CN1986488A - Coating for soft magnetic alloy core and its spraying process - Google Patents
Coating for soft magnetic alloy core and its spraying process Download PDFInfo
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Abstract
The present invention belongs to the field of soft magnetic metal material and its preparing technology, and is especially coating for soft magnetic alloy core and its spraying process. The coating consists of one or two kinds of thermoplastic resin including polyethylene, polypropylene, polyester, etc; one or two kinds of thermosetting resin including epoxy polyester, polyurethane, unsaturated polyester and polyacrylate; and at least one kind of corresponding assistant. It is formed through air spraying, fluidized bed soaking, electrostatic powder coating or other painting process, and has thickness of 50-2000 microns. Compared with available technology, the present invention has the advantages of low cost, excellent magnetic performance of the magnetic alloy core after painting, etc.
Description
Technical field
The invention belongs to metal soft magnetic material and preparation field, particularly a kind of coating of magnetically soft alloy magnetic core and spraying method thereof.
Background technology
Metal soft magnetic alloy in the prior art, as amorphous, nano-crystal soft magnetic alloy the preparation method be, at first utilize the melt supercooled technology that alloy melt is prepared into thickness 20-40 μ m amorphous ribbon, with thin coiled stock coiled magnetic core, make it to have good soft magnetic performance by suitable thermal treatment process again.Owing to become fragile after amorphous, the nanocrystalline magnet core thermal treatment, in follow-up coiling, transportation and use, be easy to generate fragmentation and fall the slag phenomenon, reduce its soft magnetic performance to a certain extent, and influenced its result of use.For addressing the above problem, normally pack into plastics, bakelite or the metal of corresponding size of magnetically soft alloy magnetic core protected box, reduce magnetic core broken in follow-up coiling, transportation and use and fall the slag phenomenon, to keep the good soft magnetic performance of magnetic core.
The shortcoming that box protection magnetic core method is protected in this utilization is soft magnetic core and protects to have a fixed gap between the box; when making current transformer; need protect the magnetic core multiturn coiling (number of turn n＞1000) of box to band, because the net sectional area A of every circle magnetic core that coil surrounds
SLower, according to Faraday's electromagnetic indution law, the induction voltage U=4.44nBfA that n circle coil produces
SAlso lower, reduced the final soft magnetic performance of multiturn coiling soft magnetic core in fact indirectly, cause the performance of current transformer of follow-up making lower.In addition, in the making of electron device, the miniaturization of device size is one of target of pursuing all the time, utilizes plastics to protect box encapsulation soft magnetic core and causes the package dimension of magnetic core bigger, is unfavorable for the compact in size of the electron device of magnetic core and follow-up making.
The another kind of making method of amorphous nano-crystalline magnetic core is at magnetic core surface applied one deck hardened protective layer, and follow-up coiling can directly be carried out on protective layer.Compare with the mode that adopts the protection box, top coat can significantly reduce protective layer and take up space, and dwindles the volume of components and parts, and resin coating and magnetic core closely combine in addition, avoid magnetic core to peel off, fall slag because of vibrations.
In existing magnetic core top coat technology, generally adopt coated materials such as organosilicon polymer, polyimide based resin, Resins, epoxy.
Chinese patent application 02803133.4,200510085586.7 and 200510085587.1 has proposed a kind of method of utilizing organosilicon polymer coating protective magnetic core end face, but the price of silicone resin is generally relatively more expensive.
Chinese patent application 02809710.6 has proposed a kind of method of utilizing polyimide based resin coating protective Fe-based amorphous alloy magnetic core end face, and this method is that the magnetic core before the thermal treatment is carried out coating processing.Because the magnetic core after applying need require coating material can tolerate up to the high temperature more than 400 ℃ through Overheating Treatment, has increased cost.
It is the magnetic core method for packing of amorphous magnetic core coated with resins powder with the heat method of dipping in that Chinese patent application 200510045671.0 has proposed a kind of, but this method is being carried out heat when dipping in to iron core, just iron core is rolled while hot and carry out final size typing, be difficult for guaranteeing to produce in batches the consistence of coating magnetic core final size like this.
Chinese patent application 200520058193.2 has proposed to add solidifying agent with Resins, epoxy and has been coated in two surfaces of Internal and external cycle of iron-base nanometer crystal alloy magnetic core body and the technological line of magnetic core body both sides end face, this method can be for guaranteeing that magnetic core has stabilized magnetic a kind of vibration-proof structure can be provided, this method does not relate to concrete coating core production technology, therefore is difficult for guaranteeing to produce in batches the final size of coating magnetic core.
Goal of the invention and content
The object of the present invention is to provide a kind of cost low, magnetic core has excellent magnetic characteristics after the coating, dimensional uniformity is good, is fit to the coating and the spraying method thereof of the magnetically soft alloy magnetic core produced in enormous quantities.
According to above-mentioned purpose, the principle of work of technical scheme proposed by the invention is:
Described surface has resin-coated magnetically soft alloy magnetic core, and this surface resin coating principal constituent is made of at least a in thermoplasticity with long-chain or the thermosetting resin, and adds at least a auxiliary agent and constitute the final surface resin coating of magnetically soft alloy magnetic core.Wherein, principal constituent is the main material that constitutes coating, and through sclerosis or solidify the back and form layer thickness coating suitable, that have suitable hardness on the magnetic core surface, magnetic core need not be packed into and protected box directly to wind the line like this.The effect of auxiliary agent be suitably regulate principal constituent sclerosis or solidify after characteristic, for example improve intensity, toughness, elasticity and the wear resistance of coating so that magnetic core prevents the distortion under the external force effect better, the softening temperature that changes coating is to adapt to the variation of environment for use.Change resin coating thickness, and the auxiliary agent proportioning, can also regulate the coefficient of linear expansion of magnetic core, to reduce the various influences of external environment to the magnetic core performance.
Described surface has the manufacture method of resin-coated magnetically soft alloy magnetic core, and 1, select to have the thermoplasticity or the thermosetting resin of long-chain, obtain the resin coating less to the soft magnetic core unrelieved stress; 2, at this thermoplasticity or thermosetting resin composition, select corresponding adjuvants, reduce the unrelieved stress that resin coating shaping back produces magnetic core, or have a mind to produce certain particular stress to improve the magnetic property of magnetic core; 3, at thermoplasticity with short chain or thermosetting resin, adopt suitable magnetic core process for surface coating, as repeatedly spraying successively, and corresponding adjusting non-retentive alloy composition, the stress that when reducing the resin coating shaping soft magnetic core is produced.
According to above-mentioned purpose and principle of work, the concrete technical scheme of the present invention is:
This coating principal constituent is any one or two kinds in the polyethylene, polypropylene, polyvinyl chloride, cellaburate, nylon, polyester in the thermoplastic resin or is any one or two kinds in the epoxy polyester in the thermosetting resin, urethane, unsaturated polyester, the polyacrylic ester, and add at least a corresponding additive and form, adopt corresponding coating process to form resin coating on the soft magnetic core surface, coat-thickness is between 50～2000 μ m.
Above-mentioned core material is any one or two kinds in Fe-based amorphous alloy, cobalt base amorphous alloy, iron-base nanometer crystal alloy, iron ni-based amorphous alloy, the permalloy.
Above-mentioned auxiliary agent is any one or two kinds in solidifying agent, softening agent, properties-correcting agent, stablizer, oxidation inhibitor, flow agent, brightening agent, matting agent, anti-wear agent, anti-hard caking agent, protective agent, fire retardant, pigment, the filler.
The spraying method of above-mentioned soft magnetic core coating is any one or two kinds in aerial spraying, fluidized bed dipping, electrostatic fluidized bed dip-coating, electrostatic powder coating, electrostatic oscillation powder coating, the static tunnel powder coating.
Aerial spraying: above-mentioned soft magnetic core is preheating to 160 ℃～350 ℃, send into powder spraying chamber, the dust gun pressure-controlling at 0.2M～1.0MPa, is injected in the magnetic core surface with toner, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
Fluidized bed dipping: above-mentioned soft magnetic core is preheating to 160 ℃～350 ℃, send in the fluidized-bed, utilize pressurized air to make toner coating be boiling state, toner is evenly sticked to the magnetic core surface, at 160 ℃～350 ℃ baking 3～10min, magnetic core surface resin coating is finally finalized the design then;
Electrostatic fluidized bed dip-coating: will send in the fluidized-bed at the soft magnetic core magnetic core of 160 ℃～350 ℃ of preheatings, electrode voltage is controlled at 20k～120kV, utilize pressurized air to make toner coating be boiling state, toner evenly is adsorbed on the magnetic core surface, at 160 ℃～450 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
Electrostatic powder coating: will send into powder spraying chamber at the soft magnetic core of 160 ℃～350 ℃ of preheatings, powder monitor applies 30k～90kV volts DS, utilize spray gun that toner is sprayed on the magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
Electrostatic oscillation powder coating: will send into paint booth at the soft magnetic core of 160 ℃～350 ℃ of preheatings, and between magnetic core and electrode, apply 3 * 10
4～7 * 10
4V voltage at the even polymeric adsorbent powder in magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, finally finalizes the design magnetic core surface resin coating then;
Static tunnel powder coating: will send into powder spraying chamber at the soft magnetic core of 160 ℃～350 ℃ of preheatings, powder monitor applies voltage at 10～100V, utilize pressurized air that charged toner is sprayed on the magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then.
It is low that the present invention compared with prior art has a cost, and magnetic core has excellent magnetic characteristics after the coating, dimensional uniformity is good, is fit to the advantage of producing in batches.Above-mentioned advantage is specific as follows:
When this magnetic core is Fe-based amorphous alloy, saturation induction density under its power frequency 50Hz is more than 1.40T, initial magnetic permeability (magnetizing field strength 0.08A/m) is more than 5000, descend less than 20% from 50Hz to 500kHz magnetic core inductance value, after the magnetic core surface applied resin coating, the magnetic core magnetic property descended less than 15%.
When this magnetic core was cobalt base amorphous alloy, the saturation induction density under its power frequency 50Hz was more than 0.60T, and the permeability under the 50kHz is more than 40000, and after the magnetic core surface applied resin coating, the magnetic core magnetic property descended less than 10%.
When this magnetic core was the iron ni-based amorphous alloy, the saturation induction density under its power frequency 50Hz was more than 0.70T, and maximum permeability is more than 200,000, and after the magnetic core surface applied resin coating, the magnetic core magnetic property descended less than 10%.
When this magnetic core was iron-base nanometer crystal alloy, the saturation induction density under its power frequency 50Hz was more than 1.20T, and initial magnetic permeability (magnetizing field strength 0.08A/m) is more than 60000, and after the magnetic core surface applied resin coating, the magnetic core magnetic property descended less than 30%.
When this magnetic core was permalloy, the saturation induction density under its power frequency 50Hz was more than 0.60T, and initial magnetic permeability (magnetizing field strength 0.08A/m) is more than 60000, and behind magnetic core surface-coated resin coating, the magnetic core magnetic property descends less than 30%.
Adopt this 40A current transformer that resin-coated soft magnetic core is made that has, the mutual inductor ratio is less than 0.1%, and angular difference was less than 7 minutes.
Adopt this common mode inductance that resin-coated soft magnetic core is made that has, initial magnetic permeability is greater than 50,000 under the 10kHz.
Embodiment
Adopt starting material preparation cobalt base amorphous alloy, Fe-based amorphous alloy, iron ni-based amorphous alloy, permalloy, iron-base nanometer crystal alloys such as pure iron, silicon metal, ferro-boron, pure molybdenum, ferro-niobium, electrolytic copper, pure nickel, fine aluminium, titanium sponge.
When the preparation permalloy, adopt following alloying constituent (weight percent): Ni:76～89, Fe:2～15, M:0～10, wherein M is Cu, Nb, V, one or more among the Mo.
Magnetic core preparation: in vacuum induction furnace, refine permalloy, permalloy is rolled into the band of thickness＜0.30mm, alloy strip steel rolled stock is wound into magnetic core, under protective atmosphere, do thermal treatment.
When the preparation Fe-based amorphous alloy, adopt following alloying constituent (weight percent): Fe:82.8%～93.6%, Si:2.5%～6.5%, B:1.1%～4.5%, M:2.5%～7.5%, wherein M is V, Cr, Ni, Co, any one among the Mo or more than one.
When the preparation cobalt base amorphous alloy, adopt following alloying constituent (weight percent): Co:75.2%～84.4%, Fe:2.3%～7.6%, Si:4.6%～1 5.5%, B:1.5%～3.5%, M:0.9%～5.3%, wherein M is Ni, Mn, Cr, any one among the V or more than one.
When preparation iron ni-based amorphous alloy, adopt following alloying constituent (weight percent): Fe:37.8%～50.6%, Ni:36.3%～53.2%, B:0.5%～3.5%, Si:1.6%～9.5%, M:0.3%～2.5%, wherein M is Ni, Mn, Cr, any one among the V or more than one.
When the preparation iron-base nanometer crystal alloy, adopt following alloying constituent (weight percent): Cu:0.8%～1.6%, Si:7.0%～9.5%, B:1.1%～2.0%, M:4.5%～7.5%, M ': 0.001%～0.05%, the Fe surplus, wherein M is Mo and/or Nb, and M ' is for improving the Al and/or the Ti of processing characteristics.
Amorphous band preparation: the mother alloy that adopts the above-mentioned cobalt base amorphous alloy of vacuum induction melting, Fe-based amorphous alloy, iron ni-based amorphous alloy, iron-base nanometer crystal alloy composition, and the fusion mother alloy is cast on the heat-eliminating medium of rapid movement, form the continuous amorphous alloy band of thickness 0.015～0.040mm.
The magnetic core preparation: with Fe-based amorphous alloy, cobalt base amorphous alloy and iron ni-based amorphous alloy roll of strip coiled is the magnetic core of corresponding size, does 300 ℃～450 ℃ annealing under protective atmosphere, to eliminate the stress in the alloy.With iron-base nanometer crystal alloy roll of strip coiled is the magnetic core of corresponding size, does 500 ℃～600 ℃ anneal under protective atmosphere, makes alloy separate out α-Fe crystal grain, forms amorphous and nanocrystalline mixed structure.Can be with the synthetic composite cores of the magnetic core set of the differing materials after the thermal treatment.
Adopt magnetically soft alloy magnetic core composition of the present invention, resin coating composition and spraying method, prepared the surface and had resin-coated magnetically soft alloy magnetic core.Form the resin coating of even compact on the magnetically soft alloy magnetic core surface, become soft magnetic core, and can further prepare other magnetic device with premium properties.
Table 1 is magnetically soft alloy magnetic core composition, resin coating composition and the contrast of the coating process that adopted.
Table 2 is 3 φ 19-11-10mm Fe-based amorphous alloy magnetic core (40 circles, 1V) inductance value test value (mH) under the different frequency of static tunnel powder spraying front and back, adopt nylon (adding the 0.5-1.5% flow agent) toner spraying magnetic core, powder monitor applies voltage at 35V, utilize powder monitor that toner is sprayed on the magnetic core surface, at 230 ℃ of baking 10min.
Table 3 is 4 φ 65-40-20mm Fe-based amorphous alloy magnetic core (10 circles, 1V) inductance value test value (mH) under the different frequency of electrostatic fluidized bed dip-coating front and back, adopt unsaturated polyester resin (adding 0.2-2.0% hiding power properties-correcting agent) powder dip-coating magnetic core, electrode voltage is controlled at 60kV, with the even dip-coating of toner on the magnetic core surface, at 200 ℃ of baking 7min, magnetic core surface resin coating is finally finalized the design.
Table 4 is 3 35-26-10mm cobalt base amorphous alloy magnetic cores soft magnetic performance test datas before and after the electrostatic oscillation powder coating, adopts polyvinyl resin (adding the 0.1-2.5% softening agent) powder coating magnetic core, applies 4 * 10 between magnetic core and electrode
4V voltage at the even coating polyethylene toner in magnetic core surface, at 190 ℃ of baking 10min, finally finalizes the design magnetic core surface resin coating.
Table 5 is 3 φ 12.5-6-5mm cobalt base amorphous alloys and Fe-based amorphous alloy composite cores (40 circles, 1V) the inductance value observed value (mH) before and after the electrostatic oscillation powder coating, adopt epoxy polyester (adding the 0.5-1.5% flow agent) and acrylic acid polyester resin (adding 1.0-4.0% sticking power properties-correcting agent) powder dip-coating magnetic core, between magnetic core and electrode, apply 5 * 10
4V voltage at first evenly applies the epoxy polyester resin powder on the magnetic core surface, at 190 ℃ of baking 10min, evenly applies the acrylic acid polyester resin powder on the magnetic core surface again, at 200 ℃ of baking 10min, magnetic core surface resin coating is finally finalized the design.
Table 6 is 3 φ 23-20-9mm iron ni-based amorphous alloy magnetic cores (number of primary turns N1: secondary coil number of turn N2=2: 400) the current-voltage output characteristic test result before and after the electrostatic fluidized bed dip-coating, adopt butyric acid-cellulose acetate resin (adding 0.5-3.0% sticking power properties-correcting agent) powder dip-coating magnetic core, above-mentioned magnetic core is sent in the fluidized-bed, electrode voltage is controlled at 75kV, with the even dip-coating magnetic core of toner, at 240 ℃ of baking 5min, magnetic core surface resin coating is finally finalized the design.
Table 7 is 3 φ 22-17-6mm permalloy magnetic cores inductance value observed values (μ H) before and after aerial spraying, adopt polyvinyl chloride (PVC) RESINS (to add the 0.3-2.5% softening agent, the 0.5-3.5% flow agent) powder spraying magnetic core, above-mentioned soft magnetic core is preheating to 160 ℃ in baking box, powder spraying chamber is put in the taking-up of preheating magnetic core, the dust gun pressure-controlling at 0.60MPa, is sprayed on the magnetic core surface with toner, at 160 ℃ of baking 15min.
Table 8 is that 2 φ 160-120-25mm permalloy magnetic cores are behind fluidized bed dipping, inductance value test value under 1kHz～100kHz frequency (μ H), adopt acrylic resin (adding the 0.5-3.0% stablizer) powder that the magnetic core surface is applied, before the hot dip coating magnetic core is preheating to 300 ℃, magnetic core spraying back is at 220 ℃ of baking 5min.
Table 9 is that 3 φ 190-160-20mm iron-base nanometer crystal alloy magnetic cores are after electrostatic spraying, inductance value test value under 1kHz～100kHz frequency (μ H), powder monitor applies voltage at 35kV, adopt urethane resin (adding the 0.2-2.0% filler) powder evenly to spray magnetic core, at 220 ℃ of baking 12min.
Table 10 is 5 φ 25-21-12mm iron-base nanometer crystal alloy magnetic cores current-voltage test datas in the aerial spraying process, adopt polyester (adding the 0.5-3.0% thermo-stabilizer) and nylon (adding 0.5-4.0% hiding power properties-correcting agent) toner spraying magnetic core, before the spraying polyester powder, the magnetic core preheating temperature is 200 ℃, the spray back is at 190 degree baking 10min, and before the spraying nylon powder, the magnetic core preheating temperature is 220 ℃, 10min are toasted at 200 degree in the spray back.
Magnetic Measurement: can carry out magnetic property to the magnetic core after the coating and measure.For example, can measure the volt-ampere characteristic (I-E characteristic) and the inductance value of magnetic core.
When measuring the I-E characteristic of coating magnetic core, utilize voltage meter to measure and the corresponding voltage U of B, measure and the corresponding electric current I of H with current meter, measuring the measurement coil turn with the rectifier type voltage meter is N
2The time the mean value U of inductive emf
AvFurther, can determine B from volt-ampere characteristic
m-H
mMagnetzation curve.Magnetizing field is: H
m=1.414I N
1/ 1; In formula, N
1Be resin coating magnetic core magnetizing coil total number of turns, I is the resin coating magnetic core magnetzation current virtual value that current meter measures, and 1 is the resin coating magnetic core sample average length of magnetic path.Magnetic induction density is: B
m=U
Av/ (4.44fN
2A
s); In formula, f is the frequency of magnetzation current, A
sSurround the net sectional area of spraying magnetic core sample for every circle coil.
When measuring the inductance value of resin coating magnetic core under different frequency, on magnetic core, twine the enameled wire coil of the corresponding number of turn, adopt electric inductance measuring-testing instrument from the high frequency to the low frequency, to measure successively.
Table 1
| Composition | Naked core dimensions (mm) | Thermoplastic resin | Thermosetting resin | ||||||||
| Polyethylene | Polypropylene | Polyvinyl chloride | Butyric acid-cellulose acetate | Nylon | Polyester | Epoxy polyester | Acrylic polyester | Unsaturated polyester | Urethane | ||
| Fe-based amorphous alloy | φ19-11-10 | - | - | - | - | Static tunnel powder spraying | - | - | - | - | - |
| φ65-40-20 | - | - | - | - | - | - | - | - | The electrostatic fluidized bed dip-coating | - | |
| Cobalt base amorphous alloy | φ35-26-10 | The electrostatic oscillation powder coating | - | - | - | - | - | - | - | - | - |
| Iron-based+cobalt base amorphous alloy | φ12.5-6-5 | - | - | - | - | - | - | The electrostatic oscillation powder coating | - | - | |
| The iron ni-based amorphous alloy | φ23-20-9 | - | - | - | The electrostatic fluidized bed dip-coating | - | - | - | - | - | - |
| Permalloy | φ22-17-6 | - | - | Aerial spraying | - | - | - | - | - | - | |
| φ160-120- 25 | - | Fluidized bed dipping | - | - | - | - | - | - | - | - | |
| Iron-base nanometer crystal alloy | φ190-160- 20 | - | - | - | - | - | - | - | - | - | Electrostatic spraying |
| φ25-21-12 | - | - | - | - | Aerial spraying | - | - | - | - | ||
Table 2
| The magnetic core state | Frequency (Hz) | Embodiment | Comparative example (protecting box) | ||
| No.1 | No.2 | No.3 | |||
| Naked magnetic core | 1k | 1.22 | 1.19 | 1.25 | 1.20 |
| 10k | 1.12 | 1.10 | 1.13 | 1.12 | |
| 100k | 1.07 | 1.06 | 1.10 | 1.10 | |
| 500k | 1.01 | 0.99 | 1.01 | 1.01 | |
| The 1st spraying | 1k | 1.17 | 1.16 | 1.20 | -- |
| 10k | 1.10 | 1.09 | 1.07 | ||
| 100k | 1.07 | 1.06 | 1.04 | ||
| 500k | 0.99 | 1.00 | 0.98 | ||
| Coating average wall thickness (μ m) | 94 | 102 | 97 | ||
| The 2nd spraying | 1k | 1.13 | 1.13 | 1.16 | |
| 10k | 1.09 | 1.10 | 1.12 | ||
| 100k | 1.05 | 1.06 | 1.07 | ||
| 500k | 0.98 | 1.01 | 0.99 | ||
| Coating average wall thickness (μ m) | 195 | 229 | 186 | ||
| Coating magnetic core size (mm) | -- | φ19.6-10.4-10.6 | φ20-10-11 | ||
Table 3
| The magnetic core state | Frequency (Hz) | Embodiment | Comparative example (protecting box) | |||
| No.4 | No.5 | No.6 | No.7 | |||
| Naked magnetic core | 1k | 0.95 | 0.97 | 1.04 | 1.09 | 0.99 |
| 10k | 0.92 | 0.93 | 1.00 | 1.04 | 0.95 | |
| 100k | 0.86 | 0.85 | 0.94 | 0.98 | 0.90 | |
| 200k | 0.83 | 0.81 | 0.90 | 0.96 | 0.86 | |
| The 1st spraying | 1k | 0.90 | 0.93 | 0.99 | 1.05 | -- |
| 10k | 0.88 | 0.90 | 0.96 | 1.02 | ||
| 100k | 0.85 | 0.87 | 0.92 | 0.98 | ||
| 200k | 0.82 | 0.84 | 0.90 | 0.96 | ||
| Coating average wall thickness (μ m) | 127 | 116 | 141 | 152 | ||
| The 2nd spraying | 1k | 0.87 | 0.91 | 0.96 | 1.03 | |
| 10k | 0.86 | 0.88 | 0.94 | 1.01 | ||
| 100k | 0.83 | 0.85 | 0.91 | 0.99 | ||
| 200k | 0.81 | 0.83 | 0.89 | 0.96 | ||
| Coating average wall thickness (μ m) | 263 | 283 | 294 | 305 | ||
| Coating magnetic core size (mm) | -- | φ66.7-39.2-20.6 | φ67-37-23 | |||
Table 4
| The magnetic core state | Magnetic property | Embodiment | Comparative example (protecting box) |
| No.8 No.9 No.10 | |||
| Naked magnetic core | μ 0.3T/50kHz | 35500 31700 33600 | 32600 |
| P 0.3T/50kHz(W/kg) | 39 42 43 | 42 | |
| μ 0.3T/100kHz | 23600 19700 23400 | 21500 | |
| P 0.3T/100kHz(W/kg) | 96 97 103 | 99 | |
| The 1st spraying | μ 0.3T/50kHz | 35100 31200 33200 | |
| P 0.3T/50kHz(W/kg) | 39 43 44 | ||
| μ 0.3T/100kHz | 21700 18600 22700 | ||
| P 0.3T/100kHz(W/kg) | 97 99 105 | ||
| Coating average wall thickness (μ m) | 224 215 237 | ||
| The 2nd spraying | μ 0.3T/50kHz | 34600 30600 32400 | |
| P 0.3T/50kHz(W/kg) | 41 44 45 | ||
| μ 0.3T/100kHz | 20200 18100 21500 | ||
| P 0.3T/100kHz(W/kg) | 100 102 107 | ||
| Coating average wall thickness (μ m) | 432 450 479 | ||
| Coating magnetic core size (mm) | φ36-25-11 | φ37-24-12 |
Table 5
| The magnetic core state | Magnetic property | Embodiment | Comparative example (protecting box) | ||
| No.11 | No.12 | No.13 | |||
| Naked magnetic core | 10kHz，1V | 27.4 | 26.5 | 27.0 | 26.6 |
| Add the 120mA direct current | 22.5 | 21.9 | 22.3 | 21.4 | |
| The 1st spraying (urethane) | 10kHz，1V | 26.6 | 25.4 | 26.2 | -- |
| Add the 120mA direct current | 21.5 | 20.7 | 20.5 | ||
| Coating average wall thickness (μ m) | 340 | 355 | 370 | ||
| The 2nd spraying (epoxy polyester) | 10kHz，1V | 26.1 | 24.9 | 25.7 | |
| Add the 120mA direct current | 21.0 | 20.3 | 19.8 | ||
| Coating average wall thickness (μ m) | 925 | 910 | 945 | ||
| Coating magnetic core size (mm) | -- | φ13.4-5.1-6.0 | φ13.9-5.0-6.5 | ||
Table 6
| The magnetic core state | Magnetic property | Embodiment | Comparative example (protecting box) | ||
| No.11 | No.12 | No.13 | |||
| Naked magnetic core | Output voltage under the 30mA (V) | 0.97 | 0.95 | 0.94 | 0.72 |
| Output voltage under the 50mA (V) | 1.46 | 1.53 | 1.47 | 1.22 | |
| The 1st dip-coating | Output voltage under the 30mA (V) | 0.90 | 0.89 | 0.88 | -- |
| Output voltage under the 50mA (V) | 1.39 | 1.48 | 1.42 | ||
| Coating mean thickness (μ m) | 174 | 183 | 182 | ||
| The 2nd dip-coating | Output voltage under the 30mA (V) | 0.86 | 0.84 | 0.84 | |
| Output voltage under the 50mA (V) | 1.34 | 1.42 | 1.37 | ||
| Coating mean thickness (μ m) | 369 | 357 | 352 | ||
| Coating magnetic core size (mm) | -- | φ23.7-19.3-9.7 | φ24-19-10 | ||
Table 7
| Frequency (Hz) | 1k | 10k | 20k | 30k | 50k | 100k | Coating magnetic core size (mm) | ||
| Embodiment | No. 14 | Before the dip-coating | 40.2 | 38.5 | 34.4 | 32.1 | 29.4 | 24.6 | φ22.9-15.8-7 |
| Dip-coating 1 time | 37.2 | 34.2 | 31.7 | 29.7 | 25.6 | 19.8 | |||
| Coating mean thickness (μ m) | 260 | ||||||||
| Dip-coating 2 times | 35.5 | 32.6 | 30.8 | 28.7 | 24.2 | 18.6 | |||
| Coating mean thickness (μ m) | 460 | ||||||||
| No. 15 | Before the dip-coating | 41.5 | 39.8 | 35.7 | 33.0 | 30.1 | 25.3 | ||
| Dip-coating 1 time | 38.0 | 34.7 | 32.5 | 30.9 | 27.3 | 20.2 | |||
| Coating mean thickness (μ m) | 232 | ||||||||
| Dip-coating 2 times | 35.5 | 32.6 | 30.8 | 28.7 | 24.2 | 18.6 | |||
| Coating mean thickness (μ m) | 490 | ||||||||
| No. 16 | Before the dip-coating | 39.4 | 36.2 | 34.1 | 31.3 | 27.7 | 23.3 | ||
| Dip-coating 1 time | 36.1 | 34.5 | 32.0 | 30.1 | 25.4 | 19.4 | |||
| Coating mean thickness (μ m) | 246 | ||||||||
| Dip-coating 2 times | 34.2 | 32.2 | 30.2 | 27.5 | 23.6 | 18.7 | |||
| Coating mean thickness (μ m) | 595 | ||||||||
| Comparative example (protecting box) | -- | φ24-14-7.5 | |||||||
Table 8
| Frequency (Hz) | Embodiment | Comparative example (protecting box) | |
| No.17 | No.18 | ||
| 1k | 19.6 | 23.8 | 21.2 |
| 10k | 19.0 | 22.9 | 19.2 |
| 50k | 17.7 | 20.2 | 18.3 |
| 100k | 15.2 | 18.9 | 16.6 |
| Coating magnetic core size (mm) | φ161.5-119.5-27 | φ165-118-28 | |
Table 9
| Frequency (Hz) | Embodiment | Comparative example (protecting box) | ||
| No.19 | No.20 | No.21 | ||
| 1k | 23.0 | 23.8 | 25.8 | 22.4 |
| 5k | 22.3 | 22.2 | 25.4 | 21.7 |
| 10k | 21.4 | 21.1 | 24.8 | 20.5 |
| 50k | 16.7 | 17.5 | 19.9 | 16.4 |
| 100k | 13.7 | 14.8 | 14.6 | 13.2 |
| Coating magnetic core size (mm) | φ192-159-22 | φ195-157-23 | ||
Table 10
| Naked magnetic core | The 1st spraying (polyester) | ||||||||||
| Received current (mA) | No. 22 | No. 23 | No. 24 | No. 25 | No 26 | Received current (mA) | No. 22 | No. 23 | No. 24 | No. 25 | No. 26 |
| 3.8(μV) | 67.8 | 69.9 | 65.9 | 69.7 | 68.4 | 3.8(μV) | 47.4 | 48.1 | 43.5 | 59.3 | 51.8 |
| 7.6(μV) | 138.1 | 140.7 | 132.2 | 140.3 | 137.1 | 7.6(μV) | 95.8 | 94.0 | 86.7 | 96.9 | 103.5 |
| 11.4(mV) | 0.211 | 0.208 | 0.193 | 0.206 | 0.205 | 11.4(μV) | 151.5 | 149.6 | 136.0 | 146.4 | 156.8 |
| 15.2(mV) | 0.285 | 0.280 | 0.270 | 0.285 | 0.285 | 15.2(mV) | 0.207 | 0.215 | 0.186 | 0.202 | 0.214 |
| 19.0(mV) | 0.374 | 0.358 | 0.337 | 0.383 | 0.381 | 19.0(mV) | 0.282 | 0.280 | 0.239 | 0.282 | 0.304 |
| 22.8(mV) | 0.455 | 0.445 | 0.425 | 0.463 | 0.476 | 22.8(mV) | 0.351 | 0.338 | 0.312 | 0.362 | 0.387 |
| 26.6(mV) | 0.553 | 0.544 | 0.531 | 0.560 | 0.600 | 26.6(mV) | 0.441 | 0.450 | 0.394 | 0.434 | 0.486 |
| 30.4(mV) | 0.647 | 0.645 | 0.621 | 0.687 | 0.721 | 30.4(mV) | 0.553 | 0.546 | 0.500 | 0.543 | 0.620 |
| 34.2(mV) | 0.769 | 0.758 | 0.704 | 0.769 | 0.840 | 34.2(mV) | 0.649 | 0.629 | 0.567 | 0.668 | 0.755 |
| 38.0(mV) | 0.960 | 0.957 | 0.821 | 0.947 | 1.054 | 38.0(mV) | 0.789 | 0.808 | 0.694 | 0.808 | 0.940 |
| Coating average wall thickness (μ m) | - | - | - | - | - | Coating average wall thickness (μ m) | 85 | 89 | 72 | 89 | 78 |
| The 2nd spraying (nylon) | The 3rd spraying (nylon) | ||||||||||
| Received current (mA) | No. 22 | No. 23 | No. 24 | No. 25 | No. 26 | Received current (mA) | No. 22 | No. 23 | No. 24 | No. 25 | No. 26 |
| 3.8(μV) | 44.0 | 45.2 | 43.6 | 46.1 | 47.9 | 3.8(μV) | 36.9 | 42.6 | 42.7 | 43.7 | 41.2 |
| 7.6(μV) | 88.5 | 96.7 | 99.3 | 86.1 | 102.7 | 7.6(μV) | 73.0 | 84.8 | 83.0 | 86.1 | 83.5 |
| 11.4(μV) | 133.2 | 141.2 | 145.7 | 149.1 | 151.8 | 11.4(μV) | 113.8 | 144.9 | 139.9 | 143.8 | 139.8 |
| 15.2(mV) | 0.180 | 0.194 | 0.205 | 0.193 | 0.205 | 15.2(μV) | 168.3 | 190.4 | 188.7 | 188.6 | 187.1 |
| 19.0(mV) | 0.246 | 0.278 | 0.256 | 0.268 | 0.294 | 19.0(mV) | 0.230 | 0.250 | 0.239 | 0.244 | 0.240 |
| 22.8(mV) | 0.328 | 0.327 | 0.317 | 0.322 | 0.363 | 22.8(mV) | 0.305 | 0.341 | 0.325 | 0.350 | 0.343 |
| 26.6(mV) | 0.414 | 0.410 | 0.399 | 0.407 | 0.456 | 26.6(mV) | 0.364 | 0.353 | 0.357 | 0.396 | 0.424 |
| 30.4(mV) | 0.508 | 0.494 | 0.466 | 0.487 | 0.568 | 30.4(mV) | 0.451 | 0.495 | 0.466 | 0.495 | 0.542 |
| 34.2(mV) | 0.618 | 0.565 | 0.576 | 0.559 | 0.702 | 34.2(mV) | 0.549 | 0.592 | 0.542 | 0.567 | 0.656 |
| 38.0(mV) | 0.721 | 0.765 | 0.712 | 0.773 | 0.885 | 38.0(mV) | 0.671 | 0.712 | 0.666 | 0.715 | 0.817 |
| Coating average wall thickness (μ m) | 162 | 179 | 167 | 147 | 182 | Coating average wall thickness (μ m) | 241 | 260 | 257 | 243 | 261 |
Claims (9)
1, a kind of coating of magnetically soft alloy magnetic core, it is characterized in that this coating principal constituent is any one or two kinds in the polyethylene, polypropylene, polyvinyl chloride, cellaburate, nylon, polyester in the thermoplastic resin or is any one or two kinds in the epoxy polyester in the thermosetting resin, urethane, unsaturated polyester, the polyacrylic ester, and add at least a corresponding additive and form, adopt corresponding coating process to form resin coating on the soft magnetic core surface, coat-thickness is between 50～2000 μ m.
2, the coating of a kind of magnetically soft alloy magnetic core according to claim 1 is characterized in that core material is any one or two kinds in Fe-based amorphous alloy, cobalt base amorphous alloy, iron-base nanometer crystal alloy, iron ni-based amorphous alloy, the permalloy.
3, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 1 is characterized in that this spraying method is any one or two kinds in aerial spraying, fluidized bed dipping, electrostatic fluidized bed dip-coating, electrostatic powder coating, electrostatic oscillation powder coating, the static tunnel powder coating.
4, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3, it is characterized in that aerial spraying is that above-mentioned soft magnetic core is preheating to 160 ℃～350 ℃, send into powder spraying chamber, with the dust gun pressure-controlling at 0.2M～1.0MPa, toner is injected in the magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
5, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3, it is characterized in that fluidized bed dipping is that above-mentioned soft magnetic core is preheating to 160 ℃～350 ℃, send in the fluidized-bed, utilize pressurized air to make toner coating be boiling state, toner is evenly sticked to the magnetic core surface, at 160 ℃～350 ℃ baking 3～10min, magnetic core surface resin coating is finally finalized the design then;
6, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3, it is characterized in that the electrostatic fluidized bed dip-coating is to send in the fluidized-bed at the soft magnetic core magnetic core of 160 ℃～350 ℃ of preheatings, electrode voltage is controlled at 20k～120kV, utilize pressurized air to make toner coating be boiling state, toner evenly is adsorbed on the magnetic core surface, at 160 ℃～450 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
7, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3, it is characterized in that electrostatic powder coating is to send into powder spraying chamber at the soft magnetic core of 160 ℃～350 ℃ of preheatings, powder monitor applies 30k～90kV volts DS, utilize spray gun that toner is sprayed on the magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then;
8, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3 is characterized in that the electrostatic oscillation powder coating is to send into paint booth at the soft magnetic core of 160 ℃～350 ℃ of preheatings, apply 3 * 10 between magnetic core and electrode
4～7 * 10
4V voltage at the even polymeric adsorbent powder in magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, finally finalizes the design magnetic core surface resin coating then;
9, the spraying method of the coating of a kind of magnetically soft alloy magnetic core according to claim 3, it is characterized in that static tunnel powder coating is to send into powder spraying chamber at the soft magnetic core of 160 ℃～350 ℃ of preheatings, powder monitor applies voltage at 10～100V, utilize pressurized air that charged toner is sprayed on the magnetic core surface, at 160 ℃～350 ℃ baking 3～30min, magnetic core surface resin coating is finally finalized the design then.
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