CN113380506A - Power type thin film inductance magnetic sheet and preparation method and application thereof - Google Patents
Power type thin film inductance magnetic sheet and preparation method and application thereof Download PDFInfo
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- CN113380506A CN113380506A CN202110638844.9A CN202110638844A CN113380506A CN 113380506 A CN113380506 A CN 113380506A CN 202110638844 A CN202110638844 A CN 202110638844A CN 113380506 A CN113380506 A CN 113380506A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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Abstract
The invention provides a power type thin film inductance magnetic sheet and a preparation method and application thereof, wherein the preparation raw materials of the power type thin film inductance magnetic sheet comprise the following components in parts by weight: 100 parts of soft magnetic alloy powder; 0.1-1.5 parts of a dispersant; 2-30 parts of an organic binder; 0.3-6 parts of a curing agent; 5-30 parts of a first solvent; 1-5 parts of a second solvent; the organic binder includes a thermoplastic resin and a thermosetting resin; the thermoplastic resin comprises a vinyl acetate resin; the thermosetting resin includes a silicone resin. The power type thin film inductance magnetic sheet prepared by the invention has the advantages of no impurity in appearance, high flatness, stable quality and good repeatability, is suitable for large-scale production, can be used after being completely cured, does not need glue discharging, sintering and other processes, effectively reduces the cost and improves the efficiency.
Description
Technical Field
The invention belongs to the technical field of power inductors, and relates to a power type thin film inductor magnetic sheet, and a preparation method and application thereof.
Background
With the development of electronic and power technologies, the development of power inductors towards miniaturization and integration is a necessary trend, and thin film inductors are more advantageous in terms of volume and quality than wound inductors, integrally molded inductors and laminated inductors. With the development of science and technology, the power type thin film inductance magnetic sheet needs to be ensured to have no impurities in appearance, high flatness, stable quality and good repeatability.
CN104446518A discloses a water-based casting slurry for an NFC magnetic core, wherein the slurry comprises ferrite powder, a dispersing agent, a binder, a plasticizer and deionized water; the adhesive is a mixture of polyvinyl alcohol and polyacrylic acid, the plasticizer is a mixture of polyethylene glycol and glycerol, and the dispersant is triethanolamine. The NFC magnetic core prepared by the water-based tape casting slurry has good toughness and excellent anti-warping capability, but the surface flatness of the magnetic core is poor.
CN107216136A discloses a method for preparing a ferrite magnetic sheet of a wireless charger by using soft magnetic waste; the method comprises the steps of adding water into a manganese-zinc waste magnetic core and a nickel-zinc waste magnetic core, carrying out ball milling and sieving, then sequentially adding powder, deionized water, PVA, PAA, PEG, PVB and latex, carrying out ball milling in a roller ball mill to prepare slurry, and carrying out tape casting on the slurry to obtain the magnetic sheets. The magnetic sheet prepared by the method has the characteristics of low cost, energy conservation, environmental protection and excellent product performance, but the surface flatness of the magnetic sheet prepared by the method is poor.
Therefore, in the art, it is desired to develop a power type thin film inductor magnetic sheet having high flatness, stable quality and good reproducibility.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a power type thin film inductance magnetic sheet and a preparation method and application thereof. The power type thin film inductance magnetic sheet has the advantages of no impurity in appearance, high flatness, stable quality and good repeatability, is suitable for large-scale production, can be used after being completely cured, does not need glue discharging, sintering and other processes, effectively reduces the cost and improves the efficiency. In addition, the preparation process is simple, the preparation time is short, the internal substances of the slurry are uniformly dispersed, and the stability is excellent.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the invention provides a power type thin film inductance magnetic sheet, which comprises the following components in parts by weight:
the organic binder includes a thermoplastic resin and a thermosetting resin;
the thermoplastic resin comprises a vinyl acetate resin;
the thermosetting resin includes a silicone resin.
In the present invention, the thermoplastic resin and the thermosetting resin are used in combination to maintain good flexibility of the magnetic sheet before curing, and to facilitate storage. And the magnetic sheet can maintain good strength and high temperature resistance after being cured. The thermoplastic resin is added mainly to impart good flexibility to the magnetic sheet, while the thermosetting resin is added to maintain good strength and high temperature resistance after the magnetic sheet is cured. The power type thin film inductance magnetic sheet prepared by the invention has the advantages of no impurity in appearance, high flatness, stable quality and good repeatability, and is suitable for mass production.
In the invention, in the raw materials for preparing the power type thin film inductance magnetic sheet, the amount of the dispersant can be 0.1 part, 0.3 part, 0.5 part, 0.8 part, 1 part, 1.3 part or 1.5 parts, etc.
In the invention, in the raw materials for preparing the power type thin film inductance magnetic sheet, the amount of the organic binder can be 2 parts, 3 parts, 5 parts, 8 parts, 10 parts, 13 parts, 15 parts, 18 parts, 20 parts, 23 parts, 25 parts, 28 parts or 30 parts and the like.
In the invention, in the raw materials for preparing the power type thin film inductance magnetic sheet, the amount of the curing agent can be 0.3 part, 0.5 part, 0.8 part, 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts, 3.5 parts, 4 parts, 4.5 parts, 5 parts, 5.5 parts or 6 parts, etc.
In the invention, in the raw materials for preparing the power type thin film inductance magnetic sheet, the amount of the first solvent may be 5 parts, 8 parts, 10 parts, 13 parts, 15 parts, 18 parts, 20 parts, 23 parts, 25 parts, 28 parts or 30 parts, etc.
In the invention, in the raw materials for preparing the power type thin film inductance magnetic sheet, the amount of the second solvent may be 1 part, 1.5 parts, 2 parts, 2.5 parts, 3 parts, 3.5 parts, 4 parts, 4.5 parts or 5 parts.
Preferably, the mass ratio of the thermoplastic resin to the thermosetting resin is 1 (1-20), such as 1:1, 1:3, 1:5, 1:8, 1:10, 1:13, 1:15, 1:18, or 1:20, etc., preferably 1 (1-10).
Preferably, the number average molecular weight of the thermoplastic resin is 20000-.
Preferably, the solids content of the thermosetting resin is 50% to 60%, such as 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, or 60%, and the like.
Preferably, the number average molecular weight of the thermosetting resin is 1000-.
Preferably, the silicone resin comprises a methyl polysiloxane resin and/or a polyester modified silicone resin.
Preferably, the soft magnetic alloy powder includes FeSiCr alloy powder and/or fesai alloy powder.
Preferably, the dispersant comprises Hypermer KD-9 and/or AKM-0531, preferably AKM-0531.
Preferably, the curing agent comprises diethylenetriamine and/or triethylenetetramine.
Preferably, the first solvent comprises isobutanol and butyl acetate. According to the preferable technical scheme, the first solvent is a mixture of isobutanol and butyl acetate, and the two solvents with different boiling points and volatilization speeds can be adopted to enable the magnetic sheets to volatilize in stages after the magnetic sheets are subjected to tape casting, so that the problem of magnetic sheet cracking caused by too fast volatilization is solved.
Preferably, the mass ratio of isobutanol to butyl acetate is (1:1) - (1:3), such as 1:1, 1:1.5, 1:2, 1:2.5 or 1:3, and the like.
Preferably, the second solvent is butyl acetate.
In a second aspect, the present invention provides a method for preparing a power type thin film inductor magnetic sheet according to the first aspect, wherein the method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, and performing ball milling and mixing to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent, then adding thermosetting resin, stirring, then adding the first suspension liquid obtained in the step (1), and performing ball milling and mixing to obtain a second suspension liquid;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing, filtering, and performing vacuum defoaming to obtain slurry;
(4) and (4) carrying out tape casting on the slurry obtained in the step (3) under stirring to obtain the power type thin film inductance magnetic sheet.
The preparation method disclosed by the invention is simple in preparation process, short in preparation time, uniform in dispersion of internal substances of the slurry and excellent in stability. In addition, the magnetic sheet can be used after being completely cured, and processes such as binder removal and sintering are not needed, so that the cost is effectively reduced, and the efficiency is improved.
Preferably, a ball milling medium is added during ball milling and mixing in the step (1).
Preferably, the ball milling media are zirconia balls.
Preferably, the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1:1 to 2:1, such as 1:1, 1.3:1, 1.5:1, 1.8:1, or 2:1, and the like.
Preferably, the rotation speed of the ball milling mixing in the step (1) is 150-300rpm, such as 150rpm, 180rpm, 200rpm, 230rpm, 250rpm, 280rpm or 300rpm, and the like, and the time of the ball milling mixing is 2-8h, such as 2h, 3h, 4h, 5h, 6h, 7h or 8h, and the like.
Preferably, the temperature of the stirring and mixing in step (2) is 40-80 deg.C, such as 40 deg.C, 45 deg.C, 50 deg.C, 55 deg.C, 60 deg.C, 65 deg.C, 70 deg.C, 75 deg.C or 80 deg.C.
Preferably, the rotation speed of the ball milling mixing in the step (2) is 150-300rpm, such as 150rpm, 180rpm, 200rpm, 230rpm, 250rpm, 280rpm or 300rpm, and the like, and the time of the ball milling mixing is 20-24h, such as 20h, 21h, 22h, 23h or 24h, and the like.
Preferably, the rotation speed of the ball milling mixing in the step (3) is 150-300rpm, such as 150rpm, 180rpm, 200rpm, 230rpm, 250rpm, 280rpm or 300rpm, and the like, and the time of the ball milling mixing is 5-30min, such as 5min, 10min, 15min, 20min, 25min or 30min, and the like.
Preferably, the filtering method in the step (3) is screen filtering.
Preferably, the mesh number of the screen is 50-100 mesh, such as 50 mesh, 60 mesh, 70 mesh, 80 mesh, 90 mesh, or 100 mesh, and the like.
Preferably, the time for vacuum defoaming in step (3) is 10-15min, such as 10min, 11min, 12min, 13min, 14min or 15 min.
Preferably, the stirring speed in step (4) is 10-30rpm, such as 10rpm, 15rpm, 20rpm, 25rpm or 30rpm, etc.
In a third aspect, the present invention provides a power type thin film inductor magnetic sheet according to the first aspect, for use as a power inductor magnetic sheet.
Compared with the prior art, the invention has the following beneficial effects:
the vinyl acetate resin in the organic binder is used as the thermoplastic resin and the organic silicon resin is used as the thermosetting resin in a synergistic manner, so that the prepared power type thin film inductance magnetic sheet has the advantages of no impurity in appearance (the particle defect rate is 0.1-0.3%), high flatness (the size instability defect rate is 0.1-0.4%), stable quality (the cracking defect rate is 0.1-0.5%), good repeatability and suitability for mass production, and the magnetic sheet can be used after being completely cured without processes such as binder removal and sintering, the cost is effectively reduced, and the efficiency is improved.
Drawings
FIG. 1 is a micro-topography of a power type thin film inductive magnetic sheet prepared in example 1.
Detailed Description
The technical solution of the present invention is further explained by the following embodiments. It should be understood by those skilled in the art that the examples are only for the understanding of the present invention and should not be construed as the specific limitations of the present invention.
The purchase manufacturer of the vinyl acetate resin used in the embodiment of the invention is the Dow group of America, the purchase manufacturer of the methyl polysiloxane resin is the chemical industry Co., Ltd in New Sihai in Hubei, and the brand of the polyester modified organic silicon resin is KR-5235.
Example 1
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 5; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is methyl polysiloxane resin, and the solid content is 50 percent; the soft magnetic alloy powder is FeSiCr alloy powder; the dispersant is AKM-0531; the curing agent is diethylenetriamine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 2; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing at the rotating speed of 300rpm for 4 hours to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 40 ℃, then adding thermosetting resin, stirring, then adding the first suspension in the step (1), and carrying out ball milling and mixing at the rotating speed of 200rpm for 24 hours to obtain a second suspension;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing for 30min at the rotating speed of 200rpm, filtering by using a 100-mesh screen, and defoaming for 15min in vacuum to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 30rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 2: 1.
The micro-topography of the power type thin film inductance magnetic sheet prepared in this example is shown in fig. 1.
Example 2
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 1; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is polyester modified organic silicon resin, and the solid content is 60 percent; the soft magnetic alloy powder is FeSiCr alloy powder; the dispersant is Hypermer KD-9; the curing agent is triethylene tetramine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 1; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing at the rotating speed of 150rpm for 8 hours to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 50 ℃, then adding thermosetting resin, stirring, then adding the first suspension in the step (1), and carrying out ball milling and mixing at the rotating speed of 250rpm for 22h to obtain a second suspension;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing for 30min at the rotating speed of 150rpm, filtering by using a 50-mesh screen, and defoaming in vacuum for 10min to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 10rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1.5: 1.
Example 3
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 10; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is methyl polysiloxane resin, and the solid content is 50 percent; the soft magnetic alloy powder is FeSiCr alloy powder; the dispersant is AKM-0531; the curing agent is diethylenetriamine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 3; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing at the rotating speed of 200rpm for 8 hours to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 60 ℃, then adding thermosetting resin, stirring, then adding the first suspension liquid obtained in the step (1), and carrying out ball milling and mixing at the rotating speed of 150rpm for 20 hours to obtain a second suspension liquid;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing at the rotating speed of 300rpm for 20min, filtering by using a 100-mesh screen, and defoaming in vacuum for 15min to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 20rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1:1.
Example 4
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 15; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is polyester modified organic silicon resin, and the solid content is 60 percent; the soft magnetic alloy powder is FeSiAl alloy powder; the dispersant is AKM-0531; the curing agent is triethylene tetramine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 1; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing for 6 hours at a rotating speed of 250rpm to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 70 ℃, then adding thermosetting resin, stirring, then adding the first suspension liquid obtained in the step (1), and carrying out ball milling and mixing at the rotating speed of 300rpm for 20 hours to obtain a second suspension liquid;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing for 10min at the rotating speed of 250rpm, filtering by using a 50-mesh screen, and defoaming for 15min in vacuum to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 30rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1.5: 1.
Example 5
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 20; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is methyl polysiloxane resin, and the solid content is 50 percent; the soft magnetic alloy powder is FeSiAl alloy powder; the dispersant is Hypermer KD-9; the curing agent is diethylenetriamine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 1; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing at the rotating speed of 200rpm for 4 hours to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 80 ℃, then adding thermosetting resin, stirring, then adding the first suspension in the step (1), and carrying out ball milling and mixing for 22h at the rotating speed of 200rpm to obtain a second suspension;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing for 15min at the rotating speed of 200rpm, filtering by using a 100-mesh screen, and defoaming in vacuum for 10min to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 10rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1:1.
Example 6
In this embodiment, a power type thin film inductor magnetic sheet is provided, where the raw materials for preparing the power type thin film inductor magnetic sheet include the following components in parts by weight:
wherein the organic binder comprises a thermoplastic resin and a thermosetting resin in a mass ratio of 1: 10; the thermoplastic resin is vinyl acetate resin; the thermosetting resin is polyester modified organic silicon resin, and the solid content is 60 percent; the soft magnetic alloy powder is FeSiAl alloy powder; the dispersant is Hypermer KD-9; the curing agent is triethylene tetramine; the first solvent is isobutanol and butyl acetate with the mass ratio of 1: 2; the second solvent is butyl acetate.
The preparation method comprises the following steps:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, adding a ball-milling medium zirconia balls, and carrying out ball-milling mixing at the rotating speed of 300rpm for 2 hours to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent at 60 ℃, then adding thermosetting resin, stirring, then adding the first suspension in the step (1), and performing ball milling and mixing at the rotating speed of 300rpm for 20 hours to obtain a second suspension;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing for 5min at the rotating speed of 300rpm, filtering by using a 100-mesh screen, and defoaming in vacuum for 10min to obtain slurry;
(4) and (4) pouring the slurry obtained in the step (3) into a trough, keeping stirring, adjusting the rotating speed of stirring to be 20rpm, adjusting the knife edge gap of a casting machine according to the slurry condition, and controlling the casting speed to carry out casting so as to obtain the power type thin film inductance magnetic sheet.
Wherein the mass ratio of the zirconia balls to the soft magnetic alloy powder is 2: 1.
Example 7
This example is different from example 1 only in that the first solvent is n-propanol and ethyl acetate in a mass ratio of 1:2, and other conditions are the same as example 1.
Comparative example 1
This comparative example is different from example 1 only in that thermosetting resin was not included in the raw materials for the production of power type thin film inductor magnetic sheet, and the other conditions were the same as example 1.
Comparative example 2
This comparative example is different from example 1 only in that the thermoplastic resin is not included in the raw materials for the production of the power type thin film inductance magnetic sheet, and the other conditions are the same as example 1.
Comparative example 3
This comparative example differs from example 1 only in that the thermoplastic resin was replaced with an equal amount of acrylic resin having a number average molecular weight of 100000, and the other conditions were the same as example 1.
Comparative example 4
This comparative example differs from example 1 only in that the thermosetting resin was replaced with an equal amount of epoxy resin, the molecular weight was 300, and the other conditions were the same as example 1.
Comparative example 5
The comparative example is different from example 1 only in that the organic binder is added in an amount of 35 parts in the raw materials for the production of power type thin film inductor magnetic sheet, and the other conditions are the same as example 1.
Comparative example 6
The comparative example is different from example 1 only in that the first solvent is added in an amount of 35 parts in the raw materials for the production of a power type thin film inductor magnetic sheet, and the other conditions are the same as example 1.
The performance of the power type thin film inductor magnetic sheet prepared in examples 1-7 and comparative examples 1-6 was tested as follows:
(1) particle defect rate: if 5 particles appear in the magnetic sheet within the length range of 10cm, marking as the occurrence of particle defects; weighing the mass of the magnetic sheet with the particle defects; the grain defect rate is the mass of magnetic flakes having a grain defect/total mass of magnetic flakes × 100%;
(2) the size instability defect rate: measuring the thickness of the magnetic sheet within the length range of 0.5m at intervals of 10cm, and recording the thickness as a size instability defect if the measured thickness deviation is more than or equal to 10 mu m; weighing the mass of the magnetic sheet with the size instability defect; the unstable dimensional defect rate is the mass of the magnetic sheet with the unstable dimensional defect/total mass of the magnetic sheet × 100%;
(3) cracking defect rate: if the magnetic sheet cracks, the crack defect is marked. Weighing the mass of the magnetic sheet with the cracking defect; the cracking defect rate is the mass of the magnetic sheet with cracking defect/total mass of the magnetic sheet multiplied by 100%;
(4) in order to store and store the magnetic sheet after casting, the magnetic sheet needs to have good flexibility. The evaluation method comprises the following steps: the magnetic sheet after casting (magnetic sheet not peeled from PET film) was wound on a winding core of a prescribed size, and left in a room temperature environment for one week, and then whether or not the magnetic sheet cracked was observed.
The results of the performance tests are shown in table 1.
TABLE 1
As can be seen from table 1, the power type thin film inductor magnetic sheets prepared in examples 1 to 6 had low grain defect rate (0.1% to 0.3%), unstable size defect rate (0.1% to 0.4%) and crack defect rate (0.1% to 0.5%), and no crack occurred after the magnetic sheets were wound up and left for one week. This demonstrates the high flatness, stable quality and good repeatability of magnetic flakes. The microstructure (figure 1) of the power type thin film inductance magnetic sheet prepared in the example 1 shows that the surface of the magnetic sheet has no defects such as agglomeration and holes, and the casting slurry prepared by the invention is even in dispersion and good in stability.
The particle defect rate, the size instability defect rate and the cracking defect rate of the power type thin film inductor magnetic sheet prepared in example 7 are all increased compared with example 1, which shows that the solvent system used in the invention has certain advantages compared with the solvent system of n-propanol and ethyl acetate.
The grain defect rate, the size unstable defect rate and the crack defect rate of the power type thin film inductance magnetic sheet prepared in comparative example 1 were hardly changed as compared with example 1, but the magnetic sheet could not be applied to a higher temperature working environment because no thermosetting resin was added to the comparative example.
The power type thin film inductance magnetic sheet prepared in comparative example 2 had a small difference in the grain defect rate, the unstable size defect rate and the crack defect rate compared to example 1, but the sheet had poor flexibility and was liable to crack during rolling and storage due to no addition of the thermoplastic resin in the comparative example.
Compared with example 1, the particle defect rate and the size instability defect rate of the power type film inductance magnetic sheet prepared in comparative example 3 and comparative example 4 are obviously increased, which shows that the resin system used in the invention is beneficial to improving the quality of the magnetic sheet compared with acrylic resin and epoxy resin systems.
The power type thin film inductor magnetic sheet prepared in comparative example 5 had higher grain defect rate, size unstable defect rate and crack defect rate compared to example 1 because the organic binder content was too large to easily cause the agglomeration in the slurry.
Compared with example 1, the power type thin film inductance magnetic sheet prepared in comparative example 6 has extremely high defect rate of dimensional instability and defect rate of cracking because the tension in the slurry casting process is large due to excessive solvent content in the slurry, and the slurry is easy to gather towards the middle, so that the thickness of the magnetic sheet is uneven, and the magnetic sheet is easy to crack due to uneven distribution of the solvent.
The applicant states that the power type thin film inductor magnetic sheet and the preparation method and application thereof are described by the above embodiments, but the invention is not limited to the above embodiments, that is, the invention is not limited to the above embodiments. It will be apparent to those skilled in the art that any modification of the present invention, equivalent substitutions of selected materials and additions of auxiliary components, selection of specific modes and the like, which are within the scope and disclosure of the present invention, are contemplated by the present invention.
Claims (10)
1. The power type thin film inductance magnetic sheet is characterized by comprising the following raw materials in parts by weight:
the organic binder includes a thermoplastic resin and a thermosetting resin;
the thermoplastic resin comprises a vinyl acetate resin;
the thermosetting resin includes a silicone resin.
2. A power type thin film inductance magnetic sheet according to claim 1, wherein the mass ratio of the thermoplastic resin to the thermosetting resin is 1 (1-20), preferably 1 (1-10);
preferably, the number average molecular weight of the thermoplastic resin is 20000-.
3. A power type thin film inductor magnetic sheet as claimed in claim 1 or 2, wherein the thermosetting resin has a solid content of 50% to 60%;
preferably, the number average molecular weight of the thermosetting resin is 1000-15000;
preferably, the silicone resin comprises a methyl polysiloxane resin and/or a polyester modified silicone resin.
4. A power type thin film inductor magnetic sheet as claimed in any one of claims 1 to 3, wherein the soft magnetic alloy powder comprises FeSiCr alloy powder and/or fesai alloy powder;
preferably, the dispersant comprises Hypermer KD-9 and/or AKM-0531, preferably AKM-0531.
5. A power type thin film inductor magnetic sheet according to any of claims 1 to 4, wherein the curing agent comprises diethylenetriamine and/or triethylenetetramine.
6. The power type thin film inductor magnetic sheet according to any one of claims 1 to 5, wherein the first solvent comprises isobutanol and butyl acetate;
preferably, the mass ratio of the isobutanol to the butyl acetate is (1:1) - (1: 3);
preferably, the second solvent is butyl acetate.
7. A method for manufacturing a power type thin film inductor magnetic sheet as claimed in any one of claims 1 to 6, wherein the method comprises the steps of:
(1) mixing a dispersing agent with a first solvent, then adding soft magnetic alloy powder, and performing ball milling and mixing to obtain a first suspension;
(2) stirring and mixing thermoplastic resin and a second solvent, then adding thermosetting resin, stirring, then adding the first suspension liquid obtained in the step (1), and performing ball milling and mixing to obtain a second suspension liquid;
(3) adding a curing agent into the second suspension liquid obtained in the step (2), ball-milling and mixing, filtering, and performing vacuum defoaming to obtain slurry;
(4) and (4) carrying out tape casting on the slurry obtained in the step (3) under stirring to obtain the power type thin film inductance magnetic sheet.
8. The preparation method according to claim 7, characterized in that, a ball milling medium is added during the ball milling and mixing in the step (1);
preferably, the ball milling media are zirconia balls;
preferably, the mass ratio of the zirconia balls to the soft magnetic alloy powder is 1:1-2: 1;
preferably, the rotation speed of the ball milling mixing in the step (1) is 150-.
9. The method for preparing a water-soluble polymer according to claim 7 or 8, wherein the temperature of the stirring and mixing in the step (2) is 40 to 80 ℃;
preferably, the rotation speed of the ball milling mixing in the step (2) is 150-;
preferably, the rotation speed of the ball milling mixing in the step (3) is 150-;
preferably, the filtering method in the step (3) is screen filtering;
preferably, the mesh number of the screen is 50-100 meshes;
preferably, the vacuum defoaming time in the step (3) is 10-15 min;
preferably, the rotation speed of the stirring in the step (4) is 10-30 rpm.
10. Use of a power type thin film inductor magnetic sheet according to any one of claims 1 to 6 as a power inductor magnetic sheet.
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| CN113380506B (en) | 2022-06-24 |
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