本研究主要以羰基鐵粉作為原料，在表面利用磷化處理生成一層磷酸鹽皮膜，此非磁性層可有效降低磁損失，使電流不容易達到飽和，可用來製備一體成形大功率電感器。結果證實添加2wt%磷酸可以得到膜厚均勻且絕緣性高之皮膜，並經由穿透式電子顯微鏡證實皮膜為非晶質結構，透過鹽霧試驗分析證實磷化處理可提高鐵粉耐腐蝕性。
為了改善鐵粉與高分子間之相容性，本研究亦利用離子型界面活性劑硬脂酸鈉及非離子型界面活性劑氨基矽烷，對經磷酸處理之羰基鐵粉進行改質。結果發現硬脂酸鈉有助於提高粉末的堆積密度，並因空間位阻效應而有較佳的流變性，即使表面經過預磨耗測試仍可提供較佳的抗腐蝕性，且可以提供磷化鐵粉成形前之潤滑性，並於樹脂固化時受到分解而不留在胚體當中，有助於提升其直流疊加特性與磁性質，但因分解所形成之胚體缺陷則會造成拉伸強度的劣化。而添加氨基矽烷改質有助於降低磷化鐵粉與環氧氯丙烷混合之黏度，並提高磷化鐵粉與環氧樹脂之相容性，使得胚體中氣隙分佈較均勻助於增加其直流疊加特性，並因矽烷與環氧樹脂產生化學鍵結使得胚體強度顯著提升。並且藉由矽烷改質可使磁區壁之移動較為容易，有效降低磁損失。

This study investigated phosphating treatment and surface modification effects on the electromagnetic properties of iron-based soft magnetic composites. Insulating coating can prevent iron rusting and provide higher saturation current effectively. It can be used to manufacture molded power inductors. The results showed that a well-distributed and high electrical resistance layer on the surfaces of the carbonyl iron powders can be obtained by the phosphating treatment using 2 wt% phosphoric acid. Based on the TEM results, a core-shell structure was successfully obtained and the phosphate shell was amorphous. To improve the compatibility between the iron powders and the polymer, the phosphated iron powders were also modified by using anionic surfactant, sodium stearate, and non-ionic surfactant, amino-silane respectively. The results showed that the fluidity, steric hindrance stability and abrasion resistance were promoted simultaneously by adding proper amount of sodium stearate. The addition of sodium stearate reduced the friction between the particles and the mold, which led to the density and magnetic properties were improved. On the other hand, the amino-silane modification can increase the compatibility between the phosphating iron powder and the polymer, and hence reducing the viscosities of the pastes composed of the phosphating iron powder and liquid epoxy resin and furthermore promoting the distribution of the air gap, rated current and power losses. The chemical bonding between the silane and epoxy can improve the tensile strength of the soft magnetic composites.

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