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研究生:陳彥同
研究生(外文):Yan-Tung Chen
論文名稱:有機添加劑配方對鎳鋅銅鐵氧磁體射出成型特性探討
論文名稱(外文):Investigation of Binder Formulation for the Injection Molding of Ni-Zn-Cu Ferrites
指導教授:王錫福
指導教授(外文):Sea-Fue Wang
口試委員:林於隆吳玉娟徐永富
口試日期:2012-01-12
學位類別:碩士
校院名稱:國立臺北科技大學
系所名稱:材料及資源工程系研究所
學門:工程學門
學類:材料工程學類
論文種類:學術論文
論文出版年:2012
畢業學年度:100
語文別:中文
論文頁數:74
中文關鍵詞:鎳鋅銅鐵氧磁體黏結劑陶瓷射出成型脫脂燒結
外文關鍵詞:Ni-Zn-Cu FerritebinderCIMdebindingsintering
相關次數:
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鐵氧磁體元件常藉由特殊的結構幾何形狀、尺寸及位置的設計,來得到所期
望的功能,為了擴展元件更廣泛之應用,本研究以射出成型製程製備鎳鋅銅鐵氧磁體製品,從射料中添加的高分子材料聚丙烯、石蠟與硬脂酸、混練方法、脫脂、以及燒結等製程參數進行探討。實驗中調整主黏結劑與次黏結劑之比例於0.83-3.70 間,粉末固含量 40 -60 vol.%,以不同配比實施混練再進行射出成型試驗,尋找出製備鎳鋅銅鐵氧磁體元件的最佳配比,且比較射料的差異性與射出之成形性。
實驗結果顯示硬脂酸預先披覆在粉末表面能改善粉末團聚現象,可達到混練均勻效果,且添加 6 vol.%的硬脂酸有助於射件之孔隙尺寸縮小使密度提升。在相同固含量下,聚丙烯與石蠟比例為 1.23 時有最高相對密度 98.79%,聚丙烯含量越高時,射件孔洞越多密度也隨之下降。固含量提升亦能提高密度且使收縮率降低,但流動性因此降低而不利於成形,必須提高射出壓力、速度與溫度,以避免射件產生短射或崩裂、脫皮之現象。在本研究中 53 vol.%為最高上限之固含量,而較易於成形之固含量為 50 vol.%。

The desired functionality of ferrite components are often designed by the special geometry of the structure, size and location. The current study is to prepare Ni-Zn-Cu ferrite via injection molding process. Process parameters including solid loading fraction, binder system, content of binders, mixing procedures and debinding processes are considered. In order to obtain the optimum of Ni-Zn-Cu ferrites, the binder ratio was at 0.83-3.70, the solid contene was controlled at 40 -60 vol.% . The relationship of basad feedstock formulation and injection molding was disscused.
According to experimental results, pre-coated surface of stearic acid can mitigate the powder agglomeration and improve mixing uniformly. Add 6 vol.% of stearic acid
are able to reduce shoot parts of the pore size and incredse density. The highest relative density of 98.79% could be at the ratio of polypropylene and paraffin wax at 1.23. Increased PP content effect porous resulting and in reduced density. Solid content improve the density and reduce shrinkage and reduce rheological behavior, consequently must enhance injection pressure must be increased;injection speed and temperature, to avoid short shots or green pieces have cracked and peeling. The experimental results show that 53 vol.% are the highest limit of the solid content and 50 vol.% are the best formulations.


目 錄

摘 要...............................................................................................................................
ABSTRACT ................................................................................................................... ii
誌 謝 ............................................................................................................................ iv
目 錄 ............................................................................................................................. v
表目錄 ....................................................................................................................... viii
圖目錄 .......................................................................................................................... ix
第一章 序論.................................................................................................................. 1
1.1 前言................................................................................................................. 1
1.2 研究目的......................................................................................................... 3
第二章 文獻回顧與理論基礎...................................................................................... 4
2.1 黏結劑的功能及選擇..................................................................................... 4
2.1.1 流變分析.............................................................................................. 6
2.1.2 硬脂酸對粉末分散性之影響.............................................................. 8
2.2 粉末固含量之影響....................................................................................... 10
2.3 收縮率........................................................................................................... 13
2.4 混練............................................................................................................... 14
2.5 脫脂機制....................................................................................................... 15
2.5.1 溶劑萃取............................................................................................ 15
2.5.2 熱脫脂................................................................................................ 18
2.5.3 缺陷的產生........................................................................................ 21
2.6 粉末射出成型之相關研究........................................................................... 22
第三章 實驗步驟與方法............................................................................................ 24
3.1 實驗設計與流程........................................................................................... 24
3.2 實驗材料....................................................................................................... 26
3.2.1 鎳鋅銅鐵氧磁體粉末性質................................................................ 26
3.2.2 黏結劑系統........................................................................................ 26
3.3 實驗步驟....................................................................................................... 29
3.3.1 混練.................................................................................................... 29
3.3.1.1 硬脂酸預先披覆粉末表面............................................................. 30
3.3.1.2 聚丙烯與石蠟預先混合................................................................. 30
3.3.2 射出成型機........................................................................................ 31
3.3.3 脫脂製程............................................................................................ 32
3.3.4 燒結製程............................................................................................ 33
3.4 材料分析及儀器規格介紹................................................................... 33
3.4.1 雷射粒徑分析.................................................................................... 33
3.4.2 密度量測............................................................................................ 33
3.4.3 收縮率量測........................................................................................ 34
3.4.4 XRD 鑑定 ........................................................................................... 34
3.4.5 微結構觀察........................................................................................ 35
3.4.6 振動樣品磁力計 (VSM) .................................................................. 36
3.4.7 電感值(L)量測 .................................................................................. 36
第四章 結果與討論.................................................................................................... 38
4.1 粉末分析與燒結體之相對密度................................................................... 38
4.2 熱差與熱重分析........................................................................................... 41
4.2.1 聚丙烯之熱分析結果........................................................................ 41
4.2.2 石蠟之熱分析結果............................................................................ 42
4.2.3 硬脂酸之熱分析結果........................................................................ 43
4.2.4 溶劑脫脂參數.................................................................................... 44
4.2.5 熱脫脂溫度設定參數........................................................................ 46
4.3 射出成型....................................................................................................... 51
4.3.1 燒結溫度對密度分析................................................................................ 51
4.3.2 聚丙烯/石蠟配比調整 ...................................................................... 55
4.3.3 固含量不同之影響............................................................................ 58
4.3.4 硬脂酸披覆於粉末之影響................................................................ 62
4.3.5 硬脂酸含量之影響............................................................................ 64
4.4 收縮率對電感值之影響............................................................................... 67
4.5 射件密度對飽和磁化量之影響................................................................... 69
第五章 結論................................................................................................................ 71
參考文獻...................................................................................................................... 73



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