Multiphase ferrites and composites comprising the same

Patent metadata

Field	Value
Publication number	US-11679991-B2
Application number	US-202016938396-A
Country	US
Kind code	B2
Filing date	Jul 24, 2020
Priority date	Jul 30, 2019
Publication date	Jun 20, 2023
Grant date	Jun 20, 2023

Abstract

In an aspect, a multiphase ferrite comprises a Co 2 W phase that is optionally doped with Ru; a CFO phase having the formula Me r “Co 1−r Fe 2+z O 4 , wherein Me” is at least one of Ni, Zn, or Mg, r is 0 to 0.5, and z is −0.5 to 6 0.5; and a CoRu-BaM phase having the formula BaCo x+y Ru y Fe 12−(2/3)x−2y O 19 , wherein x is 0 to 2, y is 0.01 to 2; and the Ba can be partially replaced by at least one of Sr or Ca. In another aspect, a composite can comprise a polymer and the multiphase ferrite. In yet another aspect, a method of making a multiphase ferrite can comprise mixing and grinding a CoRu-BaM phase ferrite and a CFO phase ferrite to form a mixture; and sintering the mixture in an oxygen atmosphere to form the multiphase ferrite.

First claim

What is claimed is:

1. A multiphase ferrite comprising:
a Co 2 W phase that optionally comprises Ru;
a CFO phase having a formula Me r “Co 1−r Fe 2+z O 4 , wherein Me” is at least one of Ni, Zn, or Mg, r is 0 to 0.5, and z is −0.5 to 0.5; and
a CoRu-BaM phase having a formula BaCo x+y Ru y Fe 12−(2/3)x−2y O 19 , wherein x is 0 to 2, y is 0.01 to 2; and the Ba is optionally partially replaced by at least one of Sr or Ca.

2. The multiphase ferrite of claim 1 , wherein the multiphase ferrite comprises:
50 to 95 volume percent of the Co 2 W phase;
1 to 20 volume percent of the CFO phase; and
5 to 50 volume percent of the CoRu-BaM phase;
all based on a total volume of the multiphase ferrite.

3. The multiphase ferrite of claim 1 , wherein the Co 2 W phase comprises Ru.

4. The multiphase ferrite of claim 3 , wherein the Co 2 W phase has the formula BaRu m Co 2 Me n Fe 16−t O 27 , wherein Me comprises at least one of Ni, Zn, Mg, or Co; m is 0 to 1; n is 0 to 2; and t is 0 to 2; or wherein the Co 2 W phase has the formula BaCo 1.88 Fe 16.12 O 27 .

5. The multiphase ferrite of claim 1 , wherein the Ba is partially replaced by at least one of Sr or Ca.

6. A composite comprising:
a multiphase ferrite; and
a polymer;
wherein the multiphase ferrite has
a Co 2 W phase that is optionally doped with Ru;
a CFO phase having a formula Me r “Co 1−r Fe 2+z O 4 , wherein Me” is at least one of Ni, Zn, or Mg, r is 0 to 0.5, and z is −0.5 to 0.5; and
a CoRu-BaM phase having a formula BaCo x+y Ru y Fe 12−(2/3)x−2y O 19 , wherein x is 0 to 2, y is 0.01 to 2; and the Ba is optionally partially replaced by at least one of Sr or Ca.

7. The composite of claim 6 , wherein the composite comprises:
10 to 90 volume percent of the multiphase ferrite; and
10 to 90 volume percent of the polymer;
both based on a total volume of the composite.

8. The composite of claim 6 , wherein the polymer comprises at least one of a fluoropolymer, a polyolefin, a polyurethane, a liquid crystalline polymer, a poly(arylene ether ketone), or a poly(phenylene sulfide).

9. The composite of claim 6 , wherein the composite has at least one of:
a permeability of greater than or equal to 1 at a frequency of 1 to 6 gigahertz;
a permittivity of 6 to 15 at a frequency of 1 to 6 gigahertz;
a magnetic loss tangent tan % of less than or equal to 0.1 at a frequency of 1 to 6 gigahertz; or
a dielectric loss tangent tank of less than or equal to 0.05 at a frequency of 1 to 6 gigahertz.

10. An article comprising the multiphase ferrite of claim 1 .

11. The article of claim 10 , wherein the article is an antenna, filter, inductor, circulator, or phase shifter.

12. The article of claim 10 , wherein the article is a microwave antenna.

13. The article of claim 10 , wherein the article is an antenna operable at a frequency of greater than or equal to 0.1 gigahertz.

14. A method of making the multiphase ferrite of claim 1 , comprising:
mixing and grinding a CoRu-BaM phase ferrite and a CFO phase ferrite to form a mixture; wherein the CoRu-BaM phase ferrite has a formula BaCo x+y Ru y Fe 12−(2/3)x−2y O 19 , wherein x is 0 to 2, and y is 0.01 to 2; and
sintering the mixture in an oxygen atmosphere to form the multiphase ferrite.

15. The method of claim 14 , further comprising grinding the multiphase ferrite to form a plurality of particulates having a median particle size (D50) by volume of 1 to 50 micrometers and annealing the plurality of particulates at 800 to 1,000° C. for 1 to 10 hours in oxygen.

16. The method of claim 14 , wherein the sintering occurs at a sintering temperature of 1,000 to 1,300° C., or 1,200 to 1,250° C. for a sintering time of 1 to 20 hours, or 5 to 12 hours.

17. The method of claim 14 , further comprising forming the CoRu-BaM phase ferrite prior to the mixing; wherein the forming comprises mixing CoRu-BaM precursor compounds comprising Fe, Ba, Co, and Ru; and sintering the CoRu-BaM precursor compounds in an oxygen atmosphere to form the CoRu-BaM phase ferrite.

18. The method of claim 14 , further comprising forming the CFO phase ferrite prior to the mixing; wherein the forming comprises mixing CFO precursor compounds comprising Fe and Co; and sintering the CFO precursor compounds in an oxygen atmosphere to form the CFO phase ferrite.

19. The method of claim 14 , wherein the mixture comprises 45 to 95 weight percent of the CoRu-BaM phase ferrite and a 5 to 55 weight percent of the CFO phase ferrite, both based on the a weight of the mixture.

20. The method of claim 14 , further comprising mixing the multiphase ferrite with a polymer to form a composite.

Assignees

• Rogers Corp

Inventors

• Li Qifan
• Chen Yajie

Classifications

• C01P2004/61

  Micrometer sized, i.e. from 1-100 micrometer · CPC title

• C01P2006/42

  Magnetic properties · CPC title

• C01P2006/40

  Electric properties · CPC title

• C08L27/12

  containing fluorine atoms · CPC title

• C08L61/16

  of ketones with phenols · CPC title