MnZn Ferrite Composition for Low Core Loss Across Wide Temperatures

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Solution Overview

Problem

Existing MnZn-based ferrites struggle to achieve a further reduction in core loss over a wide temperature range, which is necessary for reducing the size and increasing the efficiency of transformers.

Innovation Solution

The content of each component in the MnZn-based ferrite is set to specific predetermined ranges, including 50 mol % to 53 mol % Fe2O3, 8 mol % to 10 mol % ZnO, 37 mol % to 42 mol % MnO, and specific ppm ranges for minor components like CaO, SiO2, Nb2O5, ZrO2, Co3O4, and SnO2, to optimize core loss reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the content of each component in MnZn-based ferrite is set to conventional ranges, then the ferrite can be manufactured with basic properties, but the core loss cannot be sufficiently reduced over a wide temperature range

Engineering Contradiction:

Improvecore lossVSAvoidtemperature range performance

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by precisely adjusting the compositional parameters of MnZn-based ferrite. Specifically, it sets Fe2O3 content to 50-53 mol%, ZnO to 8-10 mol%, MnO to 37-42 mol%, with controlled minor components (CaO: 100-300 ppm, SiO2: ≤120 ppm, Nb2O5: 100-500 ppm, ZrO2: 0-200 ppm, Co3O4: 2000-4000 ppm, SnO2: 0-1500 ppm). This systematic parameter optimization enables the ferrite to achieve reduced core loss across the wide temperature range of 25°C to 120°C, resolving the contradiction between energy loss reduction and temperature adaptability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining multiple oxide components in specific proportions to create a synergistic ferrite composition. The combination of major components (Fe2O3, ZnO, MnO) with carefully controlled minor components (CaO, SiO2, Nb2O5, ZrO2, Co3O4, SnO2) creates a composite material system where each component contributes to reducing core loss while maintaining stability across different temperatures. This composite approach allows the material to achieve superior performance that individual components cannot provide alone.

Inventive Principle:

Principle #40Composite materials

2Loss of energy

If the content of minor components is increased to reduce core loss, then core loss reduction effect is enhanced, but abnormal grain growth occurs during sintering and core loss increases

Engineering Contradiction:

Improvecore loss reduction effectVSAvoidgrain growth control

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent resolves this contradiction by precisely controlling the parameters of minor components. It sets CaO to 100-300 ppm and SiO2 to ≤120 ppm, which are optimized levels that provide sufficient core loss reduction without causing abnormal grain growth during sintering. This precise parameter control balances the competing requirements of energy loss reduction and manufacturing quality, ensuring that the ferrite achieves low core loss while maintaining proper grain structure.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4497738A1Mnzn-based ferrite

Publication Date: 2025.01.29 TODA KOGYO CORP

AI summary

MnZn-based ferrite according to the present invention includes, as major components, 50 mol % to 53 mol % Fe2O3, 8 mol % to 10 mol % ZnO, and 37 mol % to 42 mol % MnO on an oxide basis, the MnZn-based ferrite containing, as minor components, less than or equal to 120 ppm SiO2, 100 ppm to 500 ppm Nb2O5, 0 ppm to 200 ppm ZrO2, 2000 ppm to 4000 ppm Co3O4, and 0 ppm to 1500 ppm SnO2 on an oxide basis.