Preparation and properties of iron based soft magnetic composites coated with mixed resin
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摘要:
仅采用单一成分的树脂进行有机绝缘包覆，只能在高温稳定性与粘结性能间进行选择，往往会出现“短板”。而尝试多组分共混树脂进行包覆可以得到较优的综合性能，从而拓宽铁基磁粉芯高温适用性。本文通过环氧树脂对有机硅树脂进行共混改性，采用共混改性的树脂对磷化处理后的羰基铁粉进行有机绝缘包覆，并通过对磁粉进行压制成型及固化处理制备成铁基磁粉芯。共混树脂通过形成有效的包覆层结构，减少粉末颗粒在压制过程所引入的应变，同时隔离颗粒间的接触以切断涡流，使所制备的磁粉芯密度达到6.82 g/cm3、电阻率高达1.1×106 Ω·cm，并提高了品质因数，降低了高频损耗。当共混树脂由33.3wt.%环氧树脂与66.7wt.%有机硅树脂组成时，铁基磁粉芯的综合性能最佳，在200 kHz下的功率损耗仅为1182.7 kW/m3。通过选用合适成分的共混树脂包覆剂，进一步优化铁基磁粉芯的磁性能，在中高频领域具有广阔的应用前景。 不同成分配比树脂包覆磁粉芯的功率损耗：(a) 随频率变化；(b) 随树脂成分变化 Abstract: With the rapid development of mobile communication, intelligent manufacturing, automotive electronics, electronic new energy and other emerging fields, reducing the magnetic loss and improving other properties of SMCs are required. The silicone resin mixed with epoxy resin was used to coat the phosphatized carbonyl iron powder (CIP). And the coated powders were fabricated into iron based soft magnetic composites (SMCs) through compression and curing. The effects of different mixed resins on the microstructure and electromagnetic properties of iron-based SMCs were studied. The results show that the mixed resin has been formed a reasonable coating layer on the surface of powders, which leads to reduce the strain of the powders introduced during compression and isolate the powders to cut off the eddy current. As a result, the density of SMCs can reach 6.82 g/cm3, the resistivity is as high as 1.1×106 Ω·cm. Meanwhile, its quality factor is improved and the magnetic loss at high frequency is reduced. When the mixed resin is composed of 33.3wt.% epoxy resin and 66.7wt.% silicone resin, the SMCs are provided with optimal comprehensive performance with 1182.7 kW/m3 loss only at 200 kHz. The magnetic properties of iron-based SMCs are further optimized through selecting the blending resin coating agent with suitable composition, which has a broad application prospect in the field of medium and high frequency.-
Key words:
- Soft magnetic composites /
- Mixed resin /
- Insulation coating /
- Magnetic loss /
- Quality factor
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图 1 不同成分配比树脂包覆后粉末的SEM图： (a) SMCs；(b) 16.7 wt.%EP/SMCs；(c) 33.3 wt.%EP/SMCs；(d) 50.0 wt.%EP/SMCs；(e) 83.3 wt.%EP/SMCs；(f) 100.0 wt.%EP/SMCs
Figure 1. SEM images of the powders coated with different mixed resins: (a) SMCs；(b) 16.7 wt.%EP/SMCs；(c) 33.3 wt.%EP/SMCs；(d) 50.0 wt.%EP/SMCs；(e) 83.3 wt.%EP/SMCs；(f) 100.0 wt.%EP/SMCs
图 2 不同成分配比树脂包覆磁粉芯的断面SEM图：(a) SMCs；(b) 16.7 wt.%EP/SMCs；(c) 33.3 wt.%EP/SMCs；(d) 50.0 wt.%EP/SMCs；(e) 83.3 wt.%EP/SMCs；(f) 100.0 wt.%EP/SMCs
Figure 2. Fracture surface morphology of the SMCs based on the powders coated with different mixed resins: (a) SMCs；(b) 16.7 wt.%EP/SMCs；(c) 33.3 wt.%EP/SMCs；(d) 50.0 wt.%EP/SMCs；(e) 83.3 wt.%EP/SMCs；(f) 100.0 wt.%EP/SMCs
图 3 不同成分配比树脂对磁粉芯密度的影响
Figure 3. Effects of the mixed resin composition on the SMCs density
图 4 不同成分配比树脂对磁粉芯电阻率的影响
Figure 4. Effects of the mixed resin composition on the SMCs resistivity
图 5 不同成分配比树脂包覆磁粉芯的复数磁导率：(a) 实部-环氧树脂占比曲线图；(b) 虚部-频率曲线图
Figure 5. Permeability of the cores coated with different mixed resins: (a) μ′-epoxy resin proportion curve; (b) μ″-frequency curve
图 6 不同成分配比树脂包覆磁粉芯的损耗因子
Figure 6. Loss factor of the cores coated with different mixed resins
图 7 不同成分配比树脂包覆磁粉芯的品质因数
Figure 7. Quality factor of the cores coated with different mixed resins
图 8 不同成分配比树脂包覆磁粉芯的功率损耗曲线：(a) 随频率变化；(b) 随树脂成分变化
Figure 8. Ps curves of the cores under different frequencies (a) and with different resin compositions (b)
表 1 共混树脂成分配比
Table 1. Ingredients list of the mixed resin
Samples number SMCs 16.7wt.%EP/SMCs 33.3wt.%EP/SMCs 50.0wt.%EP/SMCs 66.7wt.%EP/SMCs 83.3wt.%EP/SMCs 100.0wt.%EP/SMCs Epoxy resin：Silicone resin (mass ratio) 0∶1 1∶5 1∶2 1∶1 2∶1 5∶1 1∶0 Epoxy percent/wt.% 0.0 16.7 33.3 50.0 66.7 83.3 100.0 
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