CN107216138A - 电磁感应无线充电用锰锌铁氧体磁片及其制备方法 - Google Patents
电磁感应无线充电用锰锌铁氧体磁片及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种电磁感应无线充电用锰锌铁氧体磁片及其制备方法,包括主成分和辅助成分;所述主成分包括如下组分:Fe2O3、MnO和ZnO;所述辅助成分包括:CaCO3、Bi2O3、MoO3、Co2O3、K2CO3、TiO2、P2O5和V2O5。制备方法包括如下步骤:称料;(2)掺杂;(3)压制坯料;(4)排坯;(5)烧结处理;(6)研磨处理。本发明经科学的材料配方设计、烧结工艺及窑炉气氛优化等措施,使得制备的锰锌铁氧体磁片的致密化程度,经研磨后具有抗折强度高,不易破损和变形的特点,且磁片的居里温度高,具有良好的温升特性,温度曲线平坦、工作环境适应性强,具有良好的应用前景。
Description
技术领域
本发明涉及锰锌铁氧体材料领域,特别是涉及一种电磁感应无线充电用锰锌铁氧体磁片及其制备方法。
背景技术
随着跨领域电子设备产业的高速发展,产业设备、集成制造装备、多功能通信媒体,汽车电子设备越来越多的应用了基于电磁感应的无线充电技术,而其中最关键的技术在于嵌套的软磁铁氧体磁片。软磁铁氧体由于其成本方面的优势,越来越多的软磁在替换传统永磁的同时,良好的配合特性也能帮助实现元器件更好的特性。
电磁感应无线充电用锰锌铁氧体磁片可广泛应用于无线通讯,智能电表终端、工业集成设备等电子设备技术中,可以做通信设备、测控仪器、家用电器及新型节能灯具等中的宽带变压器、脉冲变压器、电感器、滤波器、共模扼流圈及传输***中的接口变压器、隔离变压器等。
磁性材料在滤波器、开关电源及变压器应用电子产品中均占有部分体积并消耗部分能源。因此提高磁芯初始磁导率及频率特性,使大功率产品向小型号、高效化发展,对我国电子产业结构调整,节能减排提供有效帮助。但现有的铁氧体磁片在变压器的应用中还存在诸多不足之处,如高低温度下的磁导率特性、温度特性、饱和磁通密度特性及磁芯致密化程度等不满足要求。
发明内容
本发明主要解决的技术问题是提供一种电磁感应无线充电用锰锌铁氧体磁片及其制备方法,能够解决现有铁氧体磁片存在的上述不足之处。
为解决上述技术问题,本发明采用的一个技术方案是:提供一种电磁感应无线充电用锰锌铁氧体磁片,包括主成分和辅助成分;所述主成分包括如下摩尔百分含量的组分:Fe2O3 50~56mol%、MnO 36~42mol%、ZnO 5~10mol%;相对于所述主成分的总重量,所述辅助成分及其含量为:CaCO3 1500~2500ppm、Bi2O3 500~1500ppm、MoO3 300~3000ppm、Co2O3800~1500ppm、K2CO3 100~800ppm、TiO2 50~500ppm、P2O5 30~300ppm、V2O5 50~500ppm。
在本发明一个较佳实施例中,所述Fe2O3和ZnO的纯度为95%以上。
在本发明一个较佳实施例中,所述锰锌铁氧体磁片的最小厚度为0. 35mm。
为解决上述技术问题,本发明采用的另一个技术方案是:提供一种电磁感应无线充电用锰锌铁氧体磁片的制备方法,包括如下步骤:
(1)称料:按配方称取所述主成分和辅助成分;
(2)掺杂:将步骤(1)中称取的辅助成分先后分3次以上加入到称取的主成分中,每次加入辅助成分后,将加入的辅助成分与主成分先进行混合预烧,再进行研磨处理,最后将全部的辅助成分与主成分混合研磨得到平均粒径为0.1~0.3μm的混合组分;
(3)压制坯料:向步骤(2)中得到的混合料中先后加入去离子水和分散剂,搅拌成均一的浆料,再将所述浆料用专用模具压制成磁片坯料;
(4)排坯:将步骤(3)中得到的坯料在烧结架上按一定的空间间距进行单层排坯处理,并在坯料的底部垫配烧结垫片,在烧结垫片与磁片坯料之间铺撒一层刚玉砂;
(5)烧结处理:将步骤(4)中经排坯后的磁片坯料置入烧结窑炉内,在平衡气氛下烧结成型;
(6)研磨处理,得到符合尺寸要求的锰锌铁氧体磁片。
在本发明一个较佳实施例中,所述步骤(2)中,所述混合预烧的条件为:温度400~500℃,时间5~15min;所述混合研磨在行星球磨机中进行,每次研磨时间为5~15min。
在本发明一个较佳实施例中,所述步骤(4)中,所述磁片坯料的空间间距为1~1.5cm。
在本发明一个较佳实施例中,所述步骤(5)中,所述烧结的工艺条件为:在5~8%氮气含量的平衡气压下,先以30~50℃/min的升温速率从室温升至1000℃,然后再以100℃/min的升温速率升温至1400℃,恒温保持4.5h,然后再以30~50℃/min的降温速率将至1100℃,恒温保持1~2h,最后随炉自然冷却至室温。
本发明的有益效果是:本发明经科学的材料配方设计、烧结工艺及窑炉气氛优化等措施,使得制备的锰锌铁氧体磁片的致密化程度,经研磨后具有抗折强度高,不易破损和变形的特点,且磁片的居里温度高,具有良好的温升特性,温度曲线平坦、工作环境适应性强,可为用户提供使用领域更广泛,体积更小,更高效,损耗低的电源设备,具有良好的应用前景。
具体实施方式
下面对本发明的较佳实施例进行详细阐述,以使本发明的优点和特征能更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
本发明实施例包括:
实施例1
一种电磁感应无线充电用锰锌铁氧体磁片,包括主成分和辅助成分;所述主成分包括如下摩尔百分含量的组分:Fe2O3 50mol%、MnO 42mol%、ZnO 8mol%;其中,Fe2O3和ZnO均为高纯度,其纯度为95%以上,MnO来自大比表面积的Mn3O4。
相对于主成分的总重量,所述辅助成分及其含量为:CaCO3 1500ppm、Bi2O3500ppm、MoO3 300ppm、Co2O3 800ppm、K2CO3 800ppm、TiO2 50ppm、P2O5 30ppm、V2O5 200ppm。其中,通过增加CaCO3的参杂量提高铁氧体的机械强度;通过Co2O3和V2O5的加入有效改善磁片的电磁感应性能。
上述电磁感应无线充电用锰锌铁氧体磁片的制备方法,包括如下步骤:
(1)称料:按配方称取所述主成分和辅助成分;
(2)掺杂:将上述称取的辅助成分先后分3次以上加入到称取的主成分中,每次加入辅助成分后,将加入的辅助成分与主成分先在400℃下混合预烧15min,再在行星球磨机中研磨处理5~15min,最后将全部的辅助成分与主成分混合研磨得到平均粒径为0.1~0.3μm的混合组分;
(3)压制坯料:向步骤(2)中得到的混合料中先后加入去离子水和分散剂,搅拌成均一的浆料,再将所述浆料用专用模具压制成磁片坯料;
(4)排坯:将步骤(3)中得到的坯料在烧结架上按1cm的空间间距(即前后左右间距)进行单层排坯处理,并在底层垫配烧结垫片,再在烧结垫片与磁片坯料之间撒一层刚玉砂,垫片下方设计多方向的槽口;磁片之间的空间间距及垫片的结构设计均便于热气流流通,从而使整个磁片在烧结窑炉中的受热程度均匀,可有效保证磁片的整体性能均一稳定;
(5)烧结处理:将步骤(4)中经排坯后的磁片坯料置入烧结窑炉内,在充分考虑节能及排胶、烧结均匀性及兼顾主成分及辅助成分特性的基础上,按布莱克方程式设定气氛曲线,并采用如下烧结工艺进行烧结:在5%氮气含量的平衡气压下,先以50℃/min的升温速率从室温升至1000℃,然后再以100℃/min的升温速率升温至1400℃,恒温保持4.5h,然后再以50℃/min的降温速率将至1100℃,恒温保持1~2h,最后随炉自然冷却至室温。在增加V2O5的添加量的前提下,通过适当缩短烧结温度及烧结保温时间,在保证高温功耗水平、提高TC及降低产品温度系数的前提下降低了颗粒间的活性,一方面用于减少磁芯微观间隙,增加饱和磁通密度,另一方面也间接提高了烧结后的产品强度。
(6)研磨处理,得到符合尺寸要求的锰锌铁氧体磁片。
实施例2
一种电磁感应无线充电用锰锌铁氧体磁片,包括主成分和辅助成分;所述主成分包括如下摩尔百分含量的组分:Fe2O3 53mol%、MnO 42mol%、ZnO 5mol%;其中,Fe2O3和ZnO均为高纯度,其纯度为95%以上,MnO来自大比表面积的Mn3O4。
相对于主成分的总重量,所述辅助成分及其含量为:CaCO3 2500ppm、Bi2O31500ppm、MoO3 3000ppm、Co2O3 1500ppm、K2CO3 100ppm、TiO2 500ppm、P2O5 30ppm、V2O5500ppm。其中,通过增加CaCO3的参杂量提高铁氧体的机械强度;通过Co2O3和V2O5的加入有效改善磁片的电磁感应性能。
上述电磁感应无线充电用锰锌铁氧体磁片的制备方法,包括如下步骤:
(1)称料:按配方称取所述主成分和辅助成分;
(2)掺杂:将上述称取的辅助成分先后分3次以上加入到称取的主成分中,每次加入辅助成分后,将加入的辅助成分与主成分先在500℃下混合预烧5min,再在行星球磨机中研磨处理5~15min,最后将全部的辅助成分与主成分混合研磨得到平均粒径为0.1~0.3μm的混合组分;
(3)压制坯料:向步骤(2)中得到的混合料中先后加入去离子水和分散剂,搅拌成均一的浆料,再将所述浆料用专用模具压制成磁片坯料;
(4)排坯:将步骤(3)中得到的坯料在烧结架上按1.5cm的空间间距(即前后左右间距)进行单层排坯处理,并在底层垫配烧结垫片,再在烧结垫片与磁片坯料之间撒一层刚玉砂,垫片下方设计多方向的槽口;磁片之间的空间间距及垫片的结构设计均便于热气流流通,从而使整个磁片在烧结窑炉中的受热程度均匀,可有效保证磁片的整体性能均一稳定;
(5)烧结处理:将步骤(4)中经排坯后的磁片坯料置入烧结窑炉内,在充分考虑节能及排胶、烧结均匀性及兼顾主成分及辅助成分特性的基础上,按布莱克方程式设定气氛曲线,并采用如下烧结工艺进行烧结:在8%氮气含量的平衡气压下,先以30℃/min的升温速率从室温升至1000℃,然后再以100℃/min的升温速率升温至1400℃,恒温保持4.5h,然后再以30℃/min的降温速率将至1100℃,恒温保持1~2h,最后随炉自然冷却至室温;其中,较长的保温时间有助于达到降低磁片的高温功耗水平、提高TC,降低产品温度系数, 使温度曲线趋于平坦之目的。在增加V2O5的添加量的前提下,通过适当缩短烧结温度及烧结保温时间,在保证高温功耗水平、提高TC及降低产品温度系数的前提下降低了颗粒间的活性,一方面用于减少磁芯微观间隙,增加饱和磁通密度,另一方面也间接提高了烧结后的产品强度。
(6)研磨处理,得到符合尺寸要求的锰锌铁氧体磁片。
上述方法得到的电磁感应无线充电用锰锌铁氧体磁片,具有较高的产品致密化程度,研磨后抗折强度高,不易破损和变形;磁片的研磨精度高,厚度最小可达0.35mm,其主要特点是具有良好的温升特性,温度曲线平坦,高温功耗低、工作环境适应性强。经测试,具体性能特点如下:
1)性能层面,1.0KHz,0.3V,25±3℃条件下,初始磁导率μi=2500±25%;
2)具有良好的温度特性,温度曲线平坦,适合工作温度为-30~150℃;
3)居里温度高,Tc≥220℃;
4)高温功耗低,100KHz 200mT 100℃的功耗小于350kw/m3。
本发明适应目前跨领域电子设备产业的高速发展,可为用户提供使用领域更广泛,体积更小,更高效,损耗低的电源设备,并且能够应用于与无线充电用线路板配合使用的设备设施,如无线通讯,智能电表终端、工业集成设备、海底电缆、光缆水下设备等特殊环境。
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (7)
1.一种电磁感应无线充电用锰锌铁氧体磁片,其特征在于,包括主成分和辅助成分;所述主成分包括如下摩尔百分含量的组分:Fe2O3 50~56mol%、MnO 36~42mol%、ZnO 5~10mol%;相对于所述主成分的总重量,所述辅助成分及其含量为:CaCO3 1500~2500ppm、Bi2O3 500~1500ppm、MoO3 300~3000ppm、Co2O3 800~1500ppm、K2CO3 100~800ppm、TiO250~500ppm、P2O5 30~300ppm、V2O5 50~500ppm。
2.根据权利要求1所述的电磁感应无线充电用锰锌铁氧体磁片,其特征在于,所述Fe2O3和ZnO的纯度为95%以上。
3.根据权利要求1所述的电磁感应无线充电用锰锌铁氧体磁片,其特征在于,所述锰锌铁氧体磁片的最小厚度为0. 35mm。
4.一种如权利要求1至3任一项所述的电磁感应无线充电用锰锌铁氧体磁片的制备方法,其特征在于,包括如下步骤:
(1)称料:按配方称取所述主成分和辅助成分;
(2)掺杂:将步骤(1)中称取的辅助成分先后分3次以上加入到称取的主成分中,每次加入辅助成分后,将加入的辅助成分与主成分先进行混合预烧,再进行研磨处理,最后将全部的辅助成分与主成分混合研磨得到平均粒径为0.1~0.3μm的混合组分;
(3)压制坯料:向步骤(2)中得到的混合料中先后加入去离子水和分散剂,搅拌成均一的浆料,再将所述浆料用专用模具压制成磁片坯料;
(4)排坯:将步骤(3)中得到的坯料在烧结架上按一定的空间间距进行单层排坯处理,并在坯料的底部垫配烧结垫片,在烧结垫片与磁片坯料之间铺撒一层刚玉砂;
(5)烧结处理:将步骤(4)中经排坯后的磁片坯料置入烧结窑炉内,在平衡气氛下烧结成型;
(6)研磨处理,得到符合尺寸要求的锰锌铁氧体磁片。
5.根据权利要求4所述的电磁感应无线充电用锰锌铁氧体磁片的制备方法,其特征在于,所述步骤(2)中,所述混合预烧的条件为:温度400~500℃,时间5~15min;所述混合研磨在行星球磨机中进行,每次研磨时间为5~15min。
6.根据权利要求4所述的电磁感应无线充电用锰锌铁氧体磁片的制备方法,其特征在于,所述步骤(4)中,所述磁片坯料的空间间距为1~1.5cm。
7.根据权利要求4所述的电磁感应无线充电用锰锌铁氧体磁片的制备方法,其特征在于,所述步骤(5)中,所述烧结的工艺条件为:在5~8%氮气含量的平衡气压下,先以30~50℃/min的升温速率从室温升至1000℃,然后再以100℃/min的升温速率升温至1400℃,恒温保持4.5h,然后再以30~50℃/min的降温速率将至1100℃,恒温保持1~2h,最后随炉自然冷却至室温。
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