CN110330327A - 一种高Tc高频超低损耗软磁铁氧体材料及其制备方法 - Google Patents
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,该高Tc高频超低损耗软磁铁氧体材料组成为140份‑146份的Fe2O3,39份‑48份的Mn3O4,8份‑15份ZnO为主成分,第一次添加微量的CaCO3、CoO、Cr2O3;第二次添加微量的Y2O3、Nd2O3、SiO2和V2O5;采用固相法,通过配料、砂磨、掺杂、造粒、成型和气氛烧结,制备获得高居里点、高频、超低损耗的磁芯材料。该材料Tc高达310℃,在100℃、1MHz、30mT条件下,测试功率损耗低于100 kW/m3。此发明制作能耗小、绿色环保且综合性能良好,能满足逆变焊机、通讯电源、航空航天大功率电源等大功率开关电源的核心技术需要。
Description
技术领域
本发明涉及一种软磁铁氧体材料,具体的说是一种高Tc高频超低损耗软磁铁氧体材料及其制备方法。
背景技术
软磁铁氧体是IT产业和电子工业的基础材料。工业化生产的软磁铁氧体材料目前主要分为锰锌铁氧体、镍锌铁氧体和铜锌铁氧体等,其中产量最大的是锰锌铁氧体。随着电子科学与信息技术的发展,锰锌软磁铁氧体越来越成为一种极其重要的电子元器件磁性材料,由于其具有高起始磁导率、高饱和磁通密度、低矫顽力、低功率损耗等优秀特性,锰锌软磁铁氧体被广泛应用于通信技术、电源设备、计算机产品等电子器件中。但锰锌软磁铁氧体居里点和频率却难上去,高温易停振,近年来,由于电子元器件不断向高密度、小型化、片式化、集成化方向发展,相应地要求作为磁芯的锰锌软磁铁氧体材料的各种特性也要提高。因为磁芯在传输变换电能的同时,若自身消耗太多能量发热变大,导致电源模块的效率下降甚至不能工作。故具有高Tc,300℃以上高居里点高频低损耗铁氧体材料是使开关电源模块小型化、轻量化、高效化的关键所在。
现有技术需求显示,常规以Fe2O3、Mn3O4、ZnO作为主成分的软磁铁氧体材料及磁芯的功率损耗仍然较大,适用频率也较低,居里点不够高。因此亟需开发能够工作频率为500KHz、1MHz高频条件下损耗低、300℃以上高居里点锰锌软磁铁氧体材料,以满足逆变焊机、通讯电源、高频加热电源、激光器电源、电力操、航空航天等各种大功率开关电源等领域的核心技术需要。
发明内容
本发明针对现有技术中存在的问题,提供一种高Tc高频超低损耗软磁铁氧体材料及其制备方法和应用,可实现高工作频率(1MHz)的情况下功率损耗将低于100kw/m3。
本发明解决上述技术问题的技术方案如下:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,以所述主成分Fe2O3、ZnO、Mn3O4总重量200kg为基准,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3:140份-146份;Mn3O4 39份-48份;ZnO :8份-15份;CaCO3 150g-200 g、CoO 320g-480g、Cr2O3 300g-400g ;
所述第二次添加剂成分除SiO2为粒径为50nm-100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 10-40g、 Nd2O3 5-13g、 SiO2 20g-50g、 V2O5 20-80g ;
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法包括如下步骤:
(1)一次配料按重量百分比配置一定重量200kg的的主成分Fe2O3、Mn3O4和ZnO主成分以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5~6:0.5~0.7投入砂磨机进行一次砂磨,砂磨的时间为2~4h,一次砂磨后浆料的平均粒径为0.8~1.2µm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为850~950℃,预烧时间为0.5~2h,控制预烧后粉料的磁化度在8~15µH/g ;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料平均粒径为0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型,制得样品坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉,先从室温到450℃,升温速率为以0.5℃~2.0℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.0℃~2.0℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃~3.0℃/min,改通入氮气控制氧分压在3%~5%,最后使最终的烧结温度为1250~1290℃;保温时间为4~8 h,保温段氧分压为3%~5%,再在平衡氧分压条件下降温:先从最高烧结温度降到1100℃,降温速率为2.5℃~5℃/min氧分压为5%~0.2%;然后再1100℃至室温,降温速率为1.5℃/min~4℃/min,氧分压为2%~0.2%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
本发明与现有技术相比具有如下特点:
本发明的材料制备方法首要是材料的配方,尤其是微量添加物的选择以及加添加的方式。注重二次砂磨,控制粉料平均粒径为0.7µm ~ 1.0µm,为烧结提供高活性的粉料,实现较低的烧结温度即可以生成晶粒细小而均匀,结晶较厚的微观结构,最终获得高频超低损耗的材料,其Tc高达310℃,在100℃、1MHz、30mT条件下,功率损耗低于100kW/m3。相比常规材料更加节能,利于电子设备的小型化。可应用在逆变焊机、通讯电源、高频加热电源、激光器电源、电力操作电源、大数据网络交换机伺服器、车载电子数子模块、航空航天大功率电源等领域。
具体实施方式
为了更好理解本发明,下面结合实施例对本发明做进一步地详细说明,但是本发明要求保护的范围并不局限于实施例表示的范围。
实施例1:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、 Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、 CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 6g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加物按照重量比为料:球:水=1: 5.5: 0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在11µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1260℃;保持烧结温度时间1260℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
实施例2:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 8g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5.5:0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在10µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,进行成型,制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1260℃;保持烧结温度时间1260℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
实施例3:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、 CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2 为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 10g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5.5:0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在12µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1260℃;保持烧结温度时间1260℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
实施例4:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2 为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 6g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5.5:0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在12µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1280℃;保持烧结温度时间1280℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
实施例5:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 8g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5.5:0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在12µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1280℃;保持烧结温度时间1280℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
实施例6:
一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,包括主成分和添加剂成分,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 142千克、Mn3O4 45千克、ZnO 13千克;
CaCO3 180g、CoO 380g、 Cr2O3 320g;
第二次添加剂成分除SiO2 为粒径为50nm~100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 20g、 Nd2O3 10g、 SiO2 40g 、 V2O5 50g ;
一种高Tc高频超低损耗软磁铁氧体材料制备方法,包括如下步骤:
(1)一次配料按以上质量配置称量200kg的的主成分Fe2O3、Mn3O4和ZnO,以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5.5:0.6投入砂磨机进行一次砂磨,砂磨的时间为3 h,一次砂磨后浆料的平均粒径为0.8~1.2μm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为900℃,预烧时间为1.5 h,控制预烧后粉料的磁化度在11µH/g;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料,控制粉料粒径在0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,通过成型制得坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为1℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.5℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃/min,改通入氮气,控制氧分压在4.5%,最后使最终的烧结温度为1280℃;保持烧结温度时间1280℃为5 h,保温段氧分压为3.5%,再在平衡氧分压条件下降温;先从最高烧结温度降到1100℃,降温速率为3℃/min,氧分压为2%;然后再1100℃至室温,降温速率为3℃/min,氧分压为0.5%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
表1为各实施例制备磁芯样品的性能参数。
表1 各实施例制备磁芯样品测试性能参数
Claims (10)
1.一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:制备该材料配方成分包括主成分和添加物成分;
所述主成分Fe2O3、ZnO、Mn3O4总重量200kg为基准,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 :140份-146份、Mn3O4 39份-48份、ZnO :8份-15份;CaCO3 150g-200g、CoO 320g-480g、Cr2O3 300g-400g ;
第二次添加剂成分除SiO2 为粒径为50nm-100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 10-40g、 Nd2O3 4-10g、 SiO2 20g-50g、 V2O5 20-80g 。
2.根据权利要求1所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:制备该材料配方成分包括主成分和添加物成分;
所述主成分Fe2O3、ZnO、Mn3O4总重量200kg为基准,主成分和第一次添加剂均采用市***为化学纯原料,包括如下重量份的各组分:
Fe2O3 :140份-146份;Mn3O4 39份-48份;ZnO :8份-15份;CaCO3 :150g-200g、CoO :320g-480g、Cr2O3 :300g-400g 。
3.根据权利要求1所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述主成分Fe2O3、ZnO、Mn3O4总重量200kg为基准,所述第二次添加剂成分除SiO2 为粒径为50nm-100nm外,其余均为市***为化学纯原料,包括如下掺杂量的各组分:
Y2O3 10-40g、 Nd2O3 4-10g、 SiO2 20g-50g 、 V2O5 20-80g 。
4.根据权利要求所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述第二次添加剂成分中包含的SiO2,其粒径为50nm-100nm纳米粉体。
5.一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:一种高Tc高频超低损耗软磁铁氧体材料制备方法分如下步骤:
(1)一次配料按重量百分比配置一定重量200kg的的主成分Fe2O3、Mn3O4 和ZnO主成分以及第一次添加掺杂物;
(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5~6:0.5~0.7投入砂磨机进行一次砂磨,砂磨的时间为2~4h,一次砂磨后浆料的平均粒径为0.8~1.2µm;
(3)预烧:将步骤(2)一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为850~950℃,预烧时间为0.5~2h,控制预烧后粉料的磁化度在8~15µH/g ;
(4)二次配料:向步骤(3)中预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料平均粒径为0.7µm ~ 1.0µm;
(5)成型: 将造粒后得到的粉料,进行成型,制得样品坯件;
(6)烧结: 将步骤(5)制得的坯件放进烧结炉, 先从室温到450℃,升温速率为以0.5℃~2.0℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.0℃~2.0℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃~3.0℃/min,改通入氮气控制氧分压在3%~5%,最后使最终的烧结温度为1250~1290℃;保温时间为4~-8 h,保温段氧分压为3%~5%,再在平衡氧分压条件下降温:先从最高烧结温度降到1100℃,降温速率为2.5℃~5℃/min氧分压为5%~0.2%;然后再1100℃至室温,降温速率为1.5℃/min~4℃/min,氧分压为2%~0.2%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
6.根据权利要求5所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述步骤(2)一次砂磨将配好的主成分和第一次添加掺杂物按照重量比为料:球:水=1: 5~6: 0.5~0.7投入砂磨机进行一次砂磨,砂磨的时间为2~4h,一次砂磨后浆料的平均粒径为0.8~1.2µm。
7.根据权利要求5所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述步骤(3)将一次砂磨后的浆料通过高压喷雾干燥造粒后,在回转窑中进行预烧,预烧温度为850~950℃,预烧时间为0.5~2h,控制预烧后粉料的磁化度在8~15µH/g 。
8.根据权利要求5所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述步骤(4)将预烧后的物料中加入第二次添加剂,经过二次砂磨、喷雾干燥造粒后,形成粉料平均粒径为0.7µm ~ 1.0µm。
9.根据权利要求5所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于:所述步骤(5)坯件烧结工艺参数为:先从室温到450℃,升温速率为以0.5℃~2.0℃/min,并通入空气增强排胶;再从450℃到900℃,升温速率为1.0℃~2.0℃/min,空气自然排胶;再从900℃到1100℃,升温速率为1.5℃~3.0℃/min,改通入氮气控制氧分压在3%~5%,最后使最终的烧结温度为1250~1290℃;保温时间为5 h,保温段氧分压为3%~5%,再在平衡氧分压条件下降温:先从最高烧结温度降到1100℃,降温速率为2.5~5 ℃/min氧分压为5%~0.2%;然后再1100℃至室温,降温速率为1.5 ~ 4 ℃/min,氧分压为2%~0.2%,即得到高Tc高频超低损耗锰锌软磁铁氧体磁芯产品。
10.根据权利要求1所述的一种高Tc高频超低损耗软磁铁氧体材料及其制备方法,其特征在于,该材料所制作的磁芯产品,Tc高达310℃,在100℃、1MHz、30mT条件下,功率损耗低于100 kW/m3,可应用于逆变焊机、通讯电源、航空航天大功率电源等大功率开关电源中。
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