Ferrite magnetic substance and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10388439-B2
Application number	US-201615377357-A
Country	US
Kind code	B2
Filing date	Dec 13, 2016
Priority date	Oct 5, 2016
Publication date	Aug 20, 2019
Grant date	Aug 20, 2019

Abstract

Disclosed is a method of manufacturing a ferrite magnetic substance, including: a first mixing operation of providing a first mixture composed of 47 to 49 wt % of Fe, 16 to 18 wt % of Mn, 5.2 to 7.2 wt % of Zn, and a remainder of oxygen and other inevitable impurities, a second mixing operation of providing a second mixture composed of the first mixture and an additive including, based on 100 parts by weight of the first mixture, 28 to 51 ppm of Si, 140 to 210 ppm of Nb and 155 to 185 ppm of Zr, and a finish operation of producing a ferrite magnetic substance by sintering the second mixture.

First claim

What is claimed is:

1. A method of manufacturing a ferrite magnetic substance, comprising:
providing a first mixture comprising 47 to 49 wt % of Fe, 16 to 18 wt % of Mn, 5.2 to 7.2 wt % of Zn, and a remainder of oxygen and other inevitable impurities;
providing a second mixture comprising the first mixture and an additive comprising, based on 100 parts by weight of the first mixture, 28 to 51 ppm of Si, 140 to 210 ppm of Nb and 155 to 185 ppm of Zr; and
sintering the second mixture to produce a ferrite magnetic substance,
wherein the ferrite magnetic substance comprises an insulation layer formed by grain boundary segregation with 155 to 185 ppm of Zr, wherein the ferrite magnetic substance has a core loss of 350 mW/cc or less under conditions of 100 KHz, 200 mT, and a temperature range of 80 to 100° C.

2. The method according to claim 1 , wherein providing the first mixture comprises mixing 67.8 to 69.9 wt % of iron oxide (Fe 2 O 3 ), 6.8 to 8.8 wt % of zinc oxide (ZnO), 22.3 to 24.3 wt % of manganese oxide (Mn 3 O 4 ) which are in powder.

3. The method according to claim 2 , further comprising, before providing the first mixture,
grinding the iron oxide to form iron oxide particles in a size of 1.15 μm or less.

4. The method according to claim 1 , wherein the ferrite magnetic substance has a density of 4.8 g/cm 3 or more, a permeability of 3,300 or more, and a magnetic flux density of 520 mT or more.

5. The method according to claim 1 , wherein the additive comprises, based on 100 parts by weight of the first mixture, 60 to 100 ppm of silicon oxide (SiO 2 ), 200 to 300 ppm of niobium oxide (Nb 2 O 5 ), and 200 to 250 ppm of zirconium oxide (ZrO 2 ), which are in a powder phase.

6. A ferrite magnetic substance, formed through sintering and comprising 47.42 to 48.89 wt % of Fe, 16.06 to 17.50 wt % of Mn, 5.46 to 7.07 wt % of Zn, 28 to 47 ppm of Si, 140 to 210 ppm of Nb, 148 to 185 ppm of Zr, and a remainder of oxygen and other inevitable impurities, wherein the ferrite magnetic substance comprises an insulating layer formed by grain boundary segregation with 148 to 185 ppm of Zr,
wherein the ferrite magnetic substance has a core loss of 350 mW/cc or less under conditions of 100 KHz, 200 mT, and a temperature range of 80 to 100° C.

7. The ferrite magnetic substance according to claim 6 , having a density of 4.8 g/cm 3 or more and a porosity of 3.5% or less.

8. The ferrite magnetic substance according to claim 7 , having a permeability of 3,300 or more and a magnetic flux density of 520 mT or more.

9. The ferrite magnetic substance according to claim 6 , wherein the ferrite magnetic substance is obtained by adding a first mixture comprising 67.8 to 69.9 wt % of iron oxide (Fe 2 O 3 ), 6.8 to 8.8 wt % of zinc oxide (ZnO), and 22.3 to 24.3 wt % of manganese oxide (Mn 3 O 4 ) and other inevitable impurities, with an additive comprising, based on 100 parts by weight of the first mixture, 60 to 100 ppm of silicon oxide (SiO 2 ), 200 to 300 ppm of niobium oxide (Nb 2 O 5 ), and 200 to 250 ppm of zirconium oxide (ZrO 2 ).

Assignees

• Hyundai Motor Co Ltd
• Hyundai Mobis Co Ltd

Inventors

• Kim Young Min
• Ham Choul Hwan
• Lee Kee Yang
• Kang Hee Bok

Classifications

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• H01F1/344 Primary

  Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4 · CPC title

• C04B2235/85

  Intergranular or grain boundary phases · CPC title

• C04B2235/5409

  expressed by specific surface values · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title