A method for preparing an iron-based soft magnetic composite material and the iron-based soft magnetic composite material

Abstract

This application relates to the field of materials technology and provides a method for preparing an iron-based soft magnetic composite material and the iron-based soft magnetic composite material itself. The method includes: filling pentacarbonyl iron into a nano-spray drying device and decomposing it in a laminar flow heating system within the nano-spray drying device to obtain carbonyl iron droplets; placing nano-magnetic metal particles in the laminar flow heating system to fill the carbonyl iron droplets, thus obtaining the composite material. This application utilizes the superexchange and other exchange coupling effects between the nano-magnetic metal particles and iron microspheres to reduce coercivity and improve magnetic properties, fundamentally enhancing the magnetic properties of carbonyl iron powder. Compared to the original carbonyl iron powder, the iron-based soft magnetic composite material prepared in this application exhibits excellent comprehensive magnetic properties, effectively reduces the coercivity of the carbonyl iron powder, reduces the hysteresis loss of the soft magnetic material, and the provided preparation method is convenient and easy to implement, suitable for mass production.

Description

Technical Field

[0001] This application belongs to the field of materials technology, and in particular relates to a method for preparing an iron-based soft magnetic composite material and the iron-based soft magnetic composite material. Background Technology

[0002] Soft magnetic materials generally refer to magnetic materials with a coercivity (Hc) below 0.8 kA / m. They play a role in energy coupling, conversion, and transfer, and are widely used in power supplies, communications, computers, and various electronic products. As the electronics industry increasingly focuses on miniaturization, high frequency, and high efficiency, soft magnetic composite materials are required to possess high frequency, low loss, and high saturation magnetic flux density. Iron-based soft magnetic composite materials offer adjustable composition and performance, achieving saturation magnetic flux densities up to 2T, and 10 7 -10 16 It has the advantages of high resistivity and a high Curie temperature of up to 770℃. Therefore, iron-based soft magnetic composite materials are currently the mainstream materials for soft magnetic materials.

[0003] Soft magnetic composite materials can be classified according to their matrix into iron-based, iron-silicon-aluminum-based, iron-silicon-chromium-based, iron-nickel-based, and ferrite-based types. Carbonyl iron powder, due to its unique onion-like structure, exhibits higher anti-saturation capabilities compared to alloy powders. Furthermore, carbonyl iron powder possesses high magnetic flux density at high and ultra-high frequencies, making it irreplaceable. However, its magnetic permeability is relatively low. Most researchers have addressed this by coating the surface of carbonyl iron powder with magnetic materials to reduce the overall decline in the magnetic properties of soft magnetic composite materials, or by alloying carbonyl iron powder with magnetic metals such as nickel to improve its magnetic properties. However, these methods still do not address the fundamental problem of the iron powder matrix itself. Summary of the Invention

[0004] This application provides a method for preparing an iron-based soft magnetic composite material, which aims to solve the problems mentioned in the background art.

[0005] The embodiments of this application are implemented as follows: a method for preparing an iron-based soft magnetic composite material includes:

[0006] Iron pentacarbonyl is filled into a nano spray drying device and decomposed in a laminar flow heating system in the nano spray drying device to obtain iron carbonyl droplets;

[0007] The carbonyl iron droplets are filled by placing nano-magnetic metal particles into the laminar flow heating system.

[0008] This application also provides an iron-based soft magnetic composite material, which is prepared by the above-described method for preparing iron-based soft magnetic composite materials.

[0009] The method for preparing iron-based soft magnetic composite materials provided in this application involves using nano-spray drying technology to spray carbonyl iron through a high-speed atomizing nozzle, thereby coating nano-magnetic metal particles and preparing a soft magnetic composite material matrix filled with nano-magnetic metal and carbonyl iron powder. This application utilizes the superexchange and other exchange coupling effects between the nano-magnetic metal particles and iron microspheres to reduce coercivity and improve magnetic properties, fundamentally enhancing the magnetic properties of carbonyl iron powder. Compared to raw carbonyl iron powder, the iron-based soft magnetic composite material prepared in this application exhibits excellent comprehensive magnetic properties, effectively reduces the coercivity of carbonyl iron powder, reduces hysteresis losses in soft magnetic materials, and the provided preparation method is convenient and easy to implement, suitable for mass production. Attached Figure Description

[0010] Figure 1 These are microscopic morphology images of the iron-based soft magnetic composite material provided in the embodiments of this application;

[0011] Figure 2 This is an XRD pattern of the iron-based soft magnetic composite material provided in the embodiments of this application. Detailed Implementation

[0012] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0013] The method for preparing iron-based soft magnetic composite materials provided in this application involves using nano-spray drying technology to spray carbonyl iron through a high-speed atomizing nozzle, thereby coating nano-magnetic metal particles and preparing a soft magnetic composite material matrix filled with nano-magnetic metal and carbonyl iron powder. This application utilizes the superexchange and other exchange coupling effects between the nano-magnetic metal particles and iron microspheres to reduce coercivity and improve magnetic properties, fundamentally enhancing the magnetic properties of carbonyl iron powder. Compared to raw carbonyl iron powder, the iron-based soft magnetic composite material prepared in this application exhibits excellent comprehensive magnetic properties, effectively reduces the coercivity of carbonyl iron powder, reduces hysteresis losses in soft magnetic materials, and the provided preparation method is convenient and easy to implement, suitable for mass production.

[0014] This application provides a method for preparing an iron-based soft magnetic composite material, comprising:

[0015] Iron pentacarbonyl is filled into a nano spray drying device and decomposed in a laminar flow heating system in the nano spray drying device to obtain iron carbonyl droplets;

[0016] The carbonyl iron droplets are filled by placing nano-magnetic metal particles into the laminar flow heating system.

[0017] Specifically, the process can be as follows: Ferropentacarbonyl is filled into a nano-spray drying device; nano-magnetic metal particles are cleaned and degreased with acetone and then added to the nano-spray drying device; ferropentacarbonyl is sprayed out through a high-speed nozzle and decomposed in a laminar flow heating system within the nano-spray drying device; nano-magnetic metal particles are fed into the laminar flow heating system and then filled into carbonyl iron droplets; and after passing through gravity and a collection device, a soft magnetic material of carbonyl iron powder filled with nano-magnetic metal particles with excellent magnetic properties is obtained.

[0018] In the embodiments of this application, the nano-magnetic metal particles are elemental metals or alloys formed from one or more magnetic elements selected from iron, cobalt, and nickel.

[0019] In this embodiment, the magnetic nano-metal particles are ultrafine metal powders prepared by thermal arc plasma method, with a particle size distribution of 1-100 nm.

[0020] In the embodiments of this application, magnetic nanoparticles can be prepared by thermoelectric arc plasma method or purchased; the smaller the size of the nanoparticles, the more they are within the effective exchange coupling distance Lex of the composite material, and the more effective the exchange coupling effect.

[0021] In the embodiments of this application, the amount of iron pentacarbonyl used is 1 mL to 100 mL.

[0022] In the embodiments of this application, the amount of the nano-magnetic metal particles used is 1g to 100g.

[0023] In the embodiments of this application, the more nano-magnetic metal particles used, the more significant the exchange coupling effect of the micro-nano composite material, the lower the coercivity, and the better the material performance.

[0024] In the embodiments of this application, the pentacarbonyl iron can be obtained by purchasing or by synthesizing sponge iron and carbon monoxide under medium pressure conditions, as can be found in the prior art.

[0025] This application also provides an iron-based soft magnetic composite material, which is prepared by the above-described method for preparing iron-based soft magnetic composite materials.

[0026] The following are embodiments of some implementations of this application, which are not intended to limit the scope of this application.

[0027] Additionally, it should be noted that the values ​​given in the following embodiments are as accurate as possible. However, those skilled in the art will understand that due to unavoidable measurement errors and experimental issues, each number should be understood as an approximation rather than an absolutely accurate value.

[0028] Example 1

[0029] The steps for preparing carbonyl iron powder-filled soft magnetic materials with nano-magnetic metal particles are as follows:

[0030] (1) Fill 5 ml of iron pentacarbonyl into the nano spray drying equipment;

[0031] (2) Clean and degrease 10g of nano-Co acetone, and then add it to the nano spray drying equipment;

[0032] (3) The pentacarbonyl iron in step (1) is sprayed out through a high-speed nozzle and decomposed in the laminar flow heating system of the nano spray drying equipment;

[0033] (4) The nano-magnetic particles in step (2) enter the laminar flow heating system and are then filled into carbonyl iron droplets. After gravity and collection, nano-magnetic metal particles with excellent magnetic properties are obtained to fill carbonyl iron powder soft magnetic material.

[0034] The iron-based soft magnetic composite material prepared in this embodiment has good magnetic properties, as demonstrated by the Vibrating Sample Magnetometer (VSM) test. The coercivity of the magnetic microspheres is less than 7.97 Oe when 1000 Oe is applied.

[0035] In addition, the iron-based soft magnetic composite material prepared in Example 1 was subjected to scanning electron microscopy, and the morphology of the obtained material is as follows. Figure 1 As shown.

[0036] The iron-based soft magnetic composite material prepared in Example 1 was subjected to XRD testing, and the results are as follows: Figure 2 As shown.

[0037] Example 2

[0038] The steps for preparing carbonyl iron powder-filled soft magnetic materials with nano-magnetic metal particles are as follows:

[0039] (1) Fill 5 ml of iron pentacarbonyl into the nano spray drying equipment;

[0040] (2) Clean and degrease 20g of nano Ni acetone, and then add it to the nano spray drying equipment;

[0041] (3) The pentacarbonyl iron in step (1) is sprayed out through a high-speed nozzle and decomposed in the laminar flow heating system of the nano spray drying equipment;

[0042] (4) The nano-magnetic particles in step (2) enter the laminar flow heating system and are then filled into carbonyl iron droplets. After gravity and collection, nano-magnetic metal particles with excellent magnetic properties are obtained to fill carbonyl iron powder soft magnetic material.

[0043] Tests showed that the iron-based soft magnetic composite material prepared in this embodiment has good magnetic properties, and the coercivity of the magnetic microspheres is less than 7.34 Oe when 1000 Oe is applied.

[0044] Example 3

[0045] The steps for preparing carbonyl iron powder-filled soft magnetic materials with nano-magnetic metal particles are as follows:

[0046] (1) Fill 5 ml of iron pentacarbonyl into the nano spray drying equipment;

[0047] (2) Clean and degrease 30g of nano-iron-silicon-aluminum acetone, and then add it to the nano spray drying equipment;

[0048] (3) The pentacarbonyl iron in step (1) is sprayed out through a high-speed nozzle and decomposed in the laminar flow heating system of the nano spray drying equipment;

[0049] (4) The nano-magnetic particles in step (2) enter the laminar flow heating system and are then filled into carbonyl iron droplets. After gravity and collection, nano-magnetic metal particles with excellent magnetic properties are obtained to fill carbonyl iron powder soft magnetic material.

[0050] Tests showed that the iron-based soft magnetic composite material prepared in this embodiment has good magnetic properties, and the coercivity of the magnetic microspheres is less than 6.83 Oe when 1000 Oe is applied.

[0051] In summary, the preparation method of the iron-based soft magnetic composite material provided in this application involves using nano-spray drying technology to spray carbonyl iron through a high-speed atomizing nozzle to coat nano-magnetic metal particles, thus preparing a soft magnetic composite material matrix filled with nano-magnetic metal and carbonyl iron powder. This application utilizes the superexchange and other exchange coupling effects between the nano-magnetic metal particles and iron microspheres to reduce coercivity and improve magnetic properties, fundamentally enhancing the magnetic properties of carbonyl iron powder. Compared to the original carbonyl iron powder, the iron-based soft magnetic composite material prepared in this application exhibits excellent comprehensive magnetic properties, effectively reduces the coercivity of the carbonyl iron powder, reduces hysteresis losses in the soft magnetic material, and the provided preparation method is convenient and easy to implement, suitable for mass production.

[0052] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

[0053] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for preparing an iron-based soft magnetic composite material, characterized in that, include: Ferr pentacarbonyl is filled into a nano spray drying device, and the ferric pentacarbonyl is sprayed out through a high-speed nozzle and decomposed in a laminar flow heating system in the nano spray drying device to obtain ferric carbonyl droplets. The carbonyl iron droplets are filled by placing nano-magnetic metal particles into the laminar flow heating system.

2. The method for preparing the iron-based soft magnetic composite material as described in claim 1, characterized in that, The nano-magnetic metal particles are elemental metals or alloys formed from one or more magnetic elements selected from iron, cobalt, and nickel.

3. The method for preparing the iron-based soft magnetic composite material as described in claim 1, characterized in that, The particle size distribution of the nanomagnetic metal particles is 1–100 nm.

4. The method for preparing the iron-based soft magnetic composite material as described in claim 1, characterized in that, The amount of iron pentacarbonyl used is 1 mL to 100 mL.

5. The method for preparing the iron-based soft magnetic composite material as described in claim 1, characterized in that, The amount of the nano-magnetic metal particles used is 1g to 100g.

6. The method for preparing the iron-based soft magnetic composite material as described in claim 1, characterized in that, The pentacarbonyl iron is obtained by high-temperature and high-pressure treatment of carbon monoxide and sponge iron blocks.

7. An iron-based soft magnetic composite material, characterized in that, The iron-based soft magnetic composite material is prepared by the preparation method of the iron-based soft magnetic composite material according to any one of claims 1-6.

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