CN105895290B - 一种耐高温磁粉制备方法 - Google Patents
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Abstract
本发明公开了一种耐高温磁粉制备方法，以铁硅铬作为主料，添加环氧树脂和酚醛树脂后通过合理的烘烤烧结工艺对成型后的产品进行固化，工艺步骤简单，可操作性强，生产成本低，得到的产品不仅具有优异的电磁特性，还具有优异的耐高温性能，可在190℃的高温环境中使用。
Description
技术领域
本发明涉及一种磁粉，尤其是涉及一种耐高温磁粉制备方法。
背景技术
目前在汽车电子行业使用的电感产品多为烧结铁粉芯或烧结磁粉芯产品，其制作工艺复杂且成本昂贵，使得其应用受到很大制约。同时常规的一体式电感产品使用的环境温度为125℃，无法满足日益发展的汽车电子行业要求。
因此，在保证性能和成本的前提下如何提高提高铁粉芯的使用温度（例如可长期在150~180℃温度下正常工作）是目前亟需解决的技术问题。
发明内容
本发明是为了解决现有技术的铁粉芯制作工艺复杂且成本昂贵，使用温度低的问题，提供了一种工艺步骤简单，可操作性强，生产成本低的耐高温磁粉制备方法，通过本发明制得的磁粉不仅具有优异的电磁特性，还具有优异的耐高温性能，可在190℃的高温环境中使用。
为了实现上述目的，本发明采用以下技术方案：
本发明的一种耐高温磁粉制备方法，包括以下步骤：
（1）称取所需量的铁硅铬粉后，以铁硅铬粉质量为基准，称取0.2~0.8%的磷酸和10~50%的丙酮，将磷酸加入丙酮中搅拌均匀得混合液，铁硅铬粉中各组分的质量百分比为：5~6%Cr，4~5% Si，余量Fe。本发明选择铁硅铬粉作为粉体主料，以保证最终的磁粉具备优异直流叠加特性、储能能力、高饱和磁感等电磁特性。
（2）将铁硅铬粉加入混合液中，搅拌均匀后晾干。
（3）将步骤（2）中的铁硅铬粉在60~200℃条件下烘烤2~4h后，冷却，摊晾，得预处理粉料。
（4）以预处理粉料质量为基准，称取1~10%的环氧树脂，0.1~1%的酚醛多环氧树脂，10~30%的丙酮，将与丙酮混合均匀后，加入预处理粉料，搅拌均匀后在50~100℃条件下烘烤30~60min，冷却后即得耐高温磁粉。本发明中特意添加了环氧树脂和酚醛树脂协同作用，在铁硅铬粉表面形成均匀的树脂薄膜以起到防氧化特性，从而以提高磁粉的耐高温性能。
作为优选，步骤（2）中，搅拌在真空条件下进行，且至少搅拌30min。真空条件下进行搅拌，能使铁硅铬粉表面形成均匀的树脂薄膜，以提高薄膜的均匀性。
作为优选，步骤（3）中，摊晾时间至少在0.5h以上。
作为优选，步骤（3）中，环氧树脂由7~15%的脂肪族多元胺及余量的脂肪酸甘油酯环氧树脂组成。
作为优选，所述脂肪族多元胺为二亚乙基三胺、三亚乙基四胺或二乙胺基丙胺。
因此，本发明具有如下有益效果：本发明铁硅铬作为主料，添加环氧树脂和酚醛树脂后通过合理的烘烤烧结工艺对成型后的产品进行固化，工艺步骤简单，可操作性强，生产成本低，得到的产品不仅具有优异的电磁特性，还具有优异的耐高温性能，可在190℃的高温环境中使用。
具体实施方式
下面通过具体实施方式对本发明做进一步的描述。
在本发明中，若非特指，所有百分比均为重量单位，所有设备和原料均可从市场购得或是本行业常用的，下述实施例中的方法，如无特别说明，均为本领域常规方法。
实施例1
（1）称取所需量的铁硅铬粉后，以铁硅铬粉质量为基准，称取0.8%的磷酸和50%的丙酮，将磷酸加入丙酮中搅拌均匀得混合液，铁硅铬粉中各组分的质量百分比为：5%Cr，5%Si，90%Fe。
（2）将铁硅铬粉加入混合液中，在真空条件下搅拌至少30min后晾干。
（3）将步骤（2）中的铁硅铬粉在60℃条件下烘烤4h后，冷却，摊晾至少0.5h，得预处理粉料。
（4）以预处理粉料质量为基准，称取1%的环氧树脂，0.1%的酚醛多环氧树脂，10%的丙酮，将与丙酮混合均匀后，加入预处理粉料，搅拌均匀后在50℃条件下烘烤60min，冷却后即得耐高温磁粉，其中环氧树脂由7%的二亚乙基三胺及93%的脂肪酸甘油酯环氧树脂组成。
实施例2
（1）称取所需量的铁硅铬粉后，以铁硅铬粉质量为基准，称取0.2%的磷酸和10%的丙酮，将磷酸加入丙酮中搅拌均匀得混合液，铁硅铬粉中各组分的质量百分比为：6%Cr，4%Si，90%Fe。
（2）将铁硅铬粉加入混合液中，在真空条件下搅拌至少30min后晾干。
（3）将步骤（2）中的铁硅铬粉在200℃条件下烘烤2h后，冷却，摊晾至少0.5h，得预处理粉料。
（4）以预处理粉料质量为基准，称取10%的环氧树脂，1%的酚醛多环氧树脂，30%的丙酮，将与丙酮混合均匀后，加入预处理粉料，搅拌均匀后在100℃条件下烘烤30min，冷却后即得耐高温磁粉，其中环氧树脂由15%的三亚乙基四胺及85%的脂肪酸甘油酯环氧树脂组成。
实施例3
（1）称取所需量的铁硅铬粉后，以铁硅铬粉质量为基准，称取0.5%的磷酸和20%的丙酮，将磷酸加入丙酮中搅拌均匀得混合液，铁硅铬粉中各组分的质量百分比为：5.5%Cr，4.8% Si，89.7%Fe。
（2）将铁硅铬粉加入混合液中，在真空条件下搅拌至少30min后晾干。
（3）将步骤（2）中的铁硅铬粉在100℃条件下烘烤3h后，冷却，摊晾至少0.5h，得预处理粉料。
（4）以预处理粉料质量为基准，称取5%的环氧树脂，0.5%的酚醛多环氧树脂，20%的丙酮，将与丙酮混合均匀后，加入预处理粉料，搅拌均匀后在80℃条件下烘烤40min，冷却后即得耐高温磁粉，其中环氧树脂由10%的二乙胺基丙胺及90%的脂肪酸甘油酯环氧树脂组成。
本发明铁硅铬作为主料，添加环氧树脂和酚醛树脂后通过合理的烘烤烧结工艺对成型后的产品进行固化，工艺步骤简单，可操作性强，生产成本低，得到的产品不仅具有优异的电磁特性，还具有优异的耐高温性能，可在190℃的高温环境中使用。
以上所述的实施例只是本发明的一种较佳的方案，并非对本发明作任何形式上的限制，在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (3)
1.一种耐高温磁粉制备方法，其特征在于，包括以下步骤：
（1）称取所需量的铁硅铬粉后，以铁硅铬粉质量为基准，称取0.2~0.8%的磷酸和10~50%的丙酮，将磷酸加入丙酮中搅拌均匀得混合液，铁硅铬粉中各组分的质量百分比为：5~6%Cr，4~5% Si，余量Fe；
（2）将铁硅铬粉加入混合液中，搅拌均匀后晾干；
（3）将步骤（2）中的铁硅铬粉在60~200℃条件下烘烤2~4h后，冷却，摊晾，得预处理粉料；
（4）以预处理粉料质量为基准，称取1~10%的环氧树脂，0.1~1%的酚醛多环氧树脂，10~30%的丙酮，将与丙酮混合均匀后，加入预处理粉料，搅拌均匀后在50~100℃条件下烘烤30~60min，冷却后即得耐高温磁粉；环氧树脂由7~15%的脂肪族多元胺及余量的脂肪酸甘油酯环氧树脂组成，脂肪族多元胺为二亚乙基三胺、三亚乙基四胺或二乙胺基丙胺。
2.根据权利要求1所述的一种耐高温磁粉制备方法，其特征在于，步骤（2）中，搅拌在真空条件下进行，且至少搅拌30min。
3.根据权利要求1所述的一种耐高温磁粉制备方法，其特征在于，步骤（3）中，摊晾时间至少在0.5h以上。
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