CN107352993A - 一种高频锰锌软磁铁氧体材料及其制备方法 - Google Patents

一种高频锰锌软磁铁氧体材料及其制备方法 Download PDF

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CN107352993A
CN107352993A CN201710568388.9A CN201710568388A CN107352993A CN 107352993 A CN107352993 A CN 107352993A CN 201710568388 A CN201710568388 A CN 201710568388A CN 107352993 A CN107352993 A CN 107352993A
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soft magnetic
high frequency
magnetic ferrite
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刘培元
傅膑
张凯
孔令才
谢振华
赵辉
李俊
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RUYUAN DONG YANG GUANG MATERIALS CO Ltd
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Abstract

本发明涉及一种高频锰锌软磁铁氧体材料及其制备方法，该高频锰锌软磁铁氧体材料包含如下含量的主成分：Fe2O3：54.5～57.5mol％、MnO：37～40mol％、ZnO：5.3～5.8mol％；相对主成分的总重量还包含如下含量的添加剂：Ca2CO3：0.1～0.2wt％，NiO：0.5～1.0wt％，Nb2O5：0.01～0.05wt％，SnO2：0.01～0.06wt％，Bi2O3：0.02～0.06wt％，Co2O3：0.2～0.3wt％。相比于现有技术，本发明高频锰锌软磁铁氧体材料在常高温饱和磁通密度、高频损耗等参数方面，得到了多方面的提升。

Description

一种高频锰锌软磁铁氧体材料及其制备方法
技术领域
本发明涉及电子器材及其制备技术领域，尤其涉及一种高频低损耗高磁通密度、高居里温度的锰锌软磁铁氧体材料及其制备方法。
背景技术
社会信息化不断向前发展，伴随着对电子产品器件高效化，高频化，小型化应用的强烈需求，对应用与其中的铁氧体材料提出了越来越高的要求，高直流叠加的铁氧体材料可以提高抗直流磁场干扰的能力，高饱和磁通密度有利于器件小型化。拥有较高的居里温度便于小型化后应用于较宽的使用温度范围，降低器件狭小空间或平面化发热后不能及时散热造成的器件不能正常工作的风险。
通常器件需集成在电路板上与其他器件一起工作，在工作时不可避免地受到其他器件产出的直流场的干扰，受其他工作器件形成的不同磁场的扰动，器件如要正常工作，需提高自身的抗干扰能力，比如电感器，需在干扰的磁场下，自身的电感不能有显著的跌落，需保证扰动下仍能保持足够电感量与其他器件一起正常工作。
因此，急需研究出一种同时拥有高饱和磁通密度，高居里温度，高直流叠加性能的锰锌铁氧体，其可以同时拥有高电阻率，可应用于较高的频率范围，可以实现器件的小型化，集成化，多功能化。
发明内容
本发明的目的是为了克服现有技术的不足，提供一种高频锰锌软磁铁氧体材料，该软磁材料在常温与高温均具有较高的饱和磁通密度，特别适合在高频率、大电流的多种应用场合实现更稳定的电感功能。
本发明的另一个目的是提供一种上述高频锰锌软磁铁氧体材料的制备方法。
本发明是由如下技术方案组成的：一种高频锰锌软磁铁氧体材料，包含如下含量的主成分：Fe2O3：54.5～57.5mol％、MnO：37～40mol％、ZnO：5.3～5.8mol％；相对主成分的总重量还包含如下含量的添加剂：Ca2CO3：0.1～0.2wt％，NiO：0.5～1.0wt％，Nb2O5：0.01～0.05wt％，SnO2：0.01～0.06wt％，Bi2O3：0.02～0.06wt％，Co2O3：0.2～0.3wt％。
进一步地，在1190A/m测试条件下，25℃时所述高频锰锌软磁铁氧体材料的饱和磁通密度Bs达到542mT～549mT，其剩磁密度Br为107mT～117mT，100℃时所述软磁材料的饱和磁通密度Bs达到454mT～458mT，其剩磁密度Br为111mT～116mT。可见，该高频锰锌软磁铁氧体材料在常温与高温均具有较高的饱和磁通密度。
进一步地，所述高频锰锌软磁铁氧体材料的居里温度Tc达到300℃，其密度ρ＝4.76×103kg/m3～4.81×103kg/m3。可见，该高频锰锌软磁铁氧体材料具有较高的居里温度。
进一步地，在1M、50MT测试条件下，25℃的所述高频锰锌软磁铁氧体材料的功率损耗Pcv为145mW/cm3～175mW/cm3，100℃的所述软磁材料的损耗Pcv为176mW/cm3～195mW/cm3。可见，该高频锰锌软磁铁氧体材料具有较低的损耗。
相比于现有技术，本发明的高频低损耗高磁通密度、高居里温度的锰锌软磁铁氧体材料，采用三元系主配方，并配合加入添加剂组合，其中的三元系原料配方为后续的组合添加剂作基础，添加剂组合起到辅助与促进作用，使得压制的生坯易于烧结、晶粒均匀，气孔率降低，烧结密度提高，进而获得高频低损耗高磁通密度、高居里温度的锰锌软磁铁氧体材料。相比于现有的软磁材料，本发明高频锰锌软磁铁氧体材料在常高温饱和磁通密度、高频损耗等参数方面，得到了多方面的提升。因此，本发明的高频锰锌软磁铁氧体材料能以更稳定的直流叠加适应性能，更宽的温度适用范围，保证所应用的器件更为稳定地运行，特别适合在直流叠加很大、频率较高的电感器等诸多场合的推广使用。
本发明还涉及一种上述高频锰锌软磁铁氧体材料的制备方法，包括以下步骤：
S1：对主成分按摩尔百分比含量进行配比，然后在砂磨机中加入去离子水进行混合和破碎，再循环混合后加入PVA溶液；
S2：将经破碎混合的主成分烘干后放入预烧炉内进行预烧；
S3：对经预烧的主成分加入添加剂组合，然后将主成分与添加剂组合的粉料放入砂磨机中加入去离子水、PVA和消泡剂进行二次砂磨，制得粒度为0.60～0.8μm的磨细粉料；
S4：将磨细粉料进行喷雾造粒，制得50～200μm的喷雾粉料；然后将喷雾粉料压制成型，制得密度为2.95～3.05g/cm3的样环生坯；
S5：将生坯在氮气保护气氛炉中1150～1180℃的温度条件下烧结定型，冷却后制得所述高频锰锌软磁铁氧体材料。
相比于现有技术，本发明所述的高频锰锌软磁铁氧体材料的制备方法在三元体系配方的基础上，配合组分配方促进晶粒细化、均匀化分布，经过三种原材料的一次混合、预烧，加入添加剂组合后二次混合、成型、烧结等步骤，简捷、高效地生产制得具有更高饱和磁通密度高直流叠加、高居里温度的锰锌软磁铁氧体材料；在烧结工艺上：通过控制升温速率、以缓慢升温进一步促保晶粒致密生长；通过升温段氮气保护进行致密化烧结，以控制材料中气孔大小及数量；适当延长保温时间，促进固相反应完全、晶粒生长均匀、减少气孔和异相；以获得高密度、高饱和磁通密度的锰锌软磁铁氧体材料。本发明制备方法制得的软磁材料特别适合在直流叠加很大、频率较高的场合应用。
进一步地，步骤S1中破碎持续40～50min，循环混合持续10～20min。
进一步地，步骤S2中预烧炉中温度控制在880～950℃，预烧炉保温持续2～3h。
进一步地，步骤S3中二次砂磨持续时间为120～150min。
进一步地，步骤S4中，采用成型油压机，压制H12.5-7.5-5.0样环。
进一步地，步骤S5中，氮气保护气氛炉中，氧含量为0.5-1.0％，余量为氮气；冷却是在受控的氮氧气氛中进行，冷却至室温。
具体实施方式
实施例1：
本实施例的锰锌软磁铁氧体材料按照以下工艺步骤制得：
1、配料：
按摩尔百分比称取Fe2O3为56mol％、MnO为38.5mol％、ZnO为5.5mol％的三种原料，然后在砂磨机中加入一定比例去离子水进行混合和破碎，破碎50分钟，进行循环混合15分钟后加入一定量PVA溶液，进行喷雾造粒。
2、预烧：
将喷雾料放入预烧炉内，在920℃下保温2小时进行预烧。
3、二次砂磨：
在预烧料中加入以下按预烧料(原料)重量百分比的辅助成分：Ca2CO3为0.1wt％，NiO为1.0wt％，Nb2O5为0.03wt％，SnO2为0.04wt％，Bi2O3为0.05wt％，Co2O3为0.3wt％。然后将粉料放入砂磨机中加入去离子水进行二次砂磨，砂磨时间为150分钟，粉料粒度控制在0.6～0.8μm。
4、喷雾造粒和成型：
在二次砂磨中加入一定比例的PVA和消泡剂，然后在喷雾塔中进行喷雾造粒成50～200μm的颗粒；然后成型，样环生坯密度在3.00g/cm3左右；
5、烧结：
在氮气保护气氛下，在1160℃的温度条件下保温5小时烧结，氮气保护下冷却到室温。
将烧结好的样品用岩崎SY8218和HP4284A电感仪进行测试，具体性能见表1：
表1实施例1中烧结样品的测试结果
从表1中可以看出，在1194A/m条件下，实施例1制得的高频锰锌软磁铁氧体材料25℃的Bs是543mT，100℃的Bs是456mT。因此该材料能很好的满足25℃～100℃温度范围内的直流叠加对磁性材料的要求，是一种高饱和磁通密度高直流叠加特性的软磁铁氧体粉料。
实施例2：
1、配料：
按摩尔百分比称取Fe2O3为55.7mol％、MnO为38.8mol％、ZnO为5.5mol％，三种原料，然后在砂磨机中加入一定比例去离子水进行混合和破碎，破碎50分钟，进行循环混合15分钟后加入一定量PVA溶液，进行喷雾造粒。
2、预烧：
将喷雾料放入预烧炉内，在880℃下保温2小时进行预烧。
3、二次砂磨：
在预烧料中加入以下按预烧料重量百分比的辅助成分：Ca2CO3为0.2wt％，NiO为1.0wt％，Nb2O5为0.05wt％，SnO2为0.04wt％，Bi2O3为0.02wt％，Co2O3为0.15wt％。然后将粉料放入砂磨机中加入去离子水进行二次砂磨，砂磨时间为150分钟，粉料粒度控制在0.6～0.8μm。
4、喷雾造粒和成型：
在二次砂磨中加入一定比例的PVA和消泡剂，然后在喷雾塔中进行喷雾造粒成50～200μm的颗粒；然后成型，样环生坯密度在3.00g/cm3左右；
5、烧结：
在氮气保护气氛下，在1150℃的温度条件下保温5小时烧结，氮气保护下冷却到室温。
将烧结好的样品用岩崎SY8218和HP4284A电感仪进行测试，具体性能见表2：
表2实施例2中烧结样品的测试结果
从表2中可以看出，在1194A/m条件下，实施例2制得的高频锰锌软磁铁氧体材料25℃的Bs是542mT，100℃的Bs是454mT。因此该材料能很好的满足25℃～100℃温度范围内的直流叠加对磁性材料的要求，是一种高饱和磁通密度高直流叠加特性的软磁铁氧体粉料。
实施例3：
1、配料：
按摩尔百分比称取Fe2O3为54.5mol％、MnO为39.7mol％、ZnO为5.8mol％，三种原料，然后在砂磨机中加入一定比例去离子水进行混合和破碎，破碎50分钟，进行循环混合15分钟后加入一定量PVA溶液，进行喷雾造粒。
2、预烧：
将喷雾料放入预烧炉内，在880℃下保温2小时进行预烧。
3、二次砂磨：
在预烧料中加入以下按预烧料重量百分比的辅助成分：Ca2CO3为0.1wt％，NiO为0.5wt％，Nb2O5为0.03wt％，SnO2为0.06wt％，Bi2O3为0.05wt％，Co2O3为0.3wt％。然后将粉料放入砂磨机中加入去离子水进行二次砂磨，砂磨时间为120分钟，粉料粒度控制在0.6～0.8μm。
4、喷雾造粒和成型：
在二次砂磨中加入一定比例的PVA和消泡剂，然后在喷雾塔中进行喷雾造粒成50～200μm的颗粒；然后成型，样环生坯密度在3.00g/cm3左右；
5、烧结：
在氮气保护气氛下，在1160℃的温度条件下保温5小时烧结，氮气保护下冷却到室温。
将烧结好的样品用岩崎SY8218和HP4284A电感仪进行测试，具体性能见表3：
表3实施例3中烧结样品的测试结果
从表3中可以看出，在1194A/m条件下，实施例3制得的高频锰锌软磁铁氧体材料25℃的Bs是543mT，100℃的Bs是456mT。因此该材料能很好的满足25℃～100℃温度范围内的直流叠加对磁性材料的要求，是一种高饱和磁通密度高直流叠加特性的软磁铁氧体粉料。
对比实施例
与上述3个实施例相比，传统典型的软磁铁氧体粉料的相应性能如以下表4所示：
表4传统软磁铁氧体粉料比较例的性能
由上表4各项性能逐项与表1～3对比可证：本发明的软磁材料在直流叠加要求较高、频率较高的多种应用场合，具有更高、更稳定的电感功能。
采用本发明实施例1、2、3制得的高频锰锌软磁铁氧体材料以及对比实施例中传统软磁铁氧体粉料均压制成UU磁芯产品，并制成电感线圈，分别在25℃、100℃的工作温度下，向电感线圈上叠加直流，同时，采用电感测量仪测得各电感线圈的直流～电感数据如表5和6所示。业内通常以电感跌落到叠加电流前电感60％左右时的叠加电流为磁芯性能近于失效的临界电流。
从表5可以看出，25℃时所有磁芯产品的60％电感值约为2.62μH，从表中可以看到本发明实施例1～3制得的UU26磁芯样品该电感值对应的临界电流为24A，而传统UU26磁芯样品该电感值对应的临界电流为19A，计算二者临界电流的差别率为(24A-19A)/19A*100＝26.3％。
从表6可以看出，100℃时所有磁芯产品的60％电感值约为2.62μH，从表中可以看到本发明实施例1～3制得的UU26磁芯样品对应的临界电流为18A，而传统UU26磁芯样品对应的临界电流为16A，计算二者临界电流的差别率为(28A-16A)/16A*100＝12.5％。
由表5和表6对比足证，本发明软磁铁氧体材料的直流叠加特性确实优于传统样品。且以上各项数据表明：本发明材料的直流叠加特性优异，加之较高的饱和磁通密度和较低的剩余磁通密度，较低的高频损耗，能较好的满足25℃～100℃宽温范围内的高Bs、高直流叠加、低高频损耗的材料特性要求；本发明的高频锰锌软磁铁氧体材料在直流叠大、频率高的多种应用场合，具有更高、更稳定的电感功能，能大幅度增加客户的设计器件的工作余量、加大电子器件的稳定性和使用寿命，还有利于器件的小型化和降低成本。
以上仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，凡在本发明的精神和原则之内所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

1.一种高频锰锌软磁铁氧体材料，包含如下含量的主成分：Fe2O3：54.5～57.5mol％、MnO：37～40mol％、ZnO：5.3～5.8mol％；相对主成分的总重量还包含如下含量的添加剂：Ca2CO3：0.1～0.2wt％，NiO：0.5～1.0wt％，Nb2O5：0.01～0.05wt％，SnO2：0.01～0.06wt％，Bi2O3：0.02～0.06wt％，Co2O3：0.2～0.3wt％。
2.根据权利要求1所述的高频锰锌软磁铁氧体材料，其特征在于：在1190A/m测试条件下，25℃时所述高频锰锌软磁铁氧体材料的饱和磁通密度Bs达到542mT～549mT，其剩磁密度Br为107mT～117mT，100℃时所述软磁材料的饱和磁通密度Bs达到454mT～458mT，其剩磁密度Br为111mT～116mT。
3.根据权利要求1所述的高频锰锌软磁铁氧体材料，其特征在于：所述高频锰锌软磁铁氧体材料的居里温度Tc达到300℃，其密度ρ＝4.76×103kg/m3～4.81×103kg/m3。
4.根据权利要求1所述的高频锰锌软磁铁氧体材料，其特征在于：在1M、50MT测试条件下，25℃的所述高频锰锌软磁铁氧体材料的功率损耗Pcv为145mW/cm3～175mW/cm3，100℃的所述软磁材料的损耗Pcv为176mW/cm3～195mW/cm3。
5.一种如权利要求1～4任一项所述的高频锰锌软磁铁氧体材料的制备方法，包括以下步骤：
S1：对主成分按摩尔百分比含量进行配比，然后在砂磨机中加入去离子水进行混合和破碎，再循环混合后加入PVA溶液；
S2：将经破碎混合的主成分烘干后放入预烧炉内进行预烧；
S3：对经预烧的主成分加入添加剂组合，然后将主成分与添加剂组合的粉料放入砂磨机中加入去离子水、PVA和消泡剂进行二次砂磨，制得粒度为0.60～0.8μm的磨细粉料；
S4：将磨细粉料进行喷雾造粒，制得50～200μm的喷雾粉料；然后将喷雾粉料压制成型，制得密度为2.95～3.05g/cm3的样环生坯；
S5：将生坯在氮气保护气氛炉中1150～1180℃的温度条件下烧结定型，冷却后制得所述高频锰锌软磁铁氧体材料。
6.根据权利要求5所述的制备方法，其特征在于：步骤S1中破碎持续40～50min，循环混合持续10～20min。
7.根据权利要求5所述的制备方法，其特征在于：步骤S2中预烧炉中温度控制在880～950℃，预烧炉保温持续2～3h。
8.根据权利要求5所述的制备方法，其特征在于：步骤S3中二次砂磨持续时间为120～150min。
9.根据权利要求5所述的制备方法，其特征在于：步骤S4中，采用成型油压机，压制H12.5-7.5-5.0样环。
10.根据权利要求5所述的制备方法，其特征在于：步骤S5中，氮气保护气氛炉中，氧含量为0.5-1.0％，余量为氮气；冷却是在受控的氮氧气氛中进行，冷却至室温。
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