to as being "fixed to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like are used herein for illustrative purposes only.
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 application belongs. The terminology used herein in the description of the application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.
The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
Some embodiments of the application disclose a method for preparing a composite magnetic powder. The method is described with reference to fig. 1. Fig. 1 is an exemplary flow chart of a method of preparing a composite magnetic powder according to some embodiments of the present application. As shown in fig. 1, the process 100 may include the following operations.
In step 110, a first magnetic powder and a second magnetic powder are obtained.
In some embodiments, the first magnetic powder particle size distribution and the second magnetic powder particle size distribution are different. The particle size distribution of the first magnetic powder is-50 meshes to +X meshes, and the particle size distribution of the second magnetic powder is-X meshes. X may be between 100 and 200. Alternatively or preferably, X may be between 110 and 190. Alternatively or preferably, X may be between 120-180. Alternatively or preferably, X may be between 130-170. Alternatively or preferably, X may be between 140-160. Alternatively or preferably, X may be 150.
In some embodiments, the first magnetic powder and the second magnetic powder may be obtained based on the same process flow. For example, the first magnetic powder and the second magnetic powder may be obtained based on sieving the same raw material powder with different particle sizes. The raw material powder may be a granular powder obtained by granulating a homogeneous mixture of a soft magnetic metal powder and a resin composition. For a specific description reference may be made to the part of the description of fig. 2.
Step 120, performing a first pretreatment operation on the first magnetic powder to obtain a first target powder.
In some embodiments, the first pretreatment operation may include heating the first magnetic powder to a first temperature and maintaining the first temperature for a first period of time. The first temperature may be 50 ℃ to 90 ℃. Alternatively or preferably, the first temperature may be 55 ℃ to 85 ℃. Alternatively or preferably, the first temperature may be 60 ℃ to 80 ℃. Alternatively or preferably, the first temperature may be 65 ℃ to 75 ℃. Alternatively or preferably, the first temperature may be 70 ℃. The first period of time may be 0.1-2.0 hours. Alternatively or preferably, the first period of time may be 0.2-1.8 hours. Alternatively or preferably, the first period of time may be 0.4-1.6 hours. Alternatively or preferably, the first period of time may be 0.6-1.4 hours. Alternatively or preferably, the first period of time may be 0.8-1.2 hours. Alternatively or preferably, the first period of time may be 1 hour. In some embodiments, the first pretreatment operation may be accomplished using an apparatus having heating and warming functions. For example, the first magnetic powder may be placed in an oven, and the heating and insulating operation may be performed by using the oven. The product obtained after the first magnetic powder is subjected to the first pretreatment operation may be designated as the first target powder.
And step 130, performing a second pretreatment operation on the second magnetic powder to obtain a second target powder.
In some embodiments, the second pretreatment operation may include heating the second magnetic powder to a second temperature and maintaining the temperature for a second period of time. The second temperature may be from 100 ℃ to 190 ℃. Alternatively or preferably, the second temperature may be 110 ℃ to 188 ℃. Alternatively or preferably, the second temperature may be 120 ℃ to 186 ℃. Alternatively or preferably, the second temperature may be 130 ℃ to 184 ℃. Alternatively or preferably, the second temperature may be 140 ℃ to 182 ℃. Alternatively or preferably, the second temperature may be 150 ℃ to 180 ℃. Alternatively or preferably, the second temperature may be 160 ℃ to 170 ℃. The second period of time may be 0.5-2.0 hours. Alternatively or preferably, the second period of time may be 0.6-1.8 hours. Alternatively or preferably, the second period of time may be 0.7-1.6 hours. Alternatively or preferably, the second period of time may be 0.8-1.4 hours. Alternatively or preferably, the second period of time may be 0.9-1.2 hours. Alternatively or preferably, the second period of time may be 1 hour. The second pretreatment operation may be similarly or identically performed by using an apparatus having heating and heat-retaining functions. For example, the second magnetic powder may also be placed in an oven, with the oven being used for heating and maintaining the temperature. The product obtained after the second magnetic powder is subjected to the second pretreatment operation may be designated as the second target powder. .
And step 140, mixing the first target powder and the second target powder based on a preset mass ratio to obtain the composite magnetic powder.
In some embodiments, the preset mass ratio may be a ratio between the mass of the first target powder and the mass of the second target powder. In some embodiments, the preset mass ratio may be 20:1-4:1. Alternatively or preferably, the preset mass ratio may be 18:1-6:1. Alternatively or preferably, the preset mass ratio may be 16:1-7:1. Alternatively or preferably, the preset mass ratio may be 14:1-8:1. Alternatively or preferably, the preset mass ratio may be 12:1-9:1. Alternatively or preferably, the preset mass ratio may be 10:1. In some embodiments, the mixing of the first target powder and the second target powder may be achieved using a mixing device, such as a mixer.
It should be noted that the above description of the steps in fig. 1 is only for illustration and description, and does not limit the application scope of the present specification. Various modifications and changes to the steps of fig. 1 may be made by those skilled in the art under the guidance of this specification. However, such modifications and variations are still within the scope of the present description. For example, step 120 and step 130 may be performed simultaneously, or the order of execution may be interchanged.
Fig. 2 is an exemplary flow chart of a method of obtaining a first magnetic powder and a second magnetic powder according to some embodiments of the present application. As shown in fig. 2, the process 200 may include the following steps.
At step 210, a soft magnetic metal powder and a resin composition are obtained.
In some embodiments, the soft magnetic metal powder may include, but is not limited to, one of carbonyl iron powder, reduced iron powder, atomized iron powder, ferrosilicon powder, ferronickel powder, iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, permalloy soft magnetic alloy powder, or any combination thereof. In some embodiments, the soft magnetic metal powder may be insulation treated, for example, the soft magnetic metal powder may be film-formed to form an insulation layer on the surface. For example, the film forming process may be a process of mixing, stirring, baking, sieving, etc. the film forming agent with the soft magnetic metal powder. After completion the soft magnetic metal powder surface may be coated with an insulating layer. The film forming solvent may be composed of a film forming agent and a solvent. The film former may comprise one or more mixtures of inorganic acids or inorganic acid salts having oxidizing ability. For example, the film forming agent may include phosphoric acid or phosphates such as aluminum dihydrogen phosphate, manganese dihydrogen phosphate, lithium dihydrogen phosphate, sodium dihydrogen phosphate, and the like, nitric acid and nitrates, boric acid and borates, chromic acid or chromates, silicic acid or silicates, aluminates or aluminates, permanganates or permanganates, and the like. The solvent may be water, acetone, ethanol, etc. The film forming treatment may also be an electrochemical process such as electroplating, electrochemical etching, or the like.
In some embodiments, the resin composition may include a matrix resin and a curing agent for the matrix resin. The matrix resin may include a thermosetting resin. The matrix resin may include epoxy resin and its modifications, polyester resin and its modifications, vinyl ester resin and its modifications, bismaleimide resin and its modifications, polyimide resin and its modifications, cyanate ester resin and its modifications, silicone resin and its modifications, etc. or any combination thereof. The curing agent of the matrix resin may include aromatic polyamines, anhydrides, resoles, amino resins, dicyandiamide, hydrazides, and the like.
And 220, uniformly mixing the soft magnetic metal powder and the resin composition to obtain a powder mixture.
In some embodiments, the mixing of the soft magnetic metal powder and the resin composition may be performed with a diluent. The addition of the diluent can uniformly mix the soft magnetic metal powder with the resin composition under the condition of sufficient fluidity. The diluent may be a readily removable, volatile solvent, such as acetone. For example, the resin composition may be first added to a diluent and stirred to obtain a resin mixed solution, and then the soft magnetic metal powder is added to the resin mixed solution and stirred to be uniform. After subsequent evaporation of a portion of the diluent by suction or the like, the resulting product may be the intermediate mixture.
Step 230, performing granulation operation on the powder mixture to obtain granulated powder.
In some embodiments, the granulation operation may include a mechanical granulation or spray granulation based implementation. The granulation operation may be accomplished, for example, using a ball mill granulator, or an aerosolized granulator. The resulting product may be the granulated powder.
Step 240, sieving the granulated powder to obtain the first magnetic powder and the second magnetic powder.
In some embodiments, the granulated powder may be sieved to obtain the first magnetic powder and the second magnetic powder. For example, after sieving, a granulated powder having a particle size distribution of-50 mesh to +x mesh may be designated as the first magnetic powder, and a granulated powder having a particle size distribution of-X mesh may be designated as the second magnetic powder. X may be between 100 and 200.
It should be noted that the above description of the steps in fig. 2 is only for illustration and description, and does not limit the application scope of the present specification. Various modifications and changes to the individual steps of fig. 2 may be made by those skilled in the art under the guidance of this specification. However, such modifications and variations are still within the scope of the present description.
The preparation method of the composite magnetic powder disclosed by the application can enable different magnetic powders to have different solidification states by executing different pretreatment on the different magnetic powders. The first magnetic powder is subjected to a first pretreatment operation to remove the diluent added during the preparation process, while the resin composition is contained therein without undergoing a curing reaction. After the second magnetic powder is subjected to the second pretreatment operation, the resin composition contained therein can undergo curing reaction to some extent, and the added diluent is completely removed. Therefore, the two powders subjected to different treatments have different curing shrinkage rates under the same curing conditions, and the molded inductor prepared by using the composite magnetic powder can have consistent appearance before and after curing treatment.
Some embodiments of the application also disclose an inductance preparation method. The method can be used for preparing the molded inductor. Exemplary steps may be as follows.
Composite magnetic powder, coil, and molded part as described above can be obtained. The coil may be obtained by spirally winding a conductive wire for generating a magnetic field when the inductor is used, and the molding member may be an apparatus for performing induction molding, and may include a pressing portion, a mold, and a pressing portion. The die and the pressing portion may constitute a cavity of a molded part, and the composite magnetic powder and the coil may be placed in the cavity, in which case the composite magnetic powder may be composed of the coil. The pressing portion may be pressed into the cavity and continuously press down on the composite magnetic powder to shape it. After the pressurizing part applies preset pressure and maintains the pressure for a period of time, the die can be removed. The composite magnetic powder and the coil have been pressed into a block at this time. After the block is cured to be completely cured, a final product, namely the molded inductor, can be obtained.
Examples
The present application is described in further detail below with reference to the drawings and examples. The following examples are only illustrative of the present application and are not intended to limit the scope of the application claimed.
Example 1
The preparation method comprises the steps of selecting superfine FeSiCr powder with the brand of FeSiCr-A-500 and D50=10um, passivating by adopting 0.5% phosphoric acid, passivating by adopting three types of resin, selecting cyanate ester with the brand of Wu Qiao chemical industry, CE-10, selecting bisphenol A type epoxy resin E44 for the second resin, and curing agent with fatty amine for the third type, wherein the ratio of the three types is 10:4:1, the reaction starting temperature of DSC test of the formula is 120 ℃, the peak temperature is 170 ℃, the total weight of the three types is 3.5% of metal powder, a certain amount of acetone is added for dilution and mixed and stirred with the metal powder, then granulating particles with the particle size of-60- +200 meshes are obtained by adopting a mechanical extrusion method, drying the granulating particles with the particle size of-60- +200 meshes for 80-60 minutes, and drying the granulating particles with the particle size of-200 meshes for 80-60 minutes, 100-60 minutes, 120-60 minutes, 140-60 minutes and 170-60 minutes respectively so that partial curing and complete curing (the mixture is tested by 170-60 minutes) of the DSC test), and the complete reaction of the powder with the particle size of-60 meshes of-200 meshes: the proportion of 200 meshes of powder is 10:1, the production condition of the die pressing inductor is 5.5 tons/cm < 3 >, the pressure is maintained for 2s, the specification of the product is 6.6mm by 6.5mm by 3.0mm, the inductance value is 10uH, and 100 products are prepared under each condition;
subsequently, the inductance and the dc bias characteristics were measured using an LCR table, the inductance measurement condition was 1v@100khz, and appearance cracks were counted, and the results are shown in table 1.
Table 1 example 1 preparation of sensing and dc bias characteristics of inductances detection and appearance crack statistics
According to the analysis of the results of Table 1, the appearance yield increased with an increase in the curing rate of the-200 mesh powder, but the higher the curing rate, the harder the particles, resulting in a decrease in the feel.
Example 2
The preparation method comprises the steps of selecting superfine FeSiCr powder with the brand of FeSiCr-A-500 and D50=10um, passivating by adopting 0.5% phosphoric acid, passivating by adopting three types of resin, selecting cyanate ester with the chemical industry of Wu Qiao, the brand of CE-10, selecting bisphenol A type epoxy resin E44 for the second resin, and the third type fatty amine curing agent, wherein the ratio of the three types is 10:4:1, the reaction starting temperature of DSC test of the formula is 120 ℃, the peak temperature is 170 ℃, the total weight of the three types of powder is 3.5% of metal powder, a certain amount of acetone is added for dilution and mixed and stirred with the metal powder, then granulating particles with the particle sizes of-60 meshes +200 meshes and-200 meshes are obtained by adopting a mechanical extrusion method, drying the granulating particles with the particle sizes of-60 meshes +200 meshes for 80-60 minutes, and drying the granulating particles with the particle sizes of-200 meshes for 170-60 minutes to enable the partial curing and complete curing (the DSC test of the powder with the particle sizes of-60 meshes +200 meshes). The powder proportion of 200 meshes is 20:1, 10:1, 5:1, 4:1 and 3:1 respectively, the production condition of the die pressing inductor is 5.5 tons/cm < 3 >, the pressure is maintained for 2s, the specification of the product is 6.6mm by 6.5mm by 3.0mm, the inductance value is 10uH, and 100 particles are prepared under each condition;
then, testing the inductance value and the direct current bias characteristic by adopting an LCR table, wherein the inductance value test condition is 1V@100kHz, and carrying out appearance crack statistics; the results are shown in Table 2.
Example 2 preparation of sensing and DC bias characteristics of inductors detection and appearance crack statistics
| Ratio of two particle sizes | 100:0 | 20:1 | 10:1 | 5:1 | 4:1 | 3:1 |
| Appearance yield (%) | 90 | 92 | 100 | 100 | 100 | 100 |
| Inductance value (uH) | 9.8 | 9.7 | 9.5 | 9.3 | 9.0 | 8.2 |
According to the analysis of the results of Table 2, the appearance yield increased with an increase in the amount of powder of-200 mesh, but the feel value was lower as the amount of powder added was higher, and the feel value was lowered to the range allowed by the standard product specifications when reaching 3:1.
The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The above examples merely represent a few embodiments of the present application, which are described in more detail and are not to be construed as limiting the scope of the invention. It should be noted that it would be apparent to those skilled in the art that various modifications and improvements could be made without departing from the spirit of the present application, which would be within the scope of the present application. Accordingly, the scope of protection of the present application is to be determined by the claims appended hereto.
Claims (10)
1. A method of preparing a composite magnetic powder, the method comprising:
acquiring first magnetic powder and second magnetic powder, wherein the particle size distribution of the first magnetic powder is different from that of the second magnetic powder;
performing a first pre-treatment operation on the first magnetic powder to obtain a first target powder;
performing a second pre-treatment operation on the second magnetic powder to obtain a second target powder;
and mixing the first target powder and the second target powder based on a preset mass ratio to obtain the composite magnetic powder.
2. The method of claim 1, wherein the first magnetic powder has a particle size distribution of-50 mesh to +x mesh and the second magnetic powder has a particle size distribution of-X mesh, wherein X is between 100 and 200.
3. The method of claim 1, wherein the first preprocessing comprises:
heating the first magnetic powder to a first temperature and preserving heat for a first period of time.
4. A method according to claim 3, wherein the first temperature is 50-90 ℃ and the first period of time is 0.1-2h.
5. The method of claim 1, wherein the second pre-processing comprises:
heating the second magnetic powder to a second temperature and maintaining the temperature for a second period of time.
6. The method of claim 5, wherein the second temperature is from 100 ℃ to 190 ℃ and the second time period is from 0.5 to 2 hours.
7. The method of claim 1, wherein the predetermined mass ratio is a first mass of the first target powder: the second mass of the second target powder is 20:1-4:1.
8. The method of claim 1, wherein the obtaining the first magnetic powder and the second magnetic powder comprises:
providing a soft magnetic metal powder and a resin composition;
uniformly mixing the soft magnetic metal powder and the resin composition to obtain an intermediate mixture;
performing granulation operation on the intermediate mixture to obtain granulated powder;
screening the granulated powder to obtain the first magnetic powder and the second magnetic powder.
9. The method of claim 8, wherein the soft magnetic metal powder comprises at least one of: carbonyl iron powder, reduced iron powder, atomized iron powder, ferrosilicon alloy powder, ferrosilicon aluminum alloy powder, ferrosilicon chromium alloy powder, ferronickel alloy powder, iron-based amorphous soft magnetic powder, iron-based amorphous nanocrystalline powder, and permalloy soft magnetic alloy powder; the resin composition includes a matrix resin and a curing agent for the matrix resin; the matrix resin comprises at least one of the following: epoxy resin and its modified product, polyester resin and its modified product, vinyl ester resin and its modified product, bismaleimide resin and its modified product, polyimide resin and its modified product, cyanate ester resin and its modified product, and silicone resin and its modified product.
10. An inductor, characterized in that the inductor is prepared at least based on a composite magnetic powder prepared according to the method of any one of claims 1-9.
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