Soft magnetic material, and preparation method therefor and use thereof

Abstract

The present application discloses a soft magnetic material, and a preparation method therefor and a use thereof. The soft magnetic material comprises 75-90 wt% of flake soft magnetic powder, 8-23 wt% of a binder, 0.1-3 wt% of a silane coupling agent, and 0.1-2 wt% of a lubricant. The soft magnetic material of the present application has significantly improved magnetic permeability, salt spray resistance, and higher mechanical strength, and no toughening agent is needed, thereby saving raw materials and reducing costs. In the preparation method for the soft magnetic material of the present application, the granulation process is simple, obtained granules have uniform properties, the product is stable, and the process flow is shorter.

Description

A soft magnetic material, its preparation method and application Technical Field

[0001] This application relates to the field of materials technology, and in particular to a soft magnetic material, its preparation method, and its application. Background Technology

[0002] Metal magnetic powder cores are powders made from metal or alloy soft magnetic materials. They are soft magnetic materials with excellent comprehensive properties, produced through a special pressing process. They possess some of the superior characteristics of both metallic and ferrite soft magnetic materials, resulting in low permeability but good linearity, high saturation magnetic flux density, and a wide operating frequency range. This is of great significance for the development of electronic products towards high precision, high sensitivity, large capacity, and miniaturization, and is also a key basic material for the fabrication of electronic components.

[0003] The soft magnetic powder cores used in the market mainly include metal soft magnetic powder cores (iron powder cores, iron-silicon powder cores, iron-silicon-aluminum powder cores, iron-nickel powder cores), amorphous, nanocrystalline, and ferrite powder cores. Alloy soft magnetic materials have the characteristics of high magnetic permeability, high magnetic induction intensity, and excellent DC superposition performance. However, due to limitations in molding processes, it is very difficult to manufacture thin and complex-shaped powder cores, such as those with a thickness of less than 0.5 mm. The sintering process is extremely prone to deformation, causing a sharp drop in yield and a significant increase in cost. In addition, fragility during production also leads to a significant drop in yield; after sintering, there is also the problem of easy breakage from drops. With the miniaturization and integration of consumer electronics products, the demand for thin, light, and precise devices is increasing. The aforementioned production problems become unacceptable in consumer electronics such as watches, because if the internal magnetic core of a watch breaks after a drop, it will seriously affect the charging efficiency and may even prevent the device from charging. Among alloy magnetic powder cores, iron-silicon-aluminum magnetic powder cores are the most commonly used. Ferrosilicon-aluminum magnetic powder cores possess excellent high-frequency magnetic properties, temperature stability, wide constant permeability, low loss, near-zero magnetostriction, and relatively low cost. As the operating frequency of magnetic powder cores increases, the main challenge for these products lies in balancing high permeability and low loss.

[0004] Manufacturing such magnetic cores using sintered ferrites suffers from problems such as low efficiency, extensive machining, high production costs, and insufficient toughness due to high powder content. For example, related technologies use raw materials containing iron-silicon-aluminum granules and nylon binder for intensive mixing and granulation. The mixing temperature reaches as high as 460℃, while the decomposition temperature of nylon is generally between 300 and 350℃ (e.g., PA6 decomposes at 300℃, and PA66 at 350℃). At 460℃, the nylon decomposes and becomes ineffective, leading to uneven mixing and making it difficult to produce the desired product. Summary of the Invention

[0005] This application aims to at least solve one of the aforementioned technical problems existing in the prior art. Therefore, the purpose of this application is to provide a soft magnetic material, its preparation method, and its application.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0007] The first aspect of this application provides a soft magnetic material comprising 75wt% to 90wt% flake-shaped soft magnetic powder, 8wt% to 23wt% binder, 0.1wt% to 3wt% silane coupling agent, and 0.1wt% to 2wt% lubricant.

[0008] In this application, unlike granular soft magnetic powder, the sheet-like soft magnetic powder is arranged in an orderly, stacked manner, which can significantly improve the permeability of the soft magnetic material and reduce the powder content, thus facilitating the coating of silane coupling agents and improving its mechanical properties. Secondly, the sheet-like soft magnetic powder has a higher resistance than granular soft magnetic powder, which can effectively reduce eddy currents and reduce heat generation during wireless charging, thereby improving charging efficiency. The soft magnetic material of this application also differs from soft magnetic materials that do not contain thermoplastic resin (such as those where the thermoplastic resin has decomposed after molding and calcination). The latter lacks plasticity, is brittle, has a low product yield, and is difficult to apply to the fabrication of devices with complex shapes or high precision requirements. In contrast, the soft magnetic material of this application contains a binder, retaining its plasticity and improving its permeability. The soft magnetic material is not easily broken and can be applied to the production of devices of various shapes.

[0009] In some embodiments of this application, the aspect ratio of the sheet-like soft magnetic powder is 30 to 150, such as 35 to 130, 40 to 120, 45 to 110, 50 to 100, 60, 70, 80, 90, etc. The sheet-like soft magnetic powder with this aspect ratio has better magnetic permeability, but if the aspect ratio is too high, it will affect its flowability during the preparation process, resulting in uneven dispersion and a decrease in the magnetic permeability of the product.

[0010] In some embodiments of this application, the average particle size of the sheet-like soft magnetic powder is 30-120 μm, such as 40-100 μm, 45-95 μm, 50-90 μm, 60 μm, 70 μm, 80 μm, etc.

[0011] In some embodiments of this application, the sheet-like soft magnetic powder is oriented. In this application, applying an external magnetic field or stress to achieve the directional and orderly arrangement of the sheet-like soft magnetic powder can further improve the magnetic permeability of the soft magnetic powder.

[0012] In some embodiments of this application, the sheet-like soft magnetic powder includes at least one of sheet-like manganese-zinc ferrite magnetic powder, sheet-like carbonyl iron powder, sheet-like iron-silicon-chromium, sheet-like iron-silicon-aluminum, sheet-like iron-nickel, sheet-like iron-silicon-boron-copper-niobium, and sheet-like iron-nickel-molybdenum.

[0013] In some embodiments of this application, the soft magnetic material comprises 75wt% to 90wt% flake-shaped soft magnetic powder, such as 78wt% to 88wt%, 75wt% to 85wt%, 78wt% to 85wt%, 80wt% to 88wt%, 80wt% to 85wt%, 76wt%, 77wt%, 79wt%, 81wt%, 82wt%, 83wt%, 84wt%, 86wt%, 87wt%, and 89wt%. The higher the proportion of soft magnetic powder in the soft magnetic material, the higher the magnetic permeability. However, compared to granular soft magnetic powder, the flake-shaped soft magnetic powder in this application has a significantly larger specific surface area, poor flowability, and is difficult to be effectively encapsulated by binders, which is not conducive to mixing and compatibility with other components. Excessive flake-shaped soft magnetic powder can affect the overall flowability and dispersibility of the material, leading to a decrease in the overall magnetic permeability of the soft magnetic material. Therefore, this application controls the mass percentage of flake-shaped soft magnetic powder to be below 90 wt%, reducing the impact of poor flowability of flake-shaped soft magnetic powder. Although it will reduce the overall performance of the soft magnetic material to a certain extent, this defect can be effectively compensated by the flake-shaped characteristic of the soft magnetic powder.

[0014] In some embodiments of this application, the adhesive includes at least one of nylon (such as nylon 6, nylon 12), polybutylene terephthalate, polyamide or polyphenylene sulfide, nitrile rubber (NBR), silicone rubber, polyurethane rubber, ethylene propylene rubber, and acrylate.

[0015] In some embodiments of this application, the soft magnetic material includes 8wt% to 23wt% binder, such as 10wt% to 22wt%, 8wt% to 23wt%, 8wt% to 20wt%, 10wt% to 20wt%, 12wt% to 20wt%, 15wt% to 20wt%, 11wt%, 13wt%, 14wt%, 16wt%, 17wt%, 18wt%, 19wt%, etc. In this application, increasing the amount of binder added can improve the strength of the soft magnetic material and enhance the flowability of the soft magnetic material components during the preparation process, which is beneficial for more uniform dispersion of the components. Soft magnetic materials containing granular soft magnetic powder have a high powder content and insufficient toughness, requiring the addition of additional toughening agents to improve the toughness of the soft magnetic material. However, in the technical solution of this application, the sheet-like soft magnetic powder has high toughness and does not require the addition of toughening agents, thereby allowing for a further increase in the binder content.

[0016] In some embodiments of this application, the soft magnetic material includes 0.1wt% to 3wt% of silane coupling agent, such as 0.3wt% to 2.5wt%, 0.3wt% to 2wt%, 0.3wt% to 1.5wt%, 0.5wt% to 2wt%, 0.5wt% to 1.5wt%, etc.

[0017] In some embodiments of this application, the silane coupling agent coats the flake-shaped soft magnetic powder. Flake-shaped soft magnetic powder has poor flowability; coating it with a silane coupling agent can effectively improve its compatibility with the binder and enhance its flowability.

[0018] In some embodiments of this application, the silane coupling agent includes at least one of KH171, KH151, KH172, KH792, KH550, KH560, KH570, and KH530.

[0019] In some embodiments of this application, the soft magnetic material includes 0.1wt% to 2wt% lubricant, such as 0.3wt% to 1.5wt%, 0.5wt% to 1.5wt%, 0.5wt% to 1wt%, 0.6wt%, 0.7wt%, 0.8wt%, 0.9wt%, etc. The lubricant in this application is beneficial to improving the flowability of the powder.

[0020] In some embodiments of this application, the lubricant includes at least one of zinc stearate, paraffin wax, vegetable oil, stearamide, and polyol esters; such as esters formed from polydiols, triols, tetraols, and saturated fatty acids or benzoic acid; for example, at least one of polydiol esters (diethylene glycol fatty acid esters, triethylene glycol fatty acid esters), polydiol benzoates (diethylene glycol dibenzoate, diethylene glycol dibenzoate), triol esters (glyceryl tristearate, glyceryl tripalmitate, glyceryl tribenzoate, glyceryl monolactate tribenzoate), tetraol esters (pentaerythritol tetrastearate, pentaerythritol tetraoleate, pentaerythritol tetrabenzoate), neopentyl glycol esters, trimethylolpropane esters, glyceryl esters (such as glyceryl monooleate, glyceryl monostearate), and castor oil polyol esters.

[0021] In some embodiments of this application, the soft magnetic material further includes an antioxidant, which can improve the weather resistance of the soft magnetic material.

[0022] In some embodiments of this application, the soft magnetic material further includes 0.1wt% to 2wt% antioxidant, such as 0.3wt% to 1.5wt%, 0.5wt% to 1.5wt%, 0.5wt% to 1wt%, 0.6wt%, 0.7wt%, 0.8wt%, 0.9wt%, etc.

[0023] In some embodiments of this application, the antioxidant includes at least one of organophosphates, alkylated monohydric phenols, alkylated polyhydric phenols, alkylation reaction products of polyhydric phenols and dienes, and butylation reaction products of p-cresol or dicyclopentadiene.

[0024] In some embodiments of this application, the organophosphate includes at least one of tris(nonylphenyl) phosphite, tris(2,4-di-tert-butylphenyl) phosphite (antioxidant 168), pentaerythritol diphosphite (2,4-di-tert-butylphenyl) diphosphite, and distearate pentaerythritol diphosphite.

[0025] In some embodiments of this application, the alkylation reaction product of polyphenols and dienes includes octadecyl β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (antioxidant 1076).

[0026] In some embodiments of this application, the antioxidant includes a mixture of octadecyl β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate and tris(2,4-di-tert-butylphenyl) phosphite.

[0027] In this application, antioxidant 1076 and antioxidant 168 can have a synergistic effect, improving the weather resistance, thermal stability and mechanical retention of soft magnetic materials.

[0028] In some embodiments of this application, the antioxidant comprises a mixture of tetramethyl(3,5-di-tert-butyl-4-hydroxycinnamate)methane as the primary antioxidant and tris(2,4-di-tert-butylphenyl) phosphite as the secondary antioxidant. For example, the antioxidant comprises a mixture of tetramethyl(3,5-di-tert-butyl-4-hydroxycinnamate)methane and tris(2,4-di-tert-butylphenyl) phosphite in a mass ratio of (1-3):1.

[0029] In some embodiments of this application, the soft magnetic material comprises 75wt% to 90wt% flake soft magnetic powder, 8wt% to 20wt% binder, 0.1wt% to 3wt% silane coupling agent, 0.1wt% to 2wt% lubricant, and 0.1wt% to 1wt% antioxidant.

[0030] A second aspect of this application provides a method for preparing the aforementioned soft magnetic material, comprising the following steps:

[0031] The soft magnetic material is prepared by mixing flake-shaped soft magnetic powder with a silane coupling agent, adding the remaining components, blending, and extruding.

[0032] In some embodiments of this application, the blending temperature is 15°C to 30°C.

[0033] In some embodiments of this application, the extrusion temperature is 200℃~300℃, such as 200℃~260℃, 220℃~260℃, 200℃, 210℃, 220℃, 200℃, 230℃, 250℃, 260℃, 270℃, etc.

[0034] In some embodiments of this application, the extrusion is performed using a twin-screw extruder.

[0035] In some embodiments of this application, the screw speed of the twin-screw extruder is 20 r / min to 150 r / min, for example 30 r / min to 130 r / min, 40 r / min to 120 r / min, 50 r / min, 60 r / min, 70 r / min, 80 r / min, 90 r / min, or 100 r / min.

[0036] In some embodiments of this application, after extrusion, the extruded product is further cooled and granulated.

[0037] In some embodiments of this application, the method for preparing the soft magnetic material includes the following steps: mixing sheet-like soft magnetic powder with a silane coupling agent, then adding a binder, a lubricant, and optionally an antioxidant, blending, and extruding to obtain the soft magnetic material.

[0038] A third aspect of this application provides an electronic product component comprising the aforementioned soft magnetic material.

[0039] According to some embodiments of this application, the method for preparing the electronic product component includes the following steps: injection molding the soft magnetic material to obtain the electronic product component.

[0040] In this application, the injection molding process is used to prepare soft magnetic materials, which can greatly improve the yield and obtain the required precision magnetic core without secondary processing. During the injection molding process, the stress orientation of the co-extrusion is used to achieve the orderly arrangement of the sheet-like soft magnetic powder, thereby obtaining a soft magnetic material with high magnetic permeability.

[0041] According to some embodiments of this application, the method for preparing the electronic product component includes the following steps: injection molding the soft magnetic material under a magnetic field to obtain the electronic product component.

[0042] According to some embodiments of this application, the strength of the magnetic field is at least 0.5T. In this application, applying an external magnetic field during injection molding can make the sheet-like soft magnetic powder more orderly arranged, improve its orientation, and thus improve the magnetic properties of the soft magnetic material. The external magnetic field also provides additional driving force for the soft magnetic material particles, which can improve the flowability of the soft magnetic material and is beneficial to injection molding.

[0043] According to some embodiments of this application, the electronic product component includes any one of a magnetic core, stator and rotor, magnetic head, sensor magnetic element, and choke.

[0044] According to some embodiments of this application, the electronic product components include any one of a transformer, reactor, power adapter, switching power supply, inverter, wireless charger, electromagnetic relay, filter, antenna, and sensor.

[0045] A fourth aspect of this application provides an electronic product including the aforementioned electronic product components.

[0046] According to some embodiments of this application, the electronic product includes any one of a smartphone, computer, smartwatch, headphones, speaker, and magnetic therapy device.

[0047] The beneficial effects of this application are:

[0048] The soft magnetic material of this application has significantly improved magnetic permeability, and also has salt spray resistance (48-72h), higher mechanical strength, and does not require toughening agents, thus saving raw materials and costs.

[0049] The method for preparing soft magnetic materials in this application has a simple granulation process, produces granules with uniform properties, stable products, and a shorter process.

[0050] The electronic component manufacturing method of this application can effectively solve the problems of long production process, high energy consumption, low yield and fragility of sintered ferrite, and provides a brand-new solution for wireless charging of small devices. While meeting the wireless charging efficiency requirements, it has the advantages of simple production process, high yield and low cost. Attached Figure Description

[0051] Figure 1 is a schematic diagram of the orientation magnetic field A in Embodiment 1 of this application.

[0052] Figure 2 is a schematic diagram of the orientation magnetic field B in Embodiment 1 of this application.

[0053] Figure 3 is an electron microscope image of the iron-silicon-aluminum particle powder in Comparative Example 1 of this application.

[0054] Figure 4 is a cross-sectional electron microscope image of the soft magnetic product 6 in Comparative Example 1 of this application.

[0055] Figure 5 is an electron microscope image of the sheet-like iron-silicon-aluminum powder in Example 1 of this application.

[0056] Figure 6 is an image of the soft magnetic material particles obtained in Example 1 of this application.

[0057] Figure 7 is a front electron microscope image of the soft magnetic product 1-1 in Embodiment 1 of this application.

[0058] Figure 8 is a front electron microscope image of the soft magnetic product 1-1 in Embodiment 1 of this application.

[0059] Figure 9 shows the permeability curve of the soft magnetic product 1-1 in Embodiment 1 of this application.

[0060] Figure 10 shows the permeability curves of the soft magnetic products 1-2 in Embodiment 1 of this application.

[0061] Figure 11 shows the permeability curves of soft magnetic products 1-3 in Embodiment 1 of this application.

[0062] Figure 12 shows the magnetic permeability curve of the soft magnetic product 2 in Embodiment 2 of this application.

[0063] Figure 13 shows the magnetic permeability curve of the soft magnetic product 3 of Embodiment 3 of this application.

[0064] Figure 14 shows the permeability curve of the soft magnetic product 4-1 in Embodiment 4 of this application.

[0065] Figure 15 shows the permeability curve of the soft magnetic product 4-2 in Embodiment 4 of this application.

[0066] Figure 16 shows the permeability curve of the soft magnetic product 4-3 in Embodiment 4 of this application.

[0067] Figure 17 shows the permeability curve of the soft magnetic product 5 in Embodiment 5 of this application.

[0068] Reference numerals: 1. Magnet 1; 2. Soft magnetic material; 3. Magnet 2. Detailed Implementation

[0069] The following specific embodiments further illustrate the content of this application in detail. Unless otherwise specified, the raw materials, reagents, or apparatus used in the embodiments and comparative examples are all available from conventional commercial sources or can be obtained by existing technical methods. Unless otherwise specified, the experimental or testing methods are conventional methods in the art.

[0070] The raw materials used in the following examples or comparative examples can be obtained from conventional commercial sources or by existing technical methods.

[0071] In the following examples or comparative examples, the aspect ratio of the sheet-like soft magnetic powder is 80-100, and the average particle size is 50-60 μm.

[0072] The soft magnetic product has dimensions of OD 20mm, ID 9.9mm, and thickness of 0.3mm.

[0073] Example 1

[0074] The soft magnetic material provided in this embodiment is composed of the following components by mass percentage:

[0075] 82.0 wt% flake iron-silicon-aluminum powder, 15 wt% binder nylon 12, 1.0 wt% silane coupling agent KH550, 1.0 wt% lubricant tetraol benzoate, 0.5 wt% antioxidant 1010, 0.5 wt% antioxidant 168;

[0076] The preparation method of soft magnetic materials is as follows:

[0077] The flake-shaped iron-silicon-aluminum powder is first mixed with silane using a disperser to ensure that the silane coupling agent fully coats the powder. Then, it is mixed evenly with binder, lubricant, and antioxidant. The mixture is then fed into a twin-screw extruder for melt extrusion, which is carried out in six zones, each with a constant temperature. The temperatures of each zone are 220℃, 240℃, 260℃, 260℃, 240℃, and 230℃, respectively, with a screw speed of 50 r / min. After cooling, air drying, and pelletizing, a soft magnetic material is obtained.

[0078] The obtained soft magnetic material was injection molded to produce soft magnetic product 1-1.

[0079] As shown in Figure 1, magnet 1 and magnet 2 form an orientation magnetic field A. Under the orientation magnetic field A and the magnetic field strength of 1.2 to 1.5T, the prepared soft magnetic material 2 is injection molded to obtain soft magnetic products 1-2.

[0080] As shown in Figure 2, soft magnetic products 1-3 are produced by injection molding using the prepared soft magnetic material under an orientation magnetic field B with a magnetic field strength of 1.2-1.5T.

[0081] Example 2

[0082] The soft magnetic material provided in this embodiment is composed of the following components by mass percentage:

[0083] 82.0 wt% flake iron-silicon powder, 15 wt% binder nylon 12, 1.0 wt% silane coupling agent KH560, 1.0 wt% lubricant zinc stearate, 0.5 wt% antioxidant 1010, 0.5 wt% antioxidant 168;

[0084] The preparation method of the soft magnetic material in this embodiment is the same as that in Example 1.

[0085] The obtained soft magnetic material was used for injection molding to produce soft magnetic product 2.

[0086] Example 3

[0087] The soft magnetic material provided in this embodiment is composed of the following components by mass percentage:

[0088] 82.0 wt% flake carbonyl iron powder, 15 wt% binder nylon 12, 1.0 wt% silane coupling agent KH570, 1.0 wt% lubricant zinc stearate, 0.5 wt% antioxidant 1010, 0.5 wt% antioxidant 168;

[0089] The preparation method of the soft magnetic material in this embodiment is the same as that in Example 1.

[0090] The obtained soft magnetic material was used for injection molding to produce soft magnetic product 3.

[0091] Example 4

[0092] The soft magnetic material provided in this embodiment is composed of the following components by mass percentage:

[0093] 89.0 wt% flake iron-silicon-aluminum powder, 8 wt% binder nylon 12, 1.0 wt% silane coupling agent KH550, 1.0 wt% lubricant polyol ester, 0.5 wt% antioxidant 1010, 0.5 wt% antioxidant 168;

[0094] The preparation method of the soft magnetic material in this embodiment is the same as that in Example 1.

[0095] The obtained soft magnetic material was injection molded to produce soft magnetic product 4-1.

[0096] Under an orientation magnetic field A with a magnetic field strength of 1.2 to 1.5 T, the prepared soft magnetic material is injection molded to produce soft magnetic products 4-2.

[0097] Under an orientation magnetic field B and a magnetic field strength of 1.2–1.5T, the prepared soft magnetic material is injection molded to produce soft magnetic products 4-3.

[0098] Example 5

[0099] The soft magnetic material provided in this embodiment is composed of the following components by mass percentage:

[0100] 85.0 wt% flake iron-silicon powder, 12 wt% binder nylon 6, 1.0 wt% silane coupling agent KH560, 1.0 wt% lubricant zinc stearate, 0.5 wt% antioxidant 1010, 0.5 wt% antioxidant 168;

[0101] The preparation method of the soft magnetic material in this embodiment is the same as that in Example 1.

[0102] The obtained soft magnetic material was used for injection molding to produce soft magnetic products 5.

[0103] Comparative Example

[0104] The soft magnetic material provided in this comparative example consists of the following components by mass percentage:

[0105] 91wt% iron-silicon-aluminum granular powder (average particle size 90-120μm), 5wt% binder nylon 12, 1.5wt% toughening agent POE grafted maleic anhydride, 0.5wt% silane coupling agent KH550, 1.0wt% lubricant zinc stearate, 0.5wt% antioxidant 1010, 0.5wt% antioxidant 168;

[0106] The preparation method of the soft magnetic material in this comparative example is the same as that in Example 1.

[0107] The obtained soft magnetic material was used for injection molding to produce soft magnetic products 6.

[0108] Experimental Example 1

[0109] This experiment demonstrates electron microscopy analysis of the soft magnetic powder and the resulting soft magnetic products.

[0110] Figures 3 and 4 are cross-sectional electron microscope images of iron-silicon-aluminum granular powder and soft magnetic product 6 in Comparative Example 1. It can be seen that the soft magnetic powder particles in the soft magnetic product obtained from the granular soft magnetic powder are arranged randomly and have no orientation.

[0111] Figure 5 is an electron microscope image of the sheet-like iron-silicon-aluminum powder in Example 1. Figure 6 is a particle image of the soft magnetic material prepared in Example 1 of this application. Figures 7 and 8 are front electron microscope images of the soft magnetic product 1-1 in Example 1 at different scales. As can be seen from Figure 7, the sheet-like iron-silicon-aluminum powder in the soft magnetic product 1-1 is arranged in an orderly manner. As can be seen more clearly from Figure 8, the sheet-like iron-silicon-aluminum powder is stacked under stress. This arrangement can greatly improve the magnetic permeability of the product, thereby improving the charging efficiency of the device.

[0112] The data in the figure clearly shows that the thickness of the flake powder is very small, but its length is very large, and its flake-like structure is very high. The higher the degree of flake-like structure, the greater its magnetic permeability.

[0113] Experimental Example 2

[0114] This experimental example tests the performance of the soft magnetic products prepared in the examples and comparative examples. The specific process is as follows:

[0115] Permeability testing method: Tested using Keysight E4991B (coaxial line method);

[0116] Salt spray resistance test method: ASTM B117 or ISO 9227.

[0117] Figures 9, 10, and 11 correspond to the permeability curves of soft magnetic products 1-1, 1-2, and 1-3 in Example 1, respectively. It can be seen that after magnetic field orientation, the flake powder is more neatly arranged and has smaller gaps between powder particles compared to simple stress field orientation. Comparing Figures 9 with Figures 10 and 11, it can be seen that applying an external magnetic field orientation during injection molding can increase the permeability of the resulting soft magnetic products by about 20%, with orientation magnetic field A and orientation magnetic field B having comparable effects.

[0118] Figures 12 and 13 correspond to the permeability curves of soft magnetic product 2 (Example 2) and soft magnetic product 3 (Example 3), respectively. It can be seen that the flake-shaped iron-silicon powder has higher permeability. Although the flake-shaped carbonyl iron powder has lower permeability, its saturation magnetic induction intensity is higher. The saturation magnetic induction intensity of flake-shaped iron-silicon powder is about 0.8T, while that of flake-shaped carbonyl iron powder can reach 2.0T. It possesses unique advantages in high-frequency applications and can form a good complement to flake-shaped iron-silicon and flake-shaped iron-silicon-aluminum.

[0119] Figures 14, 15, and 16 correspond to the permeability curves of soft magnetic products 4-1, 4-2, and 4-3 in Example 4, respectively. It can be seen that increasing the powder content of the soft magnetic powder in the soft magnetic products reduces the growth of the orientation magnetic field performance. However, even with a high powder content and an applied orientation magnetic field, the permeability of the resulting soft magnetic products still significantly increases by 10% to 15%.

[0120] Figure 17 shows the permeability curve of the soft magnetic product 5 in Example 5. It can be seen that the flake-shaped iron-silicon powder has moderate performance, but its price is low, which gives it a practical application advantage in fields where cost-effectiveness is a consideration.

[0121] The test results are shown in Table 1.

[0122] Table 1

[0123] The results of the salt spray resistance test are shown in Table 2:

[0124] Table 2

[0125] As shown in Table 2, all the soft magnetic products prepared in the examples can pass the salt spray resistance test.

[0126] The above embodiments are preferred embodiments of this application, but the implementation of this application is not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the protection scope and principle of this application shall be considered equivalent substitutions and shall be included within the protection scope of this application.

Claims

1. A soft magnetic material, characterized in that: It includes 75wt% to 90wt% flake soft magnetic powder, 8wt% to 23wt% binder, 0.1wt% to 3wt% silane coupling agent, and 0.1wt% to 2wt% lubricant.

2. The soft magnetic material according to claim 1, characterized in that: The aspect ratio of the sheet-like soft magnetic powder is 30 to 150; and / or the average particle size of the sheet-like soft magnetic powder is 30 to 120 μm.

3. The soft magnetic material according to claim 1, characterized in that: The sheet-like soft magnetic powder is oriented.

4. The soft magnetic material according to claim 1, characterized in that: The soft magnetic material satisfies at least one of the following conditions: (I) The sheet-like soft magnetic powder includes at least one of sheet-like manganese-zinc ferrite magnetic powder, sheet-like carbonyl iron powder, sheet-like iron-silicon-chromium, sheet-like iron-silicon-aluminum, sheet-like iron-nickel, sheet-like iron-silicon-boron-copper-niobium, and sheet-like iron-nickel-molybdenum. (II) The adhesive comprises at least one of nylon, polybutylene terephthalate, polyamide or polyphenylene sulfide, nitrile rubber, silicone rubber, polyurethane rubber, ethylene propylene rubber, and acrylate. (III) The silane coupling agent includes at least one of KH171, KH151, KH172, KH792, KH550, KH560, KH570, and KH530; (IV) The lubricant includes at least one of zinc stearate, paraffin wax, vegetable oil, stearamide, and polyol ester.

5. The soft magnetic material according to claim 1, characterized in that: The soft magnetic material also includes antioxidants.

6. A method for preparing a soft magnetic material according to any one of claims 1 to 5, characterized in that: Includes the following steps: The soft magnetic material is prepared by mixing flake-shaped soft magnetic powder with a silane coupling agent, adding the remaining components, blending, and extruding.

7. An electronic product component, characterized in that: Includes the soft magnetic material as described in any one of claims 1 to 5.

8. The electronic product component according to claim 7, characterized in that: The method for preparing the electronic product component includes the following steps: injection molding the soft magnetic material to obtain the electronic product component.

9. The electronic product component according to claim 7, characterized in that: The method for preparing the electronic product component includes the following steps: under a magnetic field, the soft magnetic material is injection molded to obtain the electronic product component.

10. An electronic product comprising the electronic product component as described in any one of claims 7 to 9.

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