Ferrite material as well as preparation method and application thereof

Abstract

The invention belongs to the field of magnetic materials, and provides a ferrite material and a preparation method and application thereof, the ferrite material comprises main components and auxiliary components; the main components comprise Fe2O3, ZnO and MnO, and the auxiliary components comprise CaCO3, Nb2O5, ZrO2 and NiO; in the auxiliary components, according to the total weight percentage of the main components, the content of CaCO3 is 200 to 2000 ppm, the content of Nb2O5 is 0 to 1000 ppm (not including 0 ppm), the content of ZrO2 is 0 to 1000 ppm (not including 0 ppm), and the content of NiO is 1000 to 10000 ppm. According to the ferrite material provided by the invention, the composition of the main components and the auxiliary components and the content of the auxiliary components are regulated and controlled, so that the ferrite material has the characteristics of high magnetic conductivity, high saturation magnetic flux density and low magnetic loss at the same time.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic materials, and particularly to a ferrite material, a preparation method thereof, and an application thereof. Background Art

[0002] In recent years, with the wide application of ferrite materials in various industries such as communication, IT industry, automotive industry, aerospace field, ship and national defense weapon equipment systems, and with the increasing use in modern communication devices, outdoor facilities, satellite equipment, smart phones, and LED TVs, and with the trend of the above devices towards larger screens, thinner thicknesses, and smaller volumes, the requirements for magnetic core components have also correspondingly increased, requiring them to be miniaturized, able to withstand higher current superposition, and have higher strength, which requires the components used to have excellent characteristics of high superposition, high stability, and long life. However, the existing manganese-zinc ferrite materials have problems such as low magnet strength, large change in magnetic permeability after applying current, and low Curie temperature, which seriously hinder their development.

[0003] CN1692089A discloses a manufacturing method of a ferrite material and the ferrite material. NiO (0.5 - 3 mol%) or Li2O (0.5 - 3 mol%) is added as the main component to the main components of the ferrite, namely Fe2O3, MnO, and ZnO, and at the same time, many impurities such as SiO2, CaCO3, Nb2O5, ZrO2, SnO2, TiO2, MoO3, V2O5, Bi2O3, and Sb2O3 are added to achieve the effects of ultra-high saturation magnetic flux density (Bs) and lower loss, but its process is relatively cumbersome and the manufacturing cost is high.

[0004] CN103214233A discloses a MnZn ferrite material with high Tc (Curie temperature) and wide-temperature ultra-high Bs (saturation magnetic flux density) and a manufacturing method thereof. The ferrite material consists of a main material and a dopant. The main material includes: 58 - 62 mol% Fe2O3, 10 - 15 mol% ZnO, 4 - 6 mol% NiO, and the balance is MnO. The additives are: MoO3, SnO2, Bi2O3, Nb2O5, Ta2O5. The ferrite material of this invention has characteristics such as ultra-high Bs and lower loss, but its magnet strength performance is poor. In addition, in the prior art, FeSiAl alloy powder is also introduced. Although it can effectively improve the saturation magnetic flux density Bs and mechanical strength of the material, its magnetic permeability is not high.

[0005] Therefore, aiming at the defects existing in the prior art, providing a ferrite material that simultaneously has the characteristics of high magnetic permeability, high saturation magnetic flux density, and low magnetic loss has become an urgent problem to be solved at present. Summary of the Invention

[0006] To solve the above technical problems, the object of the present invention is to provide a ferrite material, a preparation method thereof and an application. The ferrite material provided by the present invention realizes the characteristics of high magnetic permeability, high saturation magnetic flux density and low magnetic loss of the ferrite material through regulating the composition of the main components and the auxiliary components and regulating the content of the auxiliary components, and through the mutual cooperation between the main components and the auxiliary components with a specific content.

[0007] To achieve this purpose, the present invention adopts the following technical solutions:

[0008] In the first aspect, the present invention provides a ferrite material, which comprises main components and auxiliary components; the main components include Fe2O3, ZnO and MnO, and the auxiliary components include CaCO3, Nb2O5, ZrO2 and NiO;

[0009] Among the auxiliary components, calculated by the weight percentage of the total weight of the main components, the content of CaCO3 is 200 - 2000 ppm, such as 200 ppm, 400 ppm, 600 ppm, 800 ppm, 1000 ppm, 1200 ppm, 1400 ppm, 1600 ppm, 1800 ppm or 2000 ppm, etc.; the content of Nb2O5 is 0 - 1000 ppm, and 0 ppm is not included, such as 10 ppm, 30 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm, 400 ppm, 500 ppm, 600 ppm, 700 ppm, 800 ppm, 900 ppm or 1000 ppm, etc.; the content of ZrO2 is 0 - 1000 ppm, and 0 ppm is not included, such as 10 ppm, 30 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm, 400 ppm, 500 ppm, 600 ppm, 700 ppm, 800 ppm, 900 ppm or 1000 ppm, etc.; the content of NiO is 1000 - 10000 ppm, such as 1000 ppm, 2000 ppm, 3000 ppm, 4000 ppm, 5000 ppm, 6000 ppm, 7000 ppm, 8000 ppm, 9000 ppm or 10000 ppm, etc.

[0010] The ferrite material provided by the present invention realizes the characteristics of high magnetic permeability, high saturation magnetic flux density and low magnetic loss of the ferrite material through regulating the composition of the main components and the auxiliary components and regulating the content of the auxiliary components, and through the mutual cooperation between the main components and the auxiliary components with a specific content.

[0011] In the main components of the Mn-Zn ferrite material of the present invention, auxiliary components with specific compositions and contents are introduced. Among them, the function of CaCO3 is to increase the grain boundary thickness of the Mn-Zn ferrite material, improve the resistivity of the material, thereby reducing the magnetic loss of the material and increasing the magnetic permeability of the material; the function of Nb2O5 is to refine the crystal grain size of the Mn-Zn ferrite material, improve the density and frequency stability of the material, thereby facilitating the material to have lower magnetic loss at high frequencies and promoting the improvement of the magnetic permeability of the material; the function of ZrO2 is to form a high-resistance grain boundary, increase the volume resistivity of the material, thereby increasing the magnetic permeability of the material and reducing the magnetic loss of the material; the function of NiO is to ensure that the material has a high saturation magnetic induction intensity while increasing the power consumption valley point temperature, so that the material still has a low magnetic loss at a higher temperature. The four auxiliary components in the ferrite material cooperate with each other at specific contents and combine with the main components of the Mn-Zn ferrite material to jointly increase the magnetic permeability and saturation magnetic flux density of the Mn-Zn ferrite material, and jointly suppress the magnetic loss phenomenon of the ferrite material.

[0012] Preferably, based on the total molar amount of the main components being 100 mol%, the molar percentage content of Fe2O3 is 53.5 - 55.0 mol%, such as 53.5 mol%, 53.6 mol%, 53.7 mol%, 53.8 mol%, 53.9 mol%, 54 mol%, 54.1 mol%, 54.2 mol%, 54.3 mol%, 54.4 mol%, 54.5 mol%, 54.6 mol%, 54.7 mol%, 54.8 mol%, 54.9 mol% or 55.0 mol%, etc.

[0013] Preferably, based on the total molar amount of the main components being 100 mol%, the molar percentage content of ZnO is 2.5 - 6.0 mol%, such as 2.5 mol%, 3.0 mol%, 3.5 mol%, 4.0 mol%, 4.5 mol%, 5.0 mol%, 5.5 mol% or 6.0 mol%, etc.

[0014] Preferably, based on the total molar amount of the main components being 100 mol%, the molar percentage content of MnO is 40 - 43 mol%, such as 40 mol%, 41 mol%, 42 mol% or 43 mol%, etc.

[0015] The change in the content of the main components in the ferrite material provided by the present invention will cause the temperature of the power consumption valley point of the ferrite material to shift, affecting the increase in the magnetic loss of common devices at a specific working temperature (generally 100 °C). At the same time, the change in the content of the main components will also affect the change in the magnetic permeability or saturation magnetic flux density of the ferrite material.

[0016] Second aspect, the present invention provides a preparation method of a ferrite material as described in the first aspect, and the preparation method includes the following steps:

[0017] (1) Mix the main components in accordance with the formula amounts for the first time, and obtain a pre-sintered material through pre-sintering;

[0018] (2) Mix the auxiliary components, the pre-sintered material and a solvent in accordance with the formula amounts in a second mixing manner, then obtain mixed particles through spray granulation, and then sequentially carry out pressing forming and sintering on the mixed particles to obtain the ferrite material.

[0019] The preparation method of the ferrite material provided by the present invention promotes the solid-phase reaction between various oxides in the main components through pre-sintering after mixing the main components. Then, the pre-sintered material of the main components and the auxiliary components are mixed for the second time and spray granulated, so that the main components and the auxiliary components are fully mixed, the mixing uniformity is improved, and the size uniformity of the obtained particles is controlled, and the strength of the subsequent obtained material is improved. Finally, through the pressing forming combined with the sintering process, a ferrite material with excellent performance is finally prepared.

[0020] Preferably, the first mixing manner in step (1) is ball milling.

[0021] Preferably, the rotation speed of the first mixing in step (1) is 250 - 300 r / min, such as 250 r / min, 260 r / min, 270 r / min, 280 r / min, 290 r / min or 300 r / min, etc.

[0022] Preferably, the first mixing time in step (1) is 30 - 50 min, such as 30 min, 35 min, 40 min, 45 min or 50 min, etc.

[0023] Preferably, a grinding aid is also added during the ball milling process.

[0024] Preferably, the grinding aid includes water.

[0025] Preferably, the ratio of the total mass of the main components to the mass of the grinding aid is 1:(0.5 - 2.0), such as 1:0.5, 1:0.8, 1:1.1, 1:1.4, 1:1.7 or 1:2.0, etc.

[0026] Preferably, the ball milling medium used for the ball milling is steel balls.

[0027] Preferably, the ratio of the total mass of the main components to the mass of the ball milling medium used for the ball milling is 1:(3 - 5), such as 1:3.0, 1:3.5, 1:4.0, 1:4.5 or 1:5.0, etc.

[0028] Preferably, the mixed material after the first mixing is sprayed into the pre-firing equipment through a spray gun.

[0029] Preferably, the pre-firing equipment includes a rotary kiln.

[0030] Preferably, the pre-firing temperature in step (1) is 800 - 1000 °C, such as 800 °C, 850 °C, 900 °C, 950 °C or 1000 °C, etc.

[0031] Preferably, the pre-firing time in step (1) is 150 - 210 min, such as 150 min, 160 min, 170 min, 180 min, 190 min, 200 min or 210 min, etc.

[0032] Preferably, the speed at which the mixed material after the first mixing is sprayed into the pre-firing equipment is 400 - 500 kg / h, such as 400 kg / h, 420 kg / h, 440 kg / h, 460 kg / h, 480 kg / h or 500 kg / h, etc.

[0033] Preferably, in step (2), the mass ratio of the total mass of the auxiliary components and the pre-fired material to the mass of the solvent during the second mixing is (1 - 2) : (1 - 2), such as 1:2, 1:1 or 2:1, etc.

[0034] Preferably, the second mixing method in step (2) is ball milling.

[0035] Preferably, during the second mixing in step (2), the ball milling medium used for ball milling is steel balls.

[0036] Preferably, during the second mixing in step (2), the ratio of the total mass of the auxiliary components and the pre-fired material to the ball milling medium used for ball milling is 1 : (3 - 5), such as 1:3.0, 1:3.5, 1:4.0, 1:4.5 or 1:5.0, etc.

[0037] Preferably, the second mixing time in step (2) is 120 - 150 min, such as 120 min, 125 min, 130 min, 135 min, 140 min, 145 min or 150 min, etc.

[0038] Preferably, a binder is also added during the second mixing in step (2).

[0039] Preferably, the mass of the binder accounts for 8 - 12% of the total mass of the auxiliary components and the pre-fired material, such as 8.0%, 8.5%, 9.0%, 9.5%, 10.0%, 10.5%, 11.0%, 11.5% or 12.0%, etc.

[0040] Preferably, a dispersant is further added during the second mixing process in step (2).

[0041] Preferably, the dispersant accounts for 1-2% of the total mass of the auxiliary components and the pre-sintered material, such as 1.0%, 1.2%, 1.4%, 1.6%, 1.8% or 2.0%, etc.

[0042] Preferably, the mass concentration of the dispersant is 1-5 wt%, such as 1 wt%, 2 wt%, 3 wt%, 4 wt% or 5 wt%, etc.

[0043] Preferably, the pressure for the pressing and forming in step (2) is 5-15 MPa, such as 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa, 11 MPa, 12 MPa, 13 MPa, 14 MPa or 15 MPa, etc.

[0044] Preferably, the sintering temperature in step (2) is 1250-1350 °C, such as 1250 °C, 1270 °C, 1290 °C, 1310 °C, 1330 °C or 1350 °C, etc.

[0045] Preferably, the sintering time in step (2) is 6-8 h, such as 6 h, 7 h or 8 h, etc.

[0046] Preferably, the sintering in step (2) is carried out in an oxygen-containing atmosphere.

[0047] Preferably, the oxygen content in the oxygen-containing atmosphere is 3-5 vol%, such as 3.0 vol%, 3.5 vol%, 4.0 vol%, 4.5 vol% or 5.0 vol%, etc.

[0048] Preferably, the oxygen-containing atmosphere further includes any one of nitrogen or inert gas.

[0049] As a preferred technical method of the present invention, the preparation method of the ferrite material includes the following steps:

[0050] S1. According to the formula amount, the main components, the grinding aid and the first ball milling medium are subjected to the first ball milling. The rotation speed of the first ball milling is 250-300 r / min, and the time of the first ball milling is 30-50 min. Among them, the ratio of the total mass of the main components to the mass of the grinding aid is 1:(0.5-2), and the ratio of the total mass of the main components to the mass of the first ball milling medium is 1:(3-5). A first mixed slurry is obtained. The first mixed slurry is sprayed into a rotary furnace through a spray gun for pre-sintering for 150-210 min. The pre-sintering temperature is 800-1000 °C. The speed at which the first mixed slurry is sprayed into the rotary furnace by the spray gun is 400-500 kg / h, and a pre-sintered material is obtained.

[0051] S2. Perform secondary ball milling of the auxiliary components in the formulated amount, the pre-sintered material obtained in step S1, as well as the binder, dispersant, solvent, and secondary ball milling medium in a ball milling tank for 120 - 150 min at a rotational speed of 250 - 300 r / min to obtain a secondary mixed slurry. Among them, the binder accounts for 8 - 12% of the total mass of the auxiliary components and the pre-sintered material, the dispersant accounts for 1 - 2% of the total mass of the auxiliary components and the pre-sintered material, the concentration of the dispersant is 1 - 5 wt%, the ratio of the total mass of the auxiliary components and the pre-sintered material to the mass of the solvent is (1 - 2):(1 - 2), and the ratio of the total mass of the auxiliary components and the pre-sintered material to the mass of the secondary ball milling medium is 1:(3 - 5).

[0052] S3. After performing component analysis and correction on the secondary mixed slurry, perform spray granulation to obtain mixed particles. Press the mixed particles into a blank at 5 - 15 MPa, and then sinter at 1250 - 1350 °C for 6 - 8 h in an atmosphere of nitrogen gas or inert gas with an oxygen content of 3 - 5 vol%, and cool down to room temperature under the equilibrium oxygen partial pressure to obtain the ferrite material.

[0053] In the present invention, the "room temperature" refers to a temperature of 25 ± 5 °C, such as 20 °C, 21 °C, 22 °C, 23 °C, 24 °C, 25 °C, 26 °C, 27 °C, 28 °C, 29 °C, or 30 °C, etc.

[0054] In a third aspect, the present invention provides an application of the ferrite material as described in the first aspect, and the ferrite material is applied in the fields of communication equipment, automotive industry, or aerospace.

[0055] Compared with the prior art, the present invention has at least the following beneficial effects:

[0056] (1) In the present invention, specific components and contents of auxiliary components are introduced into the main components of the manganese-zinc ferrite material. The four specific contents of auxiliary components cooperate with each other to jointly inhibit the magnetic loss phenomenon of the ferrite material while ensuring that the manganese-zinc ferrite material has a high magnetic permeability and saturation magnetic flux density. Moreover, the ferrite material in the present invention, by regulating the composition of the main components and auxiliary components, as well as regulating the content of the auxiliary components, and through the mutual cooperation between the main components and the auxiliary components with specific contents, enables the ferrite material to simultaneously have the characteristics of high magnetic permeability, high saturation magnetic flux density, and low magnetic loss.

[0057] (2)The preparation method of the ferrite material provided by the present invention promotes the solid-phase reaction between various oxides in the main components through pre-sintering after mixing the main components. Then, the pre-sintered material of the main components and the auxiliary components are mixed for the second time and spray granulated, so that the main components and the auxiliary components are fully mixed, the mixing uniformity is improved, and the size uniformity of the obtained particles is controlled, thereby improving the strength of the subsequent obtained material. Finally, through pressing forming and sintering process, a ferrite material with excellent performance is prepared. Detailed Embodiments

[0058] To facilitate the understanding of the present invention, the following embodiments are listed. Those skilled in the art should understand that the embodiments are only for helping to understand the present invention and should not be regarded as specific limitations on the present invention.

[0059] The specific process for the correction of component analysis used in the following embodiments is as follows: The chemical composition of the material is analyzed by methods such as X-ray fluorescence analysis to determine the content of each element in the mixed slurry. According to the formula requirements, an automatic weighing device is used to accurately weigh the main components and the auxiliary components to reduce errors.

[0060] The specific process for the equilibrium oxygen partial pressure in the cooling stage used in the following embodiments is carried out under the equilibrium oxygen partial pressure: During the entire cooling process, when the temperature is 1300 °C, the oxygen content is 4 vol%, when the temperature is 1250 °C, the oxygen content is 2 vol%, when the temperature is 1200 °C, the oxygen content is 1 vol%, when the temperature is 1150 °C, the oxygen content is 0.5 vol%, and the subsequent cooling stage is carried out in a pure nitrogen environment.

[0061] The room temperature mentioned in the following embodiments refers to a temperature of 25 °C.

[0062] Embodiment 1

[0063] This embodiment provides a ferrite material, including main components and auxiliary components. Based on the total molar amount of the main components being 100 mol%, the molar percentage content of each component of the main components is: Fe2O3 is 53.6 mol%, ZnO is 5.75 mol%, and MnO is 40.65 mol%; calculated by the weight percentage of the total weight of the main components, the content of each component of the auxiliary components is: the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm.

[0064] This embodiment also provides a preparation method for the above ferrite material, and the preparation method includes the following steps:

[0065] S1. First ball-mill the main components, water, and steel balls according to the formulation amounts. The rotation speed of the first ball-milling is 260 r / min, and the time of the first ball-milling is 40 min. Among them, the ratio of the total mass of the main components to the mass of water is 1:1, and the ratio of the total mass of the main components to the mass of steel balls is 1:4, obtaining the first mixed slurry. Spray the obtained first mixed slurry into a rotary kiln using a spray gun for pre-burning for 180 min. The pre-burning temperature is 900 °C, and the spraying speed of the first mixed slurry into the rotary kiln using the spray gun is 450 kg / h, obtaining the pre-burned material.

[0066] S2. Second ball-mill the formulation amounts of the auxiliary components, the pre-burned material obtained in step S1, as well as PVA glue, citric acid, water, and steel balls in a ball-milling tank for 150 min. The rotation speed of the second ball-milling is 260 r / min, obtaining the second mixed slurry. Among them, the added amount of PVA glue accounts for 10% of the total mass of the auxiliary components and the pre-burned material, the added amount of citric acid accounts for 1.5% of the total mass of the auxiliary components and the pre-burned material, the concentration of citric acid is 1.5 wt%, the ratio of the total mass of the auxiliary components and the pre-burned material to the added amount of water is 1:1, and the ratio of the total mass of the auxiliary components and the pre-burned material to the mass of steel balls is 1:4.

[0067] S3. After performing component analysis and correction on the second mixed slurry obtained in step S2, carry out spray granulation to obtain mixed particles. Press the obtained mixed particles into a blank of H25×15×8 at 10 MPa. Then, sinter at 1300 °C for 7 h in an atmosphere of nitrogen gas with an oxygen content of 4 vol%. The cooling stage is carried out under an equilibrium oxygen partial pressure, and cool down to room temperature to obtain the ferrite material.

[0068] Example 2

[0069] This example provides a ferrite material, including main components and auxiliary components. Based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: 54 mol% of Fe2O3, 4.5 mol% of ZnO, and 41.5 mol% of MnO; calculated by the percentage by weight of the total main components, the contents of the components of the auxiliary components are: the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm.

[0070] This example also provides a preparation method for the above ferrite material. The preparation method includes the following steps:

[0071] S1. First ball-mill the main components, water and steel balls according to the formula amounts. The rotation speed of the first ball-milling is 300 r / min, and the time of the first ball-milling is 30 min. Among them, the ratio of the total mass of the main components to the mass of water is 1:2, and the ratio of the total mass of the main components to the mass of steel balls is 1:5, obtaining a first mixed slurry. Spray the obtained first mixed slurry into a rotary kiln using a spray gun for pre-burning for 210 min. The pre-burning temperature is 800 °C, and the spraying speed of the first mixed slurry into the rotary kiln is 500 kg / h, obtaining a pre-burned material.

[0072] S2. Second ball-mill the formula amounts of auxiliary components, the pre-burned material obtained in step S1, as well as PVA glue, citric acid, water and steel balls in a ball-milling tank for 120 min. The rotation speed of the second ball-milling is 300 r / min, obtaining a second mixed slurry. Among them, the addition amount of PVA glue accounts for 12% of the total mass of the auxiliary components and the pre-burned material, the addition amount of citric acid accounts for 1% of the total mass of the auxiliary components and the pre-burned material, the concentration of citric acid is 1 wt%, the ratio of the total mass of the auxiliary components and the pre-burned material to the addition amount of water is 1:2, and the ratio of the total mass of the auxiliary components and the pre-burned material to the mass of steel balls is 1:5.

[0073] S3. After performing component analysis and correction on the second mixed slurry obtained in step S2, carry out spray granulation to obtain mixed particles. Press the obtained mixed particles at 5 MPa into a blank with dimensions of H25×15×8. Then, sinter at 1330 °C for 6 h in an atmosphere of nitrogen gas with an oxygen content of 5 vol%. The cooling stage is carried out under an equilibrium oxygen partial pressure until the temperature drops to room temperature, obtaining a ferrite material.

[0074] Example 3

[0075] This example provides a ferrite material, including main components and auxiliary components. Based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: 54.6 mol% of Fe2O3, 3.5 mol% of ZnO, and 41.9 mol% of MnO; calculated by the percentage of the total weight of the main components, the contents of the components of the auxiliary components are: the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm.

[0076] This example also provides a preparation method for the above ferrite material. The preparation method includes the following steps:

[0077] S1. First ball-mill the main components, water and steel balls according to the formula amounts. The rotation speed of the first ball-milling is 250 r / min, and the time of the first ball-milling is 50 min. Among them, the ratio of the total mass of the main components to the mass of water is 1:0.5, and the ratio of the total mass of the main components to the mass of steel balls is 1:3, obtaining the first mixed slurry. Spray the obtained first mixed slurry into a rotary kiln using a spray gun for pre-burning for 150 min at a pre-burning temperature of 1000 °C. The speed of spraying the first mixed slurry into the rotary kiln using the spray gun is 400 kg / h, obtaining the pre-burned material.

[0078] S2. Second ball-mill the formula amounts of auxiliary components, the pre-burned material obtained in step S1, as well as PVA glue, citric acid, water and steel balls in a ball-milling tank for 130 min. The rotation speed of the second ball-milling is 250 r / min, obtaining the second mixed slurry. Among them, the addition amount of PVA glue accounts for 8% of the total mass of the auxiliary components and the pre-burned material, the addition amount of citric acid accounts for 2% of the total mass of the auxiliary components and the pre-burned material, the concentration of citric acid is 4 wt%, the ratio of the total mass of the auxiliary components and the pre-burned material to the addition amount of water is 2:1, and the ratio of the total mass of the auxiliary components and the pre-burned material to the mass of steel balls is 1:3.

[0079] S3. After performing component analysis and correction on the second mixed slurry obtained in step S2, spray granulate it to obtain mixed particles. Press the obtained mixed particles at 15 MPa into a blank of H25×15×8, and then sinter it at 1260 °C for 8 h in an atmosphere of nitrogen gas with an oxygen content of 3 vol%. The cooling stage is carried out under the equilibrium oxygen partial pressure, and it is cooled to room temperature to obtain the ferrite material.

[0080] Example 4

[0081] This example provides a ferrite material, including main components and auxiliary components. Calculated based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: 55 mol% of Fe2O3, 3 mol% of ZnO, and 42 mol% of MnO; calculated based on the percentage by weight of the total main components, the contents of the components of the auxiliary components are: the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm. The remaining content is the same as that of Example 1.

[0082] Example 5

[0083] The difference between this embodiment and Embodiment 1 is only that: the ferrite material provided in this embodiment includes main components and auxiliary components. Taking the total molar amount of the main components as 100 mol%, the molar percentage contents of the components of the main components are: 53.6 mol% of Fe2O3, 5.75 mol% of ZnO, and 40.65 mol% of MnO; calculated by the percentage of the total weight of the main components, the contents of the components of the auxiliary components are: the content of CaCO3 is 200 ppm, the content of Nb2O5 is 1000 ppm, the content of ZrO2 is 1000 ppm, and the content of NiO is 1000 ppm. The rest is the same as Embodiment 1.

[0084] Embodiment 6

[0085] The difference between this embodiment and Embodiment 1 is only that: the ferrite material provided in this embodiment includes main components and auxiliary components. Taking the total molar amount of the main components as 100 mol%, the molar percentage contents of the components of the main components are: 53.6 mol% of Fe2O3, 5.75 mol% of ZnO, and 40.65 mol% of MnO; calculated by the percentage of the total weight of the main components, the contents of the components of the auxiliary components are: the content of CaCO3 is 400 ppm, the content of Nb2O5 is 100 ppm, the content of ZrO2 is 100 ppm, and the content of NiO is 1000 ppm. The rest is the same as Embodiment 1.

[0086] Embodiment 7

[0087] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, taking the total molar amount of the main components as 100 mol%, the molar percentage contents of the components of the main components are: 53 mol% of Fe2O3, 6 mol% of ZnO, and 41 mol%. The rest is the same as Embodiment 1.

[0088] Embodiment 8

[0089] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, taking the total molar amount of the main components as 100 mol%, the molar percentage contents of the components of the main components are: 56 mol% of Fe2O3, 3.5 mol% of ZnO, and 40.5 mol%. The rest is the same as Embodiment 1.

[0090] Embodiment 9

[0091] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: Fe2O3 is 55 mol%, ZnO is 2 mol%, and MnO is 43 mol%. The rest is the same as Embodiment 1.

[0092] Embodiment 10

[0093] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: Fe2O3 is 53 mol%, ZnO is 7 mol%, and MnO is 40 mol%. The rest is the same as Embodiment 1.

[0094] Embodiment 11

[0095] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: Fe2O3 is 55 mol%, ZnO is 6 mol%, and MnO is 39 mol%. The rest is the same as Embodiment 1.

[0096] Embodiment 12

[0097] The difference between this embodiment and Embodiment 1 is only that: in the ferrite material provided in this embodiment, based on the total molar amount of the main components being 100 mol%, the molar percentage contents of the components of the main components are: Fe2O3 is 53.5 mol%, ZnO is 2.5 mol%, and MnO is 44 mol%. The rest is the same as Embodiment 1.

[0098] Embodiment 13

[0099] The difference between this embodiment and Embodiment 1 is only that: in the preparation method of the ferrite material provided in this embodiment, in step S1, the spraying speed of the first mixed slurry into the rotary kiln by the spray gun is 300 kg / h. The rest is the same as Embodiment 1.

[0100] Embodiment 14

[0101] The difference between this embodiment and Embodiment 1 is only that: in the preparation method of the ferrite material provided in this embodiment, in step S1, the spraying speed of the first mixed slurry into the rotary kiln by the spray gun is 600 kg / h. The rest is the same as Embodiment 1.

[0102] Comparative Example 1

[0103] The difference between this comparative example and Example 1 is only that: the ferrite material provided in this comparative example omits CaCO3 in the auxiliary components, that is, calculated by the percentage of the total weight of the main components, the content of CaCO3 is 0 ppm, the content of Nb2O5 is 425 ppm, the content of ZrO2 is 425 ppm, and the content of NiO is 1450 ppm. The rest is the same as that of Example 1.

[0104] Comparative Example 2

[0105] The difference between this comparative example and Example 1 is only that: the ferrite material provided in this comparative example omits Nb2O5 in the auxiliary components, that is, calculated by the percentage of the total weight of the main components, the content of CaCO3 is 850 ppm, the content of Nb2O5 is 0 ppm, the content of ZrO2 is 300 ppm, and the content of NiO is 1250 ppm. The rest is the same as that of Example 1.

[0106] Comparative Example 3

[0107] The difference between this comparative example and Example 1 is only that: the ferrite material provided in this comparative example omits ZrO2 in the auxiliary components, that is, calculated by the total weight of the main components, the content of CaCO3 is 850 ppm, the content of Nb2O5 is 300 ppm, the content of ZrO2 is 0 ppm, and the content of NiO is 1250 ppm. The rest is the same as that of Example 1.

[0108] Comparative Example 4

[0109] The difference between this comparative example and Example 1 is only that: the ferrite material provided in this comparative example omits NiO in the auxiliary components, that is, calculated by the total weight of the main components, the content of CaCO3 is 1200 ppm, the content of Nb2O5 is 600 ppm, the content of ZrO2 is 600 ppm, and the content of NiO is 0 ppm. The rest is the same as that of Example 1.

[0110] Comparative Example 5

[0111] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by the percentage of the total weight of the main components, the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 800 ppm. The rest is the same as that of Example 1.

[0112] Comparative Example 6

[0113] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by weight percentage of the total weight of the main components, the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 12000 ppm. The rest is the same as in Example 1.

[0114] Comparative Example 7

[0115] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by weight percentage of the total weight of the main components, the content of CaCO3 is 100 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm. The rest is the same as in Example 1.

[0116] Comparative Example 8

[0117] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by weight percentage of the total weight of the main components, the content of CaCO3 is 2200 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm. The rest is the same as in Example 1.

[0118] Comparative Example 9

[0119] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by weight percentage of the total weight of the main components, the content of CaCO3 is 800 ppm, the content of Nb2O5 is 1200 ppm, the content of ZrO2 is 200 ppm, and the content of NiO is 1200 ppm. The rest is the same as in Example 1.

[0120] Comparative Example 10

[0121] The difference between this comparative example and Example 1 is only that: in the ferrite material provided in this comparative example, calculated by weight percentage of the total weight of the main components, the content of CaCO3 is 800 ppm, the content of Nb2O5 is 200 ppm, the content of ZrO2 is 1200 ppm, and the content of NiO is 1200 ppm. The rest is the same as in Example 1.

[0122] The ferrite materials prepared in the above Examples 1-14 and Comparative Examples 1-10 were respectively tested for magnetic permeability μi, saturation magnetic flux density Bs, and core unit power loss Pcv. The results are shown in Table 1 below. Among them:

[0123] (1) Magnetic permeability μ iTest: The test instrument is an HP4284A impedance tester, and the test conditions are 10KHz and 0.25V.

[0124] (2)Test of saturation magnetic flux density Bs: The test instrument is an SY-8258 B-H analyzer, and the test conditions are 50Hz, 1194A / m, 25°C, and 50Hz, 1194A / m, 100°C respectively.

[0125] (3)Test of loss Pcv: The test instrument is an SY8218 power consumption tester, and the test conditions are 100KHz, 200mT, and 100°C.

[0126] Table 1

[0127]

[0128] It can be seen from the test results that:

[0129] (1)It can be seen from Examples 1 to 6 that the ferrite material provided by the present invention realizes the excellent comprehensive performance characteristics of the ferrite material having high magnetic permeability, high saturation magnetic flux density and low magnetic loss at the same time by regulating the composition of the main components and the auxiliary components and the mutual cooperation between the main components and the auxiliary components.

[0130] (2)It can be seen from the comparison between Example 1 and Examples 7-12 that in the main components of the ferrite material provided by the present invention, if the contents of Fe2O3, ZnO and MnO are too low or too high, the temperature of the power consumption valley point of the ferrite material will shift, resulting in an increase in the magnetic loss of the ferrite material at a specific working temperature, and if the content of Fe2O3 is too low, it will also cause a decrease in the magnetic permeability and saturation magnetic flux density of the ferrite material.

[0131] (3)It can be seen from the comparison between Example 1 and Examples 13-14 that if the spraying speed of the spray gun in the process of preparing the ferrite material of the present invention into the rotary kiln is too slow, it will affect the quality of the finally obtained ferrite material, resulting in an increase in the magnetic loss of the obtained ferrite material; if the spraying speed of the spray gun into the rotary kiln is too fast, the mixing effect of the ferrite material will become poor, affecting the performance of the ferrite material, resulting in a decrease in the magnetic permeability and saturation magnetic flux density of the obtained ferrite material and an increase in the magnetic loss of the material.

[0132] (4)It can be seen from the comparison between Example 1 and Comparative Examples 1-4 that if any one of the components in the auxiliary components of the ferrite material provided by the present invention is omitted, although the magnetic permeability of the ferrite material will be improved, it will cause a large increase in the magnetic loss of the obtained ferrite material at a specific working temperature, thereby deteriorating the comprehensive performance of the ferrite material.

[0133] (5) It can be seen from the comparison between Example 1 and Comparative Examples 5-6 that if the content of NiO in the present invention is too low, the power consumption valley point temperature of the ferrite material will shift to a lower temperature, resulting in an increase in magnetic loss under specific working temperature conditions; if the content of NiO is too high, the power consumption valley point temperature of the ferrite material will shift to a higher temperature, which will also lead to an increase in magnetic loss of the ferrite material under specific conditions, and at the same time, it will also cause a significant decrease in the magnetic permeability of the ferrite material.

[0134] (6) It can be seen from the comparison between Example 1 and Comparative Examples 7-8 that if the content of CaCO3 in the present invention is too low, it will lead to an increase in the magnetic loss of the ferrite material; if the content of CaCO3 is too high, it will lead to a decrease in the magnetic permeability of the ferrite and an increase in the magnetic loss of the material under specific conditions.

[0135] (7) It can be seen from the comparison between Example 1 and Comparative Examples 9-10 that if the content of Nb2O5 or ZrO2 in the present invention is too high, it will both result in the inability to effectively improve the effect of reducing the magnetic loss of the ferrite material, thereby increasing the magnetic loss of the ferrite material. At the same time, it will also cause a certain decrease in the magnetic permeability of the material.

[0136] In summary, in the main components of the manganese-zinc ferrite material of the present invention, auxiliary components with specific components and contents are introduced. The four auxiliary components with specific contents cooperate with each other to jointly inhibit the magnetic loss phenomenon of the ferrite material while ensuring that the manganese-zinc ferrite material has a high magnetic permeability and saturation magnetic flux density. Moreover, the ferrite material in the present invention, by regulating the composition of the main components and auxiliary components and the content of the auxiliary components, and through the mutual cooperation between the main components and the auxiliary components with specific contents, enables the ferrite material to simultaneously have the characteristics of high magnetic permeability, high saturation magnetic flux density, and low magnetic loss.

[0137] The applicant declares that the above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention fall within the protection scope and the disclosure scope of the present invention.

Claims

1. A ferrite material, characterized in that, The ferrite material includes a main component and an auxiliary component; the main component includes Fe2O3, ZnO, and MnO, and the auxiliary component includes CaCO3, Nb2O5, ZrO2, and NiO; Among the auxiliary components, calculated by the weight percentage of the total weight of the main component, the content of CaCO3 is 200 - 2000 ppm, the content of Nb2O5 is 0 - 1000 ppm and does not include 0 ppm, the content of ZrO2 is 0 - 1000 ppm and does not include 0 ppm, and the content of NiO is 1000 - 10000 ppm.

2. The ferrite material according to claim 1, characterized in that, Calculated based on the total molar amount of the main component being 100 mol%, the molar percentage content of Fe2O3 is 53.5 - 55.0 mol%; Calculated based on the total molar amount of the main component being 100 mol%, the molar percentage content of ZnO is 2.5 - 6.0 mol%; Calculated based on the total molar amount of the main component being 100 mol%, the molar percentage content of MnO is 40 - 43 mol%.

3. A method for preparing a ferrite material as described in claim 1 or 2, characterized in that, The preparation method includes the following steps: (1) Mix the main components in accordance with the formula amounts for the first mixing, and obtain a pre-sintered material through pre-sintering; (2) Mix the formula amounts of the auxiliary components, the pre-sintered material, and a solvent in a second mixing manner, then obtain mixed granules through spray granulation, and then sequentially perform pressing and sintering on the mixed granules to obtain the ferrite material.

4. The preparation method of the ferrite material according to claim 3, characterized in that, The first mixing method in step (1) is ball milling; The rotation speed of the first mixing in step (1) is 250 - 300 r / min; The time of the first mixing in step (1) is 30 - 50 min; A grinding aid is also added during the ball milling process; The ratio of the total mass of the main components to the mass of the grinding aid is 1:(0.5 - 2.0).

5. The preparation method of the ferrite material according to claim 3, wherein The mixed material after the first mixing in step (1) is sprayed into the pre-sintering equipment through a spray gun; The pre-sintering temperature in step (1) is 800 - 1000 °C; The pre-sintering time in step (1) is 150 - 210 min; The speed at which the mixed material after the first mixing is sprayed into the pre-sintering equipment is 400 - 500 kg / h.

6. The preparation method of the ferrite material according to claim 3, characterized in that, In step (2), the ratio of the total mass of the auxiliary components and the pre-sintered material to the mass of the solvent during the second mixing process is (1 - 2):(1 - 2); The second mixing method in step (2) is ball milling; The time of the second mixing in step (2) is 120 - 150 min.

7. The preparation method of the ferrite material according to claim 3, characterized in that, A binder is also added during the second mixing process in step (2); The mass of the binder accounts for 8 - 12% of the total mass of the auxiliary components and the pre-sintered material; A dispersant is also added during the second mixing process in step (2); The dispersant accounts for 1 - 2% of the total mass of the auxiliary components and the pre-sintered material; The mass concentration of the dispersant is 1 - 5 wt%.

8. The preparation method of the ferrite material according to claim 3, characterized in that, The pressure for pressing in step (2) is 5 - 15 MPa; The sintering temperature in step (2) is 1250 - 1350 °C; The sintering time in step (2) is 6 - 8 h; The sintering in step (2) is carried out in an oxygen-containing atmosphere; The oxygen content in the oxygen-containing atmosphere is 3-5 vol%; The oxygen-containing atmosphere further includes any one of nitrogen gas or inert gas; 9. The preparation method of the ferrite material according to claim 3, characterized in that, The preparation method includes the following steps: S1. According to the formula amount, the main components, the grinding aid and the first ball milling medium are subjected to first ball milling to obtain a first mixed slurry, and the first mixed slurry is sprayed into a rotary furnace through a spray gun and pre-calcined at 800-1000 °C for 150-210 min to obtain a pre-calcined material; S2. The auxiliary components in the formula amount, the pre-calcined material obtained in step S1, as well as the binder, the dispersant, the solvent and the second ball milling medium are subjected to second ball milling in a ball milling tank to obtain a second mixed slurry; S3. After the composition analysis and correction of the second mixed slurry, it is spray granulated to obtain mixed particles, and the mixed particles are pressed into a blank. Then, it is sintered at 1250-1350 °C for 6-8 h in an atmosphere of nitrogen gas or inert gas with an oxygen content of 3-5 vol%, and cooled down under the equilibrium oxygen partial pressure to obtain the ferrite material.

10. Use of a ferrite material as described in claim 1 or 2, characterized in that, The ferrite material is applied in the fields of communication equipment, automotive industry or aerospace.

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