CN86102755A - 软磁材料复合体及其成形方法 - Google Patents

软磁材料复合体及其成形方法 Download PDF

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CN86102755A
CN86102755A CN86102755.8A CN86102755A CN86102755A CN 86102755 A CN86102755 A CN 86102755A CN 86102755 A CN86102755 A CN 86102755A CN 86102755 A CN86102755 A CN 86102755A
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magnetic material
thermosetting resin
plastic agent
soft magnetic
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CN1008489B (zh
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濑琦好司
永井耕一
阪内孚史
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Kaneka Corp
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • 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
    • H01F1/34—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 non-metallic substances, e.g. ferrites
    • H01F1/36—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 non-metallic substances, e.g. ferrites in the form of particles
    • H01F1/37—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 non-metallic substances, e.g. ferrites in the form of particles in a bonding agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • 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
    • H01F1/147—Alloys characterised by their composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/58—Processes of forming magnets

Abstract

本发明提供一种由70～95％体积的软磁材料粉末和其余为液态热硬性树脂组成的软磁性材料。采用本发明所提供的方法，可生产在高密度条件下具有大初导磁率、高强度和高尺寸精度的高导磁性成形体。

Description

本发明是关于由软磁材料和作为粘接剂的液态热固树脂组成的成形性和磁导率良好的复合体及其成形方法。
以前，用作铁芯等的软磁材料，多使用在高周波范围内损耗少的尖晶石铁氧体，例如Mn-Zn铁氧体、Ni-Zn铁氧体等的烧结成形体，而这些材料由于用粉末冶金方法制造，烧结时由于收缩，存在着尺寸精度差，获得形状复杂的制品困难等问题。特别是，烧结体冲击强度低。为了弥补这些缺点，近年来，用合成树脂将软磁材料粘合起来的所谓塑料软磁材料被提出来了。例如在特公昭51-28356中提出了由粒子直径有特定范围的尖晶石铁氧体和粉末状热固性树脂组成的复合体。这种塑料软磁材料，由于以非磁性物质合成树脂作为粘合剂，缺点是成形的铁芯饱和磁化及磁导率较烧结体差。因此，要提高这种塑料软磁材料制作的铁芯的磁特性，必须在增加软磁体粉末含量的同时，增加成形压力，以降低空隙率，提高软磁体粉末的填充密度。
但是，以前的塑料软磁材料，如果软磁材料含量高，固化前成形体强度低，容易引起破损和变形，或固化后的成形体机械强度低。为进一步减小空隙率，而增加压力，在压缩成形时将引起大的变形，不仅软磁体粒子进一步破坏，铁芯的磁特性降低，而且由于模具的负载大，易造成模具损伤。
本发明者们鉴于上述各种问题，为了减轻由于加压造成变形的不良影响，同时增加成形体的密度，提高磁性能，减轻模具的负担，以及提高固化前的成形体的粘合强度，防止破损、变形，得到良好的尺寸精度，进行了深入研究，达到了本发明的目的。
本发明第1点，软磁材料复合体由体积含量70～95%软磁材料粉末和余量的液态热固性树脂、理想的是含有塑性剂的液态热固性树脂组成。本发明的第2点，由体积含量70～95%软磁材料粉末和余量的热固树脂组成的软磁材料复合体，在常温下加压成形后，于液态热固树脂固化温度使之固化，并以此为特征含塑料的高磁导率软磁材料复合体的成形方法。
本发明中使用的软磁材料粉末是尖晶石铁氧体，例如Mn-Zn铁氧体、Ni-Zn铁氧体、Mn-Mg铁氧体等，至少在1000℃以上，例如1100～1300℃烧结的粉末材料，此外软磁合金粉末是由下述一种或两种以上材料组成，例如铁粉、Fe-Ni合金粉、Fe-Al-Si合金粉、各种无定形软磁合金粉。在这些材料中，尖晶石铁氧体粉末工业上最容易得到。软磁材料是粉末状，要得到良好的磁特性，粒子直径分布很重要。希望软磁材料粉末主体粒子直径最小在0.3mm以上，最大到成形体的最小厚度。
本发明使用的液态热固树脂，在常温下是液态，如酚醛树脂、环氧树脂、尿素树脂、三聚氰酰胺树脂、呋喃树脂、不饱和聚酯树脂等，而酚醛树脂、尤其可溶性酚醛树脂是理想的。如作为粘合剂用液态热固树脂，与用固体粉末树脂相较，前者和软磁材料的混合格外良好。因为粘合剂本身的粘合力，使压缩成形后的强度高，不必担心固化前的破损和变形，而且固化后的强度也是良好的。
本发明的复合体，由体积含量70～95%软磁材料粉末和余量的液态热固性树脂构成。软磁材料粉末不足70%，不能得到所期望的磁性能，超过95%，易引起破损或变形。
只使用液态热固性树脂作为粘合剂，虽然可得到如上述的复合体，而在其中如含有塑性剂能够提供更好的复合体。即，如使用含有塑性剂的液态热固性树脂作为粘合剂，则粘合剂粘度变低，更容易均匀地分布于软磁粉末表面，与此同时，由于减轻了加压成形时软磁粒子间的摩擦，容易得到高的填充密度，提高成形体密度和初始磁导率。而且，如使用这样的粘合剂，也使加压成形的压力降低，容易实现所期望的高的成形体密度和初始导磁率，由于减轻了模具负荷，便于工业化。
本发明使用的塑性剂是：聚酯系塑性剂、邻苯二甲酸酯系塑性剂、环氧化油塑性剂、脂肪酸酯系塑性剂及其它塑性剂。可根据液态热固性树脂的种类不同选择使用。特别是用酚醛树脂时，宜于使用己二酸聚酯系塑性剂、邻苯二甲酸聚酯系塑性剂、邻苯二甲酸二丁酯及环氧化大豆油等塑性剂。塑性剂添加量如果非常少，则效果不显著，如超过粘合剂热固性树脂的固体量，成形体的强度降低。因此，通常液态热固性树脂固体重量100份，塑性剂适宜的重量范围为5～100份。
另外，为改善本发明复合体的性质，最好加入少量偶联剂、润滑剂、热稳定剂、以及其它改善质量的添加剂。
上述复合体成形时，使用热压或冷压等压力成形方法，可是使用含有塑性剂或不含塑性剂的液态粘合剂时，加压成形后，固化前的成形体的强度大，因此，没有必要采用操作麻烦的热压工艺。即，本发明的复合体成形时，在常温下使其加压粘结，然后，于热固性树脂的固化温度固化，这样生产效率高，同时成形体尺寸精确，磁特性良好。加压成形适宜的压力是2～6t/cm2。压力小于2t/cm2，即使用本发明的复合体，尽管能完成，填充密度也不够;施加压力超过6t/cm2不能期望显著地提高填充密度，反而因为软磁材料粉末粒子的破坏，导致磁性降低。
下面，根据实例说明本发明，但本发明不限于下述实例。
在下面的实例中，作为比较，把初始磁导率为1000～3000的Mn-Zn铁氧体烧结制品粉碎，得到直径为0.6～0.8mm的0.1～0.35mm的不同粒子，按重量比前者70%，后者30%混合，以此作为铁氧体原材料粉末使用。
实例1～7
以体积计把上述铁氧体原料86%和含有塑性剂的甲阶酚醛树脂14%体积用带式混合机混合，得到不同混合物。甲阶酚醛树脂中添加的塑性剂的比例是重量为100份甲阶酚醛树脂加0～80份己二酸聚酯，如表1所示。将此混合物在常温下按表1所示的压力成形，制成尺寸为30mmφ×20mmφ×10mm的环状粘合体。操作容易，不碎，不裂。然后，将其在180℃，加热固化2小时，得到外观良好的成形体样品。密度和初始磁导率良好，如表1所示。
实例8～9
在实例4中，用重量为60份邻苯二甲酸聚酯或邻苯二甲酸二丁酯代替己二酸聚酯塑性剂，同样得到环状成形体。结果如表1，外观良好，无裂纹、不破碎。
实例10～11
将重量为100份热塑性酚醛树脂粉末和100份胺基硅烷偶联剂，在200份甲醇中，常温反应，甲醇挥发后，得到粘稠含有硅烷端基的改性酚醛树脂。用改性酚醛树脂，得到和实例1和4一样具有良好外观的成形体。结果如表1所示。
比较例1～2
用热塑性酚醛树脂粉末，成形方法和实施1完全相同。比较例1施加2t/cm2压力，粘结成形体的强度非常低，没有得到供评定磁特性的试样。比较例2，施加6t/cm2压力，成形体的密度和初磁导率是非常不足的。
按照以上说明，本发明能够提供高密度、大的初始磁导率，强度高尺寸精度优良、生产率高的高磁导率成形体。这样的组合物及其以后得到的成形体，兼顾了成形性、强度、尺寸精度、磁性能诸方面。使可能精确地修正电流磁场。
Figure 86102755_IMG1

Claims (7)

1、软磁材料复合体由体积含量70～95%的软磁材料粉末和余量的液态热固树脂组成。
2、按权利要求1所述的复合体，液态热固性树脂中含有塑性剂。
3、按权利要求2所述的复合体，塑性剂至少一种是聚酯系塑性剂及邻苯二甲酸酯系塑性剂。
4、按权利要求2或3所述的复合体，塑性剂含量，以重量计液态热固性树脂固体100份时，塑性剂为5～100份。
5、按权利要求1、2、3或4所述的复合体，软磁材料是尖晶石型铁氧体。
6、由体积含量70～95%软磁材料粉末和余量液态热固性树脂组成的软磁材料复合体，在常温下加压成形后，于上述液态热固性树脂固化温度下使其固化，并以此为特征的含塑料的高磁导率软磁材料复合体的成形方法。
7、按权利要求6所述的成形方法，是在2～6t/cm2压力下，加压成形的。
CN86102755A 1985-04-19 1986-04-19 软磁材料复合体及其成型方法 Expired CN1008489B (zh)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103862048A (zh) * 2012-12-07 2014-06-18 中国科学院理化技术研究所 一种通过热压制备软磁性复合材料的方法
CN103862048B (zh) * 2012-12-07 2015-12-02 中国科学院理化技术研究所 一种通过热压制备软磁性复合材料的方法
CN105913997A (zh) * 2015-02-25 2016-08-31 株式会社村田制作所 电子部件

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CN1008489B (zh) 1990-06-20
JPH0744099B2 (ja) 1995-05-15
KR880700437A (ko) 1988-03-15
KR900008382B1 (ko) 1990-11-17
EP0220321B1 (en) 1994-08-24
JPS61242005A (ja) 1986-10-28
US4879055A (en) 1989-11-07
EP0220321A1 (en) 1987-05-06
EP0220321A4 (en) 1988-11-02
DE3650039D1 (de) 1994-09-29
WO1986006541A1 (en) 1986-11-06
DE3650039T2 (de) 1994-12-08

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