阅读说明：本技术 软磁材料及其制备方法 (Soft magnetic material and preparation method thereof ) 是由 王静然 于 2019-11-27 设计创作，主要内容包括：本申请公开了一种软磁材料及其制备方法,属于绝缘技术领域。该带有表面绝缘层的软磁材料,软磁合金带材和在所述软磁合金带材表面形成的活性炭层,所述活性炭层是由浸润液浸涂所述软磁合金带材,并经加热挥发后形成的。本申请通过在软磁合金带材的表面形成活性炭层,这样,由于活性炭是一种多孔物质,且孔径分布范围较广,从而使得活性炭具有很高的绝缘性能,也即是使得软磁材料的表面具有很高的绝缘电阻。这样对于磁芯在高、中、低频的交变磁场下工作时,每层软磁材料之间会具有很好的绝缘效果,从而减小磁芯的涡流效应,使得磁芯的涡流损耗减小。(The application discloses a soft magnetic material and a preparation method thereof, and belongs to the technical field of insulation. The soft magnetic material with the surface insulating layer comprises a soft magnetic alloy strip and an activated carbon layer formed on the surface of the soft magnetic alloy strip, wherein the activated carbon layer is formed by dip-coating the soft magnetic alloy strip by using an impregnating solution and heating and volatilizing the impregnating solution. According to the soft magnetic alloy strip, the active carbon layer is formed on the surface of the soft magnetic alloy strip, so that the active carbon is a porous substance and has a wide pore size distribution range, so that the active carbon has high insulating property, namely, the surface of the soft magnetic material has high insulating resistance. Therefore, when the magnetic core works in the high, medium and low frequency alternating magnetic field, each layer of soft magnetic material has good insulation effect, so that the eddy current effect of the magnetic core is reduced, and the eddy current loss of the magnetic core is reduced.)

1. A soft magnetic material, characterized in that the soft magnetic material comprises: the soft magnetic alloy strip comprises a soft magnetic alloy strip and an activated carbon layer formed on the surface of the soft magnetic alloy strip, wherein the activated carbon layer is formed by dip-coating the soft magnetic alloy strip by using an impregnating solution and heating and volatilizing the impregnating solution.

2. Soft magnetic material according to claim 1, wherein the thickness of the activated carbon layer lies in the range of 1 nm to 1000 nm.

3. A soft magnetic material according to claim 1, wherein the activated carbon layer has a resistance of between 100 ohms and 30 mega ohms.

4. The soft magnetic material according to claim 1, wherein the impregnating solution is an organic liquid.

5. A method for preparing a soft magnetic material, the method comprising:

selecting an immersion liquid;

immersing the soft magnetic alloy strip into the impregnating solution to obtain the soft magnetic alloy strip with the impregnating solution layer formed on the surface;

and (3) placing the soft magnetic alloy strip with the formed impregnating solution coating into a heating furnace, and heating within a temperature threshold range to obtain the soft magnetic alloy strip with the activated carbon coating formed on the surface.

6. The method of claim 5,

when the soft magnetic alloy strip is an amorphous strip, the temperature threshold range is 150-460 ℃; alternatively, the first and second electrodes may be,

when the soft magnetic alloy strip is an ultra-microcrystalline strip, the temperature threshold range is 150-600 ℃; alternatively, the first and second electrodes may be,

when the soft magnetic alloy strip is a silicon steel strip, the temperature threshold range is 150-900 ℃.

7. The method according to claim 5, wherein the step of immersing the soft magnetic alloy strip into the impregnating solution to obtain the soft magnetic alloy strip with the surface formed with the impregnating solution coating comprises the following steps:

and immersing the soft magnetic alloy strip into the impregnating solution for 60-1200 s, and vacuumizing the soft magnetic alloy strip to obtain the soft magnetic alloy strip with the impregnating solution coating formed on the surface.

8. The method according to claim 5, wherein the step of placing the soft magnetic alloy strip with the formed impregnating solution coating in a heating furnace and heating the soft magnetic alloy strip within a temperature threshold range to obtain the soft magnetic alloy strip with the activated carbon layer formed on the surface comprises the following steps:

heating the immersion liquid coating within the temperature threshold range, and simultaneously introducing oxidation activation gas into the heating furnace, wherein the oxidation activation gas is used for oxidation activation of the dip coating;

and when the heating time of the impregnating solution coating reaches a time threshold value, obtaining the soft magnetic alloy strip with the activated carbon layer formed on the surface.

9. The method of claim 8, wherein the oxidative activation gas comprises at least one of air, carbon dioxide, water vapor.

10. The method according to any one of claims 6 to 9, wherein the impregnating solution is petroleum, bitumen or resin.

Technical Field

The application relates to the technical field of insulation, in particular to a soft magnetic material and a preparation method thereof.

Background

The soft magnetic material generally needs to work under an alternating electric field, and the interior of the soft magnetic material induces the alternating electric field, so that an induced current is generated in the interior of the soft magnetic material, namely, the energy of the alternating electric field is consumed by the soft magnetic material in the form of eddy current loss. In order to reduce the eddy current loss of the soft magnetic material, some elements with higher resistivity (such as adding silicon into pure iron) are usually added in the manufacturing process of the soft magnetic material, and the manufactured soft magnetic material is made into a sheet shape. Then, the sheet-shaped soft magnetic material can be wound to form the magnetic core, and the magnetic core has good soft magnetic performance through a proper heat treatment process.

When the magnetic core works under the alternating magnetic field of high, medium, low frequency, very easily because of unsatisfactory of insulating effect between every layer of soft magnetic material for the eddy current effect who forms increases, and then leads to the eddy current loss increase of magnetic core, consequently need a magnetic core with high insulating nature urgently to guarantee that the magnetic core can not produce higher eddy current loss because of switching on under the alternating magnetic field of high, medium, low frequency.

Disclosure of Invention

The application provides a soft magnetic material and a preparation method thereof, which can solve the problem that the conduction between two adjacent layers of soft magnetic materials of a magnetic core increases the eddy current loss. The technical scheme is as follows:

there is provided a soft magnetic material with a layer insulation layer, the soft magnetic material comprising: the soft magnetic alloy strip comprises a soft magnetic alloy strip and an activated carbon layer formed on the surface of the soft magnetic alloy strip, wherein the activated carbon layer is formed by dip-coating the soft magnetic alloy strip by using an impregnating solution and heating and volatilizing the impregnating solution.

Optionally, the activated carbon layer has a thickness in a range of 1 nanometer to 1000 nanometers.

Optionally, the activated carbon layer has a resistance between 100 ohms and thirty megaohms.

Optionally, the immersion liquid is an organic liquid.

In another aspect, there is provided a method of preparing a soft magnetic material, the method comprising:

selecting an immersion liquid;

and immersing the soft magnetic alloy strip into the impregnating solution to obtain the soft magnetic alloy strip with the surface formed with the impregnating solution coating.

And (3) placing the soft magnetic alloy strip with the formed impregnating solution coating into a heating furnace, and heating within a temperature threshold range to obtain the soft magnetic alloy strip with the activated carbon coating formed on the surface.

Optionally, when the soft magnetic alloy strip is an amorphous strip, the temperature threshold range is 150-460 ℃.

When the soft magnetic alloy strip is an ultra-microcrystalline strip, the temperature threshold range is 150-600 ℃.

When the soft magnetic alloy strip is a silicon steel strip, the temperature threshold range is 150-900 ℃.

Optionally, the step of immersing the soft magnetic alloy strip into the impregnating solution to obtain the soft magnetic alloy strip with the surface formed with the impregnating solution coating includes:

and immersing the soft magnetic alloy strip into the impregnating solution for 60-1200 s, and vacuumizing the soft magnetic alloy strip to obtain the soft magnetic alloy strip with the impregnating solution coating formed on the surface.

Optionally, the step of placing the soft magnetic alloy strip with the impregnating solution coating formed thereon in a heating furnace, and heating the soft magnetic alloy strip within a temperature threshold range to obtain the soft magnetic alloy strip with the activated carbon layer formed on the surface thereof includes:

heating the immersion liquid coating within the temperature threshold range, and introducing oxidation activation gas into the heating furnace, wherein the oxidation activation gas is used for oxidation activation of the dip coating;

and when the heating time of the impregnating solution coating reaches a time threshold value, obtaining the soft magnetic alloy strip with the activated carbon layer formed on the surface.

Optionally, the oxidative activation gas comprises at least one of air, carbon dioxide, and water vapor.

Optionally, the impregnating solution is petroleum, asphalt or resin.

The technical scheme provided by the application has the beneficial effects that:

the active carbon layer is formed on the surface of the soft magnetic alloy strip, so that the active carbon is a porous substance and has a wide pore size distribution range, so that the active carbon has high insulating property, namely the surface of the soft magnetic material has high insulating resistance. Therefore, when the magnetic core made of the soft magnetic material works under the alternating magnetic field of high, medium and low frequencies, the good insulation effect can be achieved between every two layers of the soft magnetic material, so that the eddy current effect of the magnetic core is reduced, and the eddy current loss of the magnetic core is reduced.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.

Fig. 1 is a schematic structural diagram of a soft magnetic material provided in an embodiment of the present application;

fig. 2 is a schematic flow chart of a method for preparing a soft magnetic material according to an embodiment of the present application.

Detailed Description

To make the objects, technical solutions and advantages of the present application more clear, embodiments of the present application will be described in further detail below with reference to the accompanying drawings.

Fig. 1 illustrates a schematic structural diagram of a soft magnetic material according to an embodiment of the present application. As shown in fig. 1, the soft magnetic material includes: the soft magnetic alloy strip comprises a soft magnetic alloy strip 1 and an active carbon layer 2 formed on the surface of the soft magnetic alloy strip, wherein the active carbon layer 2 is formed by dip-coating the soft magnetic alloy strip by using an impregnating solution and heating and volatilizing the impregnating solution.

In the embodiment of the application, the activated carbon layer can be formed on the surface of the soft magnetic alloy strip, so that the activated carbon is a porous substance and has a wide pore size distribution range, so that the activated carbon has high insulating property, namely, the surface of the soft magnetic material has high insulating resistance. Therefore, when the magnetic core made of the soft magnetic material works under the alternating magnetic field of high, medium and low frequencies, the good insulation effect can be achieved between every two layers of the soft magnetic material, so that the eddy current effect of the magnetic core is reduced, and the eddy current loss of the magnetic core is reduced.

The specific surface area of each gram of the activated carbon is usually 500-1700 square meters, the distribution range of the pore diameters of the activated carbon can be 1-1000 nanometers, and the interlayer spacing of the microcrystalline structure of the activated carbon is 0.34-0.35 nanometers, so that the insulation effect of the activated carbon layer, namely the insulation effect between soft magnetic material layers, can be ensured.

The microcrystalline structure of the activated carbon is not converted into the microcrystalline structure of graphite at 2000 ℃, namely, the activated carbon still maintains a good structure at 2000 ℃, so that the stability of the insulating property is kept.

In some embodiments, the immersion liquid may be an organic liquid or an inorganic carbon-containing liquid, and of course, the immersion liquid may also be a mixed liquid of at least one organic liquid and/or at least one inorganic carbon-containing liquid, as long as the immersion liquid can promote volatilization of other elements except for carbon element under heating condition, which is not limited in this application.

For example, the impregnating solution may be an organic liquid such as vegetable oil, animal oil, mineral oil, or resin, or a mixture of at least one of vegetable oil, animal oil, mineral oil, and resin.

In other embodiments, the soft magnetic alloy strip may be introduced into an organic gas, in addition to the immersion liquid, as long as the soft magnetic alloy strip can promote volatilization of elements other than carbon element under heating condition, so as to form an activated carbon layer on the surface of the soft magnetic alloy strip, which is not limited in this application.

In some embodiments, the thickness of the activated carbon layer may be in a range of 1 nanometer to 1000 nanometers.

When the activated carbon layer is formed on the surface of the soft magnetic alloy strip, the soft magnetic alloy strip can be soaked in the soaking liquid with high carbon content, the thickness of the soaking liquid coating on the surface of the soft magnetic alloy strip is ensured through the soaking time, and then the soaking liquid coating is subjected to heating treatment, so that other elements except carbon in the soaking liquid coating are volatilized, and the activated carbon layer with the thickness meeting the requirement is obtained.

The immersion time of the soft magnetic alloy strip into the immersion liquid can be controlled to be 60-1200 s, and of course, the immersion time of the soft magnetic alloy strip into the immersion liquid can be other times as long as the thickness of the obtained activated carbon layer meets the requirement after the immersion liquid coating on the surface of the soft magnetic alloy strip is heated.

When the soft magnetic alloy strip is immersed in the immersion liquid, in order to prevent air accumulated in the pores on the surface of the soft magnetic alloy strip from obstructing the immersion of the immersion liquid, the soft magnetic alloy strip may be subjected to a vacuum pumping treatment to eliminate obstruction of the immersion liquid by the air accumulated in the pores, so as to ensure that the surface of the soft magnetic alloy strip can be more thoroughly infiltrated by the immersion liquid.

When the wetting liquid coating on the surface of the soft magnetic alloy strip is heated, different heating temperatures can be controlled for different soft magnetic alloy strips in order to avoid influence on the soft magnetic alloy strip coating and accelerate the rapid formation of the activated carbon layer.

For example, when the soft magnetic alloy strip is an amorphous strip, the heating temperature of the immersion liquid coating on the surface of the amorphous strip may be in the range of 150 to 460 degrees celsius, when the soft magnetic alloy strip is an ultra-microcrystalline strip, the heating temperature of the immersion liquid coating on the surface of the ultra-microcrystalline strip may be in the range of 150 to 600 degrees celsius, and when the soft magnetic alloy strip is a silicon steel strip, the heating temperature of the immersion liquid coating on the surface of the silicon steel strip may be in the range of 150 to 900 degrees celsius.

It should be noted that, when the wetting solution coating on the surface of the soft magnetic alloy strip is heated, oxidation activation gas may be introduced during the heating process, so as to promote the decomposition of molecular bonds between carbon elements and other elements in the wetting solution coating by the oxidation activation gas, thereby facilitating the volatilization of other elements except for carbon elements in the wetting solution coating.

The activated carbon layer may be formed on the surface of the soft magnetic alloy strip before the soft magnetic alloy strip is wound or laminated to obtain the magnetic core, that is, the activated carbon layer may be formed on the surface of the soft magnetic alloy strip to obtain the soft magnetic material, and then the magnetic core may be obtained by winding or laminating. It is needless to say that the activated carbon layer may be formed on the surface of the soft magnetic alloy strip after the core is obtained by winding or laminating the soft magnetic alloy strip. That is, the activated carbon layer may be formed on the surface of the soft magnetic alloy strip included in the magnetic core.

Before the soft magnetic alloy strip is wound to obtain the magnetic core, a thicker impregnating solution coating can be formed on the surface of the soft magnetic alloy strip due to the fact that the surface of the soft magnetic alloy strip is not limited, and therefore after the thicker impregnating solution coating is heated, the thickness of an obtained activated carbon layer can easily meet the insulation requirement.

And when the activated carbon layer is formed after the magnetic core is obtained by winding, the gaps between two adjacent layers of soft magnetic alloy strips are different due to different lamination coefficients of the soft magnetic alloy strips. Therefore, after the magnetic core is immersed in the impregnating solution, the thickness of the impregnating solution coating formed on the surface of the soft magnetic alloy strip is also influenced by the gap between two adjacent soft magnetic alloy strips, so that the thickness of the activated carbon layer is influenced. Because after heating the infiltration liquid coating, the thickness of infiltration liquid coating can reduce, also be after forming first active carbon layer, the clearance between the two adjacent soft magnetic alloy strips increases, can continue to be formed with the magnetic core of first layer active carbon layer and dip in the infiltration liquid this moment, and then carry out heat treatment to the infiltration liquid coating that forms on the surface of first active carbon layer for the surface of soft magnetic alloy strip forms second active carbon layer, with the thickness that increases the active carbon coating, make the thickness of active carbon coating satisfy the requirement.

In some embodiments, the activated carbon coating has a resistance between 100 ohms and 30 mega ohms.

The resistance of the activated carbon layer depends on the thickness of the activated carbon layer, and the thickness of the activated carbon layer to be set can be determined according to the proportional relation between the thickness of the activated carbon layer and the resistance in order to ensure that the resistance of the activated carbon layer is any resistance between 100 ohms and 30 mega ohms, so that the soft magnetic material with the thickness meeting the requirements can be manufactured based on the thickness of the activated carbon layer.

It should be noted that, when the thickness of the activated carbon layer is several tens to several hundreds or even several thousands of nanometers, the insulation resistance of the manufactured soft magnetic material may be several hundreds or several thousands of ohms to several tens or several hundreds of mega-ohms.

In the embodiment of the application, the soft magnetic alloy strip is immersed in the impregnating solution, the impregnating solution coating is formed on the surface of the soft magnetic alloy strip, and then the formed impregnating solution coating is heated, so that other elements except carbon in the impregnating solution coating are volatilized, and an activated carbon layer is formed on the surface of the soft magnetic alloy strip, so that the activated carbon layer has high insulation resistance, and the soft magnetic material has high insulation resistance. Therefore, the insulating property between two adjacent layers of soft magnetic materials can be ensured, and the eddy current loss caused by the eddy current effect between two adjacent layers of soft magnetic materials is avoided.

Fig. 2 illustrates a schematic flow chart of a method for preparing a soft magnetic material according to an embodiment of the present application. Referring to fig. 2, the method includes the following steps.

Step 201: and selecting the immersion liquid.

Wherein, different impregnating liquids can be selected according to different carbon contents. Of course, the immersion liquid may be selected in other manners, which is not limited in the embodiment of the present application.

In some embodiments, the immersion liquid may be an organic liquid or an inorganic carbon-containing liquid, and of course, the immersion liquid may also be a mixed liquid of at least one organic liquid and/or at least one inorganic carbon-containing liquid, as long as the immersion liquid can promote volatilization of elements other than carbon element under heating condition to form an activated carbon layer, which is not limited in this application.

For example, the immersion liquid may be petroleum, asphalt, mechanism, epoxy resin, vegetable oil, animal oil or other organic liquid.

In other embodiments, the organic gas may be selected as long as it can promote volatilization of elements other than carbon under heating conditions to form an activated carbon layer, which is not limited in the embodiments of the present application.

Step 202: and immersing the soft magnetic alloy strip into the impregnating solution to obtain the soft magnetic alloy strip with the surface formed with the impregnating solution coating.

In some embodiments, the soft magnetic alloy strip can be immersed in the impregnating solution for 60s to 1200s, and meanwhile, the soft magnetic alloy strip is vacuumized, so that the soft magnetic alloy strip with the impregnating solution coating formed on the surface is obtained.

When the activated carbon layer is formed on the surface of the soft magnetic alloy strip, the soft magnetic alloy strip can be soaked in the soaking liquid with high carbon content, and the thickness of the soaking liquid coating on the surface of the soft magnetic alloy strip is ensured through the soaking time.

The immersion time of the soft magnetic alloy strip into the impregnating solution can be other time, and mainly depends on the carbon content in the impregnating solution. For example, when the carbon content of the impregnating solution is high, the immersion time of the soft magnetic alloy strip may be short, and when the carbon content of the impregnating solution is low, the immersion time of the soft magnetic alloy strip may be long.

When the soft magnetic alloy strip is immersed in the immersion liquid, in order to prevent air accumulated in the pores on the surface of the soft magnetic alloy strip from obstructing the immersion of the immersion liquid, the soft magnetic alloy strip may be subjected to a vacuum pumping treatment to eliminate obstruction of the immersion liquid by the air accumulated in the pores, so as to ensure that the surface of the soft magnetic alloy strip can be more thoroughly infiltrated by the immersion liquid.

In some embodiments, the soft magnetic alloy strip may be placed in a container containing an immersion liquid, and then a vacuum pump is communicated with a top cover of the container, and an air suction port of the vacuum pump is higher than a liquid level of the immersion liquid, so that the soft magnetic alloy strip may be subjected to a vacuum pumping process by the vacuum pump while being immersed by the immersion liquid, so as to ensure that the surface of the soft magnetic alloy strip can be more thoroughly immersed by the immersion liquid. Of course, the vacuum pumping treatment of the soft magnetic alloy strip can be realized through the above method, and the vacuum pumping treatment can also be performed through other methods, which is not limited in the embodiment of the present application.

Step 203: and (3) placing the soft magnetic alloy strip with the formed impregnating solution coating into a heating furnace, and heating within a temperature threshold range to obtain the soft magnetic alloy strip with the activated carbon layer formed on the surface.

In some embodiments, the immersion liquid coating may be heated within a temperature threshold range, and an oxidation activation gas is introduced into the heating furnace, where the oxidation activation gas is used to perform oxidation activation on the dip coating, and when the heating duration of the immersion liquid coating reaches a duration threshold, the soft magnetic alloy strip with the activated carbon layer formed on the surface is obtained.

When the soaking liquid coating of the soft magnetic alloy strip is heated, different heating temperatures can be controlled for different soft magnetic alloy strips in order to avoid influence on the soft magnetic alloy strip coating and accelerate the rapid formation of the activated carbon layer.

For example, when the soft magnetic alloy strip is an amorphous strip, the heating temperature of the immersion liquid coating of the amorphous strip may be in the range of 150 to 460 degrees celsius, when the soft magnetic alloy strip is an ultra-microcrystalline strip, the heating temperature of the immersion liquid coating of the ultra-microcrystalline strip may be in the range of 150 to 600 degrees celsius, and when the soft magnetic alloy strip is a silicon steel strip, the heating temperature of the immersion liquid coating of the silicon steel strip may be in the range of 150 to 900 degrees celsius.

The oxidation activation gas is introduced into the heating furnace, so that the decomposition of molecular bonds between carbon elements and other elements in the impregnating solution coating can be promoted, and further, the volatilization of other elements except the carbon elements in the impregnating solution coating is facilitated. The oxidation activation gas may include at least one of air, carbon dioxide, and water vapor, and of course, the oxidation activation gas may be a mixed gas of air, carbon dioxide, and water vapor.

The time length threshold may be any time length value between 10 minutes and 180 minutes as long as it is ensured that other elements except carbon in the immersion liquid coating are volatilized, and this is not limited in this embodiment of the application.

In the embodiment of the application, the soft magnetic alloy strip is immersed in the impregnating solution, the impregnating solution coating is formed on the surface of the soft magnetic alloy strip, and then the formed impregnating solution coating is heated, so that other elements except carbon in the impregnating solution coating are volatilized, and an activated carbon layer is formed on the surface of the soft magnetic alloy strip, so that the activated carbon layer has high insulation resistance, and the soft magnetic material has high insulation resistance. Therefore, the insulating property between two adjacent layers of soft magnetic materials can be ensured, and the eddy current loss caused by the eddy current effect between two adjacent layers of soft magnetic materials is avoided.

The above description is only exemplary of the present application and should not be taken as limiting the present application, as any modification, equivalent replacement, or improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.