Patents by Inventor Francis G. Hanejko
Francis G. Hanejko has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20170113272Abstract: The present invention is directed to metallurgical powder compositions having improved lubricant properties. These compositions of the invention include at least 90 wt. % of an iron-based metallurgical powder; a Group 1 or Group 2 metal stearate; a first wax having a melting range of between about 80 and 100° C.; a second wax having a melting range of between about 80 and 90° C.; zinc phosphate; boric acid; acetic acid; phosphoric acid; and polyvinylpyrrolidone. Methods of compacting the compositions, as well as compacted articles prepared using those methods, are also described.Type: ApplicationFiled: January 3, 2017Publication date: April 27, 2017Inventors: Francis G. Hanejko, William Tambussi
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Patent number: 9533353Abstract: The present invention is directed to metallurgical powder compositions having improved lubricant properties. These compositions of the invention include at least 90 wt. % of an iron-based metallurgical powder; a Group 1 or Group 2 metal stearate; a first wax having a melting range of between about 80 and 100° C.; a second wax having a melting range of between about 80 and 90° C.; zinc phosphate; boric acid; acetic acid; phosphoric acid; and a binder. Methods of compacting the compositions, as well as compacted articles prepared using those methods, are also described.Type: GrantFiled: February 22, 2013Date of Patent: January 3, 2017Assignee: Hoeganaes CorporationInventors: Francis G. Hanejko, William Tambussi
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Publication number: 20140178576Abstract: The present invention is directed to electrically conductive compacted metal parts fabricated using powder metallurgy methods. The iron-based powders of the invention are coated with magnetic or pre-magnetic materials.Type: ApplicationFiled: February 28, 2014Publication date: June 26, 2014Applicant: Hoeganaes CorporationInventors: Kalathur S. Narasimhan, Francis G. Hanejko
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Patent number: 8703046Abstract: Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.Type: GrantFiled: December 22, 2011Date of Patent: April 22, 2014Assignee: Hoeganaes CorporationInventor: Francis G. Hanejko
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Publication number: 20130343943Abstract: Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.Type: ApplicationFiled: June 14, 2013Publication date: December 26, 2013Inventor: Francis G. Hanejko
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Publication number: 20120219451Abstract: Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.Type: ApplicationFiled: December 22, 2011Publication date: August 30, 2012Applicant: Hoeganaes CorporationInventor: Francis G. Hanejko
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Publication number: 20110239823Abstract: The present invention is directed to electrically conductive compacted metal parts fabricated using powder metallurgy methods. The iron-based powders of the invention are coated with magnetic or pre-magnetic materials.Type: ApplicationFiled: March 29, 2011Publication date: October 6, 2011Applicant: HOEGANAES CORPORATIONInventors: Kalathur S. Narasimhan, Francis G. Hanejko
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Patent number: 6635122Abstract: Methods of making and using annealable insulated metal-based powder particles are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.Type: GrantFiled: October 3, 2001Date of Patent: October 21, 2003Assignee: Hoeganaes CorporationInventors: Francis G. Hanejko, George Ellis
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Patent number: 6534564Abstract: A method is provided for compacting metal-based powder compositions containing at least one thermoplastic material at temperatures below the glass transition temperature or melting temperature of the thermoplastic material to form a metal-based component. Preferably, compaction is carried out at temperatures ranging from ambient to about 55° C. The method of the present invention is particularly useful for making magnetic core components. The present invention also provides metal-based powder compositions useful for cold compaction. The metal based powder compositions contain metal-based particles containing no iron phosphate layer; a thermoplastic material selected from polyetherimides, polyphenylene ethers, polyethersulfones, polycarbonates, polyethylene glycol, polyvinyl acetate, polyvinyl alcohol or combinations thereof, and an oligomer of a polyamide.Type: GrantFiled: May 24, 2001Date of Patent: March 18, 2003Assignee: Hoeganaes CorporationInventors: Francis G. Hanejko, Sydney Luk, Kalathur S. V. L. Narasimhan
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Patent number: 6395687Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.Type: GrantFiled: May 24, 2001Date of Patent: May 28, 2002Assignee: Hoeganaes CorporationInventor: Francis G. Hanejko
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Patent number: 6372348Abstract: Annealable insulated metal-based powder particles and methods of preparing and using the same are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.Type: GrantFiled: November 23, 1998Date of Patent: April 16, 2002Assignee: Hoeganaes CorporationInventors: Francis G. Hanejko, George Ellis
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Publication number: 20020040077Abstract: Methods of making and using annealable insulated metal-based powder particles are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.Type: ApplicationFiled: October 3, 2001Publication date: April 4, 2002Applicant: Hoeganaes CorporationInventors: Francis G. Hanejko, George Ellis
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Publication number: 20020037948Abstract: A method is provided for compacting metal-based powder compositions containing at least one thermoplastic material at temperatures below the glass transition temperature or melting temperature of the thermoplastic material to form a metal-based component. Preferably, compaction is carried out at temperatures ranging from ambient to about 55 ° C. The method of the present invention is particularly useful for making magnetic core components. The present invention also provides metal-based powder compositions useful for cold compaction. The metal based powder compositions contain metal-based particles containing no iron phosphate layer; a thermoplastic material selected from polyetherimides, polyphenylene ethers, polyethersulfones, polycarbonates, polyethylene glycol, polyvinyl acetate, polyvinyl alcohol or combinations thereof, and an oligomer of a polyamide.Type: ApplicationFiled: May 24, 2001Publication date: March 28, 2002Inventors: Francis G. Hanejko, Sydney Luk, Kalathur S.V.L. Narasimhan
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Publication number: 20020025913Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.Type: ApplicationFiled: May 24, 2001Publication date: February 28, 2002Inventor: Francis G. Hanejko
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Patent number: 5268140Abstract: A method is provided for producing a high strength iron based component by powder metallurgical techniques but without sintering. A powder composition of iron-based particles coated or admixed with a thermoplastic material is compacted under heat and pressure by traditional powder metallurgical techniques. The pressed component is then heat treated at a temperature above the glass transition temperature of the thermoplastic material for a time sufficient to bring the component to the heat treatment process temperature. The resulting component has increased strength and can be used as a structural component or as a magnetic core component.Type: GrantFiled: January 31, 1992Date of Patent: December 7, 1993Assignee: Hoeganaes CorporationInventors: Howard G. Rutz, Christopher Oliver, Francis G. Hanejko, Brooks Quin
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Patent number: 5063011Abstract: Methods of doubly coating iron particles. The methods comprise treating the iron particles with phosphoric acid to form a layer of hydrated iron phosphate at the surfaces of the iron particles. The particles are heated in an inert atmosphere at a temperature and for a time sufficient to convert the hydrated layer to an iron phosphate layer. The particles are then coated with a termoplastic material to provide a coating of thermoplastic material substantially uniformly circumferentially surrounding the iron phosphate layer. Doubly-coated iron particles provided in accordance with this invention are generally useful for forming magnetic components and cores for use in high frequency switching applications.Type: GrantFiled: June 12, 1989Date of Patent: November 5, 1991Assignee: Hoeganaes CorporationInventors: Howard Rutz, Francis G. Hanejko
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Patent number: 4499048Abstract: A method of consolidating a metallic body is disclosed. The method comprises the steps of forming an article of manufacture from powdered metal; sintering the article of manufacture so as to increase the strength thereof; coating the article with a sacrificial layer of ceramic; providing a bed of heated, generally spheroidal ceramic particles; compacting the coated article of manufacture embedded in the heated bed under pressure to thereby consolidate the article into a dense, desired shape; and, removing said sacrificial coating such that the surface of the article remains substantially free of process-related imperfections.Type: GrantFiled: February 23, 1983Date of Patent: February 12, 1985Assignee: Metal Alloys, Inc.Inventor: Francis G. Hanejko
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Patent number: 4499049Abstract: A method of consolidating a metallic or ceramic body is disclosed. The method comprises the steps of forming an article of manufacture from powdered metal; sintering the article of manufacture so as to increase the strength thereof; providing a bed of heated, generally spheroidal ceramic particles which have been coated with a thermally stable lubricant; and compacting the article of manufacture embedded in the heated bed under pressure to thereby consolidate the article into a dense, desired shape.Type: GrantFiled: February 23, 1983Date of Patent: February 12, 1985Assignee: Metal Alloys, Inc.Inventor: Francis G. Hanejko