CN1787127A - Composite powder for magnetic powder core and preparation process for magnetic powder core - Google Patents
Composite powder for magnetic powder core and preparation process for magnetic powder core Download PDFInfo
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Abstract
The invention provides a composite powder for magnetic powder core and the magnetic powder core preparing method thereof. The composite powder is mixed of powder A and powder B in the weight percents of 50-95wt% and 50-95wt%, respectively, where the powder A is one of the iron powder, iron-silicon powder, iron-silicon-aluminum powder, iron-base nano crystal powder, iron-base noncrystalline powder, iron-nickel powder, and iron-nickel-molybdenum powder; and the powder B has different demanded properties from the powder A and comprises at least one of the iron powder, iron-silicon powder, iron-silicon-aluminum powder, iron-base nano crystal powder, iron-base noncrystalline powder, iron-nickel powder, and iron-nickel-molybdenum powder. And the composite magnetic powder core preparing method anneals the powder A and powder B, respectively, so as to make both of them be in an excellent magnetic performance state, then mixes them uniformly, makes insulates and binding treatments, and finally makes press-forming and annealing treatments, thus obtaining the composite powder and the magnetic powder core thereof with synthetic and complete demanded properties.
Description
Technical field
The invention belongs to field of functional materials, relate to composite powder for magnetic powder core and preparation process for magnetic powder core thereof.
Background technology
As prior art, metal current magnetic core kind mainly contains ferrocart core, iron silica flour core, Sendust powder core, Hi-Flux powder core, MPP powder core, reaches amorphous magnetic core, the nanocrystalline magnetic core of exploitation in recent years.These magnetic cores have characteristics separately, and its application also has nothing in common with each other.
Comprise as the prior art document relevant with the present patent application:
Patent documentation 1: Chinese invention patent CN1373481A
Patent documentation 2: Chinese invention patent CN1487536A
Patent documentation 3: U.S. patent of invention US6,827,557
Patent documentation 4: U.S. patent of invention US6,594,157
Patent documentation 5: U.S. patent of invention US1,669,642
Patent documentation 6: Japanese patent of invention JP08-037107
Ferrocart core is the metal magnetic powder core of researching and developing the earliest, and its iron content is generally more than 99%, and the magnetic permeability maximum can reach 90, and main feature is cheap, and loss is higher, and temperature characterisitic is good.Because the raw material cheapness, ferrocart core is used in low-cost field extensively, and wherein most widely used is running stores.
Iron silica flour core, general siliceous is below 10%, magnetic permeability is higher slightly than ferrocart core, has comparison superior direct current biasing characteristic, is widely used under big direct current biasing condition.
Sendust powder core is a kind of magnetic core with superior performance price ratio, contains the silicon and the aluminium of 10-15 atomic percent in its composition, and all the other are iron (with reference to Japanese patent of invention JP08-037107), and maximum permeability can reach 125.Compare with ferrocart core, Sendust powder core price is high slightly, and loss is lower, and maximum permeability is also higher.Because magnetostriction coefficient is low, the noise in its course of work is also low, so this powder core has obtained using widely as the EMI inductance.
Hi-Flux powder core, its composition is generally iron 50at%, nickel 50at% (with reference to U.S. patent of invention US1,669,642), maximum permeability can reach 160.Hi-Flux powder core, the working point of design have the highest anti-Dc bias ability up to 6500 Gausses.At present main as energy storage inductor, scan transformer, be particularly suitable as the noise filtering inductance (as the differential mode inductance of Switching Power Supply etc.) of direct current and linear frequency.Compare with the iron Si-Al Magnetic Powder Core, Hi-Flux powder core, the working point height, anti-bias voltage ability is strong, the price comparison costliness.
Its composition atomic percent of MPP powder core is generally Fe
17Ni
81Mo
2, maximum permeability can reach more than 500, is that the magnetic permeability scope is the wideest in all magnetic cores.The characteristics of MPP powder core are that temperature stability is good, and loss is low, and operating noise is little, and the working point is also higher.MPP powder core combination property is superior in the present magnetic core, and price is also the highest.
What nanocrystalline magnetic core mainly adopted at present is that FeCuNbSiB system nano-crystal alloy is (with reference to Chinese invention patent CN1373481A, U.S. patent of invention US6,827,557), its composition atomic percent satisfies: Fe is 70-75%, NbCu is 4%, and SiB is 26-21%, and maximum permeability can reach 120.Nanocrystalline magnetic core has good frequency characteristic.Because powder normally adopts the method for band ball milling to obtain, there is the heteromorphosis problem in powder, and insulation is also relatively more difficult, and loss is higher.
The main at present base block amorphous system of Fe that adopts of amorphous magnetic core, be generally 70-75 by atomic percent Fe content, all the other are that amorphous forming elements such as P, Si, B, C, Al and the anti-oxidant element of part such as Cr, Mo etc. are (with reference to Chinese invention patent CN1487536A, U.S. patent of invention US6,594,157).Fe-based amorphous magnetic core, magnetic permeability is lower, can reach at present about 100, and loss is minimum in all magnetic cores.
In sum, existing magnetic core product has characteristics separately on performance, and price variance is very big, and application is also different separately.In general, its performance has weak point, and the leeway of raising is arranged; Price, especially Hi-FluxP powder core and MPP powder core, price is higher, and bigger decline space is arranged.
Summary of the invention
The objective of the invention is at existing metal magnetic core performance when using single powder preparation, the dissatisfactory problem of other demand characteristics of its magnetic core, provide a kind of and prepare composite powder for magnetic powder core and preparation process for magnetic powder core thereof by mixing two or more metal alloy powders, preparation has its magnetic core of magnetic core powder of comprehensive, comprehensive demand characteristics.
To achieve these goals, the invention provides following technical scheme:
The present invention has obtained a kind of composite powder for magnetic powder core, be evenly to mix by powders A and powder B, its content is: powders A is 50-95wt%, powder B 5-50wt%, wherein powders A is to be selected from a kind of in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder, powder B has different demand characteristicss with powders A, and is selected from least a in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder.
Wherein, described powders A has top-priority demand characteristics, and described demand characteristics is a kind of in magnetic permeability, loss, high frequency performance, anti-direct current biasing characteristic, temperature stability and the cost.
Another aspect of the present invention is the manufacture method that obtains a kind of composite powder for magnetic powder core, comprises the steps:
A, according to different demand characteristicss, prepare powders A and powder B separately;
B, powders A and powder B that preparation is finished sieve respectively;
C, adopt required separately technology to distinguish annealing in process in different types of powder.
D, powders A and powder B are evenly mixed, the content of its mass percent is: powders A is 50-95%, powder B 5-50%, wherein powders A is to be selected from a kind of in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder, powder B has different demand characteristicss with powders A, and is selected from least a in iron powder, iron silica flour, iron aluminum silicon powder, ferrous alloy powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder.
Described powder also comprises Performance Detection after screening.
Described incorporation time is: 1 minute-60 minutes.
A third aspect of the present invention is to obtain a kind of magnetic core, comprises following components in weight percentage: insulating compound 0.2%-7%, and bonding agent 0.01-5%, lubricant 0.01-2%, all the other are the aforementioned composite powder that obtains of the present invention.
Described insulating compound is selected from following at least a or its combination of respectively organizing in the material:
Be selected from SiO
2, Cao, Al
2O
3, TiO
2Oxide powder;
Be selected from the salt of silicates, phosphoric acid salt;
Be selected from mica powder, kaolinic mineral powder; With
The surface film that chemical method generates or the surface oxidation of generation.
Described bonding agent is organic bonding agent and/or inorganic adhesive, wherein: the organic bonding agent be selected from epoxylite, at least a in the epoxylite, inorganic adhesive is selected from least a in the phosphoric acid salt.
Described lubricant is selected from the stearate profit, talcum powder is at least a or its combination.
Described insulating compound 0.5%-5%.
A fourth aspect of the present invention is the preparation method who obtains a kind of magnetic core, and this method may further comprise the steps:
Insulating compound, bonding agent and the mix lubricant of e, employing claim any one described composite powder of 1-6 and desired content also is dried to dry powder;
F, above-mentioned dried powder is pressed in makes the magnetic core under the 500MPa-3000MPa pressure;
G, magnetic core annealing in process;
The processing of spraying paint of h, magnetic core;
I, magnetic core performance detect.
Described magnetic core annealing temperature is 350 ℃-600 ℃, and annealing time is 5 minutes-3 hours.
Described magnetic core annealing time is 30 minutes-60 minutes.
Described magnetic core annealing in process is in hydrogen, nitrogen or argon shield atmosphere, or carries out under the vacuum state.
In sum, composite powder for magnetic powder core of the present invention is to adopt in existing iron powder, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder two or more evenly to mix, prepare composite powder for magnetic powder core, and be prepared into magnetic core with comprehensive, comprehensive demand characteristics by preparation process for magnetic powder core.Particularly, be with in iron powder, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder, performance, price have two or more complementary powder and mix, prepare composite powder for magnetic powder core, and be prepared into magnetic core with comprehensive, comprehensive demand characteristics by magnetic core preparation technology.The magnetic core of the present invention following several mode of passing through comprehensive, demand characteristics comprehensively realizes: 1, keep serviceability, reduce price.2, improve serviceability, keep or the reduction price.3, increase substantially performance, price increases.4, reduce price significantly, performance decreases.More specifically, composite powder of the present invention can be to adopt at least a with relatively more expensive iron nickel by powder, the iron nickel molybdenum powder in less expensive iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, the Fe-based amorphous powder evenly to mix.This composite powder price is compared price with iron nickel by powder, iron nickel molybdenum powder have reduction largely, and performance is also more superior, has the higher ratio of performance to price.Composite powder of the present invention can also be to adopt iron powder, iron silica flour, iron aluminum silicon powder, the iron based nano crystal powder that quality factor is lower under the higher Fe-based amorphous powder of quality factor under the high frequency and other high frequency evenly to mix.Composite powder is compared price maintenance with original powder constant or slightly raise, but the highfrequency figure of merit effectively promoted, and therefore has magnetic core more comprehensive, comprehensive demand characteristics.
Composite magnetic powder core of the present invention, when adopting two or more powder to mix, its powder quality percentage satisfies, and except that the powder of quality maximum, all the other powder quality percentage sums are not less than 5%.If less content of powder is very few, the complementary advantage of composite magnetic powder core is difficult to give full play to, and demand characteristics is difficult to improve.The less powder quality percentage sum of preferred content of the present invention is more than 10%, more preferably more than 20%.
Composite magnetic powder core of the present invention, its preparation method may further comprise the steps:
1, powder preparation;
2, powder sieving and Performance Detection;
3, powder annealing in process;
4, powder;
5, composite powder mixes with insulating compound, bonding agent and lubricant and is dried to dry powder;
6, powder compaction becomes the magnetic core;
7, the magnetic core is carried out annealing in process;
8, the magnetic core processing of spraying paint;
9, the magnetic core performance detects.
In the composite powder of the present invention, each powder process adopts existing process preparation.For example, amorphous powder adopts the atomization method preparation, and manocrystalline powders adopts the preparation of band breaking method.
Step 2 powder sieving
The screening of powder of the present invention can be adopted testing sieve, and standard is bounced realizations such as the reciprocating sieve of formula reciprocating sieve, other types and air-flowing type powder classification equipment.
Step 3 powder core is annealed respectively
Composite powder for magnetic powder core of the present invention is by two or more powder constituent, because powder can not be realized the individual processing to various powder after mixing, therefore must before mixing, fully handle, make each powder before annealing, reach more satisfactory magnetic property state each powder.For example adopt the water atomization amorphous powder to mix with the MPP powder of breaking method preparation.The annealing temperature of MPP powder is more than 600 ℃, but not the annealing process at crystalline flour end be its below crystallization temperature, be not higher than 500 ℃ usually.For preventing the powder oxidation, the present invention preferably carries out under vacuum state or protective atmosphere in the annealing process.After these two kinds of powder, be difficult to make two kinds of powder reach more satisfactory magnetic property state simultaneously by processing.Therefore preparation process for magnetic powder core of the present invention during powder annealing, should adopt different types of powder separately technology to carry out annealing in process before mixing.
Step 4 powder
Composite powder for magnetic powder core of the present invention, for two or more powder form, the uniformity of powder has direct influence to the magnetic core performance.Mix inhomogeneously, be difficult to demonstrate fully the advantage of composite powder.In the powder process, should adopt suitable incorporation time to mix, incorporation time is 1-60 minute.Incorporation time is less than 1 minute, and powder is difficult to fully mix; Incorporation time was greater than 60 minutes, and the uniformity can not increase, and also might cause two kinds of powder separation, reduced the uniformity.
Various components in the step 5 magnetic core
In order to improve magnetic core resistivity, reduce eddy current loss, improve the magnetic permeability under the high frequency, the insulating compound of the preferred following kind of the present invention and composite powder carry out mix insulation: 1, oxide powder, as SiO
2, Cao, Al
2O
3, TiO
2Deng, the common stable in properties of oxide powder, insulation, heat resistance are good, and cheap.2, silicates, phosphoric acid salt etc.3 other mineral powder are as mica powder, kaolin etc.4, the surface film of chemical method generation or the surface oxidation of generation.
Adopt above-mentioned insulating compound that composite powder is insulated, the insulating compound percentage by weight should be between the 0.2wt%-7wt% of mixture total weight amount.If insulating compound is very few, composite powder is difficult to obtain isolating more fully, contacts more; Perhaps insulating barrier is too thin, the easy breakdown insulating effect that loses under the electromagnetic induction effect, thus the magnetic core loss is big, and the high frequency magnetic permeability is low.If insulating compound is too much, the interval between the powder is excessive, and magnetic core magnetic permeability reduces.The preferred weight percentage ranges of insulating compound is that 0.5wt% is to 5wt%.
The preferred following kind adhesive substance of the present invention is as bonding agent: 1, organic bonding agent, as epoxylite, epoxylite generally uses as adhesives is at present industrial, especially uses the back adhesive effect better mixing with curing agent.2, inorganic adhesive, as phosphoric acid salt etc., the advantage of inorganic adhesive is that thermal endurance is good, and itself has good insulation property, and insulation and bonding double action are arranged, its amount can suitably increase, thereby can sufficient bonding powder.
Adopt above-mentioned bonding agent, its bonding agent content accounts for mixture percentage and is no more than 5%.If bonding agent content is too much, the magnetic core performance descends, and magnetic permeability reduces.
The mixing of lubricant its role is to: 1, make powder the time be easy to flow, thereby improve magnetic core density in compacting, 2, magnet ring and compacting tool set be difficult for taking place bonding, thereby be easy to the demoulding.The preferred stearate profit of the present invention, talcum powder etc. are as greasing substance, and its weight should be not more than the 2wt% of mixture weight.If lubricant is too much, can cause composite powder density decline in the magnetic core, thereby the magnetic core performance worsens, magnetic permeability reduces.
Mix fully in order to obtain insulating, the densification of powder core, the composite magnetic powder core that has excellent magnetic characteristics, the total amount of the preferred insulating compound of the present invention, bonding agent and lubricant accounts for the 0.5wt% of mixture total weight amount to 10wt%; More preferably percentage by weight is that 1wt is to 7wt%.
Step 6 compression moulding
The preferred 500MPa-3000MPa of composite powder briquetting pressure of the present invention.Pressure is less than 500MPa, and powder is difficult to moulding, or has crackle to exist after the moulding, and magnetic permeability is low, and the magnetic core performance is not good.Pressure is greater than 3000MPa, and it is big that mould bears pressure, damage easily, and powder insulation difficulty, powder core loss height, quality factor are not good, and are therefore bad.Magnetic core briquetting pressure more preferably 800MPa to 2500Mpa.
The annealing of step 7 magnetic core
The composite magnetic powder core powder is subjected to the squeezing action of stirring action, press in preparation process, magnetic in-core portion exists stress, the performance of these stress influence magnetic cores.By composite magnetic powder core is carried out annealing in process, can reach the purpose of eliminating internal stress and improving magnetic property.Composite magnetic powder core annealing in process temperature should satisfy following condition: 1, annealing temperature will be fit to two kinds of powder simultaneously.For example contain manocrystalline powders in the powder, the powder heat treatment temperature should not be higher than the secondary crystallization temperature of manocrystalline powders.2, satisfy to regulate under 1 the situation, the annealing temperature height of should trying one's best, powder core annealing temperature is low excessively, thermal agitation is less, and powder in-core portion stress is difficult to fully be eliminated, and magnetic property is difficult to fully be promoted.Generally speaking, fully eliminate internal stress, annealing temperature is more than 350 ℃.3, annealing temperature should not be too high, otherwise can cause the insulation adhesive substance to lose original effect.For example adopt epoxy resin as adhesive substance, when temperature is 600 ℃, be easy to cause epoxy resin to lose efficacy, the powder adhesive strength reduces, and magnetic core is frangible, and insulating properties is bad, degradation problem under the quality factor.Powder core annealing temperature is to be advisable below 600 ℃.The composite core annealing time should satisfy following condition: 1, powder core annealing time should be less than 3 hours.Because annealing time is long, efficient is low, increases manufacturing cost.2, powder core annealing time should because annealing time is too short, be difficult to reach the purpose of uniform treatment greater than 5 minutes during batch process, and the powder core performance is difficult to homogeneous.3, between preferred 30 minutes to 90 minutes of the powder core annealing time.Above-mentioned annealing process, the present invention preferably carries out under protective atmosphere, and protective atmosphere can be vacuum state, hydrogen state, nitrogen state or argon gas state.
The processing of spraying paint of step 8 magnetic core
For reaching the erosion that protection magnetic core is avoided the dry linting phenomenon occurring and is subjected to air etc., cause magnetic property to worsen, need be to the protection of spraying paint of magnetic core, the epoxy resin that the material preferred consolidation of spraying paint stress ratio is less or epoxy resin and polyester mixture.The preferred 50 μ m of coating thickness are to 300 μ m.
Step 9 magnetic core performance detects
Following method is adopted in the detection of each parameter of amorphous magnetic core performance of the present invention respectively: 1, the detection method of inductance and quality factor q, and adopting diameter is the copper enamelled wire of 0.2mm, uniform winding 10 circles are measured with the accurate electric impedance analyzer of Agilent 4294A; 2, magnetic core direct current biasing characteristic test, adopting diameter is the copper enamelled wire of 0.9mm, uniform winding 30 circles are tested its magnetic permeability under each direct current biasing condition with the accurate LCR tester of Agilent 4284A.The magnetic permeability through type of magnetic core
Calculate, wherein l (is unit with cm) is the average length of magnetic path, and N is a coil turn, and A is that the magnetic circuit area is (with cm
2Be unit).
Description of drawings
Accompanying drawing 1 is an amorphous powder and the change curve of the ratio magnetic permeability of the composite magnetic powder core of MPP powder preparation with direct current biasing.
Composite magnetic powder core magnetic permeability that accompanying drawing 2 is mixed with for manocrystalline powders and amorphous powder and quality factor are with the change curve of frequency.
Composite magnetic powder core magnetic permeability that accompanying drawing 3 is mixed with for amorphous powder and iron sial powder and quality factor are with the change curve of frequency.
Accompanying drawing 4 is the change curves of the composite magnetic powder core quality factor of iron sial powder and the preparation of Hi-Flux powder with frequency.
Accompanying drawing 5 is an iron sial powder and the change curve of the ratio magnetic permeability of the composite magnetic powder core of Hi-Flux powder preparation with direct current biasing.
Accompanying drawing 6 is the change curves of the quality factor of the composite magnetic powder core of amorphous, iron sial and the preparation of Hi-Flux powder and Hi-Flux powder core with frequency.
Accompanying drawing 7 is the change curve of the ratio magnetic permeability of the composite magnetic powder core of amorphous, iron sial and the preparation of Hi-Flux powder and Hi-Flux with direct current biasing.
Embodiment
Present embodiment adopts the water atomization method to prepare amorphous state Fe
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Alloy powder and MPP powder.Wherein the preannealing technology of MPP powder is 650 ℃ * 60 minutes; Fe
69Ni
5Al
4Sn
2P
10C
2B
4Si
4The preannealing technology of powder is 450 ℃ * 60 minutes, and annealing process adopts vacuum atmosphere.Screening obtains negative 300 purpose powder respectively, and is mixed with composite powder, and mixed proportion sees Table 1.
Table 1
| Sequence number | Mixed proportion | The direct current biasing characteristic | ||||
| Amorphous powder | The MPP powder | Than magnetic permeability (50Oe) | Raising ratio (50Oe) | Than magnetic permeability (100Oe) | Raising ratio (100Oe) | |
| 1 | 25％ | 75％ | 63.9％ | 14.1％ | 37.0％ | 36.5％ |
| 2 | 50％ | 50％ | 85.4％ | 52.5％ | 70.4％ | 159.8 |
| Contrast | ||||||
| 1 | 0 | 100 | 56.0％ | - | 27.1％ | - |
SiO with composite powder and 1.5wt%
2Powder, 1wt% epoxy resin, 0.3wt% zinc stearate evenly mix and oven dry, adopt alcohol as cosolvent during mixing.Adopt the pressure forming powder of 2Gpa.The annealing of magnetic core is carried out under vacuum state, and annealing temperature is 400 ℃, and annealing time is 90 minutes.Adopt epoxy resin and polyester mixture that the magnetic wicking surface is sprayed, coating layer thickness is 100um.
Adopt the magnetic core of such scheme preparation, its magnetic permeability is seen Fig. 1 with the variation of direct current biasing.As seen from the figure, along with the increase of amorphous powder addition, the direct current biasing characteristic of composite magnetic powder core has been compared with MPP powder core more significantly and has been improved.At direct current biasing is under the 50Oe, and amorphous powder content is 25%, increases by 14.1% than magnetic permeability; Amorphous powder content is 50%, increases by 52.5% than magnetic permeability.And, adding 25% amorphous powder, the raw-material price of magnetic core can reduce more than 10%.Therefore compare with MPP powder core with the composite magnetic powder core of amorphous powder preparation by mixing the MPP powder, anti-direct current biasing characteristic is improved, cost has obtained reduction, and magnetic core integration requirement characteristic improves.
Embodiment 2
Present embodiment adopts the water atomization method to prepare amorphous state Fe
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Alloy powder.Nano-crystalline Fe
73.5Cu
1Nb
3Si
13.5B
9Alloy powder is the preparation method comprise: 1, prepare amorphous alloy strip steel rolled stock by the single roller rapid quenching method; 2, under nitrogen atmosphere, 550 ℃ of isothermal annealings 30 minutes; 3, adopt the planetary ball mill ball milling to obtain manocrystalline powders.Fe wherein
69Ni
5Al
4Sn
2P
10C
2B
4Si
4The preannealing technology of powder is 450 ℃ * 60 minutes, and annealing process adopts vacuum atmosphere; The annealing process of manocrystalline powders is 550 ℃ * 30 minutes, and annealing atmosphere is a nitrogen atmosphere.Sieve is got negative 400 order amorphous state Fe respectively
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Arrive positive 200 purpose manocrystalline powders with negative 100 orders, and be mixed with composite powder, mixed proportion sees Table 2.
Table 2
| Sequence number | Mixed proportion | Quality factor improves ratio | Improve ratio than magnetic permeability | |||
| Amorphous powder | Manocrystalline powders | 100kHz | 500kHz | 100kHz | 500kHz | |
| 3 | 10％ | 90％ | 96.1％ | 207.7％ | 0.5％ | 0.8％ |
| 4 | 25％ | 75％ | 125.8％ | 594.8％ | 0.5％ | 0.5％ |
| 5 | 50％ | 50％ | 127.3％ | 666.7％ | 10.1％ | 11.3％ |
| 6 | 75％ | 25％ | 114.8％ | 828.0％ | 11.2％ | 11.1％ |
| Contrast 2 | 0 | 100％ | - | - | - | - |
SiO with composite powder and 2wt%
2Powder, 1wt% epoxy resin, 0.3wt% zinc stearate evenly mix and oven dry, adopt alcohol as cosolvent during mixing.Adopt the pressure forming powder of 2Gpa.The annealing of magnetic core is carried out under vacuum state, and annealing temperature is 400 ℃, and annealing time is 90 minutes.Adopt epoxy resin and polyester mixture that the magnetic wicking surface is sprayed, coating layer thickness is 100um.
Adopt its magnetic permeability of magnetic core and the quality factor of method for preparing to see Fig. 2 with the change curve of frequency.As seen from the figure, the interpolation of amorphous powder can significantly improve magnetic core quality factor, improves magnetic core frequency characteristic, but the magnetic permeability that decreases.Listed 100kHz in the table 2, under the 500kHz, composite core is compared quality factor and is improved the concrete data of ratio than magnetic permeability with Comparative Examples nanometer crystal powder core.Amorphous powder adds 10%, can improve quality factor more than 90%.Therefore, by mixing the composite magnetic powder core of amorphous powder and manocrystalline powders preparation, can significantly improve nanometer crystal powder core quality factor, cost then remains unchanged substantially, so magnetic core integration requirement characteristic significantly improves.
Embodiment 3
Present embodiment adopts the water atomization method to prepare amorphous state Fe
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Alloy powder adopts breaking method to prepare iron sial powder.Fe wherein
69Ni
5Al
4Sn
2P
10C
2B
4Si
4The preannealing technology of powder is 450 ℃ * 60 minutes, and annealing process adopts vacuum atmosphere; The annealing process of iron sial powder is 600 ℃ * 30 minutes, and annealing atmosphere is a hydrogen atmosphere.Sieve is got negative 400 order amorphous state Fe respectively
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Powder and iron sial powder, and be mixed with composite powder, mixed proportion sees Table 3.The preparation method of composite magnetic powder core is identical with embodiment 2.
The quality factor of the quality factor of composite magnetic powder core and contrast iron Si-Al Magnetic Powder Core are seen Fig. 3, and the adding of visible amorphous powder can significantly improve magnetic core quality factor.Provided in the table 3, the amorphous powder addition is respectively the quality factor that 25%, 50% composite magnetic powder core compares with the iron Si-Al Magnetic Powder Core under 1M and 3M and improves percentage.As seen, under 1MHz, quality factor can improve 68.0%, 102.2% respectively; And under 3MHz, quality factor can improve 144.7%, 217.5% respectively.This composite magnetic powder core price is compared with original iron Si-Al Magnetic Powder Core slightly and is improved.Therefore, by mixing the composite magnetic powder core of amorphous powder and FeSiAl powder preparation, can significantly improve quality factor, and price rises slightly, demand characteristics is improved.
Table 3
| Sequence number | Mixed proportion | Quality factor improves ratio | ||
| Amorphous powder | Iron sial powder | 1MHz | 3MHz | |
| 7 | 25％ | 75％ | 68.0％ | 144.7％ |
| 8 | 50％ | 50％ | 102.2％ | 217.5％ |
| Contrast 3 | 0 | 100％ | - | - |
Embodiment 4
Present embodiment adopts the water atomization method to prepare the Hi-Flux powder, adopts breaking method to prepare iron sial powder.Wherein the preannealing technology of Hi-Flux powder is 650 ℃ * 60 minutes, and annealing process adopts hydrogen atmosphere; The annealing process of iron sial powder is 600 ℃ * 30 minutes, and annealing atmosphere is a hydrogen atmosphere.Sieve is got negative 400 order Hi-Flux powder and iron sial powder respectively, and is mixed with composite powder, and mixed proportion sees Table 4.
Table 4
| Sequence number | Mixed proportion | Quality factor improves ratio | ||
| Iron sial powder | The HighFlux powder | 1MHz | 3MHz | |
| 9 | 50％ | 50％ | 102.2％ | 217.5％ |
| Contrast 3 | 0 | 100％ | - | - |
SiO with composite powder and 2wt%
2Powder, 1wt% epoxy resin, 0.3wt% zinc stearate evenly mix and oven dry, adopt alcohol as cosolvent during mixing.Adopt the pressure forming powder of 2Gpa.The annealing of magnetic core is carried out under vacuum state, and annealing temperature is 550 ℃, and annealing time is 30 minutes.Adopt epoxy resin and polyester mixture that the magnetic wicking surface is sprayed, coating layer thickness is 100um.
The quality factor of the quality factor of composite magnetic powder core and contrast iron Si-Al Magnetic Powder Core, Hi-Flux powder core are seen Fig. 4, and visible composite magnetic powder core is compared with the iron Si-Al Magnetic Powder Core, and the ratio magnetic permeability under the highfrequency figure of merit and the high direct current biasing obtains improving more significantly; Compare with Hi-Flux powder core, descending has by a relatively large margin appearred in the highfrequency figure of merit, descends than magnetic permeability under the high direct current biasing condition.Therefore,, a kind of magnetic core can be obtained, Hi-Flux powder core can be partly substituted with comprehensive, comprehensive demand characteristics by mixing iron sial powder and Hi-Flux powder preparation composite magnetic powder core.
Present embodiment adopts the water atomization method to prepare Hi-Flux powder and amorphous state Fe
69Ni
5Al
4Sn
2P
10C
2B
4Si
4Alloy powder adopts breaking method to prepare iron sial powder.Wherein the preannealing technology of amorphous powder is 450 ℃ * 60 minutes, and annealing process adopts vacuum atmosphere; The preannealing technology of Hi-Flux powder is 650 ℃ * 60 minutes, and annealing process adopts hydrogen atmosphere; The annealing process of iron sial powder is 600 ℃ * 30 minutes, and annealing atmosphere is a hydrogen atmosphere.Sieve is got the luxuriant and rich with fragrance brilliant Fe of negative 400 orders respectively
69Ni
5Al
4Sn
2P
10C
2B
4Si
4, Hi-Flux and iron sial powder, and be mixed with composite powder, mixed proportion sees Table 5.The preparation method of composite magnetic powder core is identical with embodiment 2.
Table 5
| Sequence number | Mixed proportion | Quality factor improves ratio | ||
| Amorphous powder | Iron sial powder | The HighFlux powder | 3MHz | |
| 9 | 50％ | 30％ | 20％ | 93.8％ |
| Contrast 3 | 0 | 100％ | - | |
The quality factor of composite magnetic powder core quality factor and contrast Hi-Flux powder core are seen Fig. 6.As seen composite magnetic powder core is compared with Hi-Flux powder core, and quality factor decrease under the medium and low frequency, and the highfrequency figure of merit significantly improves, and quality factor improve 93.8% (seeing Table 5) under 3MHz.Provided the change curve of the ratio magnetic permeability of composite magnetic powder core and contrast HighFlux powder core among Fig. 7 with direct current biasing.As seen from the figure, composite magnetic powder core has suitable ratio magnetic permeability with HighFlux powder core.Composite magnetic powder core is compared the prices of raw and semifnished materials with Hi-Flux powder core and is descended significantly.Therefore, can be by mixing Fe-based amorphous powder and Hi-Flux powder preparation composite magnetic powder core, compare magnetic core high frequency quality factor with Hi-Flux powder core and obtained remarkable lifting, price significantly descends, thereby can obtain a kind of magnetic core of comprehensive, comprehensive demand characteristics, under high frequency, substitute Hi-Flux powder core.
Claims (18)
1, a kind of composite powder for magnetic powder core, it is characterized in that, be evenly to mix by powders A and powder B, its content is: powders A is 50-95wt%, powder B 5-50wt%, wherein powders A is to be selected from a kind of in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder, powder B has different demand characteristicss with powders A, and is selected from least a in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder.
According to the described composite powder of claim 1, it is characterized in that 2, described powders A has top-priority demand characteristics.
According to claim 1 or 2 described composite powders, it is characterized in that 3, described demand characteristics is a kind of in magnetic permeability, loss, high frequency performance, anti-direct current biasing characteristic, temperature stability and the cost.
4, according to the described composite powder of claim 1, it is characterized in that, described powders A is to be selected from the higher iron nickel by powder of cost, iron nickel molybdenum powder, and described powder B is selected from least a in lower-cost iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, the Fe-based amorphous powder.
5, according to the described composite powder of claim 1, it is characterized in that, described powders A is to adopt the higher Fe-based amorphous powder of quality factor under the high frequency, and described powder B is selected from least a in quality factor is lower under the high frequency iron powder, iron silica flour, iron aluminum silicon powder, the iron based nano crystal powder.
According to the described composite powder of claim 1, it is characterized in that 6, described powder B is 10-50wt%.
7, a kind of manufacture method of composite powder for magnetic powder core is characterized in that, comprises the steps:
A, according to different demand characteristicss, prepare powders A and powder B separately;
B, powders A and powder B that preparation is finished sieve respectively;
C, adopt required separately technology to distinguish annealing in process in different types of powder.
D, powders A and powder B are evenly mixed, the content of its mass percent is: powders A is 50-95%, powder B 5-50%, wherein powders A is to be selected from a kind of in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder, powder B has different demand characteristicss with powders A, and is selected from least a in iron powder, iron silica flour, iron aluminum silicon powder, iron based nano crystal powder, Fe-based amorphous powder, iron nickel powder and the iron nickel molybdenum powder.
According to the manufacture method of the described composite powder for magnetic powder core of claim 7, it is characterized in that 8, described powder also comprises Performance Detection after screening.
According to the manufacture method of the described composite powder for magnetic powder core of claim 7, it is characterized in that 9, described incorporation time is: 1 minute-60 minutes.
10, a kind of magnetic core is characterized in that, comprises following components in weight percentage: insulating compound 0.2%-7%, and bonding agent 0.01-5%, lubricant 0.01-2%, all the other are any one described composite powder of claim 1-6.
11, magnetic core according to claim 10 is characterized in that, described insulating compound is selected from following at least a or its combination of respectively organizing in the material:
Be selected from SiO
2, Cao, Al
2O
3, TiO
2Oxide powder;
Be selected from the salt of silicates, phosphoric acid salt;
Be selected from mica powder, kaolinic mineral powder; With
The surface film that chemical method generates or the surface oxidation of generation.
12, according to the described magnetic core of claim 10, it is characterized in that, described bonding agent is organic bonding agent and/or inorganic adhesive, wherein: the organic bonding agent be selected from epoxylite, at least a in the epoxylite, inorganic adhesive is selected from least a in the phosphoric acid salt.
13, magnetic core according to claim 10 is characterized in that, described lubricant is selected from the stearate profit, talcum powder is at least a or its combination.
14, magnetic core according to claim 10 is characterized in that, described insulating compound 0.5%-5%.
15, a kind of preparation method of magnetic core is characterized in that, this method may further comprise the steps:
Insulating compound, bonding agent and the mix lubricant of e, employing claim any one described composite powder of 1-6 and desired content also is dried to dry powder;
F, above-mentioned dried powder is pressed in makes the magnetic core under the 500MPa-3000MPa pressure;
G, magnetic core annealing in process;
The processing of spraying paint of h, magnetic core;
I, magnetic core performance detect.
16, preparation process for magnetic powder core according to claim 14 is characterized in that, described magnetic core annealing temperature is 350 ℃-600 ℃, and annealing time is 5 minutes-3 hours.
17, preparation process for magnetic powder core according to claim 14 is characterized in that, described magnetic core annealing time is 30 minutes-60 minutes.
18, preparation process for magnetic powder core according to claim 14 is characterized in that, described magnetic core annealing in process is in hydrogen, nitrogen or argon shield atmosphere, or carries out under the vacuum state.
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| US12/581,164 US20100034687A1 (en) | 2005-12-28 | 2009-10-19 | Compound magnetic powder and magnetic powder cores, and methods for making them thereof |
| US12/581,163 US20100031773A1 (en) | 2005-12-28 | 2009-10-19 | Compound magnetic powder and magnetic powder cores, and methods for making them thereof |
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