Permanent Magnet Patents (Class 148/101)
  • Patent number: 11837392
    Abstract: A permanent magnet includes a rare earth element R; a transition metal element T; and B. The permanent magnet includes Nd as R. The permanent magnet includes Fe as T. The permanent magnet contains main phase grains and R-rich phases. The main phase grains include R, T, and B. The R-rich phases include R. The main phase grains observed in a cross section of the permanent magnet are flat. The cross section is parallel to an easy magnetization axis direction of the permanent magnet. Each of the R-rich phases is located between the main phase grains. An average value of intervals between the R-rich phases in a direction substantially perpendicular to the easy magnetization axis direction is from 30 ?m to 1,000 ?m. An average value of lengths of short axes of the main phase grains observed in the cross section is from 20 nm to 200 nm.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: December 5, 2023
    Assignee: TDK Corporation
    Inventors: Lihua Liu, Kenichi Suzuki
  • Patent number: 11830646
    Abstract: An R-T-B based permanent magnet includes a rare earth element R, a transition metal element T, and B. The permanent magnet includes at least Nd as R. The permanent magnet includes at least Fe as T. The permanent magnet contains main phase grains and R-rich phases. The main phase grains include at least R, T, and B. The R-rich phases include at least R. The main phase grains observed in a cross section of the permanent magnet are flat. The cross section is parallel to an easy magnetization axis direction of the permanent magnet. Each of the R-rich phases is located between the main phase grains. An average value of intervals between the R-rich phases in the easy magnetization axis direction is from 5 ?m to a width of the permanent magnet in the easy magnetization axis direction.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: November 28, 2023
    Assignee: TDK Corporation
    Inventors: Kenichi Suzuki, Lihua Liu
  • Patent number: 11791093
    Abstract: A sintered magnet body (RaT1bMcBd) coated with a powder mixture of an intermetallic compound (R1iM1j, R1xT2yM1z, R1iM1jHk), alloy (M1dM2e) or metal (M1) powder and a rare earth (R2) oxide is diffusion treated. The R2 oxide is partially reduced during the diffusion treatment, so a significant amount of R2 can be introduced near interfaces of primary phase grains within the magnet through the passages in the form of grain boundaries. The coercive force is increased while minimizing a decline of remanence.
    Type: Grant
    Filed: February 26, 2020
    Date of Patent: October 17, 2023
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hiroaki Nagata, Tadao Nomura, Takehisa Minowa
  • Patent number: 11657960
    Abstract: Disclosed is a sintered body composition used in improved diffusion efficiency of heavy rare earth elements RH, and related sintered permanent magnet and preparation methods. The sintered body includes Nd2Fe14B crystal phase as a primary phase, and a rare earth rich phase as a grain boundary phase. The sintered body includes a composition expressed by RaBbGacCudAleMfCogFebalance; wherein R is one or more selected from rare earth elements, and R includes Nd; M is one or more selected from the group consisting of Zr, Ti, and Nb; and wherein “a” satisfies 13%?a?15.3%; “b” satisfies 5.4%?b?5.8%; “c” satisfies 0.05%?c?0.25%; “d” satisfies 0.08%?d?0.3%; “e” satisfies 0?e?1.2%; “f” satisfies 0.08%?f?0.2%; and “g” satisfies 0.8%?g?2.5%. Grains in Nd2Fe14B crystal phase have average size L of 4-8 ?m, and the relationship between L and t for grain boundary phases average thickness is: ?=t/L, wherein ? is defined as 0.009???0.012.
    Type: Grant
    Filed: March 17, 2020
    Date of Patent: May 23, 2023
    Inventors: Suo Bai, Shujie Wu, Yi Dong, Zhimin Wu, Shuai Zhang, Bo Yuan, Yi Yuan, Ya Chen, Wenjie Yuan
  • Patent number: 11649537
    Abstract: Provided are Ce/Co/Cu permanent magnet alloys containing certain refractory metals, such as Ta and/or Hf, and optionally Fe which represent economically more favorable alternative to Sm-based magnets with respect to both material and processing costs and which retain and/or improve magnetic characteristics useful for GAP MAGNET applications.
    Type: Grant
    Filed: December 10, 2018
    Date of Patent: May 16, 2023
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Andriy Palasyuk, Tej Nath Lamichhane, Olena Palasyuk, Vladimir Antropov, Paul C. Canfield, Ralph W. McCallum
  • Patent number: 11600417
    Abstract: A permanent magnet for a motor, a rotor assembly having the permanent magnet, a motor, and a compressor are disclosed. The permanent magnet has a Nd—Fe—B-based main phase. The main phase has a grain size of smaller than or equal to 4 micrometers. The mass ratio of dysprosium and/or terbium in the permanent magnet is less than or equal to 0.5%. The intrinsic coercivity Hcj of the permanent magnet at 25° C. satisfies Hcj?1500 kA/m. The permanent magnet according to embodiments of the present disclosure can have fewer or no heavy rare-earth elements, and meanwhile exhibit excellent performance, which improves the cost performance.
    Type: Grant
    Filed: May 13, 2020
    Date of Patent: March 7, 2023
    Assignee: ANHUI MEIZHI PRECISION MANUFACTURING CO., LTD.
    Inventors: Zhengzhong Qiao, Liyu Zheng, Xiaohua Qiu
  • Patent number: 11581113
    Abstract: A permanent magnet may include a Fe16N2 phase in a strained state. In some examples, strain may be preserved within the permanent magnet by a technique that includes etching an iron nitride-containing workpiece including Fe16N2 to introduce texture, straining the workpiece, and annealing the workpiece. In some examples, strain may be preserved within the permanent magnet by a technique that includes applying at a first temperature a layer of material to an iron nitride-containing workpiece including Fe16N2, and bringing the layer of material and the iron nitride-containing workpiece to a second temperature, where the material has a different coefficient of thermal expansion than the iron nitride-containing workpiece. A permanent magnet including an Fe16N2 phase with preserved strain also is disclosed.
    Type: Grant
    Filed: December 7, 2021
    Date of Patent: February 14, 2023
    Assignee: Regents of the University of Minnesota
    Inventors: Jian-Ping Wang, YanFeng Jiang
  • Patent number: 11482377
    Abstract: A sintered magnet body (RaT1bMcBd) coated with a powder mixture of an intermetallic compound (R1iM1j, R1xT2yM1z, R1iM1jHk), alloy (M1dM2e) or metal (M1) powder and a rare earth (R2) oxide is diffusion treated. The R2 oxide is partially reduced during the diffusion treatment, so a significant amount of R2 can be introduced near interfaces of primary phase grains within the magnet through the passages in the form of grain boundaries. The coercive force is increased while minimizing a decline of remanence.
    Type: Grant
    Filed: February 26, 2020
    Date of Patent: October 25, 2022
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hiroaki Nagata, Tadao Nomura, Takehisa Minowa
  • Patent number: 11453057
    Abstract: A samarium-iron-nitrogen alloy powder according to one embodiment of the present invention is characterized in that a value obtained by dividing the hydrogen content of the samarium-iron-nitrogen alloy powder by the BET specific surface area of the samarium-iron-nitrogen alloy powder is less than or equal to 400 ppm/(m2/g), and a value obtained by dividing the oxygen content of the samarium-iron-nitrogen alloy powder by the BET specific surface area of the samarium-iron-nitrogen alloy powder is less than or equal to 11,000 ppm/(m2/g).
    Type: Grant
    Filed: February 28, 2017
    Date of Patent: September 27, 2022
    Assignees: National Institute of Advanced Industrial Science and Technology, TDK Corporation
    Inventors: Shusuke Okada, Kazuyuki Suzuki, Kenta Takagi, Kimihiro Ozaki, Yasushi Enokido
  • Patent number: 11424055
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Grant
    Filed: September 25, 2019
    Date of Patent: August 23, 2022
    Assignee: NICHIA CORPORATION
    Inventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
  • Patent number: 11424072
    Abstract: A coating tank 1 provided with a net belt passage opening is prepared, a slurry obtained by dispersing a rare-earth-compound powder in a solvent is continuously supplied to the coating tank 1 to cause the coating tank 1 to overflow, and a plurality of sintered magnet bodies 10 are arranged on a net belt conveyor 5, continuously conveyed horizontally thereon, and passed through the slurry in the coating tank 1 via the net belt passage opening, to apply the slurry to the sintered magnet bodies. The slurry is subsequently dried to continuously apply the powder to the plurality of sintered magnet bodies. As a result, the rare-earth-compound powder can be uniformly applied to the surfaces of the sintered magnet bodies, and the application operation can be performed extremely efficiently.
    Type: Grant
    Filed: September 30, 2020
    Date of Patent: August 23, 2022
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yukihiro Kuribayashi, Shogo Kamiya, Harukazu Maegawa, Shintaro Tanaka
  • Patent number: 11376765
    Abstract: A method and system for sensing and controlling temperature with magnetic fields are provided. The method comprises placing a compound in thermal communication with a number of temperature or heat sources and placing a number of magnets in thermal communication with the compound. A number of magnetic sensors are placed in electromagnetic communication with the number of magnets. Changes in the magnetic field of the magnets are detected by the sensors and used to determine the temperature of the compound according to a model that maps magnetic field characteristics to temperature. The amount of cure of the compound can then be estimated from the temperature. The temperature or heat sources are controlled in response to the temperature measurement and the estimated amount of cure of the compound.
    Type: Grant
    Filed: August 6, 2019
    Date of Patent: July 5, 2022
    Assignee: National Technology & Engineering Solutions of Sandia, LLC
    Inventors: Yi Chen Mazumdar, Martin Nemer, Anirban Mazumdar
  • Patent number: 11289248
    Abstract: A magnetocaloric material comprising a La—Fe—Si based alloy composition that is compositionally modified to include a small but effective amount of at least one of Al, Ga, and In to improve mechanical stability of the alloy (substantially reduce alloy brittleness), improve thermal conductivity, and preserve comparable or provide improved magnetocaloric effects. The alloy composition may be further modified by inclusion of at least one of Co, Mn, Cr, and V as well as interstitial hydrogen.
    Type: Grant
    Filed: February 11, 2019
    Date of Patent: March 29, 2022
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Arjun K. Pathak, Yaroslav Mudryk, Oleksandr Dolotko, Vitalij K. Pecharsky
  • Patent number: 11217370
    Abstract: A permanent magnet may include a Fe16N2 phase in a strained state. In some examples, strain may be preserved within the permanent magnet by a technique that includes etching an iron nitride-containing workpiece including Fe16N2 to introduce texture, straining the workpiece, and annealing the workpiece. In some examples, strain may be preserved within the permanent magnet by a technique that includes applying at a first temperature a layer of material to an iron nitride-containing workpiece including Fe16N2, and bringing the layer of material and the iron nitride-containing workpiece to a second temperature, where the material has a different coefficient of thermal expansion than the iron nitride-containing workpiece. A permanent magnet including an Fe16N2 phase with preserved strain also is disclosed.
    Type: Grant
    Filed: January 22, 2016
    Date of Patent: January 4, 2022
    Assignee: REGENTS OF THE UNIVERSITY OF MINNESOTA
    Inventors: Jian-Ping Wang, YanFeng Jiang
  • Patent number: 11145445
    Abstract: A method of preparing a permanent magnet nanocomposite. The method includes melting a precursor alloy having a hard magnetic phase and a magnetically soft phase. The hard magnetic phase has less than a stoichiometric amount of rare earth metal or noble metal. The melted precursor is cast into flakes and milled into a powder. The powder may then be pressure crystalized.
    Type: Grant
    Filed: October 24, 2017
    Date of Patent: October 12, 2021
    Assignee: United States of America as represented by the Secretary of the Air Force
    Inventor: Zafer Turgut
  • Patent number: 11101057
    Abstract: Provided are a highly thermostable rare-earth permanent magnetic material, a preparation method thereof and a magnet containing the same. A composition of the rare-earth permanent magnetic material by an atomic percentage is as follows: SmxRaFe100-x-y-z-aMyNz, wherein R is at least one of Zr and Hf, M is at least one of Co, Ti, Nb, Cr, V, Mo, Si, Ga, Ni, Mn and Al, x+a is 7-10%, a is 0-1.5%, y is 0-5% and z is 10-14%.
    Type: Grant
    Filed: January 11, 2018
    Date of Patent: August 24, 2021
    Assignee: GRIREM ADVANCED MATERIALS CO., LTD.
    Inventors: Guiyong Wu, Yang Luo, Hongwei Li, Yuanfei Yang, Dunbo Yu, Ningtao Quan, Chao Yuan, Wenlong Yan
  • Patent number: 10984929
    Abstract: A rare earth magnet includes main phase grains having an R2T14B type crystal structure. The main phase grains include C. A concentration ratio A1 (A1=?C/?C) of the main phase grains is 1.50 or more, where ?C and ?C are respectively a highest concentration of C and a lowest concentration of C in one main phase grain.
    Type: Grant
    Filed: March 25, 2016
    Date of Patent: April 20, 2021
    Assignee: TDK CORPORATION
    Inventors: Wakako Okawa, Syota Goto, Yoshinori Fujikawa
  • Patent number: 10937586
    Abstract: A micro fabricated electromagnetic device and method for fabricating its component structures, the device having a layered magnetic core of a potentially unlimited number of alternating insulating and magnetic layers depending upon application, physical property and performance characteristic requirements for the device. Methods for fabricating the high performing device permit cost effective, high production rates of the device and its component structures without any degradation in device performance resulting from component layering.
    Type: Grant
    Filed: August 5, 2016
    Date of Patent: March 2, 2021
    Assignee: Teledyne Scientific & Imaging, LLC
    Inventors: Vivek Mehrotra, Rahul Ganguli, Jennifer Kuo, Payam Minoofar, Robert Mihailovich
  • Patent number: 10854380
    Abstract: A method for producing an NdFeB sintered includes forming a layer containing Dy and/or Tb on the surface of an NdFeB sintered magnet base material and then performing a grain boundary diffusion process for diffusing Dy and/or Tb from the aforementioned layer through the crystal grain boundaries of the magnet base material into the magnet base material by heating the magnet base material to a temperature equal to or lower than the sintering temperature thereof. In this method: a) the content of a rare earth in a metallic state in the magnet base material is equal to or higher than 12.7 at %; b) the aforementioned layer is a powder layer formed by depositing a powder; and c) the powder layer contains Dy and/or Tb in a metallic state by an amount equal to or higher than 50 mass %.
    Type: Grant
    Filed: February 27, 2013
    Date of Patent: December 1, 2020
    Assignee: DAIDO STEEL CO., LTD.
    Inventors: Masato Sagawa, Naoki Fujimoto
  • Patent number: 10832864
    Abstract: A coating tank 1 provided with a net belt passage opening is prepared, a slurry obtained by dispersing a rare-earth-compound powder in a solvent is continuously supplied to the coating tank 1 to cause the coating tank 1 to overflow, and a plurality of sintered magnet bodies 10 are arranged on a net belt conveyor 5, continuously conveyed horizontally thereon, and passed through the slurry in the coating tank 1 via the net belt passage opening, to apply the slurry to the sintered magnet bodies. The slurry is subsequently dried to continuously apply the powder to the plurality of sintered magnet bodies. As a result, the rare-earth-compound powder can be uniformly applied to the surfaces of the sintered magnet bodies, and the application operation can be performed extremely efficiently.
    Type: Grant
    Filed: April 18, 2016
    Date of Patent: November 10, 2020
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yukihiro Kuribayashi, Shogo Kamiya, Harukazu Maegawa, Shintaro Tanaka
  • Patent number: 10807167
    Abstract: The present invention provides a producing method of a rare earth sintered magnet which is suitable as a producing method of a high performance rare earth sintered magnet which can reduce the number of steps for reusing defective molded bodies generated in a wet molding step of the rare earth sintered magnet, and which has a small content amount of oxygen. The invention also provides a slurry recycling method used for the producing method, and a slurry recycling apparatus. Each of the methods includes a crushing step of crushing, in mineral oil and/or synthetic fluid, a molded body in which slurry formed from alloy powder for a rare earth sintered magnet and mineral oil and/or synthetic fluid is wet molded in magnetic field, and recycling the crushed molded body into slurry.
    Type: Grant
    Filed: August 4, 2015
    Date of Patent: October 20, 2020
    Assignee: HITACHI METALS, LTD.
    Inventor: Mitsuaki Mochizuki
  • Patent number: 10741326
    Abstract: A method for improvement of magnetic performance of sintered NdFeB magnet includes the following steps. Firstly, material containing element R, H and X is to be covered on a surface of the sintered NdFeB magnet to form a finish coat. After that, proceed with a diffusion treatment and an aging treatment to the sintered NdFeB magnet with the finish coat in the environment of vacuum or inert gas. R is at least one of such elements as Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu. H is hydrogen. X is at least one of such elements as C, O, N, S, B, Cl and Si.
    Type: Grant
    Filed: July 12, 2016
    Date of Patent: August 11, 2020
    Assignees: NINGBO YUNSHENG CO., LTD., NINGBO YUNSHENG MAGNET DEVICES TECHNOLOGY CO., LTD.
    Inventors: Xiangke Lv, Chunguo Wang, Min Zhang, Yong Ding, Qingzhong Yang, Yiqun Hu, Jiangfeng Wang
  • Patent number: 10726980
    Abstract: A rare earth magnet includes main phase grains having an R2T14B type crystal structure. The main phase grains include B. A concentration ratio A (A=?B/?B) of the main phase grains is 1.05 or more, where ?B and ?B are respectively a highest concentration of B and a lowest concentration of B in one main phase grain.
    Type: Grant
    Filed: March 25, 2016
    Date of Patent: July 28, 2020
    Assignee: TDK CORPORATION
    Inventors: Wakako Okawa, Syota Goto, Yoshinori Fujikawa
  • Patent number: 10703012
    Abstract: A tool to differentially compress a powder material comprises a differential compression piston and a support. The piston comprises a first part configured to apply a pressure on a first region of an external surface of the powder material. The piston comprises a second part with a recess which is located at a lateral distance from the first part and which is configured to face a second region of the external surface of the powder material. The tool further comprises a membrane that can be deformed by the piston. The deformable membrane is configured to at least partially retain the powder material in the tool.
    Type: Grant
    Filed: December 7, 2016
    Date of Patent: July 7, 2020
    Assignee: COMMISSARIAT A L'ENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES
    Inventor: Mathieu Boidot
  • Patent number: 10658094
    Abstract: A NdFeB magnet containing cerium and a manufacturing method thereof are provided. The manufacturing method includes steps of: refining a part of raw materials pure iron, ferro-boron, and rare earth fluoride in a crucible, adding a rest of the raw materials into the crucible and refining, casting a refined solution to a surface of a water-cooled rotation roller through a tundish and forming alloy flakes, processing the alloy flakes containing at least two different compositions with hydrogen decrepitation, milling powders, magnetic field pressing, vacuum presintering, machining and sintering, and obtaining the NdFeB magnet containing cerium. The NdFeB magnet containing cerium has a density of 7.5-7.7 g/cm3 and an average particle size of 3-7 ?m; comprises a main phase and a grain boundary phase distributed around the main phase. A composite phase containing Tb is provided between the main phase and the grain boundary phase.
    Type: Grant
    Filed: December 23, 2016
    Date of Patent: May 19, 2020
    Assignee: SHENYANG GENERAL MAGNETIC CO., LTD
    Inventors: Baoyu Sun, Yongli Duan
  • Patent number: 10646922
    Abstract: The invention relates to a method for pressing a green compact (1) for producing a sintered molded part from a sintering powder, according to which the sintering powder is filled into a mold cavity (43a) of a die (43), and then the sintering powder is pressed by at least one punch, which is pushed at least partly into the mold cavity (43a), to form a green compact (1), wherein to form an undercut in the green compact (1) a portion of the sintering powder is pushed by a punch out of a first plane of the die (43) by forming an opening (11) in the first plane in pressing direction into a second plane of the die (11) different from the first plane. The invention also relates to a device (12) for performing said method and a correspondingly produced sintered molded part.
    Type: Grant
    Filed: June 1, 2015
    Date of Patent: May 12, 2020
    Assignee: Miba Sinter Austria GmbH
    Inventor: Christian Kronberger
  • Patent number: 10620015
    Abstract: A magnetic sensor device includes: a magnetic circuit for forming a magnetic field, a magnetoresistance effect element, and a heat dissipater. The magnetoresistance effect element outputs changes in the magnetic field as changes in a resistance value, and is arranged on a surface (of a +Z side) of the magnetic circuit at a conveyance path side thereof. The heat dissipater is arranged in close contact with the magnetic circuit at the opposite side thereof (?Z side) from the conveyance path.
    Type: Grant
    Filed: October 10, 2018
    Date of Patent: April 14, 2020
    Assignee: Mitsubishi Electric Corporation
    Inventors: Hideki Matsui, Tatsuya Kunieda, Tomokazu Ogomi, Masaaki Okada, Sadaaki Yoshioka
  • Patent number: 10614952
    Abstract: A sintered magnet body (RaT1bMcBd) coated with a powder mixture of an intermetallic compound (R1iM1j, R1xT2yM1z, R1iM1jHk), alloy (M1dM2e) or metal (M1) powder and a rare earth (R2) oxide is diffusion treated. The R2 oxide is partially reduced during the diffusion treatment, so a significant amount of R2 can be introduced near interfaces of primary phase grains within the magnet through the passages in the form of grain boundaries. The coercive force is increased while minimizing a decline of remanence.
    Type: Grant
    Filed: March 9, 2017
    Date of Patent: April 7, 2020
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hiroaki Nagata, Tadao Nomura, Takehisa Minowa
  • Patent number: 10593472
    Abstract: A step of, while a powder of an RLM alloy (where RL is Nd and/or Pr; M is one or more elements selected from among Cu, Fe, Ga, Co, Ni and Al) which is produced through atomization and a powder of an RH compound (where RH is Dy and/or Tb) are present on the surface of a sintered R-T-B based magnet, performing a heat treatment at a sintering temperature of the sintered R-T-B based magnet or lower is included. The RLM alloy contains RL in an amount of 65 at % or more, and the melting point of the RLM alloy is equal to or less than the temperature of the heat treatment. The heat treatment is performed while the RLM alloy powder and the RH compound powder are present on the surface of the sintered R-T-B based magnet at a mass ratio of RLM alloy:RH compound=9.6:0.4 to 5:5.
    Type: Grant
    Filed: September 8, 2015
    Date of Patent: March 17, 2020
    Assignee: HITACHI METALS, LTD.
    Inventor: Shuji Mino
  • Patent number: 10593453
    Abstract: A magnetic sheet comprises, by vol. %, Fe—Si—Al alloy flat powder: 36% or more. The Fe—Si—Al alloy flat powder comprises, by wt %, 9.3%?Si?9.7%, 5.7%?Al?6.1%, and remaining Fe. The Fe—Si—Al alloy flat powder has: an aspect ratio in a range of 20 or more and 50 or less; a 50% particle size D50 in a range of 50 ?m or more and 100 ?m or less; and a coercivity Hc of 60 A/m or less. The magnetic sheet has a temperature characteristic of permeability ?? measured at 1 MHz exhibiting a maximum value in a range of 0° C. or more and 40° C. or less.
    Type: Grant
    Filed: July 24, 2017
    Date of Patent: March 17, 2020
    Assignee: TDK CORPORATION
    Inventors: Atsuhito Matsukawa, Yoshihiro Honjo, Mitsuhiro Matsuhashi
  • Patent number: 10586640
    Abstract: A bulk high performance permanent magnet comprising a neodymium-iron-boron core having an outer surface, and a coercivity-enhancing element residing on at least a portion of said outer surface, with an interior portion of said neodymium-iron-boron core not having said coercivity-enhancing element therein. Also described herein is a method for producing the high-coercivity bulk permanent magnet, the method comprising: (i) depositing a coercivity-enhancing element on at least a portion of an outer surface of a neodymium-iron-boron core substrate to form a coated permanent magnet; and (ii) subjecting the coated permanent magnet to a pulse thermal process that heats said outer surface to a substantially higher temperature than an interior portion of said neodymium-iron-boron core substrate, wherein said substantially higher temperature is at least 200° C.
    Type: Grant
    Filed: January 25, 2017
    Date of Patent: March 10, 2020
    Assignees: UT-BATTELLE, LLC, IOWA STATE UNIVERSITY RESEARCH FOUNDATION, INC., LAWRENCE LIVERMORE NATIONAL SECURITY, LLC
    Inventors: Mariappan Parans Paranthaman, Michael A. McGuire, David S. Parker, Orlando Rios, Brian C. Sales, Huseyin Ucar, Scott K. McCall, R. William McCallum, Cajetan I. Nlebedim
  • Patent number: 10563295
    Abstract: A step is provided which performs a heat treatment at the sintering temperature of a sintered R-T-B based magnet or lower, while a powder of an RLM alloy (where RL is Nd and/or Pr; M is one or more selected from among Cu, Fe, Ga, Co and Ni) and a powder of an RH fluoride (where RH is Dy and/or Tb) are present on a surface of the sintered R-T-B based magnet. The RLM alloy contains RL in an amount of 50 at % or more, and a melting point of the RLM alloy is equal to or less than a temperature of the heat treatment. The heat treatment is performed while the RLM alloy powder and the RH fluoride powder are present on the surface of the sintered R-T-B based magnet at a mass ratio of RLM alloy:RH fluoride=96:4 to 5:5.
    Type: Grant
    Filed: April 23, 2015
    Date of Patent: February 18, 2020
    Assignee: HITACHI METALS, LTD.
    Inventor: Shuji Mino
  • Patent number: 10563276
    Abstract: A high-performance NdFeB permanent magnet including a nitride phase and a production method thereof are provided. A main phase of the NdFeB permanent magnet has a structure of R2T14B; a grain boundary phase is distributed around the main phase and contains N, F, Zr, Ga and Cu; a composite phase containing R1, Tb and N exists between the main phase and the grain boundary phase and includes a phase having a structure of (R1, Tb)2T14(B, N). R represents at least two rare earth elements, and includes Pr and Nd; T represents Fe, Mn, Al and Co; R1 represents at least one rare earth element, and includes at least one of Dy and Tb; the main phase contains Pr, Nd, Fe, Mn, Al, Co and B; and the grain boundary phase further contains at least one of Nb and Ti. Through placing partially B by N, a magnetic performance is increased.
    Type: Grant
    Filed: December 18, 2016
    Date of Patent: February 18, 2020
    Assignee: SHENYANG GENERAL MAGNETIC CO., LTD
    Inventors: Baoyu Sun, Yongli Duan
  • Patent number: 10566862
    Abstract: A rotor, a rotary electric machine, and a rotor production method that reduce parts count, allow easy fixing, and prevent displacement. The rotor includes a rotor core having a cylindrical shape and a plurality of insertion holes, and a sensor magnet having an annular shape and placed coaxially with the rotor core, in which the sensor magnet has a plurality of protrusions protruding toward the rotor core, the plurality of protrusions are inserted into the plurality of insertion holes, and the rotor core and the sensor magnet are firmly fixed to each other by resin.
    Type: Grant
    Filed: November 13, 2015
    Date of Patent: February 18, 2020
    Assignee: Mitsubishi Electric Corporation
    Inventors: Jun Tsuruha, Ryo Nabika, Hiroshi Yamanaka
  • Patent number: 10535452
    Abstract: A high-performance permanent magnet is provided. The magnet is expressed by a composition formula: RpFeqMrCutCo100-p-q-r-t. The magnet includes a sintered body including: a plurality of crystal grains each having a Th2Zn17 crystal phase; and a plurality of grain boundaries between the crystal grains. If an oxide phase of the R element is defined by a continuous region that is disposed in the sintered body and contains the R element and oxygen having a concentration of 85 atomic percent or more, a ratio of the number of the oxide phases in the grain boundaries to the number of the crystal grains is 1.1 or less.
    Type: Grant
    Filed: March 2, 2018
    Date of Patent: January 14, 2020
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Masaya Hagiwara, Toshihide Takahashi, Yosuke Horiuchi, Shinya Sakurada
  • Patent number: 10510483
    Abstract: A step of, while a powder of an RLM alloy (where RL is Nd and/or Pr; M is one or more elements selected from among Cu, Fe, Ga, Co, Ni and Al) and a powder of an RH compound (where RH is Dy and/or Tb; and the RH compound is one, or two or more, selected from among an RH fluoride, an RH oxide, and an RH oxyfluoride) are present on the surface of a sintered R-T-B based magnet, performing a heat treatment at a sintering temperature of the sintered R-T-B based magnet or lower is included. The RLM alloy contains RL in an amount of 65 at % or more, and the melting point of the RLM alloy is equal to or less than the temperature of the heat treatment. The heat treatment is performed while the RLM alloy powder and the RH compound powder are present on the surface of the sintered R-T-B based magnet at a mass ratio of RLM alloy:RH compound=9.6:0.4 to 5:5.
    Type: Grant
    Filed: September 8, 2015
    Date of Patent: December 17, 2019
    Assignee: HITACHI METALS, LTD.
    Inventor: Shuji Mino
  • Patent number: 10504640
    Abstract: The disclosure describes magnetic materials including iron nitride, bulk permanent magnets including iron nitride, techniques for forming magnetic materials including iron nitride, and techniques for forming bulk permanent magnets including iron nitride.
    Type: Grant
    Filed: June 24, 2014
    Date of Patent: December 10, 2019
    Assignee: Regents of the University of Minnesota
    Inventors: Jian-Ping Wang, Yanfeng Jiang
  • Patent number: 10497498
    Abstract: The object of the present invention relates to ferrite particles for bonded magnets and a resin composition for bonded magnets which is capable of obtaining a bonded magnet molded product having a good magnetic force and a magnetic waveform as well as high iHc and Hk by injection molding. The present invention aims at providing a bonded magnet molded product using the ferrite particles and the resin composition. The aforementioned object of the present invention can be achieved by ferrite particles for bonded magnets which have a crystal distortion of not more than 0.14 as measured by XRD, and an average particle diameter of not less than 1.30 ?m as measured by Fisher method; a resin composition for bonded magnets; and a molded product obtained by injection-molding the resin composition.
    Type: Grant
    Filed: September 29, 2015
    Date of Patent: December 3, 2019
    Assignee: TODA KOGYO CORP.
    Inventors: Yasushi Nishio, Satoshi Nomura, Yasuhiko Fujii, Hiromitsu Sakurai
  • Patent number: 10468167
    Abstract: A high-performance NdFeB permanent magnet produced with NdFeB scraps and a production method thereof are provided. The production method includes steps of: under a vacuum condition, sending a portion of raw materials, including pure iron, ferro-iron, the NdFeB scraps and rare earth fluorides, into a crucible, refining, and obtaining a first melting liquid; absorbing slags by a slag cleaning device, and moving the slag cleaning device out; sending a rest of raw materials into the crucible, refining the first melting liquid and the rest of raw materials in the crucible, and obtaining a second melting liquid; pouring the second melting liquid after refining onto a surface of a water-cooled rotation roller through a tundish, and forming alloy flakes; processing the alloy flakes with hydrogen decrepitation, milling the alloy flakes into powders by a jet mill, then magnetic field pressing, presintering and sintering.
    Type: Grant
    Filed: January 9, 2017
    Date of Patent: November 5, 2019
    Assignee: SHENYANG GENERAL MAGNETIC CO., LTD
    Inventors: Baoyu Sun, Yongli Duan
  • Patent number: 10460871
    Abstract: A method for fabricating a non-planar magnet includes extruding a precursor material including neodymium iron boron crystalline grains into an original anisotropic neodymium iron boron permanent magnet having an original shape, wherein the original anisotropic neodymium iron boron permanent magnet has at least about 90 percent neodymium iron boron magnetic material by volume. The original anisotropic neodymium iron boron permanent magnet is heated to a deformation temperature. The original anisotropic neodymium iron boron permanent magnet is deformed into a reshaped anisotropic neodymium iron boron permanent magnet having a second shape substantially different from the original shape using heated tooling to apply a deformation load to the original anisotropic neodymium iron boron permanent magnet.
    Type: Grant
    Filed: October 11, 2016
    Date of Patent: October 29, 2019
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Frederick E. Pinkerton, Anil K. Sachdev
  • Patent number: 10428408
    Abstract: An R-T-B-based rare earth sintered magnet, comprising a rare earth element R, B, a metallic element M which includes one or more metals selected from Al, Ga and Cu, a transition metal T which includes Fe as a main component, and inevitable impurities, wherein the sintered magnet includes 13 atom % to 15.5 atom % of R, 5.0 atom % to 6.0 atom % of B, 0.1 atom % to 2.4 atom % of M, and T and the inevitable impurities as a balance, and wherein the sintered magnet includes 0.015 atom % to 0.10 atom % of Zr as the transition metal T.
    Type: Grant
    Filed: March 10, 2016
    Date of Patent: October 1, 2019
    Assignee: TDK Corporation
    Inventors: Takashi Yamazaki, Akifumi Muraoka, Kenichiro Nakajima
  • Patent number: 10418171
    Abstract: A step of, while an RLM alloy powder (where RL is Nd and/or Pr; M is one or more elements selected from among Cu, Fe, Ga, Co, Ni and Al) and an RH compound powder (where RH is Dy and/or Tb; and the RH compound is an RH fluoride and/or an RH oxyfluoride) are present on the surface of a sintered R-T-B based magnet, performing a heat treatment at a sintering temperature of the sintered R-T-B based magnet or lower is included. The RLM alloy contains RL in an amount of 50 at % or more, and the melting point of the RLM alloy is equal to or less than the temperature of the heat treatment. The heat treatment is performed while the RLM alloy powder and the RH compound powder are present on the surface of the sintered R-T-B based magnet at a mass ratio of RLM alloy:RH compound=9.6:0.4 to 5:5.
    Type: Grant
    Filed: December 4, 2015
    Date of Patent: September 17, 2019
    Assignee: HITACHI METALS, LTD.
    Inventor: Shuji Mino
  • Patent number: 10410776
    Abstract: A step of, while an RLM alloy powder (where RL is Nd and/or Pr; M is one or more elements selected from among Cu, Fe, Ga, Co, Ni and Al) and an RH oxide powder (where RH is Dy and/or Tb) are present on the surface of a sintered R-T-B based magnet, performing a heat treatment at a sintering temperature of the sintered R-T-B based magnet or lower is included. The RLM alloy contains RL in an amount of 50 at % or more, and the melting point of the RLM alloy is equal to or less than the temperature of the heat treatment. The heat treatment is performed while the RLM alloy powder and the RH oxide powder are present on the surface of the sintered R-T-B based magnet at a mass ratio of RLM alloy:RH oxide=9.6:0.4 to 5:5.
    Type: Grant
    Filed: December 4, 2015
    Date of Patent: September 10, 2019
    Assignee: HITACHI METALS, LTD.
    Inventor: Shuji Mino
  • Patent number: 10388443
    Abstract: The present invention provides an R-T-B based sintered magnet having an R-T-B based compound as main phase grains, wherein, the content of Zr contained in the R-T-B based sintered magnet is 0.3 mass % to 2.0 mass %, the main phase grains have Zr, and the R-T-B based sintered magnet have main phase grains with the mass concentration of Zr at the edge portion of the main phase grain being 70% or less of that at the central portion of the main phase grain at the cross-section of the main phase grain.
    Type: Grant
    Filed: February 4, 2016
    Date of Patent: August 20, 2019
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Takurou Iwasa, Haruna Nakajima
  • Patent number: 10381140
    Abstract: The present invention provides a method for preparing a rare earth permanent magnet material. The preparation method of the present invention comprises atomizing spray process and infiltrating process, wherein the atomizing-sprayed sintered rare earth magnet is placed in a closed container before infiltrating. Through the atomizing spray process a solution containing a heavy rare earth element is coated on the surface of a sintered R1-Fe(Co)—B-A-X-M rare earth magnet, and after baking, heat treatment is performed to infiltrate the sprayed heavy rare earth element to the grain boundary phase of the sintered rare earth magnet. This method decreases the amount of a heavy rare earth element used, increases the coercive force of magnets with a little decrease of remanence, decreases the remanence temperature coefficient and coercive force temperature coefficient of the magnet, and improves resistance of the magnet against demagnetization at a high temperature.
    Type: Grant
    Filed: March 3, 2016
    Date of Patent: August 13, 2019
    Assignee: Tianhe (Baotou) Advanced Tech Magnet Co., Ltd.
    Inventors: Shulin Diao, Yi Dong, Haibo Yi, Yuelin Fan, Juchang Miao, Shujie Wu, Yi Yuan, Ya Chen, Wenjie Yuan
  • Patent number: 10347406
    Abstract: An internally segmented magnet is disclosed. The magnet may include a first layer of a permanent magnetic material, a second layer of a permanent magnetic material, and an insulating layer separating the first and second layers. The insulating layer may include a ceramic mixture of at least a first ceramic material and a second ceramic material. The mixture having a melting point of up to 1,100° C. and may be a eutectic, or near eutectic, composition. The magnet may be formed by forming a first layer of powdered permanent magnetic material, depositing an insulating layer over the first layer, depositing a second layer of powdered permanent magnetic material over the insulating layer to form an internally segmented magnet stack, and sintering the magnet stack. The ceramic materials may include a halogen and an alkaline earth metal, alkali metal, or a metal having a +3 or +4 oxidation state.
    Type: Grant
    Filed: September 28, 2015
    Date of Patent: July 9, 2019
    Assignee: Ford Global Technologies, LLC
    Inventor: Wanfeng Li
  • Patent number: 10323300
    Abstract: A method to separate rare earth material from a rare earth magnet. At least one embodiment comprises a method that heats a provided rare earth magnet to at least 600° C. whereby the rare earth magnet absorbs a dry gas. Separated rare earth materials are created. Magnetic rare earth materials are produced from the separated rare earth materials.
    Type: Grant
    Filed: September 1, 2016
    Date of Patent: June 18, 2019
    Assignee: U.S. Department of Energy
    Inventors: Prahbat K. Tripathy, William D Swank, Delon C. Haggard, Tedd E. Lister, Eric S. Peterson
  • Patent number: 10160037
    Abstract: A rare earth magnet is prepared by disposing a R1-T-B sintered body comprising a R12T14B compound as a major phase in contact with an R2-M alloy powder and effecting heat treatment for causing R2 element to diffuse into the sintered body. The alloy powder is obtained by quenching a melt containing R2 and M. R1 and R2 are rare earth elements, T is Fe and/or Co, M is selected from B, C, P, Al, Si, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Ge, Zr, Nb, Mo, Ag, In, Sn, Sb, Hf, Ta, W, Pt, Au, Pb, and Bi.
    Type: Grant
    Filed: August 18, 2014
    Date of Patent: December 25, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Tadao Nomura, Hiroaki Nagata, Takehisa Minowa
  • Patent number: 10096410
    Abstract: An R-T-B based sintered magnet having R2T14B crystal grains and a grain boundary formed by two or more adjacent R2T14B crystal grains. An R—Co—Cu—N concentrated part whose concentrations of R, Co, Cu and N are respectively higher than those in the R2T14B crystal grains may be in the grain boundary. An R—O—C concentrated part or an R—O—C—N concentrated part may be further provided in the grain boundary.
    Type: Grant
    Filed: July 3, 2014
    Date of Patent: October 9, 2018
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Haruna Nakajima, Koji Mitake, Chikara Ishizaka
  • Patent number: 10096411
    Abstract: Provided is a high-strength, bonded La(Fe, Si)13-based magnetocaloric material, as well as a preparation method and use thereof. The magnetocaloric material comprises magnetocaloric alloy particles and an adhesive agent, wherein the particle size of the magnetocaloric alloy particles is less than or equal to 800 ?m and are bonded into a massive material by the adhesive agent; the magnetocaloric alloy particle has a NaZn13-type structure and is represented by a chemical formula of La1-xRx(Fe1-p-qCopMnq)13-ySiyA?, wherein R is one or more selected from elements cerium (Ce), praseodymium (Pr) and neodymium (Nd), A is one or more selected from elements C, H and B, x is in the range of 0?x?0.5, y is in the range of 0.8?y?2, p is in the range of 0?p?0.2, q is in the range of 0?q?0.2, ? is in the range of 0???3.0. Using a bonding and thermosetting method, and by means of adjusting the forming pressure, thermosetting temperature, and thermosetting atmosphere, etc.
    Type: Grant
    Filed: May 17, 2012
    Date of Patent: October 9, 2018
    Assignees: INSTITUTE OF PHYSICS, CHINESE ACADEMY OF SCIENCES, HUBEI QUANYANG MAGNETIC MATERIALS MANUFACTURING CO., LTD.
    Inventors: Fengxia Hu, Ling Chen, Lifu Bao, Jing Wang, Baogen Shen, Jirong Sun, Huayang Gong