CN113223843B - Insulation coating method of composite soft magnetic powder - Google Patents
Insulation coating method of composite soft magnetic powder Download PDFInfo
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- CN113223843B CN113223843B CN202110448966.1A CN202110448966A CN113223843B CN 113223843 B CN113223843 B CN 113223843B CN 202110448966 A CN202110448966 A CN 202110448966A CN 113223843 B CN113223843 B CN 113223843B
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
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- H—ELECTRICITY
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/026—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets protecting methods against environmental influences, e.g. oxygen, by surface treatment
Abstract
The invention discloses an insulation coating method of composite soft magnetic powder, which comprises the following steps: s1, screening soft magnetic alloy powder; s2, uniformly dispersing the soft magnetic ferrite fine powder into an ethanol solution of a silane coupling agent to obtain a first dispersion liquid; s3, adding soft magnetic alloy powder into the first dispersion liquid for pretreatment; step S4, adding ammonia water and ethyl orthosilicate into the composite powder dispersion liquid to generate a composite coating layer; s5, dissolving the binder and the lubricant in acetone, and uniformly dispersing the ferrite fine powder into the solution to obtain a second dispersion liquid; and S6, uniformly mixing the coated soft magnetic alloy powder into a second dispersion liquid, granulating and drying. The invention has the beneficial effects that: the silicon dioxide coating layer and the binding agent are doped with a proper amount of soft magnetic ferrite fine powder, so that the magnetic conductivity of the magnetic part formed by pressing is improved, and meanwhile, the high-frequency loss is low, so that a rear-end device of the magnetic part has more excellent comprehensive performance.
Description
Technical Field
The invention relates to the field of magnetic materials, in particular to an insulation coating method of composite soft magnetic powder.
Background
The amorphous nanocrystalline soft magnetic material has excellent comprehensive properties such as high saturation magnetization, high magnetic conductivity, low coercive force, low loss, good strong hardness, wear resistance and corrosion resistance, good temperature and environmental stability and the like, embodies the advantages of small volume, high efficiency, energy conservation and the like in the power electronic technology, and has better performance price in all metal soft magnetic materials.
In the preparation process of the amorphous nanocrystalline magnetic powder core, the performance of the insulating coating layer is an important factor influencing the high-frequency loss of the magnetic powder core, and if the insulating coating layer is not completely coated or damaged, the eddy current loss among magnetic powder particles is sharply increased, so that the high-frequency loss of the magnetic powder core is increased. The insulation coating is divided into organic coating and inorganic coating, and common organic insulation coating agents include epoxy resin, phenolic resin, organic silicon resin and the like. The organic coating agent has good bonding property, but has poor heat resistance, is difficult to eliminate the internal stress of the magnetic core, and limits the heat treatment temperature of the magnetic powder core. The inorganic coating agent is mainly mineral powder, silicate and various oxides with high resistivity. It is widely used for insulating coated magnetic powder core due to its advantages of high heat treatment temperature, high resistivity, low cost, etc. At present, most of the magnetic powder cores are mainly prepared by inorganic coating, and although the coating agents have good insulation effect, most of the coating agents are non-magnetic substances, so that the magnetic performance of the magnetic powder cores is greatly reduced.
In the prior art, an acid solution is generally used for corrosive insulation coating treatment in the insulation coating process, for example, patent documents such as the prior applications CN110181036A and CN104078180B disclose that a phosphoric acid solution is used for passivation treatment of powder, and then an insulating agent and a binder are added for insulation coating of the powder, wherein the acid solution is generally diluted by a volatile organic compound, which causes cost increase and environmental damage; the reaction control difficulty in the corrosion process is high, and the change of the amorphous nanocrystalline structure on the surface of the powder particles caused by nonuniform coating and excessive local heat release of the powder particles is easy to occur; the corrosion of powder particles can cause the adverse effects of the reduction of powder magnetic conductivity and the increase of hysteresis loss, so that in order to solve the problems, an insulation coating method of the composite soft magnetic powder is urgently needed to be designed so as to meet the requirements of practical use.
Disclosure of Invention
In view of the above problems in the prior art, a method for insulating and coating a composite soft magnetic powder is provided, which can prepare a powder material with high magnetic permeability and low eddy current loss.
The specific technical scheme is as follows:
an insulating coating method for composite soft magnetic powder features that a chemical reaction is used to form a compact and uniform composite coating layer of silicon dioxide and soft magnetic ferrite particles on the surface of soft magnetic alloy powder, and the ferrite particles are uniformly mixed in adhesive. The method comprises the following steps:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size, and weighing according to a preset mass;
step S2, preparing a first dispersion of ferrite fine powder: mixing a silane coupling agent, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the silane coupling agent, the absolute ethyl alcohol and the deionized water, then adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder into the solution, and obtaining a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, pretreating soft magnetic alloy powder: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding a certain amount of ammonia water into the composite powder dispersion liquid prepared in the step S3 to adjust the pH value of the mixed solution to be alkalescent, adding a certain amount of ethyl orthosilicate, then carrying out water bath, keeping the temperature for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain soft magnetic alloy powder with a silicon dioxide and soft magnetic ferrite micro-particle composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: completely dissolving a binder and a lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite fine powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite fine powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite fine powder;
step S6, insulating and coating: and (4) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, stirring, kneading and granulating the composite soft magnetic slurry on a granulating device, and drying in an oven to obtain the composite soft magnetic powder with good insulation coating.
Preferably, in step S1, the soft magnetic alloy powder is at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, iron-silicon-aluminum alloy powder, iron-silicon-chromium alloy powder, iron-silicon-nickel alloy powder, iron-silicon-aluminum-nickel alloy powder, iron-nickel-aluminum alloy powder, and carbonyl iron powder.
Preferably, in the step S1, the grain size of the soft magnetic alloy powder is less than 100 μm.
Preferably, in the step S2, the mass of the soft magnetic ferrite fine powder is 0.5% to 3% of the preset mass of the soft magnetic alloy powder;
the content of the silane coupling agent is 0.5-5% of the preset mass of the soft magnetic alloy powder.
Preferably, the particle diameters of the soft magnetic ferrite fine powder in both the step S2 and the step S5 are less than 1 μm.
Preferably, in the step S4, the content of the tetraethoxysilane is 1% to 10% of the preset mass of the soft magnetic alloy powder.
Preferably, in the step S5, the mass of the soft magnetic ferrite fine powder is 0.5% to 5% of the preset mass of the soft magnetic alloy powder.
Preferably, in the step S5, the content of the binder is 1% to 5% of the total mass of the soft magnetic alloy powder with the composite coating layer obtained in the step S4;
the content of the lubricant is 0.5-1% of the total mass of the soft magnetic alloy powder with the composite coating layer.
Preferably, in the step S4, a water bath is performed by using a water bath kettle;
the temperature of the water bath is 30-70 ℃, and the stirring is carried out for 1-12h at a preset speed.
Preferably, in the step S6, drying is performed in a vacuum oven;
the temperature is set to be 50-100 ℃, and the drying time is more than 1 h.
The invention utilizes a chemical reaction method to form a compact and uniform silicon dioxide and soft magnetic ferrite fine particle composite coating layer outside the soft magnetic alloy powder particles, and uniformly mixes ferrite fine particles into a binder. The beneficial effects of this technical scheme lie in:
firstly, the solution is alkalescent in the process of preparing the composite coating layer, so that the problems of magnetic performance reduction and the like caused by corrosion of powder particles are avoided, and the soft magnetic ferrite has higher high-frequency magnetic conductivity and good insulativity, so that compared with the existing soft magnetic alloy powder insulation coating technology, the technical scheme remarkably improves the high-frequency magnetic conductivity of a magnetic part formed by pressing composite soft magnetic powder, simultaneously keeps lower high-frequency loss, and ensures that the rear-end magnetic part, an inductor and other devices have more excellent comprehensive performance;
secondly, because the technical scheme avoids the corrosion to the powder particles, the prepared insulating coating has better uniformity and compactness, and the composite coating is made of stable silicon dioxide and ferrite materials, so that the prepared magnetic part, inductor and other devices have higher electric breakdown resistance and better stability.
Drawings
FIG. 1 is a schematic flow chart of a method for insulation coating of composite soft magnetic powder according to the present invention.
Fig. 2 is a schematic diagram of a powder microstructure of a magnetic ring component compression molded using composite soft magnetic powder in accordance with the present invention.
The figures are numbered: 1. soft magnetic alloy powder particles; 2. fine particles of soft magnetic ferrite; 3. a composite coating layer; 4. and (3) a binder.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive efforts based on the embodiments of the present invention, shall fall within the scope of protection of the present invention.
It should be noted that the embodiments and features of the embodiments of the present invention may be combined with each other without conflict.
The invention is further described with reference to the following drawings and specific examples, which are not intended to be limiting.
The invention provides an insulation coating method of composite soft magnetic powder, belonging to the field of magnetic materials, as shown in figure 1, comprising the following steps:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size by using an ultrasonic vibration screen, and weighing according to a preset mass, wherein the particle size of the soft magnetic alloy powder is preferably less than 100 micrometers;
step S2, preparing a first dispersion liquid of ferrite micro powder: weighing a silane coupling agent which is 0.5-5% of the preset mass of the soft magnetic alloy powder, weighing soft magnetic ferrite micro powder which is 0.5-3% of the preset mass of the soft magnetic alloy powder, mixing the silane coupling agent, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the soft magnetic ferrite micro powder, adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder in the solution, and obtaining a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding a certain amount of ammonia water into the composite powder dispersion liquid prepared in the step S3 to adjust the pH value of the mixed solution to be alkalescent, adding a certain amount of ethyl orthosilicate, carrying out water bath through a water bath kettle at the water bath temperature of 30-70 ℃, stirring for 1-12h at a preset constant speed, preserving heat for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain the soft magnetic alloy powder with the silicon dioxide and soft magnetic ferrite micro-fine powder composite coating layer;
step S5, preparing a second dispersion liquid of the ferrite micro powder: weighing a binder and a lubricant, wherein the binder is 1% -5% of the total mass of the soft magnetic alloy powder with the composite coating layer obtained in the step S4, the lubricant is 0.5% -1% of the total mass of the soft magnetic alloy powder with the composite coating layer, weighing soft magnetic ferrite micro powder again, the soft magnetic ferrite micro powder is 0.5% -5% of the preset mass of the soft magnetic alloy powder, completely dissolving the binder and the lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite micro powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite micro powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite micro powder;
step S6, insulating and coating: and (5) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, stirring, kneading and granulating the composite soft magnetic slurry on granulation equipment, and drying in a vacuum oven at the set temperature of 50-100 ℃ for more than 1h to obtain the composite soft magnetic powder with good insulation coating.
The invention utilizes a chemical reaction method to form a compact and uniform silicon dioxide and soft magnetic ferrite fine particle composite coating layer outside the soft magnetic alloy powder particles, and uniformly mixes ferrite fine particles into a binder to improve the magnetic conductivity of a magnetic part formed by pressing the soft magnetic alloy powder.
The first embodiment is as follows:
the soft magnetic alloy powder in the embodiment is Fe-Si-B-C-Cr amorphous soft magnetic alloy powder with the grain diameter of 7-15 mu m, wherein the median grain diameter D50 is about 10 mu m; the ferrite fine powder is Mn-Zn soft magnetic ferrite powder, and the median particle size D50 is about 750nm; the insulation coating method comprises the following steps:
step S1, powder screening: screening soft magnetic alloy powder with proper particle size by an ultrasonic vibration screen, and weighing according to preset mass;
step S2, preparing a first dispersion of ferrite fine powder: respectively weighing a silane coupling agent according to 1.5% of the preset mass of the soft magnetic alloy powder in the step S1, weighing Mn-Zn soft magnetic ferrite fine powder according to 1% of the preset mass of the soft magnetic alloy powder in the step S1, fully stirring and mixing the silane coupling agent, absolute ethyl alcohol and deionized water, then adding the Mn-Zn soft magnetic ferrite fine powder into the solution, fully stirring for 1h at room temperature, and uniformly dispersing the Mn-Zn soft magnetic ferrite fine powder into the solution to obtain a first dispersion liquid of the Mn-Zn soft magnetic ferrite fine powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding a certain amount of ammonia water into the composite powder dispersion liquid prepared in the step S3, adjusting the pH value of the mixed solution to 9-10, weighing tetraethoxysilane according to 5% of the preset mass of the magnetically soft alloy powder, adding the tetraethoxysilane into the mixed solution, then putting the mixture into a water bath kettle, stirring at a constant speed for 3 hours at the water bath temperature of 40 ℃, preserving heat for 0.5 hour, and finally repeatedly cleaning and drying the composite powder to obtain the magnetically soft alloy powder with the silicon dioxide and Mn-Zn magnetically soft ferrite powder micro-fine composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: respectively weighing a binder and a lubricant according to 3% and 0.8% of the total mass of the soft magnetic alloy powder with the composite coating layer prepared in the step S4, completely dissolving the binder and the lubricant in acetone to form an acetone solution, weighing Mn-Zn soft magnetic ferrite micro powder again according to 1% of the preset mass of the soft magnetic alloy powder in the step S1, doping the Mn-Zn soft magnetic ferrite micro powder into the acetone solution, fully stirring for 1h at room temperature, and uniformly dispersing the Mn-Zn soft magnetic ferrite micro powder into the acetone solution to obtain a second dispersion liquid of the Mn-Zn soft magnetic ferrite micro powder;
step S6, insulating and coating: and (5) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the Mn-Zn soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, then stirring, kneading and granulating the composite soft magnetic slurry on granulation equipment, drying in a vacuum oven at the set temperature of 80 ℃ for more than 1h, screening the powder with the particle size of-80 meshes to +200 meshes by using an ultrasonic vibration sieve, and thus obtaining the Fe-Si-B-C-Cr composite soft magnetic powder material with good insulation coating.
The Fe-Si-B-C-Cr composite soft magnetic powder coated with insulation in the embodiment is used for preparing a magnetic component, and then a performance test is carried out, and the specific steps are as follows:
step A1, weighing the prepared composite soft magnetic powder material, wherein the mass of the composite soft magnetic powder material is 3g, placing the weighed composite soft magnetic powder material in an annular die, and performing cold pressing to form a magnetic ring blank, wherein preferably, the outer diameter of the annular die is 20mm, and the inner diameter of the annular die is 12mm; ultrasonic vibration is applied in the cold pressing process, the vibration frequency is 20KHz, and the pressure maintaining pressure is 6t/cm 2 Keeping the pressure for 60s, and demolding to obtain a magnetic ring blank;
and step A2, placing the magnetic ring blank in a vacuum oven at 180 ℃, keeping the temperature for 2 hours, and taking out the magnetic ring blank after the magnetic ring blank is cooled to normal temperature to obtain a solidified magnetic ring component. As shown in fig. 2, fig. 2 is a schematic view of a microstructure of the powder inside the magnetic ring component, a compact and uniform composite coating layer 3 of silica and soft magnetic ferrite fine particles 2 is formed outside the soft magnetic alloy powder particles 1 by using a chemical reaction method, and the soft magnetic ferrite fine particles 2 are uniformly doped in a binder 4, so as to achieve the purpose of improving the magnetic permeability of the magnetic ring component.
Step A3, testing the main magnetic property: winding 15 turns of enameled copper wires on the cured magnetic ring component prepared in the step A2, testing the inductance of the cured magnetic ring component through an impedance analyzer under the test condition of 1MHz, and calculating to obtain the magnetic conductivity mu' according to the inductance; the loss value is tested by a B-H analyzer under the test condition of 1MHz/20mT.
Table 1 performance parameters of magnetic ring parts obtained in example one and comparative examples one and two
In the above table 1, 1 indicates that the Mn — Zn ferrite is added in the corresponding step, and the addition amount is 1% of the predetermined mass of the soft magnetic alloy powder in step S1; 0 means that no Mn-Zn ferrite was added in the corresponding step.
When the magnetic component is prepared from the Fe-Si-B-C-Cr composite soft magnetic powder with good insulation coating prepared in the embodiment, the measured value of the magnetic component is 1MHz through an impedance analyzerThe permeability mu' under the condition is 28; the loss Pcv measured by a B-H analyzer was 805kW/m under the condition of 1MHz/20mT 3 。
The first comparative example adopts the same preparation process and parameters as the first example, and is only different in that fine powder of the Mn-Zn soft magnetic ferrite is not added in the step S5, and the magnetic permeability mu' of the magnetic ring component finally prepared in the first comparative example is 25; the loss Pcv is 816kW/m 3 。
The second comparative example adopts the same preparation process and parameters as the first example, and is different in that fine Mn-Zn soft magnetic ferrite powder is not added in the whole preparation process, and the magnetic permeability mu' of the magnetic ring component finally prepared in the second comparative example is 21; the loss Pcv is 830kW/m 3 。
Example two:
the soft magnetic alloy powder in the embodiment is Fe-Si-B-Cu-Nb nanocrystalline soft magnetic alloy powder with the particle size of 5-22 μm, wherein the median particle size D50 is about 10 μm; the ferrite fine powder is Mn-Zn soft magnetic ferrite powder, and the median grain diameter D50 is about 750nm.
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the embodiment are the same as those of the embodiment one, and the differences are that the composition of the nanocrystalline soft magnetic alloy powder is different, the particle size is different, and the parameters of the magnetic ring part are shown in table 2.
Table 2 performance parameters of magnetic ring parts obtained in example two, comparative example three, and comparative example four
When the magnetic component is prepared from the Fe-Si-B-Cu-Nb composite soft magnetic powder with good insulation coating prepared in the embodiment, the magnetic permeability mu' under the condition of 1MHz is measured to be 36 by an impedance analyzer; the loss Pcv under the condition of 1MHz/20mT is 465kW/m measured by a B-H analyzer 3 。
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the third comparative example are the same as those of the second example, except that the Mn-Zn soft magnet is removed only in the step S4Magnetic permeability mu' of the finally prepared magnetic ring component is 31 under the same test condition by using the oxygen body micro-fine powder; the loss Pcv measured by a B-H analyzer under the condition of 1MHz/20mT was 470kW/m 3 。
The preparation process of the insulated and coated soft magnetic alloy powder and the preparation process and parameters of the magnetic ring blank obtained in the fourth comparative example are the same as those of the second embodiment, except that fine Mn-Zn soft magnetic ferrite powder is not added in the whole preparation process, and the magnetic permeability mu' of the finally prepared magnetic ring component is 27; the loss Pcv under the condition of 1MHz/20mT measured by a B-H analyzer is 482kW/m 3 。
As can be seen from tables 1 and 2: compact and uniform silicon dioxide and soft magnetic ferrite fine particle composite coating layers are formed outside the soft magnetic alloy powder particles, and the ferrite fine particles are uniformly mixed into the binder, so that on one hand, eddy current paths among the ferromagnetic particles can be effectively blocked, magnetic fields among the ferromagnetic particles can be well coupled, eddy current loss is effectively reduced, and iron loss is reduced; on the other hand, the ferrite has higher high-frequency magnetic conductivity, the magnetic conductivity of the magnetic part formed by pressing soft magnetic powder is improved to more than 30%, and meanwhile, lower high-frequency loss is kept, thereby being very beneficial to high-frequency miniaturization and miniaturization of inductance devices.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
Claims (10)
1. An insulation coating method of a composite soft magnetic powder, characterized by comprising:
step S1, powder screening: screening soft magnetic alloy powder with a preset particle size, and weighing according to a preset mass;
step S2, preparing a first dispersion of ferrite fine powder: mixing a silane coupling agent, absolute ethyl alcohol and deionized water according to a certain proportion, fully stirring to uniformly mix the silane coupling agent, the absolute ethyl alcohol and the deionized water, then adding the soft magnetic ferrite micro powder into the solution, fully stirring to uniformly disperse the soft magnetic ferrite micro powder into the solution, and obtaining a first dispersion liquid of the soft magnetic ferrite micro powder;
step S3, soft magnetic alloy powder pretreatment: adding the soft magnetic alloy powder obtained in the step S1 into the first dispersion liquid of the soft magnetic ferrite micro powder obtained in the step S2, and fully stirring to obtain a composite powder dispersion liquid;
step S4, generating a coating layer: adding a certain amount of ammonia water into the composite powder dispersion liquid prepared in the step S3 to adjust the pH value of the mixed solution to be alkalescent, adding a certain amount of ethyl orthosilicate, then carrying out water bath, keeping the temperature for a certain time, and finally repeatedly cleaning and drying the composite powder to obtain soft magnetic alloy powder with a silicon dioxide and soft magnetic ferrite micro-particle composite coating layer;
step S5, preparing a second dispersion liquid of ferrite fine powder: completely dissolving a binder and a lubricant in acetone to form an acetone solution, doping the soft magnetic ferrite fine powder into the acetone solution, and uniformly dispersing the soft magnetic ferrite fine powder into the acetone solution to obtain a second dispersion liquid of the soft magnetic ferrite fine powder;
step S6, insulating and coating: and (4) uniformly mixing the soft magnetic alloy powder with the composite coating layer obtained in the step (S4) and the second dispersion liquid of the soft magnetic ferrite micro-fine powder obtained in the step (S5), stirring to obtain composite soft magnetic slurry, stirring, kneading and granulating the composite soft magnetic slurry on a granulating device, and drying in an oven to obtain the composite soft magnetic powder with good insulation coating.
2. The method for insulation coating of composite soft magnetic powder according to claim 1, wherein in step S1, said soft magnetic alloy powder is at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, iron silicon aluminum alloy powder, iron silicon chromium alloy powder, iron silicon nickel alloy powder, iron silicon aluminum nickel alloy powder, iron nickel aluminum alloy powder, carbonyl iron powder.
3. The insulation coating method of composite soft magnetic powder as recited in claim 1, wherein said soft magnetic alloy powder has a particle size of less than 100 μm in said step S1.
4. The insulation coating method of the composite soft magnetic powder according to claim 1, wherein in the step S2, the mass of the soft magnetic ferrite fine powder is 0.5 to 3% of the predetermined mass of the soft magnetic alloy powder;
the content of the silane coupling agent is 0.5-5% of the preset mass of the soft magnetic alloy powder.
5. The method for insulation coating of composite soft magnetic powder according to claim 1, wherein said soft magnetic ferrite fine powder has a particle size of less than 1 μm in both said step S2 and said step S5.
6. The insulation coating method of composite soft magnetic powder as claimed in claim 1, wherein the content of said tetraethoxysilane is 1% to 10% by mass of the predetermined soft magnetic alloy powder in said step S4.
7. The insulation coating method of a composite soft magnetic powder as recited in claim 1, wherein the mass of said soft magnetic ferrite fine powder is 0.5-5% of the predetermined mass of said soft magnetic alloy powder in said step S5.
8. The method for insulation coating of composite soft magnetic powder as claimed in claim 1, wherein in step S5, the content of said binder is 1% -5% of the total mass of the soft magnetic alloy powder with composite coating layer obtained in step S4;
the content of the lubricant is 0.5-1% of the total mass of the soft magnetic alloy powder with the composite coating layer.
9. The insulation coating method of composite soft magnetic powder as claimed in claim 1, wherein in said step S4, a water bath is performed using a water bath;
the temperature of the water bath is 30-70 ℃, and the stirring is carried out for 1-12h at a preset speed.
10. The insulation coating method of composite soft magnetic powder as claimed in claim 1, wherein said step S6 is drying in a vacuum oven;
the temperature is set to be 50-100 ℃, and the drying time is more than 1 h.
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| DE112014001651T5 (en) * | 2013-03-27 | 2015-12-17 | Hitachi Chemical Company, Ltd. | Powder magnetic core for reactor |
| US20210060642A1 (en) * | 2018-02-20 | 2021-03-04 | Dowa Electronics Materials Co., Ltd. | Silicon oxide-coated soft magnetic powder and method for producing same |
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| JP2011214026A (en) * | 2010-03-31 | 2011-10-27 | Doshisha | Magnetic nanocomposite and method for producing the same |
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