CN113480302B - 一种汽车电子用宽温高磁导率锰锌软磁铁氧体及制备方法 - Google Patents

一种汽车电子用宽温高磁导率锰锌软磁铁氧体及制备方法 Download PDF

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CN113480302B
CN113480302B CN202111032368.2A CN202111032368A CN113480302B CN 113480302 B CN113480302 B CN 113480302B CN 202111032368 A CN202111032368 A CN 202111032368A CN 113480302 B CN113480302 B CN 113480302B
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魏凌霄
邢冰冰
段金柱
王鸿健
金辉
缪思敏
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TDG Holding Co Ltd
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Abstract

本发明属于磁性材料技术领域,公开了一种汽车电子用宽温高磁导率锰锌软磁铁氧体及制备方法。该汽车电子用宽温高磁导率锰锌软磁铁氧体包含主成分和辅助成分,所述主成分包括Fe2O3:53mol%~55mol%,ZnO:16mol%~19mol%,其余为Mn3O4,按主成分总重量计,所述辅助成分包括:纳米CaCO3:400ppm~1000ppm、纳米TiO2:4000ppm~6000ppm、纳米Co2O3:500ppm~2000ppm,纳米Nb2O5:100ppm~350ppm、纳米SiO2:20ppm~150ppm、纳米CuO:0ppm~600ppm。本发明通过合适的主成分与纳米掺杂,采用气流磨和低温烧结的工艺,获得的锰锌铁氧体材料在‑40~+125℃范围内具有宽温、高磁导率的特性,其综合磁性能更优,主要应用于汽车电子行业。

Description

一种汽车电子用宽温高磁导率锰锌软磁铁氧体及制备方法
技术领域
本发明涉及汽车电子用宽温高磁导率锰锌软磁铁氧体及制备方法,属于磁性材料技术领域。
背景技术
我国汽车电子市场规模持续快速增长,成为推动汽车电动化、智能化、网联化发展的重要引擎。在人工智能、云计算、无人驾驶、5G等技术的有力带动下、新能源汽车发展战略指导下,我国汽车电子进入新一轮技术迭代、产业升级,汽车电子在整车中的成本占比持续增长,车规级芯片与传感器有望成为产业发展的核心驱动力,我国汽车电子发展进入又一个黄金期。
汽车电子产品的工作环境非常恶劣,温度对电子产品的影响非常大。汽车发动机本身是热源,在炎热的地区,汽车在满负荷行驶,如立即停车将发动机熄火,这时排气管散出的热量会使发动机室的温度升到100℃以上。在寒冷地区,车辆长时间停放在室外,会使发动机室内的温度降低至-40℃以下。因此,一般安装在发动机室内的汽车电子产品,都要求在-40℃~+125℃温度范围内都能正常工作,否则将影响汽车行驶,甚至是出现安全问题。这就需要汽车电子产品中的元件在-40℃~+125℃温度范围内具有优异的温度稳定性,而现有的高磁导率材料往往在过高或过低的温度下,磁导率变化过大。在这样的极端温度下,汽车电子产品难以正常使用。研究表明,通过合理的配方及制备工艺研究,能够改善材料的温度特性,对制备汽车电子用宽温高磁导率锰锌软磁铁氧体具有重要的指导意义。
公开号为CN101620908A的专利公开了一种宽温宽频高居里点低损耗锰锌铁氧体材料及其制备方法,相较于该专利,本发明采用了气流磨和低温烧结的工艺,材料磁导率更高,-40~+125℃范围内磁导率的温度稳定性更好。公开号为CN112194480A的专利公开了一种宽温高Bs低温度系数锰锌铁氧体材料及其制备方法,该专利使用的配方及掺杂体系与本材料不同,其起始磁导率在2500-3300范围间,远远低于本发明材料的磁导率性能,而且本发明采用了气流磨及低温烧结的方式,使得材料具有更高的磁导率和更好的温度稳定性。公开号为CN103896567A的专利公开了一种低温度系数铁氧体材料的制备技术,在制备工艺上与本发明有很大差异,其工作温度范围仅在-10℃—55℃范围内,且比温度系数远低于本发明材料。公开号为CN106747396B的专利公开了一种汽车电子用高磁导率锰锌铁氧体材料及其制备方法,与本材料的掺杂体系及工艺有较大差异,未用到Co2O3和TiO2,未采用气流磨工艺,只在25℃~80℃具有较好的温度稳定性。公开号为CN109626981A的专利公开了一种宽温宽频高磁导率锰锌铁氧体及其制备方法,但是其工作温度范围仅是2℃~110℃,并未有其在负温度范围内的磁导率特性。
综上,目前现有技术中缺少一种在-40℃~+125℃范围内具有宽温高磁导率特性的锰锌软磁铁氧体材料,以便能够应用于汽车电子产品中,适用于极端温度条件下的正常运作。本发明材料在-40℃~+125℃范围内具有较高的磁导率及其温度稳定性、优异的比温度系数、较低的比损耗因子、高居里温度和较高的Bs,可以充分满足材料在汽车电子方向的应用。
发明内容
为了解决以上问题,本发明提供了一种汽车电子用宽温高磁导率锰锌软磁铁氧体及其制备方法。本发明通过对磁性材料配方(特别是辅助成分的配方)以及制备工艺(尤其是气流磨和烧结工艺)进行深入研究后,在调整配方含量以及工艺参数不具备明显规律性的情况下,摸索出了一种汽车电子用宽温高磁导率锰锌软磁铁氧体及其制备方法。
本发明特征在于,材料包含主成分和辅助成分,主成分包括Fe2O3:53mol%~55mol%,ZnO:16mol%~19mol%,其余为Mn3O4,按主成分总重量计,所述辅助成分包括:纳米CaCO3:400ppm~1000ppm、纳米TiO2:4000ppm~6000ppm、纳米Co2O3:500ppm~2000ppm,纳米Nb2O5:100ppm~350ppm、纳米SiO2:20ppm~150ppm、纳米CuO:0ppm~600ppm。
上述汽车电子用宽温高磁导率锰锌软磁铁氧体及其制备方法,包括如下步骤:
步骤1:配料:Fe2O3:53mol%~55mol%,ZnO:16mol%~19mol%,其余为Mn3O4,然后进行湿法球磨混合,混合时间为10min~40min;
步骤2:预烧:对步骤1中所得混合料烘干后进行预烧,预烧温度为700℃~1000℃,升温速率为3℃/min~5℃/min,保温时间1小时-3小时;
步骤3:砂磨:对步骤2所得预烧料振磨,然后加入辅助成分:纳米CaCO3:400ppm~1000ppm、纳米TiO2:2000ppm~6000ppm、纳米Nb2O5:100ppm~350ppm、纳米SiO2:20ppm~150ppm、纳米CuO:0ppm~600ppm。采用流化床气流磨的方式,气压0.6 MPa ~1.0MPa,分级轮转速8000rpm,气流磨时间30~60min,粉碎后的D50粒度范围为1.0μm ~1.3μm,D90粒度范围为2.1μm ~2.6μm;
步骤4:造粒:对气流磨后的粉料,根据得到粉料总重量,加入3wt%~20wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.15g/cm3~3.35g/cm3
步骤6:烧结:烧结温度为1200℃~1280℃,保温时间为4h~8h,平衡氧含量为3.0%~8.0%,烧结后晶粒粒径细化至15μm~20μm 。
作为一种优选,一种汽车电子用宽温高磁导率锰锌软磁铁氧体的主成分包括Fe2O3:53.0mol%~54.0mol%,ZnO:16.0mol%~17.5mol%,其余为Mn3O4,按主成分总重量计,所述辅助成分包括:纳米CaCO3:400ppm~800ppm、纳米TiO2:4000ppm~6000ppm、纳米Co2O3:500ppm~2000ppm,纳米Nb2O5:100ppm~300ppm、纳米SiO2:20ppm~100ppm、纳米CuO:0ppm~600ppm。
作为一种优选,步骤6中,烧结温度为1200℃ ~1240℃,保温时间为4h~8h,平衡氧含量为3.0%~8.0%。
通过TiO2和Co2O3的联合作用,调控材料的磁晶各向异性常数K1,使软磁铁氧体在宽温条件下磁导率变化小,稳定性好,优化了材料整体μ-T曲线。另外,由于TiO2与Co2O3的掺杂受烧结温度影响很大,为了避免烧结温度高使材料特性恶化,通过掺杂Nb2O5、SiO2、CuO的方式降低烧结温度,同时细化晶粒粒径,使软磁铁氧体具有良好晶粒一致性,可以减小应力,使不同温度下磁导率的变化减小。
所述步骤3中,采用流化床气流磨的方式进行颗粒的自粉碎,使用压缩空气等作为工作介质,颗粒进入气流磨后主要与其他颗粒进行碰撞发生破碎。当开始进料后,气流磨中颗粒逐渐累积,同时颗粒不断被粉碎,小颗粒被分级轮分级出去成为产品,其粉碎原理主要是冲击和碰撞,相较于传统的球磨,一方面,可以得到粒度更小,分布更加均匀的粉料,有效缩小D50~D90;另一方面,这种气流磨方式不会在研磨过程中产生不必要的杂质,最终所得产品的纯度较高,这是因为其采用气流的作用使颗粒间产生自粉碎,而与传统球磨机不同,传统球磨机采用球体材料与颗粒发生摩擦碰撞,球体材料在摩擦过程中会出现磨损,产生不必要的杂质,从而在研磨的最终产品中存在杂质。D50~D90减小,可以使粉料活性提高,配合低温烧结条件可以使晶粒生长更均匀,得到具有高磁导率,更好温度稳定性的铁氧体材料。同时引入杂质的减少可以避免不必要的影响,防止晶粒异常长大。
与现有技术相比,本发明的有益效果为:
本发明的汽车电子用宽温高磁导率锰锌软磁铁氧体,在-40℃~+125℃具有优秀的μ-T特性,磁导率稳定在5000以上,磁导率的温度稳定性高,同时达到技术性能、指标和参数如下:
(1)起始磁导率μi≥5000(T=25℃,B<0.25mT,10kHz);
(2)比损耗因子tanδ/μi<3(T=25℃,B<0.25mT,100kHz);
(3)相对温度因数αF: (-0.5-0.5)×10-6(f=10kHz, B<0.25mT,-40~+125℃);
(4)饱和磁感应强度BS≥460mT(25℃,H=1194A/m);
(5)居里温度TC≥180℃。
本发明的汽车电子用宽温高磁导率锰锌软磁铁氧体的高磁导率可以满足器件滤波和小型化的需求,优异的温度稳定性可以保证元件在极端的温度条件下都可以正常运行,确保了汽车电子产品的安全稳定。
附图说明
图1 实施例与比较例的αF(-40℃~+125℃)差异图;
图2 实施例与比较例中锰锌软磁铁氧体的磁导率随温度变化曲线图。
具体实施方式
下面通过具体的实施案例,对本发明所制备的汽车电子用宽温高磁导率锰锌软磁铁氧体及制备工艺进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.1mol%,ZnO:17mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4000ppm、Co2O3:1000ppm,纳米Nb2O5:200ppm、纳米SiO2:60ppm、纳米CuO:200ppm,用流化床气流磨50min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3
步骤6:烧结:烧结温度为1220℃,平衡氧含量为4%,保温5h。
实施例2:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.1mol%,ZnO:17mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为950℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4000ppm、Co2O3:1000ppm,纳米Nb2O5:200ppm、纳米SiO2:60ppm、纳米CuO:100ppm,用流化床气流磨50min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1240℃,平衡氧含量为4%,保温5h。
实施例3:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.3mol%,ZnO:16.9mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4800ppm、Co2O3:1200ppm,纳米Nb2O5:200ppm、纳米SiO2:20ppm、纳米CuO:200ppm,用流化床气流磨50min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1240℃,平衡氧含量为4%,保温5h。
比较例1:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.1mol%,ZnO:17mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4000ppm、Co2O3:1000ppm,纳米Nb2O5:200ppm、纳米SiO2:60ppm、纳米CuO:200ppm,球磨机粉碎80min;
步骤4:造粒:根据球磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1220℃,平衡氧含量为4%,保温5h。
比较例2:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.2mol%,ZnO:16.6mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4800ppm、Co2O3:1200ppm,纳米Nb2O5:200ppm、纳米SiO2:20ppm、纳米CuO:200ppm,用流化床气流磨50min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1300℃,平衡氧含量为4%,保温5h。
比较例3:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.1mol%,ZnO:17mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:4800ppm、Co2O3:1200ppm,纳米Nb2O5:200ppm、纳米SiO2:20ppm、纳米CuO:200ppm,用流化床气流磨20min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1300℃,平衡氧含量为4%,保温5h。
比较例4:一种汽车电子用宽温高磁导率锰锌软磁铁氧体材料,由主成分和辅助成分组成,制备方法如下:
步骤1:配料:Fe2O3:53.6mol%,ZnO:16.7mol%和其余的Mn3O4配料,然后进行湿法球磨混合,混合时间为20min;
步骤2:预烧:对步骤1中所得混合料烘干后在进行预烧,预烧温度为900℃,升温速率为5℃/min,保温2h;
步骤3:砂磨:对所得预烧料振磨,然后加入辅助成分:纳米CaCO3:500ppm、纳米TiO2:6000ppm、Co2O3:800ppm,纳米Nb2O5:200ppm、纳米SiO2:40ppm、纳米CuO:200ppm,用流化床气流磨50min;
步骤4:造粒:根据气流磨后得到粉料总重量,加入15wt%聚乙烯醇,研磨过筛成一定尺寸的颗粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.2g/cm3;
步骤6:烧结:烧结温度为1220℃,平衡氧含量为4%,保温5h。
实施例与比较例温度磁导率测试结果如下表:
Figure 437126DEST_PATH_IMAGE002
通过对比实施例与比较例表明:通过采用合适的组成主成分和辅助成分,并对材料的工艺进行优化,尤其是采用了气流磨及低温烧结工艺,对材料的磁导率和温度特性都有得到了极大的改善。通过上表及图1、图2可以看出,实施例磁导率高,温度稳定性好,而比较例2和比较例3在-40℃~+125℃温度范围内的起始磁导率稳定性差,比较例温度系数偏差大,比较例1和比较例4磁导率虽然磁导率的温度稳定性较好,但磁导率偏低。实施例起始磁导率稳定在5000以上,温度稳定性高,且对温度系数有严格的把控,同时-40℃~+125℃磁导率变化都很小。
以上所述仅为本发明的一些实施方式,但本发明的保护范围并不局限于此。

Claims (8)

1.一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,材料包含主成分和辅助成分,主成分包括Fe2O3:53mol%~55mol%,ZnO:16mol%~19mol%,其余为Mn3O4,按主成分总重量计,所述辅助成分包括:纳米CaCO3:400ppm~1000ppm、纳米TiO2:2000ppm~6000ppm、纳米Co2O3:500ppm~2000ppm,纳米Nb2O5:100ppm~350ppm、纳米SiO2:20ppm~150ppm、纳米CuO:0ppm~600ppm,材料制备方法包括以下步骤:
步骤1:配料:按照比例将主成分Fe2O3、ZnO、Mn3O4称取后进行湿法球磨混合,混合时间为10min~40min;
步骤2:预烧:对步骤1中所得混合料进行烘干,并在700℃~1000℃预烧,保温时间为1小时~3小时;
步骤3:砂磨:对步骤2所得预烧料进行振磨,按照比例加入辅助成分纳米CaCO3、纳米TiO2、纳米Co2O3、纳米Nb2O5、纳米SiO2、纳米CuO,并采用流化床气流磨的方式对预烧料进行粉碎;
步骤4:造粒:对气流磨后的粉料造粒;
步骤5:压制成型:压制成尺寸为Φ25mm*Φ15mm*7.5mm环形生坯,密度为3.15g/cm3~3.35g/cm3;
步骤6:烧结,烧结温度为1200℃~1280℃,保温时间为4h~8h,平衡氧含量为3.0%~8.0% 。
2.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,所述主成分包括Fe2O3:53.0mol%~54.0mol%,ZnO:16.0mol%~17.5mol%,其余为Mn3O4,按主成分总重量计,所述辅助成分包括:纳米CaCO3:400ppm~800ppm、纳米TiO2:4000ppm~6000ppm、纳米Co2O3:500ppm~2000ppm,纳米Nb2O5:100ppm~300ppm、纳米SiO2:20ppm~100ppm、纳米CuO:0ppm~600ppm。
3.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,所述步骤2中,在空气中进行预烧,预烧温度升温速率为3℃/min~5℃/min。
4.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,所述步骤3中,粉碎时间是30min~60min,气压0.6~1.0MPa,分级轮转速8000rpm。
5.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,所述步骤3中,粉碎后的D50粒度范围为1.0μm ~1.3μm,D90粒度范围为2.1μm ~2.6μm。
6.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,所述步骤6中,烧结温度为1200℃~1240℃,保温时间为4h~8h,平衡氧含量为3.0%~8.0%。
7.根据权利要求1所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,所述步骤6中,烧结后的晶粒粒径为15μm~20μm。
8.根据权利要求1-7任一所述的一种汽车电子用宽温高磁导率锰锌软磁铁氧体,其特征在于,所述汽车电子用宽温高磁导率锰锌软磁铁氧体在-40℃~+125℃范围内的比温度系数为-0.5~0.5,磁导率稳定在5000以上。
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