CN1768397A - 具有线形b－h回线的磁性工具 - Google Patents

具有线形b－h回线的磁性工具 Download PDF

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CN1768397A
CN1768397A CNA2004800077135A CN200480007713A CN1768397A CN 1768397 A CN1768397 A CN 1768397A CN A2004800077135 A CNA2004800077135 A CN A2004800077135A CN 200480007713 A CN200480007713 A CN 200480007713A CN 1768397 A CN1768397 A CN 1768397A
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R·哈赛加瓦
V·H·哈蒙德
J·奥赖利
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Metgras Co.
University of Dayton
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Abstract

具有大矫顽力Hc的磁粉采用非磁性粘结剂固结，形成具有所需尺寸和形状的磁性工具。该磁性工具显示出线形B－H回线和低磁损。它可在宽的磁场范围里工作，可用于电流和脉冲变压器、承载大电流的感应器、稳态带通滤波器等。

Description

具有线形B-H回线的磁性工具
发明背景
1、发明领域
本发明涉及用于传感器、变压器、电扼流圈和磁性感应器等的磁性元件；更特别涉及响应外加磁场显示线形磁化特性的磁性工具。
2、现有技术描述
当磁性材料被外部磁场，“H”，磁化时，在材料内会发生磁极化或者磁感应现象。感应量用磁通密度，一般称作“B”，来衡量。软磁材料通常获得了线形B-H特性，在软磁材料中易磁化轴和励磁方向垂直。在这种材料中，外磁场H倾向于使磁通量B的平均方向倾斜，从而使B的测量值和H成正比。由于不容易得到理想的线形B-H响应曲线，所以大多数磁性材料显示非线形B-H行为。和理想B-H线形度的任何偏差都会在对外加磁场H的磁响应中带来相应的偏差。
显示出线形B-H特性的磁性材料的经典例子是冷轧50％Fe-Ni合金，其称作恒导磁率铁镍合金(Isoperm)。在无定形磁性合金中，已知热处理过的富Co合金具有线形B-H特性，目前用做现有变压器的磁芯材料。通常，富Co无定形合金的饱和磁感应强度小于约10kG，或1特斯拉，从而限制了可以施加的最大磁场水平。最近研制出了一种Fe基无定形合金，其在正确热处理后显示出线形B-H行为。美国专利申请No.10/071990公开了这种Fe基无定形合金及其热处理。这种Fe基材料显示出大于10kG或1特斯拉的饱和磁感应强度，从而将线形B-H行为的使用范围扩展到了较高的励磁区域。
为了使磁性设备在更大的外加磁场下工作，需要将B-H线形行为进一步扩展到更强的磁场。这种需要源于不断增大的电流水平，而在电力设备和电力电子设备中必须对此进行控制或监控。对传感器而言，高磁场容量会扩展现有设备的电流上限。而对于暴露在较宽磁场激励下的设备，显然需要具有线形B-H行为的磁性材料。
发明综述
本发明提供一种兼有线形B-H回线和低磁损的磁性工具。当用于脉冲变压器时，该工具增大的B-H线形区域使得能够偏置变压器中的大型DC元件。当该工具用于带通滤波电路时，会显著提高该电路的频率稳定性。
另外，本发明提供制备兼有线形B-H回线和低磁损的磁性工具的方法。该工具包括具有大矫顽力，Hc，的磁粉。采用非磁性粘结剂将这些磁粉固结在一起，形成具有所需尺寸和形状的最终工具。本文所述的粉末矫顽力，Hc，定义为所选磁粉的B-H回线宽度的1/2。该工具应该能在尽可能宽的磁场下工作。相应地，需要大矫顽力的粉末。适用于本发明的磁粉从半硬粉到硬质粉。它们包括基于稀土过渡金属的磁体。根据本发明的方法制备的磁性工具，尤其适用于要求对磁场做出线形B-H响应的设备，诸如电流和脉冲变压器、携带大电流的电感器和稳态带通滤波器。
附图简述
参考下面的附图和描述，可以更充分地理解本发明，而且其它优点也将变得明显，其中：
图1描述了本发明的环形磁性环的B-H磁性响应曲线；
图2比较了图1的环形芯和含有钼铁镍合金粉的常规芯的导磁率比和DC偏磁的关系曲线；
图3比较了图2的环形芯和基于钼铁镍合金粉末的芯的导磁率比和频率的关系曲线。
发明详述
在磁性材料中引入磁隙倾向于剪切B-H回线的形状，有时会得到线形B-H回线。磁隙可以通过在固结的磁粉产品中的非磁性粘结剂提供。下面将详细描述的图2和图3将通过这种方式制备的常规芯和根据本发明制备的芯进行了比较。
适用于本发明的磁粉可以通过含有磁性元素，包括Fe、Co和Nd，的盐溶液制备，其中Fe任选被最多达约10原子％的Ni代替，Nd任选由Pr和/或Sm代替。随后，采用环氧树脂将磁粉固结在一起，制成本发明的磁芯。固结任选通过其它聚合物，包括聚氨酯、聚酰亚胺、高性能聚合物和其杂化物完成。这样制成的磁芯显示出线形B-H磁性响应。
图1示出了实施例1的试样C的典型B-H回线。该B-H回线显示线形B-H行为，并且DC导磁率约为14。图2比较了试样C和常规芯的导磁率和DC偏磁的关系曲线，其中常规芯含有DC导磁率也约为14的钼铁镍合金粉末。从图2中可以明显看出，本发明的芯的导磁率在DC偏磁水平达到100Oe时没有变化，但常规芯在高于约10Oe的DC偏磁场下开始明显下降。作为DC偏磁场函数的恒定导磁率的上限随着所用磁粉矫顽力的增加而增加。为了获得在适当宽范围的施加磁场下的B-H线性度，需要大于约20Oe的粉末矫顽力。也需要具有较高饱和磁化强度，即超过约35emu/g的粉末，因为它扩展了线形B-H行为。当励磁频率提高到10MHz区域以上时，图1所示的芯的线形B-H行为保持不变。
图3比较了常规芯和根据本发明构造的芯的芯导磁率的频率依从关系。常规磁工具的数据范围最高达到10MHz。而本发明的磁工具的导磁率最高到40MHz还保持不变，这是所使用工具的上限。这些特征说明了本发明的芯和常规磁工具相比所具有的巨大优点。和常规芯相比时，本方面的磁工具能够在感应器磁芯中容纳更大的电流。根据本发明构造的感应器在高于10MHz的励磁频率下工作良好，而此时常规工具将丧失有效性。组合起来看，本发明的磁工具的这些特征使其能够用于更多的磁性设备，例如电力设备中的感应器、电力电子设备、传感器和性能改善的带通滤波器。
下述实施例用以提供对本发明更全面的理解。用来解释本发明的原理和实践的特定技术、条件、材料、比例和报导的数据，都是示例性的，不应理解为对本发明范围的限制。
实施例
实施例1
Fe-Co基的粉末芯
用于制备芯试样A、B和C的粉末分别通过100％FeSO4盐溶液、65％FeSO4/35％CoCl2盐溶液和50％FeSO4/50％CoCl2盐溶液的硼氢化物还原来制备。然后，采用环氧树脂将粉末制成环形磁性工具。这种环形芯的尺寸为OD＝25.5mm，ID＝13.0mm，高度＝1.3mm。下表1列出了粉末和所得磁芯的性能：
表1
  芯试样 粉末化学(wt％)   饱和磁化强度(emu/g)   矫顽力Hc(Oe)   粉末的体积分数(％)   DC导磁率
  A Fe95.3B11.8O9   135   380   83   14
  B Fe58.4Co27.7B6.6O8.9   120   510   79   11
  C Fe33.6Co37.2B6.9O12.9   92   620   84   14
试样A、B和C的每一个都显示了最高到100Oe的线形B-H行为，这是本实施例采用的芯-线圈组件的上限。
表1中，芯的导磁率直到所用电感电桥的频率上限(40MHz)都没有变化。
实施例2
Fe-Nd-B基的粉末芯
用于制备芯试样D和E的粉末分别是通过85％/15％ FeSO4/NdCl2盐溶液和72％/28％ FeSO4/NdCl2盐溶液制备。然后，采用环氧树脂将粉末固结成环形磁性工具。这种环形芯的尺寸为OD＝24.2mm，ID＝12.0mm，高度＝1.5mm。下表2列出了粉末和所得磁芯的性能：
表2
  芯试样 粉末化学(wt％)   饱和磁化强度(emu/g)   矫顽力Hc(Oe)   粉末的体积分数(％)   DC导磁率
  D Fe36.9Nd18.1B5.9O24.5   39   30   75.9   13
  E Fe24.5Nd27.1B6.9O25.5  41   20   81.5   13
试样D和E都显示了直到约80Oe外加磁场下的线形B-H行为，这是本实施例采用的芯-线圈组件的上限。
表2中，芯的导磁率直到所用电感电桥的频率上限(40MHz)都没有变化。
实施例3
试样制备
通过化学还原金属盐的水溶液制备Fe-Co-B和Fe-Nd-B合金的纳米颗粒。对Fe-Co-B粉末而言，通过在400mL蒸馏水中加入所需量的金属盐(FeSO4和CoCl2)制备0.1M盐溶液。该溶液中所用的FeSO4和CoCl2的量在Fe/Co百分比为50/50-100/0的范围内变化，以制备不同组成的粉末。对Fe-Nd-B粉而言，利用FeSO4和NdCl2制备250mL盐溶液，其中Fe/Nd百分比为72/28和85/15。通过在250mL蒸馏水中溶解3.78g NaBH4，制备了0.4M的硼氢化物溶液，然后在约30分钟内逐滴加到盐溶液中。在加入硼氢化物溶液的过程中，一直采用磁性搅拌盘和搅拌棒进行搅拌。
将硼氢化物溶液加到Fe-Co溶液后，很快形成黑色沉淀。但是，在Fe-Nd溶液中开始沉淀要慢得多，需要多达20mL硼氢化物溶液才能开始形成微细的沉淀物。反应完成后，用水清洗粉末，再用丙酮清洗，然后真空干燥24小时。干燥后，钝化后的粉末保存在真空干燥器中，使额外的氧暴露最小化。典型粉产量是约3g。
采用选中的Fe-Co-B和Fe-Nd-B粉末，通过在约1g粉末中加入所需量的环氧树脂，制成复合物环。然后加入丙酮制成浆料，用力搅拌使聚合物均匀分布在粉末里。干燥后，将这些涂覆有聚合物的粉末在22Mpa下于压缩模具中冷压成型，然后在121℃固化3小时，得到外径约为25mm、内径为12.5mm的环。该环氧/粉末纳米复合物中，粉末含量大约是80重量％。
磁性测量
采用常规振动试样磁力计测量根据实施例3制备的磁粉的禀磁性。由这些测量结果推导出的饱和磁化强度和矫顽力数据如表1和2所示。
采用常规B-H磁滞曲线记录仪测试实施例3的环形磁性工具，获得B-H特性。图1给出了一个这样的例子。在环形芯上测出的导磁率，用B/H定义，是DC偏磁场和频率的函数。图2给出了本发明的芯和常规芯的导磁率和DC偏磁场的关系。当偏磁场为0时，两种芯的DC导磁率都为约14。
采用电感电桥测量导磁率和励磁频率的关系，其中励磁频率最高达40MHz。图3给出了一个这样的例子。
X射线和热性能测量
采用常规X射线衍射仪确定粉末材料的原子结构。结果表明根据实施例3的教导制备的粉末主要是无定形的，虽然试样A的粉末具有一定的结晶度。通过差示扫描量热仪确认X射线的测量结果。结果表明，试样A、B和C的粉末的初级结晶发生在约480℃，而试样D和E的粉末发生在约625℃。
至此已经相当详细地描述了本发明，但应该理解这些细节并不是对本发明范围的严格限制，对本领域技术人员有提示作用的各种改变和修改也在本发明由所附权利要求定义的范围内。

Claims (11)

1.一种由半硬磁粉或硬磁粉制备的磁性工具，所述工具在宽的磁场和频率范围内具有线形B-H特性。
2.权利要求1的磁性工具，其中所述粉末通过含有磁性元素的盐溶液的硼氢化物还原来制备，其中所述磁性元素包括Fe、Co和Nd，其中可以用Ni代替最多达约10原子％的Fe，并且可以用Pr和/或Sm代替Nd。
3.权利要求2的磁性工具，其中所述盐溶液包含FeSO4、CoCl2和NdCl2。
4.权利要求2的磁性工具，其中所述粉末包含Fe-Nd-B、Fe-Co-B和Fe-B的元素组合中的至少一个，其中Fe可以用最多达约10原子％的Ni代替，Nd可以用Sm或Pr代替。
5.权利要求2的磁性工具，其中所述粉末的饱和磁化强度大于35emu/g，矫顽力大于约20Oe。
6.权利要求2的磁性工具，其中所述粉末具有无定形结构。
7.权利要求2的磁性工具，其中所述粉末包含具有无定形和结晶结构的粉末的混合物。
8.权利要求2的磁性工具，其中所述粉末具有结晶结构。
9.权利要求1的磁性工具，其中所述制备是采用环氧树脂、聚氨酯、聚酰亚胺、高性能聚合物和其杂化物进行的。
10.权利要求1的磁性工具，其中所述线形B-H特性是在施加约20-100Oe的磁场的条件下存在。
11.权利要求1的磁性工具，其中所述线形B-H特性是在励磁频率大于10MHz的条件下存在。
CN2004800077135A 2003-01-21 2004-01-13 具有线形b-h回线的磁性工具 Expired - Fee Related CN1768397B (zh)

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