CN108129143A - 高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法 - Google Patents

高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法 Download PDF

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CN108129143A
CN108129143A CN201810049072.3A CN201810049072A CN108129143A CN 108129143 A CN108129143 A CN 108129143A CN 201810049072 A CN201810049072 A CN 201810049072A CN 108129143 A CN108129143 A CN 108129143A
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soft magnetic
magnetic ferrite
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黄有东
李申华
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Nantong Sanjia Magnetic Industry Co ltd
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Abstract

本发明公开了一种高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法,包括主体组分和掺杂组分;主体组分包括Fe2O3 68.5~69.8wt%、ZnO 4.2~4.8wt%,余量为MnO,总量为100%;掺杂组分包括NiO、CaCO3、Nb2O5、TiO2、SnO2、Co2O3、Ta2O5、K2CO3和Li2CO3;掺杂组分占主体组分的2~4wt%。本发明在配方调整的基础上,通过两次研磨细化颗粒料及恰当的预烧和烧结成型工艺调控,有效减少气孔数量,并使得晶粒得到充分细化,减少不规则的大晶粒的概率,有效改善了锰锌软磁铁氧体材料的功率损耗和叠加特性,所得的材料密度大、居里温度高,适用温度宽,性能优异。

Description

高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法
技术领域
本发明涉及软磁铁氧体领域,特别是涉及一种高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法。
背景技术
MnZn铁氧体材料兼具优异的软磁性能和高电阻率双重特性,综合性能优异,所以在中、高频领域具有非常广泛的用途及应用前景,而且是在这些领域应用时的首选软磁材料之一。近些年来在高频开关电源领域作为功率材料(即变压器磁芯),软磁MnZn铁氧体材料得到了十分广泛的应用,而且其使用量也在逐年增长。
目前,随着电压器向更小、更轻量化的发展,对铁氧体材料也提出了更高的要求,要求其具有宽温使用特性、叠加性能,尤其是直流叠加性能优异,另外还应具备优异的高低温低磁滞损耗特定。现有工艺方法制备的软磁铁氧体,经扫描电镜观察,在晶粒中及晶界上存在许多气孔,也有一些异常生长的粗大晶粒,导致软磁铁氧体材料的微结构均匀性差。
发明内容
本发明主要解决的技术问题是提供一种高叠加特性宽温低功耗锰锌软磁铁氧体及其制备方法,能够赋予磁芯材料优异的叠加特性和较低的高温功耗,同时改善其微结构。
为解决上述技术问题,本发明采用的一个技术方案是:提供一种高叠加特性宽温低功耗锰锌软磁铁氧体,包括:主体组分和掺杂组分;所述主体组分包括如下质量百分含量的成分:Fe2O3 68.5~69. 8%、ZnO 4.2~4.8%,余量为MnO,总量为100%;所述掺杂组分包括NiO、CaCO3、Nb2O5、TiO2、SnO2、Co2O3、Ta2O5、K2CO3和Li2CO3;其中,所述掺杂组分占所述主体组分总质量的2~4%。
在本发明一个较佳实施例中,所述掺杂组分中,所述NiO占所述掺杂组分总质量的50~65%;所述Co2O3占所述掺杂组分总质量的8~10%;所述CaCO3、Nb2O5、TiO2、SnO2、Ta2O5、K2CO3和Li2CO3的质量相同。
在本发明一个较佳实施例中,所述Fe2O3的纯度为99.8%,比表面积为4.3m2/g;所述MnO的纯度在99.8%以上,比表面积为16.8m2/g。
为解决上述技术问题,本发明采用的另一个技术方案是:提供一种高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,包括如下步骤:
(1)称料:按配方量称取主体组分和掺杂组分备用;
(2)一次研磨:将配方量的主体组分和掺杂组分中的NiO、CaCO3、K2CO3、Li2CO3加入到球磨机中,加入去离子水进行球磨处理,取出后烘干,得到平均粒径为1~3μm的混合料;
(3)预烧:将步骤(2)中经一次研磨和烘干后的混合物料加入预烧炉中,预烧处理,得到预烧粉料;
(4)二次研磨:向步骤(3)中得到的预烧粉中加入掺杂组分中的Nb2O5、TiO2、SnO2、Ta2O5和Co2O3,然后加入去离子水进行球磨处理,取出,烘干,得到平均粒径为0.5~0.8μm的混合料;
(5)制坯:向步骤(4)中经二次研磨所得的混合料中加入粘合浆料,混合均匀后,压饼碾碎并过35~45目筛,过筛后的颗粒凉干后成型为坯样;
(6)烧结成型:将步骤(5)中所得的坯样放入钟罩炉内,在一定的氧分压下进行加热烧结和降温冷却处理,得到所述宽温低功耗高直流叠加特性锰锌铁氧体材料。
在本发明一个较佳实施例中,所述步骤(2)中,所述料、球和去离子水的质量比为1∶3.5~4∶1.2~1.5;所述球磨处理的时间为6h以上;所述步骤(4)中,所述料、球和去离子水的质量比为1∶3.5~4∶0.8~1.0;所述球磨处理的时间为12h以上。
在本发明一个较佳实施例中,所述步骤(3)中,所述预烧处理的工艺条件为:空气气氛下,在950~1000℃下恒温烧结2~3h,然后通入氮气,使氧分压在为5~8%,随炉降温至500℃,再控制氧分压为2~3%,继续降温至室温。
在本发明一个较佳实施例中,所述步骤(5)中,所述粘合浆料为质量浓度为6~8%的PVA浆料,其加入质量占所述主体组分和掺杂组分总质量的8~10%。
在本发明一个较佳实施例中,所述步骤(6)中,所述烧结工艺条件为:先在大气气氛中,以1~1.5℃/min的升温速率从室温升至650℃,然后在氧分压为0.05%的条件下,以2~3℃/min的升温速率从650℃升至1000℃,再调整氧分压至1%,以5~8℃/min的升温速率从1000℃升至1150℃,再以10℃/min的升温速率从1150℃升温至1380℃,保温3.5~6.5h;降温阶段,在1~3%的氧分压下,以2~2.5℃/min的降温速率从1380℃降温至1100℃,再在氧分压为0.5~1.5%,以5~8℃/min的降温速率从1100℃降至500℃,最后以0.01~0.05%的氧分压,2.5~3℃/min的速率将至室温。
本发明的有益效果是:本发明一种高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,在配方调整的基础上,通过两次研磨细化颗粒料及恰当的预烧和烧结成型工艺调控,有效减少气孔数量,并使得晶粒得到充分细化,减少不规则的大晶粒的概率,有效改善了锰锌软磁铁氧体材料的功率损耗和叠加特性,优异其直流叠加特性得到有效改善,所得的材料密度大、居里温度高,适用温度宽,性能优异。
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
本发明揭示了一种高叠加特性宽温低功耗锰锌软磁铁氧体,包括:主体组分和掺杂组分;所述主体组分包括如下质量百分含量的成分:Fe2O3 68.5%、ZnO 4.2%,MnO 27.3;所述掺杂组分包括NiO、CaCO3、Nb2O5、TiO2、SnO2、Co2O3、Ta2O5、K2CO3和Li2CO3;其中,所述掺杂组分占所述主体组分总质量的2%。具体地,掺杂组分中,所述NiO占所述掺杂组分总质量的50%;所述Co2O3占所述掺杂组分总质量的8%;所述CaCO3、Nb2O5、TiO2、SnO2、Ta2O5、K2CO3和Li2CO3的质量相同。
其中,所用原材料均为高纯度,并具有高的比表面积,保证磁芯具有高的饱和磁通密度Bs和低的功耗。具体地,所述Fe2O3的纯度为99.8%,比表面积为4.3m2/g;所述MnO的纯度在99.8%以上,比表面积为16.8m2/g。
上述高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,包括如下步骤:
(1)称料:按配方量称取主体组分和掺杂组分备用;
(2)一次研磨:将配方量的主体组分和掺杂组分中的NiO、CaCO3、K2CO3、Li2CO3加入到球磨机中,加入去离子水使料、球和去离子水的质量比为1∶3.5∶1.2,然后球磨处理6h以上,取出后烘干,得到平均粒径为1~3μm的混合料;
(3)预烧:将步骤(2)中经一次研磨和烘干后的混合物料加入预烧炉中,空气气氛下,在950℃下恒温烧结2h,然后通入氮气,使氧分压在为5%,随炉降温至500℃,再控制氧分压为2%,继续降温至室温,得到预烧粉料;
(4)二次研磨:向步骤(3)中得到的预烧粉中加入掺杂组分中的Nb2O5、TiO2、SnO2、Ta2O5和Co2O3,然后加入去离子水,使料、球和去离子水的质量比为1∶3.5∶0.8,球磨处理12h以上,取出,烘干,得到平均粒径为0.5~0.8μm的混合料;
(5)制坯:向步骤(4)中经二次研磨所得的混合料中加入占所述主体组分和掺杂组分总质量的80%的质量浓度为6%的PVA浆料作为粘合浆料,混合均匀后,压饼碾碎并过35~45目筛,过筛后的颗粒凉干后成型为坯样;
(6)烧结成型:将步骤(5)中所得的坯样放入钟罩炉内,在一定的氧分压下进行加热烧结和降温冷却处理,得到所述宽温低功耗高直流叠加特性锰锌铁氧体材料。所述烧结工艺条件为:先在大气气氛中,以1℃/min的升温速率从室温升至650℃,然后在氧分压为0.05%的条件下,以2℃/min的升温速率从650℃升至1000℃,再调整氧分压至1%,以5℃/min的升温速率从1000℃升至1150℃,再以10℃/min的升温速率从1150℃升温至1380℃,保温3.5h;降温阶段,在1%的氧分压下,以2℃/min的降温速率从1380℃降温至1100℃,再在氧分压为0.5%,以5℃/min的降温速率从1100℃降至500℃,最后以0.015%的氧分压,2.5℃/min的速率将至室温。
实施例2
本发明揭示了一种高叠加特性宽温低功耗锰锌软磁铁氧体,包括:主体组分和掺杂组分;所述主体组分包括如下质量百分含量的成分:Fe2O3 69.8%、ZnO 4.8%,MnO 25.4;所述掺杂组分包括NiO、CaCO3、Nb2O5、TiO2、SnO2、Co2O3、Ta2O5、K2CO3和Li2CO3;其中,所述掺杂组分占所述主体组分总质量的4%。具体地,掺杂组分中,所述NiO占所述掺杂组分总质量的65%;所述Co2O3占所述掺杂组分总质量的10%;所述CaCO3、Nb2O5、TiO2、SnO2、Ta2O5、K2CO3和Li2CO3的质量相同。
其中,所用原材料均为高纯度,并具有高的比表面积,保证磁芯具有高的饱和磁通密度Bs和低的功耗。具体地,所述Fe2O3的纯度为99.8%,比表面积为4.3m2/g;所述MnO的纯度在99.8%以上,比表面积为16.8m2/g。
上述高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,包括如下步骤:
(1)称料:按配方量称取主体组分和掺杂组分备用;
(2)一次研磨:将配方量的主体组分和掺杂组分中的NiO、CaCO3、K2CO3、Li2CO3加入到球磨机中,加入去离子水使料、球和去离子水的质量比为1∶4∶1.5,然后球磨处理6h以上,取出后烘干,得到平均粒径为1~3μm的混合料;
(3)预烧:将步骤(2)中经一次研磨和烘干后的混合物料加入预烧炉中,空气气氛下,在1000℃下恒温烧结2h,然后通入氮气,使氧分压在为8%,随炉降温至500℃,再控制氧分压为3%,继续降温至室温,得到预烧粉料;
(4)二次研磨:向步骤(3)中得到的预烧粉中加入掺杂组分中的Nb2O5、TiO2、SnO2、Ta2O5和Co2O3,然后加入去离子水,使料、球和去离子水的质量比为1∶4∶1.0,球磨处理12h以上,取出,烘干,得到平均粒径为0.5~0.8μm的混合料;
(5)制坯:向步骤(4)中经二次研磨所得的混合料中加入占所述主体组分和掺杂组分总质量的10%的质量浓度为8%的PVA浆料作为粘合浆料,混合均匀后,压饼碾碎并过筛,筛网为35~45目,过筛后的颗粒凉干后成型为坯样;
(6)烧结成型:将步骤(5)中所得的坯样放入钟罩炉内,在一定的氧分压下进行加热烧结和降温冷却处理,得到所述宽温低功耗高直流叠加特性锰锌铁氧体材料。所述烧结工艺条件为:先在大气气氛中,以1.5℃/min的升温速率从室温升至650℃,然后在氧分压为0.05%的条件下,以3℃/min的升温速率从650℃升至1000℃,再调整氧分压至1%,以8℃/min的升温速率从1000℃升至1150℃,再以10℃/min的升温速率从1150℃升温至1380℃,保温6.5h;降温阶段,在3%的氧分压下,以2.5℃/min的降温速率从1380℃降温至1100℃,再在氧分压为1.5%,以8℃/min的降温速率从1100℃降至500℃,最后以0.05%的氧分压,3℃/min的速率将至室温。
上述方法得到的高叠加特性宽温低功耗锰锌软磁铁氧体,经测试,密度为4.98g/cm3,在25℃下的初始磁导率大于等于3050;100KHZ,200mT,25℃下的功率损耗低于425KW/m3;100KHZ,200mT,100℃下的功率损耗低于325KW/m3;居里温度大于等于240℃;1194A/m,25℃下的饱和磁通密度高于550mT,1194A/m,100℃下的饱和磁通密度高于480mT;在1KHZ,0.3V,常温,加电流6A条件下,使用4284A电感电桥测试仪检测,其电感为2.8~3.8mH,叠加电感为41~44μH。
本发明所得的锰锌软磁铁氧体材料,在配方调整的基础上,通过两次研磨细化颗粒料及恰当的预烧和烧结成型工艺调控,有效减少气孔数量,并使得晶粒得到充分细化,减少不规则的大晶粒的概率,有效改善了锰锌软磁铁氧体材料的功率损耗和叠加特性,优异其直流叠加特性得到有效改善,所得的材料密度大、居里温度高,适用温度宽,性能优异。
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 (8)

1.一种高叠加特性宽温低功耗锰锌软磁铁氧体,其特征在于,包括:主体组分和掺杂组分;所述主体组分包括如下质量百分含量的成分:Fe2O3 68.5~69. 8%、ZnO 4.2~4.8%,余量为MnO,总量为100%;所述掺杂组分包括NiO、CaCO3、Nb2O5、TiO2、SnO2、Co2O3、Ta2O5、K2CO3和Li2CO3;其中,所述掺杂组分占所述主体组分总质量的2~4%。
2.根据权利要求1所述的高叠加特性宽温低功耗锰锌软磁铁氧体,其特征在于,所述掺杂组分中,所述NiO占所述掺杂组分总质量的50~65%;所述Co2O3占所述掺杂组分总质量的8~10%;所述CaCO3、Nb2O5、TiO2、SnO2、Ta2O5、K2CO3和Li2CO3的质量相同。
3.根据权利要求1所述的高叠加特性宽温低功耗锰锌软磁铁氧体,其特征在于,所述Fe2O3的纯度为99.8%,比表面积为4.3m2/g;所述MnO的纯度在99.8%以上,比表面积为16.8m2/g。
4.一种如权利要求1-3任一项所述的高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,其特征在于,包括如下步骤:
(1)称料:按配方量称取主体组分和掺杂组分备用;
(2)一次研磨:将配方量的主体组分和掺杂组分中的NiO、CaCO3、K2CO3、Li2CO3加入到球磨机中,加入去离子水进行球磨处理,取出后烘干,得到平均粒径为1~3μm的混合料;
(3)预烧:将步骤(2)中经一次研磨和烘干后的混合物料加入预烧炉中,预烧处理,得到预烧粉料;
(4)二次研磨:向步骤(3)中得到的预烧粉中加入掺杂组分中的Nb2O5、TiO2、SnO2、Ta2O5和Co2O3,然后加入去离子水进行球磨处理,取出,烘干,得到平均粒径为0.5~0.8μm的混合料;
(5)制坯:向步骤(4)中经二次研磨所得的混合料中加入粘合浆料,混合均匀后,压饼碾碎并过35~45目筛,过筛后的颗粒凉干后成型为坯样;
(6)烧结成型:将步骤(5)中所得的坯样放入钟罩炉内,在一定的氧分压下进行加热烧结和降温冷却处理,得到所述宽温低功耗高直流叠加特性锰锌铁氧体材料。
5.根据权利要求4所述的高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,其特征在于,所述步骤(2)中,所述料、球和去离子水的质量比为1∶3.5~4∶1.2~1.5;所述球磨处理的时间为6h以上;所述步骤(4)中,所述料、球和去离子水的质量比为1∶3.5~4∶0.8~1.0;所述球磨处理的时间为12h以上。
6.根据权利要求4所述的高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,其特征在于,所述步骤(3)中,所述预烧处理的工艺条件为:空气气氛下,在950~1000℃下恒温烧结2~3h,然后通入氮气,使氧分压在为5~8%,随炉降温至500℃,再控制氧分压为2~3%,继续降温至室温。
7.根据权利要求4所述的高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,其特征在于,所述步骤(5)中,所述粘合浆料为质量浓度为6~8%的PVA浆料,其加入质量占所述主体组分和掺杂组分总质量的8~10%。
8.根据权利要求4所述的高叠加特性宽温低功耗锰锌软磁铁氧体的制备方法,其特征在于,所述步骤(6)中,所述烧结工艺条件为:先在大气气氛中,以1~1.5℃/min的升温速率从室温升至650℃,然后在氧分压为0.05%的条件下,以2~3℃/min的升温速率从650℃升至1000℃,再调整氧分压至1%,以5~8℃/min的升温速率从1000℃升至1150℃,再以10℃/min的升温速率从1150℃升温至1380℃,保温3.5~6.5h;降温阶段,在1~3%的氧分压下,以2~2.5℃/min的降温速率从1380℃降温至1100℃,再在氧分压为0.5~1.5%,以5~8℃/min的降温速率从1100℃降至500℃,最后以0.01~0.05%的氧分压,2.5~3℃/min的速率将至室温。
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