Magnetic Materials Patents (Class 148/100)
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Patent number: 7192491Abstract: In order to dampen magnetization changes in magnetic devices, such as magnetic tunnel junctions (MTJ) used in high speed Magnetic Random Access Memory (MRAM), a transition metal selected from the 4d transition metals and 5d transition metals is alloyed into the magnetic layer to be dampened. In a preferred form, a magnetic permalloy layer is alloyed with osmium (Os) in an atomic concentration of between 4% and 15% of the alloy.Type: GrantFiled: July 15, 2002Date of Patent: March 20, 2007Assignee: International Business Machines CorporationInventors: Snorri T. Ingvarsson, Roger H. Koch, Stuart S. Parkin, Gang Xiao
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Patent number: 7144642Abstract: A ferrite magnet obtained by adding a ferrite having a hexagonal W-type magnetoplumbite structure to a ferrite having a hexagonal M-type magnetoplumbite structure, in which a portion of Sr, Ba, Pb or Ca is replaced with at least one element that is selected from the group consisting of the rare-earth elements (including Y) and Bi and that always includes La, during the fine pulverization process thereof. By adding a small amount of the element such as Co, Ni, Mn or Zn to the ferrite already having the hexagonal M-type magnetoplumbite structure during the fine pulverization process thereof, the magnetic properties can be improved.Type: GrantFiled: February 6, 2002Date of Patent: December 5, 2006Assignee: Neomax Co., Ltd.Inventors: Etsushi Oda, Seiichi Hosokawa, Sachio Toyota
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Patent number: 7089648Abstract: There is provided a magnetoresistive head which can realize high sensitivity and low noise even when the reading track is being reduced. Longitudinal biasing is performed to a ferromagnetic free layer whose magnetization is rotated according to an external magnetic field by providing unidirectional magnetic anisotropy by exchange coupling to an antiferromagnetic layer. A hard magnetic film is arranged at the edge of a magnetoresistive film to reduce an effective reading track width.Type: GrantFiled: July 23, 2004Date of Patent: August 15, 2006Assignee: Hitachi, Ltd.Inventors: Kenichi Meguro, Hisashi Kimura, Katsuro Watanabe
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Patent number: 7056599Abstract: A steel sheet for a magnetic shield comprising less than 0.005% by weight of C and 0.0003 to 0.01% by weight of B, and having a thickness of 0.05 to 0.5 mm and an anhysteresis magnetic permeability of 7500 or more.Type: GrantFiled: July 8, 2003Date of Patent: June 6, 2006Assignees: JFE Steel Corporation, Sony CorporationInventors: Reiko Sugihara, Tatsuhiko Hiratani, Hideki Matsuoka, Yasushi Tanaka, Satoshi Kodama, Kenji Tahara, Yasuyuki Takada, Ken-ichi Mitsuzuka
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Patent number: 6960240Abstract: Rare earth magnet scrap and/or sludge is remelted for reuse. Once a rare earth-free magnet-constituent metal feed is loaded in a melting furnace and heated into a melt, a rare earth-containing metal feed and the rare earth magnet scrap and/or sludge are added to the melt, a particulate flux of an alkali metal, alkaline earth metal or rare earth metal halide and having an average particle size of 1-50 ?m, preferably wrapped in a metal foil, is added to the melt, and the resulting mixture is melted, from which an alloy ingot is obtained. The valuable elements in the scrap and/or sludge can be recycled. Better separation between the slag and the molten metal ensures that the ingot is obtained from the melt in a high yield.Type: GrantFiled: July 10, 2002Date of Patent: November 1, 2005Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Koichi Hirota, Takehisa Minowa
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Patent number: 6941637Abstract: The method of manufacturing rare earth thick film magnet comprising a step of forming an alloy layer of 30-100 ?m thick having a general formula RXBYTMZ on a substrate by a physical deposition process, and a step of heat-treating the alloy layer to form a thick film magnetic layer having R2TM14B phase as a main phase. In the general formula, R is at least one of rare earth elements, B is boron, TM is iron or its alloy partly substituted by cobalt. X is 0.1-0.2, Y is 0.05-0.2 and Z=1-X-Y. Further, the method of the present invention includes a step of laminating a plurality of alloy layers formed on a substrate together with the substrate. A motor comprising rare earth thick film magnet of the present invention is extremely small while obtaining high output.Type: GrantFiled: March 8, 2002Date of Patent: September 13, 2005Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Hirotoshi Fukunaga, Masaki Nakano, Fumitoshi Yamashita
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Publication number: 20040258436Abstract: The long magnet includes a magnet block made of a mixture of rare earth magnetic powder, thermoplastic resin particles, fluidity additive, pigment, wax and charge control agent, and a reinforcing member to reinforce the magnet block. At least part of the reinforcing member is arranged inside of the magnet block.Type: ApplicationFiled: April 8, 2004Publication date: December 23, 2004Inventors: Makoto Nakamura, Mieko Kakegawa, Sumio Kamoi, Tsuyoshi Imamura, Kyohta Koetsuka, Noriyuki Kamiya
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Publication number: 20040245492Abstract: A ferroelectric material for forming a ferroelectric that is described by a general formula ABO3, includes an A-site compensation component which compensates for a vacancy of an A site, and a B-site compensation component which compensates for a vacancy of a B site.Type: ApplicationFiled: March 24, 2004Publication date: December 9, 2004Applicant: SEIKO EPSON CORPORATIONInventors: Yasuaki Hamada, Takeshi Kijima, Junichi Karasawa, Koji Ohashi, Eiji Natori
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Publication number: 20040216810Abstract: A magnetic material having a structure of a material having a ferromagnetic phase at ordinary temperature as a core and a material having an antiferromagnetic phase at ordinary temperature surrounding the periphery of the core in the form of a shell, wherein a ratio between a volume of the ferromagnetic phase material and the volume of the antiferromagnetic phase material in the magnetic material is in a range where no exchange biasing field of the magnetic material appears and a rotational hysteresis loss of the magnetic material is made the maximum, a method of producing the same, and a magnetic recording medium using the same.Type: ApplicationFiled: May 28, 2004Publication date: November 4, 2004Inventors: Yoh Iwasaki, Yuichi Sasaki, Mikihisa Mizuno
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Publication number: 20040182479Abstract: A method is provided for preserving the transverse biasing of a GMR (or MR) read head during back-end processing. In a first preferred embodiment, the method comprises magnetizing the longitudinal biasing layers of the read head in a transverse direction, so that the resulting field at the position of the transverse biasing layer places it in a minimum of potential energy which stabilizes its direction. The field of the longitudinal biasing layer is then reset to the longitudinal direction in a manner which maintains the transverse biasing direction. In a second embodiment, a novel fixture for mounting the read head during processing includes a magnetic portion which stabilizes the transverse bias of the read head. The two methods may be used singly or in combination.Type: ApplicationFiled: March 21, 2003Publication date: September 23, 2004Applicant: Headway Technologies, Inc.Inventors: Yimin Guo, Li-Yan Zhu
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Publication number: 20040168746Abstract: The present invention is a production method of an R-T-B-C rare earth alloy (R is at least one element selected from the group consisting of rare earth elements and yttrium, T is a transition metal including iron as a main component, B is boron, and C is carbon). An R-T-B bonded magnet containing a resin component, or an R-T-B sintered magnet with a resin film formed on the surface thereof is prepared, and a solvent alloy containing a rare earth element R and a transition metal element T is prepared. Thereafter, the R-T-B bonded magnet is molten together with the solvent alloy. In this way, a rare earth alloy can be recovered from a spent bonded magnet or a defective one generated in a production process stage, and a rapidly quenched alloy magnet can be obtained. As a result, magnet powder is recovered from the R-T-B magnet, and the recycling of a magnet including a resin component can be realized.Type: ApplicationFiled: December 17, 2003Publication date: September 2, 2004Inventors: Hiroyuki Tomizawa, Koji Nakahara, Yuji Kaneko
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Patent number: 6780338Abstract: The subject invention pertains instruments for use in nuclear spin tomography comprising a metal alloy comprising aluminum, vanadium, and titanium. In a specific embodiment, the subject invention relates to cardiovascular stents which can exhibit a low incidence of artifacts and are viewable in a nuclear spin tomography unit. The subject invention also pertains to a method for processing instruments for use in nuclear spin tomography. Such processing can comprise application of a wet chemical etching solution. In a specific embodiment, the wet chemical etching solution can comprise three parts hydrochloric acid and two parts saltpeter acid.Type: GrantFiled: March 5, 2002Date of Patent: August 24, 2004Assignee: MRI Devices Daum GmbHInventors: Wolfgang Daum, Axel Winkel
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Publication number: 20040007289Abstract: Disclosed herein is an insulating material between adjacent metal layers of a soft magnetic core, and a process for forming this insulating material. The insulating material is composed of the native metal oxides of the metallic core material.Type: ApplicationFiled: June 5, 2003Publication date: January 15, 2004Inventors: Richard Wood, Richard Lathlaen, William C. Beckham
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Publication number: 20030196730Abstract: Permanent magnets, devices including permanent magnets and methods for manufacture are described with the permanent magnet comprising, for example: iron-boron-rare earth alloy particulate having an intrinsic coercive force of at least about 1591 kiloamperes/meter (about 20 kiloOersteds) and a residual magnetization of at least about 0.8 tesla (about 8 kiloGauss), wherein the rare earth content comprises praseodymium, a light rare earth element selected from the group consisting of cerium, lanthanum, yttrium and mixtures thereof, and balance neodymium; and a binder bonding the particulate.Type: ApplicationFiled: May 12, 2003Publication date: October 23, 2003Inventors: Ralph James Carl, Gerald Burt Kliman, Juliana Chiang Shei, Mark Gilbert Benz, Judson Sloan Marte
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Patent number: 6635361Abstract: A steel sheet for magnetic shields is provided containing 0.15% by weight or less of C and having a thickness of 0.05-0.5 mm and an anhysteretic magnetic permeability of 7500 or higher.Type: GrantFiled: March 26, 2001Date of Patent: October 21, 2003Assignees: NKK Corporation, Sony CorporationInventors: Reiko Sugihara, Tatsuhiko Hiratani, Hideki Matsuoka, Yasushi Tanaka, Satoshi Kodama, Kenji Tahara, Yasuyuki Takada, Ken-ichi Mitsuzuka
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Publication number: 20030180553Abstract: The present invention provides a grain-oriented silicon steel sheet excellent in adhesiveness to tension-creating insulating coating films formed on the grain-oriented silicon steel sheet produced by removing inorganic mineral films composed of forsterite and so on with pickling or the like or by deliberately preventing the formation thereof, characterized by: having, at the interface between each of the tension-creating insulating coating films and the steel sheet, an external oxidation type membranous oxide film of 2 to 500 nm in average thickness mainly composed of amorphous silica and/or a mixed oxide film consisting of an external oxidation type membranous oxide film of 2 to 500 nm in average thickness mainly composed of amorphous silica and particulate oxides mainly composed of amorphous silica: and satisfying any one or more of the specified requirements.Type: ApplicationFiled: December 23, 2002Publication date: September 25, 2003Inventors: Genichi Shigesato, Hiroyasu Fujii, Kenichi Murakami, Yoshiyuki Ushigami, Shuichi Nakamura, Masaaki Sugiyama
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Patent number: 6623566Abstract: A method for selecting alloying elements for complex, multi-component amorphous metal alloys is provided in which the solvent element is the largest atom with a concentration of 40-80 at %, the second most concentrated element has a radius of 65-83 % the radius of the solvent atom and a concentration of 10-40 at % in the alloy, with other elements selected at lower concentrations. For ternary alloys specified by this invention, the third element must have an atomic radius within 70-92 % of the solvent atom radius. In the preferred embodiment, alloys with four or more elements are specified, where the third elements must have an atomic radius within 70-80 %, the fourth element must have an atomic radius within 80-92 % of the solvent atom radius, and all other solute elements must have atomic radii within 70-92 % of the solvent atom radius.Type: GrantFiled: August 22, 2001Date of Patent: September 23, 2003Assignee: The United States of America as represented by the Secretary of the Air ForceInventors: Oleg N. Senkov, Daniel B. Miracle
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Publication number: 20030116230Abstract: An exchange-spring magnet is prepared using a magnet alloy containing Ta and C in addition to Nd, Fe and B. This exchange-spring magnet uses the magnet alloy prepared by a liquid quenching method or a mechanical alloying method. Further, by subjecting the magnetic alloy having a part set in an amorphous state to heat treatment, an exchange-spring magnet exhibits good properties regarding magnetic flux density and coercive force.Type: ApplicationFiled: November 18, 2002Publication date: June 26, 2003Applicant: Nissan Motor Co., Ltd.Inventors: Hideaki Ono, Tetsurou Tayu, Munekatsu Shimada, Makoto Kano
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Publication number: 20030113582Abstract: Magnetic films are annealed by radio frequency (RF) radiation. During the RF annealing process, the layers may be subjected to a magnetic field in order to control their anisotropy axes. The RF annealed layers are useful for applications such as longitudinal and perpendicular magnetic recording layers of magnetic data storage media.Type: ApplicationFiled: November 27, 2002Publication date: June 19, 2003Applicant: Seagate Technology LLCInventors: Dmitri Litvinov, Nisha Shukla, Erik Bjorn Svedberg, Sakhrat Khizroev, Dieter K. Weller
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Patent number: 6562473Abstract: Electrical steel sheets having superior magnetic properties, anti-noise properties, and workability, are ideal for use a compact iron core material in electric apparatuses, such as compact transformers, motors, and electric generators. A totally new electrical steel sheet and a manufacturing method therefor are proposed, in which the electrical steel sheet is not only most advantageous in magnetic properties but also advantageous from economic point of view. That is, the electrical steel sheet of the present invention is composed of from about 2.0 to 8.0 wt % Si, from about 0.005 to 3.0 wt % Mn, from about 0.0010 to 0.020 wt % Al, balance essentially iron. The magnetic flux density B50(L) in a rolling direction and the magnetic flux density B50(C) in the direction perpendicular thereto are 1.70 T or more, and the B50(L)/B50(C) is 1.005 to 1.100.Type: GrantFiled: November 27, 2000Date of Patent: May 13, 2003Assignee: Kawasaki Steel CorporationInventors: Seiji Okabe, Yasuyuki Hayakawa, Takeshi Imamura, Mitsumasa Kurosawa
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Publication number: 20030075243Abstract: A method of forming a shimming body for a NMR assembly is provided. A magnetizable metal powder of known magnetic properties is provided. The powder is uniformly dispersed into a non-magnetic material to form a mixture having a selected uniform density. A selected weight of magnetic material is determined for a particular installation of an NMR assembly. The mixture is heated. A selected volume corresponding to the selected weight of magnetic material is extruded into a container. The mixture is cooled to form a shimming body.Type: ApplicationFiled: January 7, 2002Publication date: April 24, 2003Inventors: Gregory F. Hayworth, Delton A. Grey, Granville G. Ward
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Patent number: 6538572Abstract: The present invention replaces the conventional bias magnets for EAS markers with a paintable or printable bias magnet material, which is either directly painted onto the EAS marker or first placed onto a substrate material, which is then placed into the EAS marker. The material includes a magnetic powder mixed with resin and solvent. This “bias paint” is then applied onto the EAS marker. The magnetic powder, resin, and solvent provide a very dense layer after drying, which has a magnetic material density that is usually lower than a rolled product, but is higher than that of the injection-molded magnet material. Printing the bias magnet allows nondeactivatable magnetomechanical EAS markers to be made using web-based mass production methods.Type: GrantFiled: July 30, 2001Date of Patent: March 25, 2003Assignee: Sensormatic Electronics CorporationInventors: Ming-Ren Lian, Richard L. Copeland, Kevin Romer
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Publication number: 20030037844Abstract: A permanent magnet is provided which retains its magnetic properties and exhibits a linear extrinsic demagnetization curve at elevated temperatures up to 700° C. The magnet is represented by the general formula RE(CoWFeVCuXTY)Z, where RE is a rare earth metal selected from the group consisting of Sm, Gd, Pr, Nd, Dy, Ce, Ho, Er, La, Y, Tb, and mixtures thereof and T represents a transition metal(s) selected from the group consisting of Zr, Hf, Ti, Mn, Cr, Nb, Mo, W, V, Ni, Ta, and mixtures thereof.Type: ApplicationFiled: September 12, 2002Publication date: February 27, 2003Inventors: Marlin S. Walmer, Joanne H. Walmer, Christina H. Chen, Shiqiang Liu, Michael H. Walmer, G. Edward Kuhl
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Publication number: 20030034091Abstract: An iron alloy strip having a gage of 0.1 to 5 mm and a magnetic field strength variation within the strip of 0 to 10 Hz, made of an iron alloy consisting essentially of, in % by weight, 0.0001-0.02% of C, 0.0001-5% of Si, 0.001-0.2% of Mn, 0.0001-0.05% of P, 0.0001-0.05% of S, 0.0001-5% of Al, 0.001-0.1% of O, 0.0001-0.03% of N, 0-10% of Co, 0-10% of Cr, 0.01-5% in total of Ti, Zr, Nb, Mo, V, Ni, W, Ta and/or B, and the balance of Fe, and having a saturation magnetic flux density of 1.7-2.3 Tesla, a maximum relative permeability of 1,200-22,000 and a coercive force of 20-380 A/m is suited for use as yokes in voice coil motor magnetic circuits. The iron alloy strip is highly resistant to corrosion and eliminates a need for a corrosion resistant coating.Type: ApplicationFiled: August 7, 2002Publication date: February 20, 2003Inventors: Masanobu Shimao, Masaaki Nishino, Takehisa Minowa
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Patent number: 6517934Abstract: A rare earth-iron-boron magnetic powder comprising a rare earth element, iron and boron, which has a coercive force of 80 to 400 kA/m, a saturation magnetization of 10 to 25 &mgr;W/g, an average particle size of 5 to 200 nm, and a particulate or ellipsoidal particle shape, and a magnetic recording medium having a magnetic layer which contains this magnetic powder and a binder, in which magnetic recording medium it is possible to practically use a very thin magnetic layer of 0.3 &mgr;m or less.Type: GrantFiled: October 10, 2000Date of Patent: February 11, 2003Assignee: Hitachi Maxell, Ltd.Inventor: Mikio Kishimoto
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Publication number: 20020179185Abstract: Rotors for stepping motors used in analog timepieces are produced from a mixture of prealloyed rare earth magnetic particles and a thermoplastic binder. The mixture is either tape cast in a magnetic field following blanking of green rotors or injection molded in a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better tolerances and 100% material utilization are claimed.Type: ApplicationFiled: March 11, 2002Publication date: December 5, 2002Inventors: Romain L. Billiet, Hanh Thi Nguyen
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Publication number: 20020153066Abstract: The present invention offers a minute-sized magnet with superior magnetic energy product (BH)max and coercivity iHc, as well as superior anti-corrosive properties. This magnet is comprised of an alloy comprised of 35-55 atomic % platinum, 0.0 01-10 atomic % third element, which is one or more elements from groups IVa, Va, IIIb, or IVb, and a remainder of iron and other unavoidable impurities. The average crystal size of this FePt alloy is 0.3 &mgr;m. By mixing an FePt alloy with a specific element in a designated ratio, an FePt magnet with more excellent characteristics than ones made from previous alloys was successfully made.Type: ApplicationFiled: March 4, 2002Publication date: October 24, 2002Applicant: AICHI STEEL CORPORATIONInventors: Hitoshi Aoyama, Yoshinobu Honkura, Takumi Asano
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Publication number: 20020108677Abstract: A composition of material used for making hfMLCIs having a sintering temperature below 1000°. The composition comprises a major component and a minor component, said major component being a general formula: Ba3Co2-x-yZnxCuyMnxFe24-z-wO41, wherein x, z, w,=0-1.0 and y=0-0.8, and said minor component comprising at least one compound selected from the group of Bi2O3, V2O5,PbO,B2O3, Lif and CaF2. HfMLCIs made from the composition of the present invention are capable of functioning in the frequency region of 300-800 MHz.Type: ApplicationFiled: August 27, 2001Publication date: August 15, 2002Inventors: Xiaohui Wang, Longtu Li, Ji Zhou, Zhengxing Yue, Zhenwei Ma, Shuiyuan Su
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Patent number: 6423264Abstract: A method of a manufacturing rotating electromagnetic component to have both soft and hard (permanent) magnet regions, in which powder technologies are used to net-shape mold the component. A soft magnet powder material and an insert or powder of a permanent magnet material are compacted to form a rotating electromagnetic body containing soft and hard magnet regions. A partial sintering operation is then performed on the body at a temperature of 1600° F. (about 870° C.) or less, preferably about 1400° F. to 1500° F. (about 760° C. and 830° C.), and most preferably at 1500° F. to at least partially fuse the soft magnet powder materials with the permanent magnet material. The soft powder component of the resulting electromagnetic body is sufficiently fused to exhibit mechanical properties comparable to a fully sintered body (i.e., sintered at 2050° F. (about 1120° C.) or more), but without degrading the magnetic properties of the hard magnet region.Type: GrantFiled: October 14, 1999Date of Patent: July 23, 2002Assignee: Delphi Technologies, Inc.Inventor: David Earl Gay
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Patent number: 6423386Abstract: The magnet powder-resin compound particles substantially composed of rare earth magnet powder and a binder resin are in such a round shape that a ratio of the longitudinal size a to the transverse size b (a/b) is more than 1.00 and 3 or less, and that an average particle size defined by (a/b)/2 is 50-300 &mgr;m. They are produced by charging a mixture of rare earth magnet powder and a binder resin into an extruder equipped with nozzle orifices each having a diameter of 300 &mgr;m or less; extruding the mixture while blending under pressure though the nozzle orifices to form substantially cylindrical, fine pellets; and rounding the pellets by rotation.Type: GrantFiled: April 6, 1999Date of Patent: July 23, 2002Assignee: Hitachi Metals, Ltd.Inventors: Katsunori Iwasaki, Kazunori Tabaru
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Patent number: 6416879Abstract: The object of the present invention is to provide an Fe-based amorphous alloy thin strip capable of realizing an excellent soft magnetic property for use in alternating current applications while keeping a high magnetic flux density even in a composition range with a high Fe content, and an Fe-based amorphous alloy thin strip with which a core having an excellent soft magnetic property can be manufactured, even if there occurs a temperature difference among different portions of the core during annealing. The present invention is an Fe-based amorphous alloy thin strip having a high magnetic flux density, consisting of the main component elements of Fe, Si, B, C, and P and unavoidable impurities, characterized by having: a composition, in atomic %, of 82<Fe≦90, 2≦Si<4, 5<B≦16, 0.02≦C≦4, and 0.2≦P≦12; Bs of 1.74 T or more after annealing; B80 exceeding 1.5 T; and a low core loss of 0.12 W/kg or less.Type: GrantFiled: September 21, 2001Date of Patent: July 9, 2002Assignee: Nippon Steel CorporationInventors: Hiroaki Sakamoto, Yuichi Sato
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Patent number: 6387522Abstract: The present invention provides a grain-oriented electrical steel sheet, for a low noise transformer, capable of reducing higher harmonics which are highly audible and lowering noise effectively, and relates to a grain-oriented electrical steel sheet for a low noise transformer, characterized by imposing a film tension of 0.5 to 6.0 MPa on the surface by coating or a method corresponding thereto, without forming a glass film on the grain-oriented electrical steel sheet or, if a glass film is formed, after removing the glass film by an arbitrary method.Type: GrantFiled: May 30, 2001Date of Patent: May 14, 2002Assignee: Nippon Steel CorporationInventors: Hisashi Mogi, Akira Sakaida, Masahiro Fujikura, Masato Mizokami
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Patent number: 6383406Abstract: Insertion of light elements such as H,C, or N in the R2Fe17 (R=rare earth metal) series has been found to modify the magnetic properties of these compounds, which thus become prospective candidates for high performance permanent magnets. The most spectacular changes are increases of the Curie temperature, Tc, of the magnetization, Ms, and of coercivity, Hc, upon interstitial insertion. A preliminary product having a component R—Fe—C,N phase is produced by a chemical route. Rare earth metal and iron amides are synthesized followed by pyrolysis and sintering in an inert or reduced atmosphere, as a result of which, the R—Fe—C,N phases are formed. Fabrication of sintered rare earth iron nitride and carbonitride bulk magnet is impossible via conventional process due to the limitation of nitridation method.Type: GrantFiled: May 25, 2000Date of Patent: May 7, 2002Assignee: Chemat Technology, Inc.Inventors: Yuhong Huang, Qiang Wei, Haixing Zheng
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Publication number: 20020050309Abstract: A Y-type hexagonal oxide magnetic material is provided containing at least Fe, Co, and M (where M is at least one of Ba and Sr) as well as O, wherein the relationship of x+3&sgr;≦4 is satisfied, in which x represents the average grain size (&mgr;m) of a sintered compact thereof, and &sgr; represents the standard deviation of the grain size. When this material is used for a magnetic body of an inductor element, a high Q factor can be maintained in a high frequency range of not less than 200 MHZ.Type: ApplicationFiled: August 31, 2001Publication date: May 2, 2002Applicant: Murata Manufacturing Co., Ltd.Inventor: Hiroshi Marusawa
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Publication number: 20020036029Abstract: The chemical conversion film containing, at least as the constituent components thereof, (a) at least one of the metals selected from molybdenum, zirconium, vanadium, and tungsten; (b) a rare earth metal constituting the magnet; and (c) oxygen, which is formed on the surface of a rare earth metal-based permanent magnet according to the present invention, contains a composite metal oxide provided on the surface of the R-rich phase having a lower oxidation-reduction potential through a preferential reaction of the metallic ions that are present in the form of complex ions or oxide ions, such as of molybdenum, contained in the treatment solution, with the rare earth metals that elute from the magnet. Thus formed composite metal oxide reduces the difference in corrosion potential as to realize a uniform surface potential, and effectively suppresses the corrosion based on potential difference.Type: ApplicationFiled: August 9, 2001Publication date: March 28, 2002Applicant: SUMITOMO SPECIAL MEALS CO., LTD.Inventors: Atsushi Kikugawa, Fumiaki Kikui
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Publication number: 20020023697Abstract: Disclosed herein is a magnetic powder which can provide a bonded magnet having high mechanical strength and excellent magnetic properties. The magnetic powder has an alloy composition containing a rare-earth element and a transition metal, wherein the magnetic powder includes particles each of which is formed with a number of ridges or recesses on at least a part of a surface thereof. In this magnetic powder, it is preferable that when the mean particle size of the magnetic powder is defined by a&mgr;m, the average length of the ridges or recesses is equal to or greater than a/40&mgr;m. Further, preferably, the ridges or recesses are arranged in roughly parallel with each other so as to have an average pitch of 0.5-100&mgr;m.Type: ApplicationFiled: April 23, 2001Publication date: February 28, 2002Inventors: Akira Arai, Hiroshi Kato
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Publication number: 20020020514Abstract: Disclosed herein is a method of manufacturing a magnetic material which can provide a bonded magnet having excellent magnetic properties and having excellent reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 in which gas expelling grooves 54 are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 6 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas expelling grooves 54.Type: ApplicationFiled: April 12, 2001Publication date: February 21, 2002Inventors: Akira Arai, Hiroshi Kato
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Publication number: 20020014280Abstract: To provide a powder for dust cores capable of improving magnetic properties such as magnetic permeability in a molded compacted powder magnetic core and mechanical properties such as size precision of the molded compacted powder magnetic core and radial crushing strength and, a dust core using the powder. A powder for a dust core contains a ferromagnetic powder, an insulating material containing silicone resin and/or phenol resin, and a lubricant, wherein the lubricant contains aluminum stearate, and a dust core using the powder for a dust core.Type: ApplicationFiled: June 26, 2001Publication date: February 7, 2002Inventor: Hideharu Moro
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Patent number: 6344168Abstract: The method of producing an R—Fe—B type sintered magnet according to the present invention includes the steps of: (a) preparing an alloy powder material in a first state, in which a first amount of lubricant has been applied to a surface of an alloy powder; (b) partially evaporating said lubricant in said alloy powder material in said first state to transform said alloy powder material into a second state, in which the amount of said lubricant has been reduced to a second amount; (c) compacting said alloy powder material in said second state to form a compact; and (d) sintering said compact.Type: GrantFiled: August 29, 2000Date of Patent: February 5, 2002Assignee: Sumitomo Special Metals Co., Ltd.Inventor: Futoshi Kuniyoshi
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Publication number: 20020011282Abstract: A steel sheet for heat shrink band of the present invention has anhysteretic magnetic permeability of 15,000 or higher at 0.35 Oe and yield stress of 24 kgf/mm2 or more. The steel sheet can be manufactured by a method comprising the steps of: hot rolling and/or cold rolling a steel containing 0.01 to 0.15% C by weight; annealing the rolled steel sheet at a temperature ranging from 650 to 900° C.; and temper rolling the annealed steel sheet at a rolling reduction rate of 1.5% or less. A CRT made of the steel sheet causes very little color deviation and practically no deformation of the panel surface.Type: ApplicationFiled: March 9, 2001Publication date: January 31, 2002Inventors: Tatsuhiko Hiratani, Hideki Matsuoka, Yasushi Tanaka, Reiko Sugihara
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Patent number: 6328825Abstract: An alloy used for the production of a rare-earth magnet alloy, particularly the boundary-phase alloy in the two-alloy method is provided to improve the crushability. The Alloy consists of (a) from 35 to 60% of Nd, Dy and/or Pr, and the balance being Fe, or (b) from 35 to 60% of Nd, Dy and/or Pr, and at least one element selected from the group consisting of 35% by weight or less of Co, 4% by weight or less of Cu, 3% by weight or less of Al and 3% by weight or less of Ga, and the balance being Fe. The volume fraction of R2Fe17 phase (Fe may be replaced with Cu, Co, Al or Ga) is 25% or more in the alloy and the average size of an R2Fe17 phase is 20 &mgr;m or less. The alloy can be produced by a centrifugal casting at an average accumulating rate of melt at 0.1 cm/second or less.Type: GrantFiled: May 19, 1999Date of Patent: December 11, 2001Assignees: Showa Denko K.K., TDK Corp.Inventors: Hiroshi Hasegawa, Shiro Sasaki, Yoichi Hirose, Shinya Fujito, Koichi Yajima
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Patent number: 6312494Abstract: A thin arc segment magnet made of a rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe, wherein R is at least one rare earth element including Y, and T is Fe or Fe and Co, which has an oxygen content of 0.3 weight % or less, a density of 7.56 g/cm3 or more, a coercivity iHc of 1.1 MA/m (14 kOe) or more at room temperature, and an orientation Br/4&pgr;Imax of 96% or more in an anisotropy-providing direction at room temperature can be produced by using a slurry mixture formed by introducing fine alloy powder of the above composition into a mixture liquid comprising 99.7-99.99 parts by weight of a mineral oil, a synthetic oil or a vegetable oil and 0.01-0.3 parts by weight of a nonionic surfactant and/or an anionic surfactant.Type: GrantFiled: July 5, 2000Date of Patent: November 6, 2001Assignee: Hitachi Metals, Ltd.Inventors: Hisato Tokoro, Kimio Uchida, Kazuo Oda, Tsukasa Mikamoto
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Patent number: 6254662Abstract: A method and structure for forming magnetic alloy nanoparticles includes forming a metal salt solution with a reducing agent and stabilizing ligands, introducing an organometallic compound into the metal salt solution to form a mixture, heating the mixture to a temperature between 260° and 300° C., and adding a flocculent to cause the magnetic alloy nanoparticles to precipitate out of the mixture without permanent agglomeration. The deposition of the alkane dispersion of FePt alloy particles, followed by the annealing results in the formation of a shiny FePt nanocrystalline thin film with coercivity ranging from 500 Oe to 6500 Oe.Type: GrantFiled: July 26, 1999Date of Patent: July 3, 2001Assignee: International Business Machines CorporationInventors: Christopher Bruce Murray, Shouheng Sun, Dieter K. Weller
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Patent number: 6221270Abstract: A process for producing a compound for a rare earth metal resin-bonded magnet includes: a slurry preparation step of mixing materials containing a magnetic alloy powder of a rare earth metal alloy, a resin binder, and an organic solvent into a slurry; and a drying step of spraying and drying the slurry by means of a spray dryer apparatus to produce the compound containing the magnetic alloy powder of the rare earth metal alloy and the resin binder.Type: GrantFiled: June 18, 1999Date of Patent: April 24, 2001Assignee: Sumitomo Special Metal Co., Ltd.Inventors: Katsuyoshi Saito, Yasunari Kaneko, Naoyuki Ishigaki, Shin Mishima, Shinji Otsuki, Yoshihiko Nishino
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Patent number: 6171410Abstract: A hard magnetic alloy in accordance with the present invention is composed of at least element T selected from the group consisting of Fe, Co and Ni, at least one rare earth element R, and boron (B). The hard magnetic alloy has an absolute value of the temperature coefficient of magnetization of 0.15%/° C. or less and a coercive force of 1 kOe, when being used in a shape causing a permeance factor of 2 or more. A hard magnetic alloy compact in accordance with the present invention has a texture, in which at least a part or all of the texture comprises an amorphous phase or fine crystalline phase having an average crystal grain size of 100 nm or less, is subjected to crystallization or grain growth under stress, such that a mixed phase composed of a soft magnetic or semi-hard magnetic phase and a hard magnetic phase is formed in the texture, and anisotropy is imparted to the crystal axis of the hard magnetic phase.Type: GrantFiled: February 20, 1998Date of Patent: January 9, 2001Assignee: Alps Electric Co. Ltd.Inventors: Akinori Kojima, Akihiro Makino, Takashi Hatanai, Yutaka Yamamoto, Akihisa Inoue
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Patent number: 6136456Abstract: Grain oriented electrical steel sheet with a very low iron loss and a method for producing the same, wherein the surface of the iron substrate of the grain oriented electrical steel sheet is subjected to an enhancement treatment of crystal grain orientation or surface smoothing to a mean roughness of about 0.20 .mu.m or less, electroplating a chromium plating layer on the substrate with heterogeneous growth, and applying a tension coating film to the plating layer.Type: GrantFiled: October 23, 1998Date of Patent: October 24, 2000Assignee: Kawasaki Steel CorporationInventors: Michiro Komatsubara, Hiroi Yamaguchi, Minoru Takashima, Mineo Muraki
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Patent number: 6117205Abstract: Corrosion-resistant, soft magnetic metal components manufactured by powder metallurgy and infiltration processes are disclosed. The magnetic components are manufactured by a powder metallurgy process using acicular metal particles to form a skeleton, and thermally infiltrating the skeleton.Type: GrantFiled: November 20, 1998Date of Patent: September 12, 2000Assignee: Magnetics International, Inc.Inventors: Robert F. Krause, Harold R. Kokal, Joseph H. Bularzik
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Patent number: 6060172Abstract: The present invention relates to a rapidly quenched metal strip used as a core material for transformers, magnetic shields, choke coils, etc., and to an Fe-based rapidly quenched metal strip having a strip thickness exceeding 20 .mu.m and up to 70 .mu.m, wherein nonmetallic inclusions contained in said metal strip have a maximum particle size up to 50% of the strip thickness, and densities of the nonmetallic inclusions are up to 10 nonmetallic inclusions/mm.sup.3 for nonmetallic inclusions having a particle size exceeding 10 .mu.m and up to 50% of the strip thickness, up to 3.times.10.sup.3 nonmetallic inclusions/mm.sup.3 for nonmetallic inclusions having a particle size of at least 3 .mu.m to up to 10 .mu.m, and up to 5.times.10.sup.5 nonmetallic inclusions/mm.sup.3 for nonmetallic inclusions having a particle size of at least 0.3 .mu.m to less than 3 .mu.m, and showing the following average value <.epsilon..sub.f > of a bending fracture strain .epsilon..sub.Type: GrantFiled: April 10, 1998Date of Patent: May 9, 2000Assignee: Nippon Steel CorporationInventors: Yoshiharu Inoue, Hiroaki Sakamoto
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Patent number: 6027576Abstract: In a method for manufacturing a permanent magnet, a powder of a magnetic base alloy and powders of first and second binder alloys are mixed. The magnetic base alloy has a general formula SE.sub.2 T.sub.14 B, wherein SE is at least one rare earth element, including Y, and T is Fe or a combination of Fe and Co, wherein Co does not exceed 40 wt % of the combination of Fe and Co. Each of the first and second binder alloys has a general formula SE.sub.a Fe.sub.b Co.sub.c B.sub.d Ga.sub.e, wherein 15<a<40, 0<b.ltoreq.80, 5.ltoreq.c.ltoreq.85, 0<d.ltoreq.20, 0<e.ltoreq.20, and a+b+c+d+e=100, and wherein the second binder alloy contains approximately 2.5 wt % fewer rare earth elements and approximately 1.5 wt % less gallium compared to the first binder alloy. The base alloy and the binder alloys are mixed in a weight ratio of base alloy to binder alloys between 99:1 and 90:10, and is subsequently compressed and sintered in a vacuum and/or in an inert gas atmosphere.Type: GrantFiled: March 5, 1999Date of Patent: February 22, 2000Assignee: Vacuumschmelze GmbHInventors: Peter Schrey, Mircea Velicescu
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Patent number: 6017490Abstract: A powder of composite particles is prepared by adhering to the surfaces of particles of an amorphous magnetically soft alloy particles of a glass having a softening point lower than the crystallization temperature of the alloy to coat the surfaces of the alloy particles with the glass. The powder of composite particles prepared is pressed at a temperature higher than the softening point of the glass and lower than the crystallization temperature of the alloy to bond the alloy particles with the glass. The pressed powder body is at least 0.5 in the ratio of the magnetic permeability at 10.sup.7 Hz to the magnetic permeability at 10.sup.4 Hz.Type: GrantFiled: November 19, 1997Date of Patent: January 25, 2000Assignee: Kubota CorporationInventors: Isamu Otsuka, Isao Endo, Hideo Koshimoto, Hiroshi Yamamoto, Ryosei Okuno