Soft Magnetic Composite Powder Coating That Resists Press Cracking
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Solution Overview
Problem
Existing methods for producing iron-based soft magnetic composite powders face issues with insulating coatings breaking during compression molding, leading to increased production costs and safety burdens due to the use of organic solvents and impurities like aluminum orthophosphate affecting coating strength.
Innovation Solution
A method involving the use of aluminum dihydrogen tripolyphosphate dihydrate and silicone resin coatings on iron-based soft magnetic particles, with specific intensity ratios and temperature controls to form robust insulating layers without organic solvents, ensuring high adhesion and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If condensed phosphate metal compound (e.g., aluminum tripolyphosphate) is added to harden the insulating coating, then the adhesion strength between the soft magnetic powder and the insulation layer increases, but the insulating coating may break during compression molding due to the high hardness of added substances like Al2O3 and SiO2
Solution Approach 1:
The invention changes the chemical composition parameters of the insulating coating by specifying precise ratios of Al2O3 (0.1-5 wt%) and SiO2 (0.1-5 wt%) within the condensed phosphate metal compound. This parameter optimization ensures the coating has sufficient adhesion strength while maintaining flexibility and preventing breakage during compression molding.
Solution Approach 2:
The invention uses a composite insulating coating formed by condensed phosphate metal compound that contains both Al2O3 and SiO2 in controlled amounts. This composite structure combines the adhesion benefits of aluminum compounds with the flexibility and crack-resistance benefits of silicon compounds, resolving the contradiction between strength and integrity.
2Temperature
If basic substances like Al2O3 and SiO2 are added as hardening accelerators to the condensed phosphate metal compound, then the hardening effect is enhanced, but the insulating coating becomes more prone to breaking during compression molding
Solution Approach 1:
The invention optimizes the concentration parameters of hardening accelerators by limiting Al2O3 to 0.1-5 wt% and SiO2 to 0.1-5 wt% of the total condensed phosphate metal compound. This controlled parameter adjustment provides sufficient hardening effect while preventing excessive brittleness that would cause coating breakage during compression molding.
3Ease of manufacture
If impurities like aluminum orthophosphate are present in condensed phosphoric acid metal salts, then the availability and cost-effectiveness are improved, but the strength of the insulating coating is negatively affected
Solution Approach 1:
The invention establishes precise compositional parameters for the condensed phosphate metal compound, specifying Al2O3 at 0.1-5 wt% and SiO2 at 0.1-5 wt%. This parameter control allows the use of commercially available condensed phosphoric acid metal salts that may contain impurities like aluminum orthophosphate, while ensuring the final coating meets strength requirements through controlled composition.
4Strength
If organic solvents are used when adding silane coupling agent to strengthen adhesion, then the adhesion between inorganic insulating powder and soft magnetic powder is improved, but production costs increase due to solvent drying treatment and safety control burdens
Solution Approach 1:
The invention extracts and eliminates the organic solvent step from the production process. Instead of using silane coupling agents requiring organic solvents and subsequent drying, the invention directly uses condensed phosphate metal compounds that form insulating coatings through simple mixing and heating, removing the complex solvent handling and drying equipment requirements.
Solution Approach 2:
The invention replaces expensive and complex organic solvent-based adhesion processes with a simpler, more economical approach using condensed phosphate metal compounds. This substitution eliminates the need for costly solvent recovery systems and safety infrastructure while achieving comparable or superior adhesion strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces an iron-based soft magnetic composite powder with insulating coatings that are less likely to break during compression molding, maintaining high efficiency and reducing production costs by avoiding solvent use and impurity effects.
Implementation Method 1
stirring and mixing the aluminum dihydrogen tripolyphosphate dihydrate powder and the iron-based soft magnetic powder while heating the powders to a maximum arrival temperature of 130° C. or higher and 200° C. or lower
Implementation Method 2
for the spectrum when the aluminum dihydrogen tripolyphosphate dihydrate powder is analyzed by X-ray diffraction method, the peak intensity of the (112) plane of aluminum dihydrogen tripolyphosphate dihydrate is 1.5 times higher than the peak intensity of the (102) plane of aluminum orthophosphate
Implementation Method 3
adding a silicone resin powder to the first composite powder and stirring and mixing the silicone resin powder and the first composite powder, wherein the temperature of the powders during the stirring and mixing is 80° C. or higher
Data Source
AI summary
It is provided a method for producing an iron-based soft magnetic composite powder and the iron-based soft magnetic composite powder. The method for producing an iron-based soft magnetic composite powder includes a first mixing step of adding an aluminum dihydrogen tripolyphosphate dihydrate powder to an iron-based soft magnetic powder and stirring and mixing the aluminum dihydrogen tripolyphosphate dihydrate powder and the iron-based soft magnetic powder to obtain a first composite powder in which coating layers of aluminum dihydrogen tripolyphosphate dihydrate are formed on the surfaces of iron-based soft magnetic particles, wherein, for the spectrum when the aluminum dihydrogen tripolyphosphate dihydrate powder is analyzed by the X-ray diffraction method, the peak intensity of the (112) plane of aluminum dihydrogen tripolyphosphate dihydrate is 1.5 times higher than the peak intensity of the (102) plane of aluminum orthophosphate.