Patent Application
20230042168
The present invention relates to the technical field of manganese-zinc ferrites, and in particular to a manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature and a method for preparing the same.
With development of the eras and progress of the society, more and more attention has been paid to energy conservation, emission reduction and efficiency improvement. Similarly, loss reduction has also become a hot research topic in the field of magnetic material application. In the prior art, it is known that ferrite materials, such as PC47 and PC45, manufactured by TDK in Japan have low loss at only single points, and cannot meet the current requirements for energy conservation, emission reduction and efficiency improvement so far. Compared with the PC47 and the PC45, a PC95 ferrite material manufactured by TDK has low loss in a wider temperature range, but has low loss only in a temperature range of 25-100° C. Similarly, materials, such as 3C97, manufactured by Ferroxcube also have low loss only in a temperature range of 60-140° C. Some products manufactured by other manufacturers in China, such as a TPW33 ferrite material manufactured by TDG and a JPP97 ferrite material manufactured by A-CORE, also have similar situations. However, these ferrite materials have low loss only in a high temperature range, and cannot have a high magnetic permeability in a low temperature range or even a subzero temperature range.
In order to solve the problems above, the present invention provides a manganese-zinc ferrite material with both a high magnetic permeability at about −20° C. and low loss in a temperature range of 120-140° C. to meet the requirements for operation of electronic components in extremely harsh environments.
The present invention further discloses a method for preparing the manganese-zinc ferrite.
In order to achieve the objective above, the present invention adopts the following technical solutions.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature includes main materials consisting of the following raw materials by mole percent: 52.35-52.45 mol % of Fe2O3, 37.6-37.9 mol % of MnO and 9.65-10.05 mol % of ZnO.
Preferably, the manganese-zinc ferrite further includes additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material (a powder obtained after the main materials are pre-sintered), 0.06-0.10 wt % of CaCO3, 0.015-0.04 wt % of ZrO2, 0.3-0.45 wt % of Co2O3 and 0.1-0.2 wt % of SnO2.
Preferably, the additives are added after the main materials are mixed and sintered to obtain the pre-sintered material.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature includes the following steps:
(a) mixing various components in the main materials, and conducting primary sanding to obtain a sanded slurry;
(b) adding a binder aqueous solution into the sanded slurry for uniform mixing, and conducting spray granulation and pre-sintering to obtain a pre-sintered material;
(c) adding the additives into the pre-sintered material, and conducting secondary sanding to obtain a secondary sanded slurry; and
(d) adding a binder aqueous solution into the secondary sanded slurry for uniform mixing, conducting spray granulation and compression molding to obtain a standard ring, and sintering the standard ring to obtain the manganese-zinc ferrite.
Preferably, the binder aqueous solution is a polyvinyl alcohol solution with a concentration of 7-8 wt %. In the primary sanded slurry, the binder aqueous solution is added at 8-12 wt % of a weight of the main materials. In the secondary sanded slurry, the binder aqueous solution is added at 8-12 wt % of a weight of the pre-sintered material.
Preferably, in step (a), deionized water is used as a sanding medium in the primary sanding, a weight ratio of the materials to a ball to the deionized water is 1:(5-7):(0.5-0.6), and the sanding is conducted for 50-70 min.
Preferably, in step (c), deionized water is used as a sanding medium in the secondary sanding, a weight ratio of the materials to a ball to the deionized water is 1:(5-7):(0.4-0.5), and the sanding is conducted for 120-160 min.
Preferably, in step (b), the pre-sintering is conducted at a temperature of 900-920° C.
Preferably, in step (d), the compression molding is conducted under a pressure of 7-9 MPa.
Preferably, in step (d), the sintering is conducted at a temperature of 1,280-1,320° C.
In the prior art, it is known that when the content of the Co2O3 is increased, the magnetic permeability at −20° C. is reduced, and loss reduction at 120-140° C. is not facilitated.
The reason is that the high content of Co2O3 will shift the valley toward the low temperature direction.
In the present invention, it is known that the magnetic permeability at −20° C. is not necessarily related to the content of the Co2O3, and the magneto-crystalline anisotropy constant K1 of the material is the core factor affecting the magnetic permeability at −20° C. When the K1 is small, the magnetic permeability is high. When the K1 is large, the magnetic permeability is low. In addition, by appropriately increasing the content of the Co2O3, the loss reduction at 120-140° C. is facilitated. The present invention provides a method for increasing the magnetic permeability at −20° C. and reducing the loss at 120-140° C. by increasing the content of the Co2O3, which is completely different from the traditional perception that when the content of the Co2O3 is increased, the magnetic permeability at −20° C. is reduced, and the loss at 120-140° C. is increased.
As core innovations, the present invention can provide a manganese-zinc ferrite material with two valleys in a loss-temperature curve and a method for preparing the same. Specifically, the valleys of the material are supposed to be fully used. When the valleys are determined, the magneto-crystalline anisotropy constant K1 at −20° C., 120° C. and 140° C. is reduced by adding an appropriately high amount of Co2O3. Here, it is necessary to fully explain that the valley is different from that in the prior art. The valley in the prior art refers to the lowest loss in a range of 25-120° C. The valley in the present invention refers to both the valley in the prior art and the valley at about −20° C.
Therefore, the present invention has the following beneficial effects. The present invention, by reasonably adjusting a ratio of Mn to Zn to Fe and appropriately increasing the content of Co in the additives, a manganese-zinc ferrite material with both a high magnetic permeability and low loss at about −20° C. and low loss at 120-140° C. is obtained. The manganese-zinc ferrite material has two loss valleys at about −20° C. and about 100° C. in a temperature range of −30° C. to 140° C., which expands the application range of the manganese-zinc ferrite material.
The technical solutions of the present invention are further described below in conjunction with specific embodiments.
Apparently, the described examples are merely a part, rather than all of examples of the present invention. Based on the examples of the present invention, all other examples obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
In the present invention, unless otherwise specified, all equipment and raw materials may be purchased from the market or are commonly used in the industry. Unless otherwise specified, methods in the following examples are conventional methods in the field.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.35 mol % of Fe2O3, 37.6 mol % of MnO and 10.05 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.08 wt % of CaCO3, 0.02 wt % of ZrO2, 0.4 wt % of Co2O3 and 0.1 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 60 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.55;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 900° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 120 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.45; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 8 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,300° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.45 mol % of Fe2O3, 37.9 mol % of MnO and 9.65 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.08 wt % of CaCO3, 0.02 wt % of ZrO2, 0.44 wt % of Co2O3 and 0.1 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 60 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.55;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 920° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 140 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.45; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 8 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,300° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.45 mol % of Fe2O3, 37.8 mol % of MnO and 9.75 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.06 wt % of CaCO3, 0.015 wt % of ZrO2, 0.3 wt % of Co2O3 and 0.15 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 70 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:5:0.5;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 910° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7 wt %, and was added at 12 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 160 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:5:0.4; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 7 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,280° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7 wt %, and was added at 12 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.43 mol % of Fe2O3, 37.65 mol % of MnO and 9.92 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.07 wt % of CaCO3, 0.025 wt % of ZrO2, 0.45 wt % of Co2O3 and 0.2 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 50 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:7:0.6;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 920° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 8 wt %, and was added at 8 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 120 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:7:0.5; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 9 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,310° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 8 wt %, and was added at 8 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.40 mol % of Fe2O3, 37.90 mol % of MnO and 9.70 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.10 wt % of CaCO3, 0.04 wt % of ZrO2, 0.35 wt % of Co2O3 and 0.13 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 60 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.55;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 910° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 140 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.45; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 8 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,300° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included main materials consisting of the following raw materials by mole percent:
52.38 mol % of Fe2O3, 37.85 mol % of MnO and 9.77 mol % of ZnO.
The manganese-zinc ferrite further included additives consisting of the following raw materials by weight percent: in the additives, based on a total weight of a pre-sintered material, 0.09 wt % of CaCO3, 0.03 wt % of ZrO2, 0.39 wt % of Co2O3 and 0.18 wt % of SnO2.
A method for preparing the manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature included the following steps:
(a) various components in the main materials were mixed, and primary sanding was conducted for 60 min by using deionized water as a sanding medium to obtain a sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.55;
(b) a binder aqueous solution was added into the sanded slurry for uniform mixing, spray granulation was conducted, and then pre-sintering was conducted at 900° C. to obtain a pre-sintered material, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the main materials;
(c) the additives were added into the pre-sintered material, and secondary sanding was conducted for 150 min by using deionized water as a sanding medium to obtain a secondary sanded slurry, where, a weight ratio of the materials to a ball to the deionized water was 1:6:0.45; and
(d) a binder aqueous solution was added into the secondary sanded slurry for uniform mixing, spray granulation was conducted, compression molding was conducted under a pressure of 8 MPa to obtain a standard ring, and the standard ring was sintered at a temperature of 1,300° C. to obtain the manganese-zinc ferrite, where, the binder aqueous solution was a polyvinyl alcohol solution with a concentration of 7.5 wt %, and was added at 10 wt % of the weight of the pre-sintered material.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.75 mol % of Fe2O3, 37.2 mol % of MnO and 10.05 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.25 mol % of Fe2O3, 38.00 mol % of MnO and 9.75 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.44 mol % of Fe2O3, 37.96 mol % of MnO and 9.60 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.35 mol % of Fe2O3, 37.55 mol % of MnO and 10.10 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.25 mol % of Fe2O3, 37.75 mol % of MnO and 10.00 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
A manganese-zinc ferrite included main materials consisting of the following raw materials by mole percent:
52.55 mol % of Fe2O3, 37.70 mol % of MnO and 9.75 mol % of ZnO.
In this comparative example, additives of the manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
Main materials of a manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
The manganese-zinc ferrite included following additives by weight percent: based on a total weight of a pre-sintered material, 0.08 wt % of CaCO3, 0.02 wt % of ZrO2, 0.20 wt % of Co2O3 and 0.1 wt % of SnO2.
Main materials of a manganese-zinc ferrite and a method for preparing the manganese-zinc ferrite were the same with those in Example 1.
The manganese-zinc ferrite included following additives by weight percent: based on a total weight of a pre-sintered material, 0.08 wt % of CaCO3, 0.02 wt % of ZrO2, 0.50 wt % of Co2O3 and 0.1 wt % of SnO2.
Performance of the manganese-zinc ferrite materials obtained in each of the examples and comparative examples above was tested, including the magnetic permeability μi at −20° C. and the loss Pcv at 120° C. and 140° C. (100 kHz 200 mT), as shown in the Table 1 below.
A loss Pcv curve of the manganese-zinc ferrite material obtained in Example 1 in a temperature range of −30° C. to 140° C. was drawn according to actual conditions, as shown in
From Table 1, following information could be known.
1. In Comparative Example 1, since the content of the Fe2O3 was too high and the content of the MnO was low, the loss at high temperature was high, and the magnetic permeability at −20° C. was much lower than that of the samples in the examples.
2. In Comparative Example 2, since the content of the Fe2O3 was low and the content of the MnO was too high, the loss at high temperature was high, and the magnetic permeability at −20° C. was much lower than that of the samples in the examples but slightly higher than that of the sample in Comparative Example 1.
3. In Comparative Example 3, since the content of the MnO was too high and the content of the ZnO was low, the loss at high temperature was high, and the magnetic permeability at −20° C. was much lower than that of the samples in the examples.
4. In Comparative Example 4, since the content of the MnO was low and the content of the ZnO was too high, the loss at high temperature was high, and the magnetic permeability at −20° C. was much lower than that of the samples in the examples and lower than that of the sample in Comparative Example 3.
5. In Comparative Example 5, since the content of the Fe2O3 was low, the loss at high temperature was much higher than that of the samples in the examples, and the magnetic permeability at −20° C. was low.
6. In Comparative Example 6, since the content of the Fe2O3 was too high, the loss at high temperature was much higher than that of the samples in the examples, and the magnetic permeability at −20° C. was low and even lower than that of the sample in Comparative Example 5.
7. In Comparative Example 7, since the content of the Co2O3 was low, the loss at high temperature was high, and the magnetic permeability at −20° C. was low.
8. In Comparative Example 8, since the content of the Co2O3 was too high, the loss at high temperature was high, and the magnetic permeability at −20° C. was greatly reduced and even lower than that of the sample in Comparative Example 7.
It should be understood that improvements and modifications may be made by those of ordinary skill in the art based on the descriptions above, and all these improvements and modifications shall fall within the protection scope of the appended claims of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202010101797.X | Feb 2020 | CN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2020/101986 | 7/15/2020 | WO |
