NOVEL HIGH-DENSITY MAGNETIC COMPOSITE MATERIAL FOR INDUCTOR

Abstract

Disclosed is a novel high-density magnetic composite material for an inductor. The material is composed of 6-12% of high-temperature resin glue and 88-94% of magnetic powder body in percentage by weight. An integrated inductor magnetic core is simply prepared by means of the magnetic composite material of the disclosure without a large press, thus saving the device investment. The mold loss in a pressing process is reduced, and the production cost is reduced. The operation is simple, a magnet of a complex shape can be produced, and an oversized magnet can be produced. A closed magnetic circuit is formed, and the EMI effect is good. The magnetic composite material of the disclosure enables the density of a solidified magnet to be high under the action of special high-temperature resin glue, it can be guaranteed that the density is 5.5-6.2 g/cm3, the sensitive quality value for preparing an inductor is high, and the initial permeability can be 14μ or above. The magnetic composite material of the disclosure can bear a higher temperature, and can work at the temperature of 180° C. The magnetic composite material of the disclosure is high in utilization rate, low in scrap rate and low in dust rate, and meets the requirement for environmental protection.

Claims

1. A high-density magnetic composite material for an inductor, comprising: a high-temperature resin glue having a concentration in a range from 6 to 12%; and a magnetic powder body having a concentration in a range from 88 to 94% in percentage by weight.

2. The high-density magnetic composite material for the inductor as claimed in claim 1, wherein the high-temperature resin glue comprises a resin glue having a concentration in a range from 70 to 80%, a coupling agent having a concentration in a range from 5 to 10%, and an accelerant having a concentration in a range from 15 to 20% in percentage by weight.

3. The high-density magnetic composite material for the inductor as claimed in claim 2, wherein the resin glue is a modified epoxy silicone resin.

4. The high-density magnetic composite material for the inductor as claimed in claim 2, wherein the coupling agent is a 3-Mercaptopropylmethyldimethoxysilane.

5. The high-density magnetic composite material for the inductor as claimed in claim 2, wherein the accelerant is an isophthalic diamine.

6. The high-density magnetic composite material for the inductor as claimed in claim 1, wherein a size-ratio of the magnetic powder body is: −100 mesh to 200 mesh having a concentration in a range from 20 to 30%, −200 mesh to 500 mesh having a concentration in a range from 30 to 40%, and −500 mesh having a concentration in a range from 30 to 50% in percentage by weight.

7. The high-density magnetic composite material for the inductor as claimed in claim 6, wherein the magnetic powder body is at least one of a ferrosilicon powder, an iron powder, ferrosilicon aluminum powder, iron nickel powder, and ferrosilicochromium powder.

8. The high-density magnetic composite material for the inductor as claimed in claim 1, wherein the solidified novel high-density magnetic composite material has a density in a range from 5.5 to 6.2 g/cm.sup.3, and has an initial permeability in a range from 14 to 55μ.

Description

DETAILED DESCRIPTION

[0026] A number of embodiments are disclosed below for elaborating the disclosure. However, the embodiments of the disclosure are for detailed descriptions only, not for limiting the scope of protection of the disclosure. It is clear that the described embodiments are merely part of the embodiments of the disclosure, but not all embodiments. Based on the embodiments of the present disclosure, all other embodiments that persons skilled in the art have no creative work are within the scope of the disclosure.

Embodiment 1

[0027] A method for manufacturing a novel high-density magnetic composite material for an inductor includes the steps of:

[0028] 1. Preparation of a high-temperature resin glue: it takes 3 minutes to uniformly mix and stir a modified epoxy silicone resin of 0.42 kg, a 3-Mercaptopropylmethyldimethoxysilane of 0.06 kg, and an isophthalic diamine of 0.12 kg to ensure the uniform distribution.

[0029] 2. Preparation of a magnetic powder body: it takes 30 minutes to uniformly mix and stir a ferrosilicon powder of 1.88 kg having a size mesh of −100 to 200, a ferrosilicon powder of 2.82 kg having a size mesh of −200 to 500, and a ferrosilicon powder of 4.7 kg having a size mesh of −500.

[0030] 3. Taking 30 minutes to uniformly mix and stir the high-temperature resin glue of 0.6 kg and the magnetic powder body of 9.4 kg to form a uniform high-temperature resin glue in the surface of the magnetic powder to produce the insulating properties, and to ensure that the mixture has the ability of stable flowing features.

[0031] 4. After the magnet is molded, taking 2 hours at 130 degrees Celsius to solidify the magnet to obtain a composite material having a density of 6.2 g/cm.sup.3, and having an initial permeability of up to 35μ. The inner magnet of the composite material is dense and void-free, ensuring the insulating properties between the powders, and reducing the eddy current loss between the particles.

Embodiment 2

[0032] A method for manufacturing a novel high-density magnetic composite material for an inductor includes the steps of:

[0033] 1. Preparation of a high-temperature resin glue: it takes 3 minutes to uniformly mix and stir a modified epoxy silicone resin of 0.75 kg, a 3-Mercaptopropylmethyldimethoxysilane of 0.07 kg, and an isophthalic diamine of 0.18 kg to ensure the uniform distribution.

[0034] 2. Preparation of a magnetic powder body: it takes 30 minutes to uniformly mix and stir a ferrosilicon powder of 2.25 kg having a size mesh of −100 to 200, a ferrosilicon powder of 3.15 kg having a size mesh of −200 to 500, and a ferrosilicon powder of 3.6 kg having a size mesh of −500.

[0035] 3. Taking 30 minutes to uniformly mix and stir the high-temperature resin glue of 1 kg and the magnetic powder body of 9 kg to form a uniform high-temperature resin glue in the surface of the magnetic powder to produce the insulating properties, and to ensure that the mixture has the ability of stable flowing features.

[0036] 4. After the magnet is molded, taking 2.5 hours at 125 degrees Celsius to solidify the magnet to obtain a composite material having a density of 5.9 g/cm.sup.3, and having an initial permeability of up to 19μ. The inner magnet of the composite material is dense and void-free, ensuring the insulating properties between the powders, and reducing the eddy current loss between the particles.

Embodiment 3

[0037] A method for manufacturing a novel high-density magnetic composite material for an inductor includes the steps of:

[0038] 1. Preparation of a high-temperature resin glue: it takes 3 minutes to uniformly mix and stir a modified epoxy silicone resin of 0.96 kg, a 3-Mercaptopropylmethyldimethoxysilane of 0.06 kg, and an isophthalic diamine of 0.18 kg to ensure the uniform distribution.

[0039] 2. Preparation of a magnetic powder body: it takes 30 minutes to uniformly mix and stir a ferrosilicon powder of 2.64 kg having a size mesh of −100 to 200, a ferrosilicon powder of 3.52 kg having a size mesh of −200 to 500, and a ferrosilicon powder of 2.64 kg having a size mesh of −500.

[0040] 3. Taking 30 minutes to uniformly mix and stir the high-temperature resin glue of 1.2 kg and the magnetic powder body of 8.8 kg to form a uniform high-temperature resin glue in the surface of the magnetic powder to produce the insulating properties, and to ensure that the mixture has the ability of stable flowing features.

[0041] 4. After the magnet is molded, taking 1.5 hours at 140 degrees Celsius to solidify the magnet to obtain a composite material having a density of 5.5 g/cm.sup.3, and having an initial permeability of up to 14μ. The inner magnet of the composite material is dense and void-free, ensuring the insulating properties between the powders, and reducing the eddy current loss between the particles.

Embodiment 4

[0042] A method for manufacturing a novel high-density magnetic composite material for an inductor includes the steps of:

[0043] 1. Preparation of a high-temperature resin glue: it takes 3 minutes to uniformly mix and stir a modified epoxy silicone resin of 0.7 kg, a coupling agent of 0.1 kg, and an accelerant of 0.2 kg to ensure the uniform distribution.

[0044] 2. Preparation of a magnetic powder body: it takes 30 minutes to uniformly mix and stir an iron nickel powder of 1.8 kg having a size mesh of −100 to 200, an iron nickel powder of 2.7 kg having a size mesh of −200 to 500, and an iron nickel powder of 4.5 kg having a size mesh of −500.

[0045] 3. Taking 30 minutes to uniformly mix and stir the high-temperature resin glue of 1 kg and the magnetic powder body of 9 kg to form a uniform high-temperature resin glue in the surface of the magnetic powder to produce the insulating properties, and to ensure that the mixture has the ability of stable flowing features.

[0046] 4. After the magnet is molded, taking 2 hours at 130 degrees Celsius to solidify the magnet to obtain a composite material having a density of 6.0 g/cm.sup.3, and having an initial permeability of up to 26μ. The inner magnet of the composite material is dense and void-free, ensuring the insulating properties between the powders, and reducing the eddy current loss between the particles.

[0047] The inductors are manufactured to the same condition by the composite material of the embodiments 1 to 4, and the inductors are tested by the electrical performance comparison test with the conventional inductor. The data are shown as below:

TABLE-US-00001 The conventional The The The The inductor embodiment 1 embodiment 2 embodiment 3 embodiment 4 Coil number 30 30 30 30 30 The length of 15.8 15.8 15.8 15.8 15.8 effective magnetic circuit 1 (cm) Initial 201.54 269.62 268.64 268.59 269.77 inductance L@0A The 180.26 266.69 265.51 265.54 266.85 inductance in the 5A L@5A

[0048] For the skilled in the art, it is clear that the disclosure is not limited to the details of an exemplary embodiment. And without departing from the spirit or essential characteristics of the present disclosure, it is possible to realize the disclosure with other specific forms. Therefore, no matter with any points, it should be seen as an exemplary embodiment, but not limiting, the scope of the present disclosure is defined by the appended claims rather than the foregoing description define, and therefore intended to fall claim All changes which come within the meaning and range of equivalents of the elements to include in the present invention.