CN106531391A - Soft magnetic powder composition and method for producing magnetic element - Google Patents

Abstract

A method for manufacturing a soft magnetic powder composition and a magnetic element, the method for manufacturing a magnetic element comprising: firstly, mixing a soft magnetic powder composition to form a mixed material, then coating the mixed material on a base material, and then cooling the mixed material; wherein the soft magnetic powder composition comprises the following components (in weight percent): (A) 80% to 93% of a magnetic material comprising at least one of a sendust magnetic alloy powder, a Ni-Zn ferrite powder, and a Mn-Zn ferrite powder; and (B)7 to 20% of a polymer material. The soft magnetic powder composition provided by the invention can be fully cured at normal temperature or medium-low temperature, so that high-temperature sintering treatment is not required in the forming process; in addition, the magnetic element manufactured by the method of the present invention has the advantages of sufficient flexible mechanical strength, maximum permeability, magnetic flux density (induction), etc., and simultaneously can keep the eddy current at a low level and minimize the hysteresis loss.

Description

Soft magnetic powder composition and manufacturing method of magnetic element

technical field

The invention relates to a ferrite magnet material, in particular to a soft magnetic powder composition that can be cured at room temperature or at a medium-low temperature, and a method for making a magnetic element using the soft magnetic powder composition.

Background technique

With the development of science and technology, electronic products are developing toward miniaturization and high output. At the same time, the frequency bands used by devices such as mobile phones and computers are becoming more high-frequency, and have reached GHz specifications at present. The accompanying magnetic components must have the characteristics of high magnetic permeability, low core loss, high saturation induction, and high mechanical strength over an extended frequency range.

The main materials of the above-mentioned magnetic elements are soft magnetic metal materials and ferrite materials. As far as soft magnetic metal materials are concerned, although their saturation magnetic flux density is higher than that of ferrite materials, they have high loss and high price in use. Problems such as high specific gravity and poor rust resistance; as far as ferrite materials are concerned, not only are they cheaper, but they also have the advantage of lower loss in the frequency band of several 10 kHz to several 100 kHz.

It is worth noting that ferrite materials (such as: powder) are usually pressed and then sintered at high temperature to form magnetic elements. In other words, the existing manufacturing methods of magnetic elements must overcome the sinterability of ferrite materials problem, the hardening conditions must also be strictly controlled to prevent the reduction of sinterability, the reduction of magnetic permeability and the low frequency of frequency characteristics, and the reduction of dielectric constant; and the composite ferrite composition based on ferrite materials The hardening reaction must be sufficiently complete under high temperature.

Contents of the invention

The technical problem to be solved by the present invention is to provide a soft magnetic powder composition that can be solidified and molded under relatively relaxed conditions in view of the deficiencies of the prior art.

In order to achieve the above object, the present invention adopts the following technical means: a soft magnetic powder composition, comprising the following components (by weight percentage): (A) 80% to 93% magnetic material, which includes sendust magnetic alloy powder, at least one of Ni-Zn ferrite powder, and Mn-Zn ferrite powder; and (B) 7% to 20% of polymer material.

Another object of the present invention is to provide a method for manufacturing a magnetic element, which has high operating efficiency, meets the miniaturization requirements of various elements, and can produce the required magnetic elements in an automated manner.

In order to achieve the above-mentioned purpose, the present invention adopts the following technical means: a manufacturing method of a magnetic element, comprising the following steps: first, kneading the above-mentioned soft magnetic powder composition to form a kneaded product; then, coating the kneaded knead on a substrate; finally, cool the knead.

In other words, the present invention provides a soft magnetic powder composition comprising the following components (by weight): (A) 80% to 93% of a magnetic material comprising sendust At least one of magnetic alloy powder, Ni-Zn ferrite powder, and Mn-Zn ferrite powder; and (B) 7% to 20% of polymer material.

The magnetic material of component (A) contains 85% to 90% of flake sendust magnetic alloy powder, and the polymer material of component (B) contains 10% to 15% of thermoplastic resin.

10% to 15% of the thermoplastic resin is ethylene vinyl acetate resin (EVA).

Alternatively, the magnetic material of component (A) includes 85% to 88% of Mn-Zn ferrite powder and 2% to 5% of sendust magnetic alloy powder, and the polymer material of component (B) is thermoplastic resin.

85% to 88% of the Mn-Zn ferrite powder is spherical Mn-Zn ferrite powder, and 2% to 5% of the sendust powder contains 1% to 3% flake Sendust magnetic alloy powder, 0.5% to 1% of irregular or spherical sendust magnetic alloy powder, and 0.5% to 1% of acicular sendust magnetic alloy powder, and the thermoplastic resin is ethylene-vinyl acetate Ester resin (EVA).

Alternatively, the magnetic material of component (A) includes 85% to 88% of Ni—Zn ferrite powder and 2% to 5% of sendust magnetic alloy powder, and the polymer material of component (B) is thermoplastic resin.

85% to 88% of the Ni-Zn ferrite powder is spherical Ni-Zn ferrite powder, and 2% to 5% of the sendust powder contains 1% to 3% flake Sendust magnetic alloy powder, 0.5% to 1% of irregular or spherical sendust magnetic alloy powder, and 0.5% to 1% of acicular sendust magnetic alloy powder, and the thermoplastic resin is ethylene-vinyl acetate Ester resin (EVA).

Alternatively, the magnetic material of component (A) contains 80% to 88% of flake sendust magnetic alloy powder, and the polymer material of component (B) contains 10% to 15% of thermosetting resin.

The soft magnetic powder composition further comprises component (C) 2% to 5% of additives, which includes 0.5% to 1% of solvent, 0.3% to 1% of curing agent, 0.1% to 0.5% of coupling agent, 0.3% to 0.5% leveling agent, and 0.3% to 0.5% defoamer, 0.4% to 1.3% plasticizer, and 0.1% to 0.2% accelerator.

The solvent is cyclohexanone, the curing agent is dicyandiamide (DICY), the coupling agent is a silicone coupling agent, the leveling agent is a mixture of organic silicon and cyclohexanone, and the defoaming The agent is a mixture of silicone and polymer, and the thermosetting resin is carboxyl-terminated liquid nitrile rubber (CTBN) modified epoxy resin, and the plasticizer is diethyl oxalate, glycerin, triethylene glycol Alcohol, Butyl-Benzyl Butyl Phthalate, Butyl Phthalate (DBP), Polyethylene Glycol (PEG), Triethylene Glycol Hexane, Octyl Phthalate (DDP), butyl-benzyl phthalate, or dioctyl phthalate.

The present invention also provides a method for manufacturing a magnetic element, comprising the following steps: kneading the above-mentioned soft magnetic powder composition to form a kneaded product; processing the kneaded product on a substrate; and The knead was cooled to fully solidify.

In the step of kneading the soft magnetic powder composition, the kneading temperature ranges from 100°C to 200°C, and the kneading speed ranges from 60rpm to 100rpm.

The step of forming the kneaded product on a substrate includes forming the kneaded product by coating method or molding method.

The present invention has at least the following beneficial effects: based on the soft magnetic powder composition provided by the present invention, it can be fully solidified at room temperature or at medium and low temperatures, so high-temperature sintering treatment is not required during the molding process.

In addition, the magnetic element made by the method of the present invention has the advantages of sufficient flexible mechanical strength, maximum magnetic permeability, and magnetic flux density (induction), and can keep the eddy current at a low level and make the magnetic hysteresis Losses are minimized.

In order to further understand the features and technical content of the present invention, please refer to the following detailed description and accompanying drawings of the present invention. However, the accompanying drawings are provided for reference and illustration only, and are not intended to limit the present invention.

Description of drawings

FIG. 1 is a schematic flow chart of the manufacturing method of the magnetic element of the present invention.

detailed description

Based on the characteristics of ceramic magnetic materials such as good magnetic permeability, high resistivity and low loss, especially the role of soft magnetic materials (such as: magnetic nanoparticles) in the development of science and technology is becoming more and more important, the present invention provides a special compatibility composition Soft magnetic powder composition to meet the market demand for various magnetic components or their components (such as: microwave absorbing materials, magnetic conductive films, floppy disks, and planar coil induction materials).

Compared with the composite ferrite composition used for electromagnetic interference shielding materials on the market today, it must also overcome various problems caused by sintering. The soft magnetic powder composition provided by the present invention can not only provide good operability, Moreover, the soft magnetic components/components made of this raw material also have the advantages of sufficient flexible mechanical strength, maximum magnetic permeability, and magnetic flux density (induction), while keeping the eddy current at a low level, and Minimize hysteresis losses. However, it is particularly worth noting that the soft magnetic powder composition can be solidified at room temperature or at a medium-low temperature (200° C. or lower), and no high-temperature sintering treatment is required during the molding process.

Next, the composition and weight ratio of the soft magnetic powder composition will be briefly introduced, and then the reaction mechanism of the polysiloxane resin composition will be supplemented in due course. Those skilled in the art can understand the advantages and technical effects of the present invention from the content of this specification. It should be understood that all the details recorded in this specification can be implemented or applied based on different viewpoints, therefore various modifications and changes within the spirit of the present invention fall within the creative scope of the equivalent structure of the present invention.

In a preferred embodiment of the present invention, considering from the viewpoints of processability, curability, and product effects, the soft magnetic powder composition comprises the following components (by weight percentage): (A) 80% to 93% magnetic material, which contains at least one of sendust magnetic alloy powder, Ni-Zn ferrite powder, and Mn-Zn ferrite powder, wherein the sendust magnetic alloy powder contains 84% to 85% iron, 9% to 10% silicon, and 5% to 6% aluminum, Mn-Zn ferrite powder has the following chemical formula: (Mn _x -Zn _1-x )Fe ₂ O ₄ ,x In the range of 0.005-0.995, the Ni-Zn ferrite powder has the following chemical formula: (Nix-Zn _{1-x )} Fe ₂ O ₄ , with x in the range of 0.005-0.995; and (B) 7% to 20% of Polymer Materials. It is worth noting that the magnetic material of component (A) has different structures and shapes, so it can be made with low cost, ultra-thin, and durable Magnetic components with good flexibility and other advantages.

Furthermore, different processing techniques can be used to impart a specific shape to the magnetic material of component (A); for example, sendust magnetic alloy powder can be formed into a flake structure by rolling, or sendust magnetic alloy powder can be Irregular structures are formed by ball milling, or sendust magnetic alloy powders can be formed into spherical structures by spray granulation. On the other hand, Ni-Zn ferrite powder and Mn-Zn ferrite powder are not easy to form into needle-like and sheet-like structures due to the properties of ceramic materials and their crystal structure; Ni-Zn ferrite powder and Mn-Zn ferrite powder can form irregular structure by ball milling, or the two can form spherical structure by chemical hydrothermal method; it can also use hydrothermal method to grow acicular titanium oxide or flaky silicon oxide substrate , Deposit a Ni-Zn or Mn-Zn ferrite film on the surface of the substrate by hydrothermal method or chemical evaporation method, and use this method to prepare ferrite powder with acicular or flaky structure.

The polymer material of component (B) is used to bond the magnetic material of component (A) together to facilitate subsequent molding operations. In this specific embodiment, the polymer material of component (B) can be a thermoplastic resin or a thermosetting resin, and the thermoplastic resin can be listed as follows: thermoplastic polyimide (PI), polyacrylic acid (PAA), polybutylene (PB), polycarbonate (PC), polyethylene (PE), polyether ether ketone (PEEK), polyethylene terephthalate (PET), polyisobutylene (PIB), polylactic acid (PLA), poly Methyl methacrylate (PMMA), polyacetal (POM), polypropylene (PP), polystyrene (PS), plastic starch material (PSM), polysulfone (PSU/PSF), polyvinylidene fluoride (PVDF ), polytetrafluoroethylene (PTFE), polyvinyl alcohol (PVA), polyvinyl butyral (PVB), polyvinyl chloride (PVC), polyvinylpyrrolidone (PVP), polyphenylene sulfide (PPS), poly Amidimide resin (PAI), polyacrylonitrile, polybutylene terephthalate (PBT), polyoxyxylene (PPO), polyphenylene ether (PPE), polyhydroxybutyrate (PHB), polyhydroxy Alkanoate (PHA), polyphthalamide (PPA), celluloid (CN), cellulose acetate (CA), vinylon (vinylon), thermoplastic polyurethane (TPU), ethylene vinyl acetate (EVA), thermal Plastic acrylic resin, thermoplastic polyester elastomer (TPEE), thermoplastic rubber (TPR), polyamide (PA) hot-melt adhesive, polyolefin (PP) hot-melt adhesive, moisture-curing polyurethane (PUR) hot-melt adhesive, Acrylonitrile-butadiene-benzenediene tri-monomer polymer (ABS) and polyamide resin (PA), etc.

The thermosetting resin can be listed as follows: thermosetting polyimide (PI) resin, polyamideimide (PAI) resin, phenolic (PF) resin, vinyl ester resin, urea formaldehyde (UF) resin, silicone resin (silicone), epoxy resin (Epoxy), thermosetting polytetrafluoroethylene (PTFE), thermosetting polyimide (PI), unsaturated polyester (UP) resin, polyurethane (PU) resin, Flexible thermosetting resin carboxyl-terminated liquid nitrile rubber (CTBN) or amine-terminated liquid nitrile rubber (ATBN) modified epoxy resin and bismaleimide-cyanate (BT) resin, etc.

The soft magnetic powder composition may selectively add 2% to 5% additives of component (C) based on various application requirements within the range of not destroying the desired effect of the present invention. In this specific embodiment, the additive of component (C) includes 0.5% to 1% solvent, 0.3% to 1% curing agent, 0.1% to 0.5% coupling agent, 0.3% to 1% leveling agent, 0.3 % to 0.5% defoamer, 0.4% to 1.3% plasticizer, and 0.1% to 0.2% accelerator.

The solvent is used to adjust the viscosity of the composition coating, and can dissolve or uniformly disperse the film-forming substance (i.e. magnetic material/macromolecular material) in the composition, and has a plasticizing function; the solvent can be listed as follows: Isopropyl Alcohol (IPA), Propylene Glycol Methyl Ether Acetate (PMA), Dipropylene Glycol Methyl Ether Acetate (DPMA), Dimethyl Sulfoxide (DMSO), Propylene Glycol Methyl Ether Acetate (PGMEA), Dimethylaminoethanol (DMAE), butanone (MEK), xylene (Xylene), dipropylene glycol methyl ether (DPM) and cyclohexanone (Cyclohexanone), ethylene glycol monobutyl ether (BCS), diethylene glycol ethyl ether (EC) , tripropylene glycol methyl ether (TPM), propylene glycol methyl ether (PM), phthalates (DP), trimethylolpropane triacrylate (TMPTA), etc.

The curing agent is used for bridging and curing the polymer monomers. The curing agents used in this specific embodiment mainly include aliphatic amine curing agents, aromatic amine curing agents, imidazole curing agents, and organic acid anhydrides. Curing agent, organic hydrazide curing agent, microcapsule latent curing agent, and light-curing curing agent.

The aliphatic amine curing agent can be listed as follows: ethylenediamine, hexamethylenediamine, diethylenetriamine, triethylenetetramine, and the like. The aromatic amine curing agent can be listed as follows: diaminodiphenylsulfone (DDS), diaminodiphenylmethane (DDM), m-phenylenediamine (m-PDA), and the like. The imidazole curing agent can be listed as follows: imidazole, 2-methylimidazole, 2-ethyl-4-methylimidazole, 2-phenylimidazole and the like. The organic acid anhydride curing agent can be listed as follows: tertiary amine/tertiary amine salt, quaternary phosphonium salt, Lewis acid-amine complex, acetylacetone transition metal complex, Lewis acid (such as: BF ₃ , AlCl ₃ , ZnCl ₂ , PF ₅ , etc.) form complexes with primary/secondary amines, etc. The organic hydrazide curing agent can be listed as follows: succinic acid hydrazide, adipic acid dihydrazide, sebacic acid hydrazide, isophthalic acid hydrazide, p-hydroxybenzoic acid hydrazide (POBH) and the like. The light-curable curing agent can be listed as follows: aromatic diazonium salts, triarylsulfonium salts, diaryl sulfonium salts, iron arene compounds, and the like.

The accelerator is used to increase the polymer curing speed and reduce the curing time; the accelerator used in this specific embodiment can be listed as follows: comprise tertiary polyamine (tertiary) embedded in the polymer matrix material, such as infiltrated poly (para 2,4,6-tris(dimethylaminomethyl)phenol in the matrix material of vinylphenol) or OMICURE ^TM , 24EMI, 33-DD5, BC120, U-210 (N-( 4-chlorophenyl)-N,N-dimethyladeno), U-35 (cycloaliphatic-diurea compound), U-415=U52 (4' methanebis(phenyldimethylurea)), U-24 (2,4-toluene-bis(dimethylurea)), U-405 (phenyldimethylurea), U410 (80/20 toluenedimethylurea).

The coupling agent is used to increase the bonding between organic and inorganic materials; the coupling agent used in this specific embodiment is mainly a silane coupling agent. The leveling agent is used to adjust the surface tension of the composition coating to increase the smoothness of the surface of the colloid/film after molding; the leveling agent used in this specific embodiment is mainly a mixture of organosilicon and cyclohexanone, such as : BYK-108 sold by BYK Germany, BYK300 sold by BYK Germany, etc. Described defoamer is used for regulating the surface tension of composition coating, and can eliminate the air bubble inside colloid/film and surface; The defoamer used in this specific embodiment is mainly the mixture of organosilicon and polymer, for example: BYK088, BYK PMA, etc. sold by BYK in Germany.

The plasticizer is used to improve the flexibility of the magnetic element of the soft magnetic powder composition, so as to avoid the problem of film rupture or rupture in the film-forming process or in use; the plasticizer used in this specific embodiment can be listed as follows: Diethyl oxalate, glycerin, triethylene glycol, butyl (yl)-benzyl (yl) butyl phthalate, butyl phthalate (DBP), polyethylene glycol (PEG), tri Ethylene Glycol Hexane, Octyl Phthalate (DDP), Butyl-Benzyl Phthalate, Dioctyl Phthalate.

Please refer to FIG. 1 , the characteristics of the soft magnetic powder composition of the present invention have been described in detail above, and the manufacturing method of the magnetic element according to the soft magnetic powder composition will be further described next. As shown in Figure 1, the manufacturing method of the magnetic element includes: step S100, kneading the soft magnetic powder composition to form a kneaded product; step S102, processing the kneaded product on a substrate molding; and step S104, cooling the kneaded product to fully solidify.

When step S100 is actually implemented, sendust magnetic alloy powders, Ni-Zn ferrite powders, and/or Mn-Zn ferrite powders with different structures and shapes can be selected according to the applicable frequency range, and the It is mixed with polymer materials. The technical means adopted in this specific embodiment can be different depending on whether the solvent is used or not. Specifically, an extruder (extruder), a mixer (compounder), a mixer (internal mixer), a kneader ( kneader), plastic spectrometer (brabender), or roll mill (roll miller), etc., and mix the magnetic material and the polymer material uniformly in the absence of solvent; ideally, the mixing temperature is about 100 ° C to 200°C, and 150°C is the best, the rotation speed is about 60rpm to 100rpm, and the mixing time is about 3 hours to 6 hours, so that excellent properties (such as: strength, elongation, toughness) can be obtained. ) of the mixture.

On the other hand, the magnetic material and the polymer material can also be mixed with a solvent, and the technical means adopted is: use three rollers at room temperature to mix the two evenly. It should be noted that any other mixing methods known to those skilled in the art can be applied in step S100.

When step S102 is actually implemented, the kneaded product can be formed by using a suitable processing method. The technical means adopted in this specific example can be different according to the final use of the material. Specifically, a part of the kneaded material can be attached by means of a scraper, and then the attached kneaded material can be coated on a and scrape it on the substrate; ideally, the distance between the scraper and the substrate is kept at about 0.05mm to 3mm, and the speed of the substrate is kept at about 0.5m/min to 3m/min. The temperature of the cloth is between 130°C and 200°C. In this way, the kneaded material can form a uniform thickness on the substrate.

In addition, the mixture can also be molded directly. For example, a corresponding male mold and a female mold can be used to mold the mixture under a vacuum environment; and the ideal conditions are , the distance between the male mold and the female mold is kept at about 0.05 mm to 3 mm, the forming degree is about 120° C. to 150° C., and the time is about 0.5 hour to 1 hour. It should be noted that any other processing methods known to those skilled in the art can be applied in step S102.

When step S104 is actually implemented, the formed kneaded product can be fully solidified at room temperature or at a medium-low temperature. It should be noted that the kneaded product can also be heated according to actual needs; and the ideal condition is that, in The kneaded mixture is cooled within a temperature range of about 10° C. to 30° C. for about 10 seconds to 30 seconds, and the cooled and solidified magnetic element has sufficient flexible mechanical strength, maximum magnetic permeability, and magnetic flux density ( Induction) and other advantages, while keeping the eddy current at a low level and minimizing the hysteresis loss, it can be further made into various components, such as microwave absorbing materials, magnetic conductive films, soft disks, planar coil induction materials, etc.

Please refer to Table 1 and Table 2. The magnetic colloid/adhesive film made by the method of the present invention (without sintering, Examples 1-5) and the existing method (without sintering, Comparative Examples 1-5) will be described below. 2) The prepared colloid/glue film is used to carry out multiple experiments to illustrate the technical effects that can be produced by the soft magnetic powder composition with special composition and weight ratio. In the following table, Examples 1 to 5 are magnetic colloids/adhesive films that can be cured at medium and low temperatures based on different soft magnetic powder compositions, as follows:

Example 1

The applicable frequency range of the soft magnetic powder composition of the present embodiment is between 0.01MHz and 4GHz, wherein the magnetic material of component (A) comprises 85% to 90% of flaky sendust magnetic alloy powder, and the magnetic material of component (B) The polymer material contains 10% to 15% of ethylene-vinyl acetate resin (EVA).

Example 2

The applicable frequency range of the soft magnetic powder composition of the present embodiment is between 0.01MHz and 2MHz, wherein the magnetic material of component (A) comprises 85% to 88% of Mn-Zn ferrite powder and 2% to 5% of In the sendust magnetic alloy powder, the polymer material of component (B) contains 10% of ethylene-vinyl acetate resin (EVA).

Furthermore, 85% to 88% of the Mn-Zn ferrite powders are spherical Mn-Zn ferrite powders, and 2% to 5% of the sendust magnetic alloy powders contain 1% to 3% flake sendust magnetic alloy powder, 0.5% to 1% irregular or spherical sendust magnetic alloy powder, and 0.5% to 1% acicular sendust magnetic alloy powder.

Example 3

The applicable frequency range of the soft magnetic powder composition of the present embodiment is between 2MHz and 1GHz, wherein the magnetic material of component (A) comprises 85% to 88% of Ni-Zn ferrite powder and 2% to 5% of iron In the silicon-aluminum magnetic alloy powder, the polymer material of component (B) contains 10% ethylene-vinyl acetate resin (EVA).

Furthermore, 85% to 88% of the Ni-Zn ferrite powder is spherical Ni-Zn ferrite powder, and 2% to 5% of the sendust magnetic alloy powder contains 1% to 3% flake sendust magnetic alloy powder, 0.5% to 1% irregular or spherical sendust magnetic alloy powder, and 0.5% to 1% acicular sendust magnetic alloy powder.

Example 4

The applicable frequency range of the soft magnetic powder composition of this embodiment is between 0.01 MHz and 4 GHz, and the composition includes: the magnetic material of component (A) contains 80% to 88% of flaky sendust magnetic alloy powder; The polymer material of component (B) comprises 10% to 15% of carboxyl-terminated liquid nitrile rubber (CTBN) modified epoxy resin; and component (C) 2% to 5% of additives, which comprises 1% to 3% solvent, 0.3% to 0.5% curing agent, 0.1% to 0.5% coupling agent, 0.3% to 0.5% leveling agent, and 0.3% to 0.5% defoamer.

Example 5

The applicable frequency range of the soft magnetic powder composition of this embodiment is between 0.01MHz and 4GHz, and the composition includes: component (A) magnetic material comprising 80% to 88% of flaky sendust magnetic alloy powder; component (B) The polymer material contains 10% to 15% of polyvinyl alcohol (PVA) and/or polyvinyl butyral (PVB) and/or polyvinylpyrrolidone (PVP); and component (C) 2% to 5% % of additives, which include 1% to 3% of solvents, 0.3% to 0.5% of plasticizers, 0.1% to 0.5% of coupling agents, 0.3% to 0.5% of leveling agents, and 0.3% to 0.5% of defoamer.

Furthermore, the solvent of 1% to 3% is cyclohexanone, the curing agent of 0.3% to 0.5% is dicyandiamide (DICY), and the coupling agent of 0.1% to 0.5% is silicone Alkane coupling agent, 0.3% to 0.5% of the leveling agent is a mixture of silicone and cyclohexanone, and 0.3% to 0.5% of the defoamer is a mixture of silicone and polymer.

Table 1 According to the test results of the magnetic elements of the comparative example and the embodiment (1)

Table 2 According to the test results (two) of the magnetic elements of the comparative example and the embodiment

From the above comparison results, it can be seen that Examples 1-4 all conform to the basic definition of soft magnetic materials; in addition, the saturation magnetic flux density (Bs) and initial magnetic permeability (μi) of Examples 1-4 are better than those of Comparative Examples 1-4. 2. It shows that the amount of induced current produced by the magnetic material according to Examples 1-4 is larger than that produced by the magnetic material produced by Comparative Examples 1-2; in addition, the magnetic material according to Examples 1-4 The resistance values of the magnetic materials are all greater than 10 ⁶ Ω, so they are suitable for use in low, medium and high frequency environments. On the other hand, the resistance values of the magnetic materials according to Comparative Examples 1 and 2 are too high and are not suitable for use in high frequency environments.

In summary, compared with the common composite ferrite compositions on the market today, which must also overcome various problems caused by sintering, the soft magnetic powder composition provided by the present invention can fully Curing, high temperature sintering treatment is not required during the molding process.

Based on the above, the cooled and solidified magnetic element has the advantages of sufficient mechanical strength, maximum magnetic permeability, and magnetic flux density (inductance), and at the same time can keep the eddy current at a low level and minimize the hysteresis loss, which can be further manufactured into various components, such as microwave absorbing materials, magnetically permeable films, floppy disks, planar coil induction materials, etc.

In addition, in the soft magnetic powder composition, since the magnetic materials of component (A) have different structures and shapes, they can be made with a low cost according to a special proportion and by using simple manufacturing processes and multiple stacking methods. , ultra-thin, and flexible magnetic components such as good advantages.

In addition, the present invention can integrate the advantages of sendust magnetic alloy powder, Ni-Zn ferrite powder, and Mn-Zn ferrite powder, so the application level is wider.

Aiming at the advantages presented by the present invention in the above description, those skilled in the art can propose modifications and other embodiments of the present invention. Therefore, it is to be understood that the invention is not to be limited to the particular embodiments disclosed, and that modifications and other embodiments are possible within the scope of the present invention. Even if specific terms are used herein, they are used generically and to describe concepts only and do not limit the scope of protection defined by the claims.

Claims (13)

1. a kind of soft magnetic powder composition, it is characterised in that the soft magnetic powder composition Comprising consisting of composition (by weight percentage)：

(A) 80% to 93% magnetic material, which includes alsifer powder, Ni-Zn At least one among ferrite powder and Mn-Zn ferrite powders；And

(B) 7% to 20% macromolecular material.

2. soft magnetic powder composition as claimed in claim 1, it is characterised in that composition (A) Magnetic material comprising 85% to 90% sheet alsifer powder, composition (B) Macromolecular material includes 10% to 15% thermoplastic resin.

3. soft magnetic powder composition as claimed in claim 2, it is characterised in that 10% to 15% thermoplastic resin is ethylene-vinyl acetate resin (EVA).

4. soft magnetic powder composition as claimed in claim 1, it is characterised in that composition (A) Magnetic material comprising 85% to 88% Mn-Zn ferrite powders and 2% to 5% iron sial Magnetic alloy powder, the macromolecular material of composition (B) is thermoplastic resin.

5. soft magnetic powder composition as claimed in claim 4, it is characterised in that 85% to The 88% Mn-Zn ferrite powders are all spherical Mn-Zn ferrite powders, and 2% to The 5% alsifer powder includes 1% to 3% sheet alsifer powder End, 0.5% to 1% irregular or spherical alsifer powder and 0.5% to 1% Needle-like alsifer powder, and the thermoplastic resin is ethylene-vinyl acetate resin (EVA)。

6. soft magnetic powder composition as claimed in claim 1, it is characterised in that composition (A) Magnetic material comprising 85% to 88% Ni-Zn ferrite powders and 2% to 5% iron sial Magnetic alloy powder, the macromolecular material of composition (B) is thermoplastic resin.

7. soft magnetic powder composition as claimed in claim 6, it is characterised in that 85% to The 88% Ni-Zn ferrite powders are all spherical Ni-Zn ferrite powders, and 2% to 5% The alsifer powder comprising 1% to 3% sheet alsifer powder, 0.5% to 1% irregular or spherical alsifer powder and 0.5% to 1% needle-like Alsifer powder, and the thermoplastic resin is ethylene-vinyl acetate resin (EVA)。

8. soft magnetic powder composition as claimed in claim 1, it is characterised in that composition (A) Magnetic material comprising 80% to 88% sheet alsifer powder, composition (B) Macromolecular material includes 10% to 15% thermosetting resin.

9. soft magnetic powder composition as claimed in claim 8, it is characterised in that described soft The Magnaglo composition further additive comprising composition (C) 2% to 5%, which includes 0.5% Solvent, 0.3% to 1% curing agent, 0.1% to 0.5% couplant to 1%, 0.3% to 0.5% levelling agent and 0.3% to 0.5% defoamer, 0.4% to 1.3% plasticizer and 0.1% to 0.2 accelerator.

10. soft magnetic powder composition as claimed in claim 9, it is characterised in that described Solvent is cyclohexanone, and the curing agent is dicyandiamide (DICY), and the couplant is siloxanes coupling Mixture, the levelling agent are the mixture of organosilicon and cyclohexanone, and the defoamer is organosilicon With the mixture of polymer, and the thermosetting resin be carboxyl end of the liquid acrylonitrile-butadiene rubber (CTBN) Modified epoxy, the plasticizer be diethyl oxalate ester, glycerine, trietbhlene glycol, Fourth (base)-(base) butyl phthalate, butyl phthalate (DBP), poly- second two Alcohol (PEG), trietbhlene glycol hexane, octyl phthalate (DDP), fourth (base)- (base) phthalic acid ester or dioctyl phthalate.

11. a kind of preparation methods of magnetic element, it is characterised in that comprise the following steps：

Soft magnetic powder composition as claimed in claim 1 is kneaded, to form a mixing thing；

The machine-shaping on the base material by the mixing thing；And

Cool down the mixing thing fully to solidify.

12. preparation methods as claimed in claim 11, it is characterised in that described soft kneading In the step of Magnaglo composition, the temperature range of mixing is kneaded between 100 DEG C to 200 DEG C Rotating speed between 60rpm to 100rpm.

13. preparation methods as claimed in claim 11, it is characterised in that by the mixing thing Comprising being given the mixing thing using rubbing method or die pressing the step of machine-shaping on the base material To be molded.