WO2023165096A1 - Poudre à faible perte pour inducteur formé d'un seul tenant et son procédé de préparation - Google Patents

Poudre à faible perte pour inducteur formé d'un seul tenant et son procédé de préparation Download PDF

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Publication number
WO2023165096A1
WO2023165096A1 PCT/CN2022/112981 CN2022112981W WO2023165096A1 WO 2023165096 A1 WO2023165096 A1 WO 2023165096A1 CN 2022112981 W CN2022112981 W CN 2022112981W WO 2023165096 A1 WO2023165096 A1 WO 2023165096A1
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Prior art keywords
powder
loss
low
mass
agent
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PCT/CN2022/112981
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English (en)
Chinese (zh)
Inventor
李伟健
邢冰冰
盖鹏祥
宋岩岩
张芹
缪思敏
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天通控股股份有限公司
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Priority to KR1020237026628A priority Critical patent/KR20230145060A/ko
Publication of WO2023165096A1 publication Critical patent/WO2023165096A1/fr

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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
    • 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
    • H01F1/147—Alloys characterised by their composition
    • H01F1/14766—Fe-Si based alloys
    • H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder

Definitions

  • the invention belongs to the field of magnetic functional materials, and in particular relates to an integrally formed low-loss powder for inductors and a preparation method thereof.
  • One-piece inductors are mostly made of carbonyl iron powder or iron-silicon-chromium alloy powder, which is pressed with the coil embedded in it after insulating coating.
  • Carbonyl iron powder is characterized by good DC superposition characteristics, low powder hardness, and high density after pressing, but its magnetic permeability is low.
  • High DC resistance R DC ; FeSiCr alloy powder has the advantages of good anti-rust properties and adjustable magnetic permeability range, but the powder is relatively hard, difficult to compact and compact, and has high loss.
  • the Chinese patent with the notification number CN111063501B has announced a preparation method for producing low-loss powders for integrally formed inductors, that is, after mixing carbonyl iron powder with iron silicon powder or amorphous powder Coating granulation, but the loss of iron-silicon powder is the highest among commonly used soft magnetic metal powders.
  • Amorphous powder has no grain boundaries, which makes it difficult to effectively coat, and its hardness is relatively high, so it is difficult to compress, so the obtained powder is still difficult to achieve Aim for low loss.
  • the Chinese patent with the publication number CN113380487A discloses a magnetic core powder for integrally formed inductors and its preparation method. Its core is still iron-silicon-chromium alloy powder for inorganic and organic coating. Although the obtained magnetic core has a stable structure and is not easy to crack , but still failed to solve the problem of excessive loss.
  • the purpose of the present invention is to overcome the deficiencies of the prior art and provide a low-loss powder for integrally formed inductors and its preparation method, which can not only reduce the loss caused by magnetic substances, but also reduce the use of copper wires in integrally formed inductors In turn, the resistance and the loss caused by the heating of the copper wire are reduced, and the overall efficiency is improved.
  • the low-loss powder for integrated molding inductors of the present invention is mainly composed of carbonyl iron powder, gas-atomized iron-silicon-aluminum alloy powder, phosphate coating agent, composite coating agent and lubricant, and carbonyl iron powder and gas-atomized iron
  • the mass of the mixed powder after mixing the silicon-aluminum alloy powder is the basis for calculation, where:
  • the phosphate coating agent is produced by the reaction of mixed powder and phosphate-acetone solution, wherein the mass of phosphoric acid is 0.1-0.3% of the mass of the mixed powder, and the acetone is 8-10% of the mass of the mixed powder;
  • the composite coating agent consists of 0.3-1.2% nickel-zinc ferrite powder, 0.2-0.6% quartz fiber powder, 0.1-0.3% film-forming agent, 0.1-0.4% plasticizer, 1.5-2.8% ring Oxygen resin, 0.3-0.5% of curing agent and 0.1-0.4% of coupling agent are mixed in acetone solvent to form; the lubricant accounts for 0.2-0.4% of the mass of the mixed powder.
  • the agent is an epoxy curing agent;
  • the coupling agent is ethyltriethoxysilane;
  • the lubricant is one or more mixtures of stearic acid, paraffin wax powder and magnesium stearate.
  • the outermost layer of the powder is a net-shaped coating film layer composed of a composite coating agent
  • the second outer layer is a phosphate film layer composed of a phosphate coating agent
  • the innermost layer is a matrix composed of sendust and carbonyl iron powder , and finally formed a double-layer coating structure.
  • a method for preparing low-loss powder for integrated molding inductors comprising the following steps:
  • Lubrication and sieving Weigh the lubricant and mix it with the granulated powder, and then sieve it with a mesh size of 50-270.
  • the powder with an intermediate particle size is the powder for low-loss integrated molding inductors.
  • the present invention has the following advantages:
  • the selection of original powder is carbonyl iron powder and gas atomized iron silicon aluminum powder, and its principle is that carbonyl iron is easy to press and form, and has better direct-current superposition characteristic, and powder particle size is little, and in the device
  • the eddy current loss is proportional to the particle size of the powder, so the eddy current loss generated is lower than that of the conventional powder, and the gas-atomized iron-silicon-aluminum powder is due to its high sphericity, low oxygen content, magnetostriction coefficient close to zero, and magnetic crystals.
  • the anisotropy constant is close to zero, which is the lowest loss among conventional soft magnetic materials.
  • the overall loss after mixing the two powders of the present invention is much lower than that of conventional powders, while maintaining the DC superposition characteristics close to conventional powders;
  • the inductance value of the integrally formed inductor is proportional to the square of the powder magnetic permeability and the number of turns of the coil. Since the magnetic permeability of the pressed powder in the present invention is higher than that of the conventional carbonyl iron powder, the integrally formed inductor with the same inductance value The amount of copper wire used will be reduced, which can reduce the loss caused by the heating of the copper wire in the integrated inductor, and the reduction in the number of copper wires will also help reduce production costs;
  • quartz fiber powder is Under the bonding action of film-forming agent, plasticizer, epoxy resin, curing agent, coupling agent and other materials, it can be evenly coated on the surface of the powder.
  • the quartz fiber powder has a certain aspect ratio, under microscopic conditions , can form a net-like coating film layer based on quartz fiber powder, the net-like structure helps to increase the toughness of the coating film layer, and is not easily damaged during the pressing process, thereby maintaining the powder with high insulation resistance, so The film layer has good insulation and reliability, and reduces the overall loss by reducing eddy current loss.
  • Lubrication and sieving Weigh 2g of stearic acid and mix it with the powder, and then sieve it with 50-270 meshes.
  • Example 1 The difference between this comparative example and Example 1 is that all the original powders used are carbonyl iron powders.
  • Example 1 The difference between this comparative example and Example 1 is that all the original powders used are iron-silicon-chromium alloy powders.
  • Example 1 The difference between this comparative example and Example 1 is that the composite coating agent used is to mix 1g plasticizer diethylene glycol dibenzoate, 24g epoxy resin, 5.5g curing agent, 1.5g ethyl triethoxy The base silane coupling agent is dissolved in the solvent of 100g acetone.
  • Example 1 and Comparative Example 1, Comparative Example 2, Comparative Example 3, and Comparative Example 4 was pressed into a magnetic ring with an outer diameter of 10.15 mm, an inner diameter of 5.1 mm, and a height of 3.98 ⁇ 0.02 mm, and after baking, the magnetic ring was made into a coil.
  • Embodiment 1 and comparative example 1, comparative example 2, comparative example 3, comparative example 4 characteristic test results are as shown in table 1:
  • Example 1 By comparing Example 1 with Comparative Examples 1-3, it can be seen from Table 1 that the present invention uses the mixed powder of sendust powder and carbonyl iron as the original powder, and the magnetic permeability of the prepared material is significantly improved, because the gas mist The magnetostriction coefficient and magnetic anisotropy constant of iron silicon aluminum powder are close to 0, so it has lower loss than iron silicon chromium alloy powder and carbonyl iron powder after mixing.
  • Example 1 and Comparative Example 4 it can be seen that after the composite coating of the present invention, the magnetic permeability of the material is higher than that of the ordinary coating process, and the loss is significantly lower than that of the ordinary coating process.
  • the spherical nickel-zinc-iron Oxygen powder is magnetic, and after coating and pressing, it can be filled into the gaps between carbonyl iron powders, so the performance has been improved.
  • the addition of quartz fiber powder, film-forming agent, and plasticizer can greatly improve the uniformity of coating and the insulation and toughness of the film layer, so that the film layer will not be easily damaged during the pressing process, and the coupling agent can improve The connection between the film layer and the powder matrix, so the coating effect of the film layer is better, the resistivity between the powder and the powder is greatly improved, and the eddy current loss generated between the particles is reduced, so the overall loss is reduced.
  • Lubrication and sieving Weigh 3g of magnesium stearate and mix it with the powder. After mixing, sieve it with a mesh size of 50-270. The powder with an intermediate particle size is the powder for low-loss integral molding inductors.
  • Example 2 The difference between this comparative example and Example 2 is that the composite coating agent used is an acetone solution mixed with 19g of nickel-zinc ferrite powder, 25g of epoxy resin, 5g of curing agent, and 3g of ethyltriethoxysilane coupling agent.
  • the composite coating agent used is an acetone solution mixed with 19g of nickel-zinc ferrite powder, 25g of epoxy resin, 5g of curing agent, and 3g of ethyltriethoxysilane coupling agent.
  • Example 2 The difference between this comparative example and Example 2 is that the composite coating agent used is to mix 6g film-forming agent tripropylene glycol n-butyl ether (TPnB), 4g plasticizer dipropylene glycol dibenzoate, 30g epoxy resin, 9g curing Agent, 3g ethyltriethoxysilane coupling agent in acetone solution.
  • TPnB tripropylene glycol n-butyl ether
  • plasticizer dipropylene glycol dibenzoate 30g epoxy resin
  • 9g curing Agent 9g curing Agent
  • 3g ethyltriethoxysilane coupling agent in acetone solution.
  • Example 2 The difference between this comparative example and Example 2 is that the composite coating agent used is to mix 10g nickel-zinc ferrite powder, 4g quartz fiber powder, 5g film-forming agent tripropylene glycol n-butyl ether (TPnB), 28g epoxy resin, 5g Acetone solution of curing agent.
  • the composite coating agent used is to mix 10g nickel-zinc ferrite powder, 4g quartz fiber powder, 5g film-forming agent tripropylene glycol n-butyl ether (TPnB), 28g epoxy resin, 5g Acetone solution of curing agent.
  • Embodiment 2 and comparative example 5 are as shown in table 2:
  • Example 2 By comparing Example 2 with Comparative Examples 5-8, it can be seen from Table 2 that the present invention uses the mixed powder of sendust powder and carbonyl iron as the original powder, and uses a composite coating agent to coat it.
  • the magnetic permeability of the prepared material is obviously improved, and the loss is obviously reduced.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Manufacturing & Machinery (AREA)
  • Soft Magnetic Materials (AREA)

Abstract

L'invention concerne une poudre à faible perte pour un inducteur formé d'un seul tenant et son procédé de préparation. Le procédé comprend : la soumission d'un corps de poudre magnétique formé par mélange d'une poudre d'alliage d'alimentation atomisée au gaz de grande taille de particule et d'une poudre de fer carbonyle de petite taille de particule à un traitement de phosphatation, de façon à obtenir une poudre de phosphatation ; puis le mélange de ladite poudre avec un agent de revêtement composite constitué de poudre de ferrite de nickel-zinc, de poudre de fibre de quartz, d'un agent filmogène, d'un plastifiant, d'une résine époxy, d'un agent de durcissement et d'un agent de couplage ; la granulation et la cuisson après agitation uniforme ; et après refroidissement à température ambiante, l'ajout d'un lubrifiant pour le mélange et le tamisage au moyen d'un tamis à mailles de 50 à 270, de façon à obtenir la poudre à faible perte pour l'inducteur formé d'un seul tenant. La poudre préparée présente les caractéristiques d'une conductivité magnétique élevée et d'une faible perte, et l'inducteur formé d'un seul tenant compacté au moyen de la poudre présente les avantages d'un faible coût, d'une faible perte, d'une faible chaleur, d'une efficacité élevée et analogues.
PCT/CN2022/112981 2022-03-02 2022-08-17 Poudre à faible perte pour inducteur formé d'un seul tenant et son procédé de préparation WO2023165096A1 (fr)

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CN114255952B (zh) * 2022-03-02 2022-05-17 天通控股股份有限公司 一种一体成型电感用低损耗粉末及其制备方法
CN114582580B (zh) * 2022-05-06 2022-07-29 天通控股股份有限公司 一种软磁金属粉末及其制备方法

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CN114255952A (zh) * 2022-03-02 2022-03-29 天通控股股份有限公司 一种一体成型电感用低损耗粉末及其制备方法

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