	US 11,945,753 B2
	Low loss power ferrites and method of manufacture
Yajie Chen, Brighton, MA (US); and Yiying Yao, Woburn, MA (US)
Assigned to ROGERS CORPORATION, Chandler, AZ (US)
Appl. No. 17/288,363
Filed by Rogers Corporation, Chandler, AZ (US)
PCT Filed Oct. 16, 2019, PCT No. PCT/US2019/056462 § 371(c)(1), (2) Date Apr. 23, 2021, PCT Pub. No. WO2020/092004, PCT Pub. Date May 7, 2020.
Claims priority of provisional application 62/754,938, filed on Nov. 2, 2018.
Prior Publication US 2021/0380486 A1, Dec. 9, 2021
Int. Cl. C04B 35/26 (2006.01); C04B 35/626 (2006.01); C04B 35/634 (2006.01); C04B 35/64 (2006.01); H01F 10/22 (2006.01)

CPC C04B 35/2658 (2013.01) [C04B 35/2675 (2013.01); C04B 35/62695 (2013.01); C04B 35/63416 (2013.01); C04B 35/6342 (2013.01); C04B 35/64 (2013.01); H01F 10/22 (2013.01); C04B 2235/3262 (2013.01); C04B 2235/3274 (2013.01); C04B 2235/3284 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5445 (2013.01); C04B 2235/604 (2013.01); C04B 2235/6584 (2013.01); C04B 2235/80 (2013.01)]

22 Claims

1. A method for manufacturing a multiphase ferrite composition, comprising combining

MnZn ferrite particles,

0.01 to 10 weight percent microscaled inclusion particles comprising an orthoferrite RFeO₃wherein R is a rare earth ion, and

optionally 0.01 to 5 weight percent additive

to form a ferrite mixture,

wherein weight percent is based on the total weight of the ferrite mixture,

wherein the microscaled inclusion particles have an average particle size (D50) of 0.1 micron to 5 microns, and

wherein the D50 of the microscaled inclusion particles is smaller than the D50 of the MnZn ferrite particles;

granulating a slurry comprising the ferrite mixture and a binder solution to obtain granules of 50 to 750 microns;

compressing the granules to form a green body; and

sintering the green body in 0.01 to 20% oxygen to form a multiphase ferrite composition.