With Special Compositions Patents (Class 148/122)
  • Publication number: 20090260719
    Abstract: A method in one embodiment includes applying a current to a lead of a tunneling magnetoresistance sensor for inducing joule heating of the lead or a heating layer, the level of joule heating being sufficient to anneal a magnetic layer of the sensor; and maintaining the current at the level for an amount of time sufficient to anneal the tunneling magnetoresistive (TMR) sensor. A system in one embodiment comprises a first lead coupled to one end of a tunneling magnetoresistance sensor stack; a second lead coupled to another end of the sensor stack; and a third lead coupled to the first lead, the third lead being selectively coupleable to a ground, wherein a current applied to the first lead at a predetermined level when the third lead is coupled to the ground induces joule heating of the first lead or a heating layer coupled to the first and third leads, the joule heating applied for a predetermined amount of time being sufficient to anneal a magnetic layer of the sensor.
    Type: Application
    Filed: April 18, 2008
    Publication date: October 22, 2009
    Inventor: Icko E. Tim Iben
  • Patent number: 7589161
    Abstract: A polymeric quenchant. The polymeric quenchant comprises an inorganic nanoparticle, a water-soluble polymer, and water, wherein a weight ratio of the inorganic nanoparticle, water-soluble polymer and water is about 0.05-5:1-5:100. The cooling rate of steel during a quenching process can be adjusted by regulating the components and ratios of the adjusted by regulating the components and ratios of the polymeric quenchant to achieve desirable steel properties.
    Type: Grant
    Filed: November 20, 2007
    Date of Patent: September 15, 2009
    Assignees: Industrial Technology Research Institute, Gelie Co., Ltd.
    Inventors: George Ho, Li Kuei Lin, Wen-Faa Kuo
  • Publication number: 20090145522
    Abstract: Disclosed are soft magnetic alloys that consist essentially of 10% by weight?Co?22% by weight, 0% by weight?V?4% by weight, 1.5% by weight?Cr?5% by weight, 1% by weight?Mn?2% by weight, 0% by weight?Mo?1% by weight, 0.5% by weight?Si?1.5% by weight, 0.1% by weight?Al?1.0% by weight, rest iron. Also disclosed are methods of making the alloys, and products containing them, such as actuator systems, electric motors, and the like.
    Type: Application
    Filed: July 27, 2007
    Publication date: June 11, 2009
    Applicant: Vacuumschmelze GmbH & Co. KG
    Inventors: Witold Pieper, Joachim Gerster
  • Patent number: 7481895
    Abstract: Disclosed is an isotropic SmFeN powdery magnet material for producing resin-bonded magnets. The magnet powder is prepared by melt-spinning of a molten alloy and nitriding the alloy powder thus obtained to form a magnet alloy having an alloy composition of one of the formulae, by atomic %: SmxFe100-x-vNv, SmxFe100-x-y-vM1yNv and SmxFe100-x-z-vM2zNv wherein M1 is at least one member selected from the group consisting of Hf and Zr; and M2 is at least one member selected from the group consisting of Si, Nb, Ti, Ga, Al, Ta and C; 7?x?12, 0.1?y?1.5, 0.1?z?1.0 and 0.5?v?20; the crystal structure is TbCu7 type; and the thickness of the flakes is 10-40 ?m.
    Type: Grant
    Filed: January 20, 2004
    Date of Patent: January 27, 2009
    Assignee: Daido Steel Co., Ltd.
    Inventors: Takahiko Iriyama, Ryo Omatsuzawa, Takayuki Nishio
  • Publication number: 20080277398
    Abstract: Welded 36% Ni—Fe alloy steel and a method of making such welded steel for use in storage tanks, pipelines, and other equipment associated with cryogenic substances is disclosed. The welded steel has a similar coefficient of thermal expansion in both the weld and base steel.
    Type: Application
    Filed: May 9, 2007
    Publication date: November 13, 2008
    Applicant: ConocoPhillips Company
    Inventor: Stuart L. Wilson
  • Patent number: 7438768
    Abstract: Hydrogen embrittlement is prevented in Sm2Co17-based magnets and R2Fe14B-based magnets by metal plating the magnet, then carrying out heat treatment, or by forming a metal oxide or metal nitride layer on the metal plating layer or directly on the magnet itself.
    Type: Grant
    Filed: December 24, 2002
    Date of Patent: October 21, 2008
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuaki Sakaki, Masaki Kasashima, Ryuji Hamada, Takehisa Minowa
  • Patent number: 7435304
    Abstract: There are provided a coating composition for siliconizing, and a method for manufacturing a high silicon electrical steel sheet using the same. The coating composition includes: a Fe—Si-based composite compound sintered powder having a grain size of ?325 mesh and containing 20-70% silicon by weight; and a colloidal silica solution containing 15-30 part by weight of silica solid matter with respect to 100 part by weight of the sintered powder.
    Type: Grant
    Filed: November 11, 2003
    Date of Patent: October 14, 2008
    Assignee: POSCO
    Inventors: Kyu-Seung Choi, Jong-Soo Woo
  • Patent number: 7399368
    Abstract: A permanent magnet comprises a hard magnetic material that contains at least a rare earth element and an anti-ferromagnetic material, wherein the hard magnetic material and the anti-ferromagnetic material are magnetically coupled. A volume ratio of the anti-ferromagnetic material is 20% or less, based on the permanent magnet.
    Type: Grant
    Filed: May 9, 2006
    Date of Patent: July 15, 2008
    Assignee: Hitachi, Ltd.
    Inventors: Matahiro Komuro, Katsuhiro Komuro
  • Publication number: 20080099106
    Abstract: Disclosed are soft magnetic alloys that consist essentially of 10% by weight?Co?22% by weight, 0% by weight?V?4% by weight, 1.5% by weight?Cr?5% by weight, 1% by weight?Mn?2% by weight, 0% by weight?Mo?1% by weight, 0.5% by weight?Si?1.5% by weight, 0.1% by weight?Al?1.0% by weight, rest iron. Also disclosed are methods of making the alloys, and products containing them, such as actuator systems, electric motors, and the like.
    Type: Application
    Filed: July 27, 2007
    Publication date: May 1, 2008
    Applicant: Vacuumschmelze GmbH & Co. KG
    Inventors: Witold Pieper, Joachim Gerster
  • Patent number: 7361235
    Abstract: A method of manufacturing an oxide dispersion strengthened ferritic steel excellent in high-temperature creep strength having a coarse grain structure. The method comprises mixing alloy powders and an Y2O3 powder, subjecting the mixed powder to mechanical alloying treatment, solidifying the alloyed powder by hot extrusion, and subjecting the extruded solidified material to final heat treatment involving heating to and holding at a temperature of not less than the Ac3 transformation point and slow cooling at a rate of not more than a ferrite-forming critical rate which comprises, 0.05-0.25% C, 8.0-12.0% Cr, 0.1-4.0% W, 0.1-1.0% Ti, 0.1-0.5% Y2O3 by weight, with the balance being Fe. In this method, by using a TiO2 powder as a Ti component to be mixed at the mechanical alloying treatment or by adding a Fe2O3 powder, the bonding of Ti with C is suppressed, and the C concentration in the matrix does not decrease.
    Type: Grant
    Filed: August 7, 2003
    Date of Patent: April 22, 2008
    Assignee: Japan Nuclear Cycle Development Institute
    Inventors: Satoshi Ohtsuka, Shigeharu Ukai, Takeji Kaito, Masayuki Fujiwara
  • Patent number: 7270718
    Abstract: The invention provides a method for manufacturing a soft magnetic powder material covered by oxide layers at surfaces of the powder, by using a soft magnetic alloy powder containing a soft magnetic powder material and a second element such as Si having an oxidizing reactivity higher than iron, and heating the soft magnetic alloy powder in an atmosphere of a weak oxidizing gas by mixing a weak oxidizing gas in an inert gas, and oxidizing selectively the second element at surface layers of the powder while restraining an oxidation of iron to form thin oxide layers with high electrical resistance.
    Type: Grant
    Filed: November 19, 2004
    Date of Patent: September 18, 2007
    Assignee: DENSO Corporation
    Inventors: Yoshiaki Nishijima, Yurio Nomura, Kouichi Yamaguchi, Yuuichi Ishikawa, Hidekazu Hayama
  • Patent number: 7208056
    Abstract: An R-T-B system rare earth sintered magnet having a high mechanical strength and excellent corrosion resistance is provided. The R-T-B system rare earth sintered magnet of the present invention comprises a sintered body comprising a main phase consisting of an R2T14B phase where R represents one or more rare earth elements and T represents one or more transition metal elements essentially containing Fe, or Fe and Co, and a grain boundary phase containing a higher amount of R than the above described main phase, wherein the surface of the above described sintered body is partially covered with a carbon compound layer. In the R-T-B system rare earth sintered magnet of the present invention, the area ratio of the partial surface of the above described sintered body covered with the above described carbon compound layer to the entire surface thereof is preferably between 10% and 90%.
    Type: Grant
    Filed: January 31, 2005
    Date of Patent: April 24, 2007
    Assignee: TDK Corporation
    Inventors: Makoto Iwasaki, Chikara Ishizaka, Taku Takeishi
  • Patent number: 7179337
    Abstract: The invention provides a method for preparing a soft magnetic material which meets demands for low iron loss, high density, high strength and high productivity. The method comprises a surface oxidation step of forming oxide films on the surfaces of a soft magnetic powder, a step of preparing a molding compound of the soft magnetic powder by mixing a soft magnetic powder and a binder with a predetermined blending ratio, a press molding step of press-molding the molding compound of the soft magnetic powder into a predetermined shape, and a sintering step of sintering the press-molded soft magnetic powder to produce a soft magnetic material, wherein a millimeter wave sintering apparatus or a discharge plasma sintering apparatus is used as a heating means in the surface oxidation step or in the sintering step.
    Type: Grant
    Filed: October 17, 2003
    Date of Patent: February 20, 2007
    Assignee: Denso Corporation
    Inventors: Yasuyoshi Suzuki, Yurio Nomura, Yoshiaki Nishijima, Shoji Miyake, Yukio Makino, Teppei Satoh
  • Patent number: 7166172
    Abstract: A ferromagnetic iron alloy powder for a magnetic recording medium is composed of acicular iron-base particles of an average major axis length (X) of not less than 20 nm and not greater than 80 nm and have oxygen content of not less than 15 wt % and coercive force (Hc) of not less than [0.0036 X3?1.1 X2+110 X?1390 (Oe)] (where X is average major axis length expressed in nm). The ferromagnetic iron alloy powder is obtained by reacting metal powder composed of acicular iron-base particles having an average major axis length of not less than 20 nm and not greater than 80 nm with pure water in substantial absence of oxygen to form a metal oxide film on the particle surfaces. Optionally, the particles can be reacted with a weak oxidizing gas by a wet or dry method.
    Type: Grant
    Filed: December 3, 2004
    Date of Patent: January 23, 2007
    Assignee: Dowa Mining Co., Ltd.
    Inventors: Kazuyuki Matsumoto, Kimitaka Sato, Takatoshi Fujino, Kenichi Inoue
  • Patent number: 7141126
    Abstract: Rare earth alloy powder having an oxygen content of 50 to 4000 wt. ppm and a nitrogen content of 150 to 1500 wt. ppm is compacted by dry pressing to produce a compact. The compact is impregnated with an oil agent and then sintered. The sintering process includes a first step of retaining the compact at a temperature of 700° C. to less than 1000° C. for a period of time of 10 to 420 minutes and a second step of permitting proceeding of sintering at a temperature of 1000° C. to 1200° C. The average crystal grain size of the rare earth magnet after the sintering is controlled to be 3 ?m to 9 ?m.
    Type: Grant
    Filed: June 22, 2004
    Date of Patent: November 28, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Futoshi Kuniyoshi, Hitoshi Morimoto
  • Patent number: 7138018
    Abstract: A method for manufacturing an anisotropic magnet powder includes a high-temperature hydrogenation process of holding an RFeB-based alloy containing rare earth elements (R), B and Fe as main ingredients in a treating atmosphere under a first treating pressure (P1) of which a hydrogen partial pressure ranges from 10 to 100 kPa and at a first treating temperature (T1) which ranges from 953 to 1133 K, a structure stabilization process of holding the RFeB-based alloy after the high-temperature hydrogenation process under a second treating pressure (P2) of which a hydrogen partial pressure is 10 or more and at a second treating temperature (T2) which ranges from 1033 to 1213 K such that the condition T2>T1 or P2>P1 is satisfied, a controlled evacuation process of holding the RFeB-based alloy after the structure stabilization process in a treating atmosphere under a third treating pressure (P3) of which a hydrogen partial pressure ranges from 0.
    Type: Grant
    Filed: January 15, 2004
    Date of Patent: November 21, 2006
    Assignee: Aichi Steel Corporation
    Inventors: Yoshinobu Honkura, Norihiko Hamada, Chisato Mishima
  • Patent number: 7138019
    Abstract: In the step of sintering a compact that is finally to be a magnetostrictive element, when the temperature in a furnace is elevated, the atmosphere in the furnace is evacuated by a vacuum pump to keep the pressure in the furnace at negative pressure in a temperature range that allows thermal decomposition of hydride present in the compact to release hydrogen gas to accelerate release of hydrogen from the compact.
    Type: Grant
    Filed: July 26, 2004
    Date of Patent: November 21, 2006
    Assignee: TDK Corporation
    Inventors: Seigo Tokoro, Shiro Tomizawa, Teruo Mori
  • Patent number: 7132018
    Abstract: 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: Grant
    Filed: April 28, 2003
    Date of Patent: November 7, 2006
    Assignee: Magnetic Metals Corporation
    Inventors: Richard Wood, Richard Lathlaen
  • Patent number: 7077919
    Abstract: 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: Grant
    Filed: June 5, 2003
    Date of Patent: July 18, 2006
    Assignee: Magnetic Metals Corporation
    Inventors: Richard Wood, Richard Lathlaen, William C. Beckham
  • Patent number: 7056393
    Abstract: A method of making a sintered body for a rare earth magnet includes the steps of (a) preparing a first coarse powder by coarsely pulverizing a rare earth alloy sintered body by a hydrogen pulverization process, (b) preparing a first fine powder by finely pulverizing the first coarse powder, (c) preparing a second fine powder by pulverizing an alloy block of a rare earth alloy material, and (d) sintering a mixed powder including the first and second fine powders. The first and second fine powders each includes a main phase represented by (LR1-xHRx)2T14A, where T is Fe and/or at least one non-Fe transition metal element; A is boron and/or carbon; LR is at least one light rare earth element; HR is at least one heavy rare earth element; and 0?x<1.
    Type: Grant
    Filed: May 28, 2002
    Date of Patent: June 6, 2006
    Assignee: Neomax, Co., Ltd.
    Inventors: Koki Tokuhara, Hitoshi Morimoto
  • Patent number: 7018485
    Abstract: An apparatus for subjecting a rare earth alloy block to a hydrogenation process includes a casing, gas inlet and outlet ports, a member arranged to produce a gaseous flow, and a windbreak plate. The casing defines an inner space for receiving a container. The container includes an upper opening and stores the rare earth alloy block therein. A hydrogen gas and an inert gas are introduced into the inner space through the gas inlet port, and are exhausted from the inner space through the gas outlet port. The gaseous flow is produced by a fan, for example, in the inner space. The windbreak plate is disposed upstream with respect to the gaseous flow that has been produced inside the inner space. Also, the windbreak plate reduces a flow rate of the gaseous flow that has been produced near the upper opening of the container.
    Type: Grant
    Filed: June 25, 2002
    Date of Patent: March 28, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Akihito Tsujimoto, Katsumi Okayama, Shinji Kidowaki, Tadayoshi Muneto
  • Patent number: 7011718
    Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
    Type: Grant
    Filed: October 24, 2002
    Date of Patent: March 14, 2006
    Assignee: Metglas, Inc.
    Inventors: Nicholas J. Decristofaro, Gordon E. Fish, Scott M. Lindquist, Peter J. Stamatis
  • Patent number: 6989062
    Abstract: The present invention concerns a method of improving the properties of powder metallurgically produced SMC compacted body consisting of a soft magnetic material of insulated powder particles and a lubricant, to a stress relieving heat treatment in a furnace until the component has reached a temperature of at least 400° C. in an oxygen containing atmosphere having a CO content is less than 0.25% by volume.
    Type: Grant
    Filed: February 14, 2003
    Date of Patent: January 24, 2006
    Assignee: Höganäs AB
    Inventors: Ye Zhou, Per-Olof Larsson, Henrik Andersson, Lars Hultman
  • Patent number: 6955729
    Abstract: An alloy for bonded magnets of the present invention includes at least a main component of iron (Fe), 12-16 atomic % (at %) of rare-earth elements (R) including yttrium (Y), and 10.8-15 at % of boron (B), and is subjected to a hydrogen treatment method as HDDR process or d-HDDR process. Using the magnet powder obtained from carrying out d-HDDR processing, etc. on this magnet alloy, pellets with superior insertion characteristics into bonded magnet molding dies can be obtained, and bonded magnets with superior magnetic properties and showing low cost can be obtained.
    Type: Grant
    Filed: June 28, 2002
    Date of Patent: October 18, 2005
    Assignee: Aichi Steel Corporation
    Inventors: Yoshinobu Honkura, Norihiko Hamada, Chisato Mishima
  • Patent number: 6780255
    Abstract: A magnetic powder of an Sm—Fe—N alloy, which has a mean particle diameter of 0.5 to 10 &mgr;m, and either an average acicularity of 75% or above or an average sphericity of 78% or above. The powder exhibits an extremely high residual magnetization and an extremely high coercive force, since particles characterized by the above acicularity or sphericity have particle diameters approximately equal to that of the single domain particle and nearly spherical particle shapes. The powder can be produced by preparing an Sm—Fe oxide by firing a coprecipitate corresponding to the oxide, mixing the obtained oxide with metallic calcium and subjecting the mixture to reduction/diffusion and nitriding successively.
    Type: Grant
    Filed: November 13, 2001
    Date of Patent: August 24, 2004
    Assignee: Nichia Chemical Industries, Ltd.
    Inventors: Yohsiyuki Kawano, Michiya Kume, Keiji Ichinomiya
  • Publication number: 20040161600
    Abstract: An object of the present invention is to provide a composite soft magnetic sintered material that has high density, high mechanical strength and high relative magnetic permeability at high frequencies and, in order to achieve this object, the present invention provides a method of producing the composite soft magnetic sintered material, which comprises mixing a composite soft magnetic powder, that consists of iron powder, Fe—Si based soft magnetic iron alloy powder, Fe—Al based soft magnetic iron alloy powder, Fe—Si—Al based soft magnetic iron alloy powder, Fe—Cr based soft magnetic iron alloy powder or nickel-based soft magnetic alloy powder (hereinafter these powders are referred to as soft magnetic metal powder) of which particles arc coated with a ferrite layer which has a spinel structure, with 0.05 to 1.
    Type: Application
    Filed: April 6, 2004
    Publication date: August 19, 2004
    Inventors: Kazunori Igarashi, Ryoji Nakayama, Koichiro Morimoto, Muneaki Watanabe
  • Patent number: 6764607
    Abstract: A powder for forming a R—Fe—B bonded magnet, wherein an R compound, such as an R oxide, an R carbide, an R nitride or an R hydride, which is contained in a raw material powder such as a super rapidly cooled powder or a hydrogen treated powder (HDDR powder) and reacts with water vapor to change into R(OH)3, has been converted to a R hydroxide R(OH)3 being stable in the air by subjecting the raw material powder to a heat treatment in an atmosphere of a pressured water vapor. The powder for forming an R—Fe—B bonded magnet is free from the generation of a white powder in the surface of or inside a bonded magnet formed from the powder and accordingly, is free from the occurrence or cracking, chipping, swelling or the like in the bonded magnet caused by volume expansion of a white powder.
    Type: Grant
    Filed: April 2, 2002
    Date of Patent: July 20, 2004
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventor: Takashi Ikegami
  • Patent number: 6758915
    Abstract: The invention is a grain-oriented magnetic steel sheet having extremely low iron loss, suitable for use as an iron core material for transformers and power generators, and a method for producing the same. The method includes forming a coating layer on a surface of a steel sheet having a thickness of 0.27 mm or less by vapor deposition in a low oxidizing atmosphere with an oxygen partial pressure (Po2) of less than 0.1 atm and a total pressure of 0.1 atm or more. The steel sheet has extremely low iron loss with a thickness of 0.27 mm or less and includes a coating layer formed by vapor deposition on a matrix surface.
    Type: Grant
    Filed: December 5, 2002
    Date of Patent: July 6, 2004
    Assignee: JFE Steel Corporation
    Inventors: Minoru Takashima, Mineo Muraki, Hiroi Yamaguchi, Mitsumasa Kurosawa, Michiro Komatsubara
  • Patent number: 6758918
    Abstract: Disclosed is an isotropic SmFeN powdery magnet material for producing resin-bonded magnets. The magnet powder is prepared by melt-spinning of a molten alloy and nitriding the alloy powder thus obtained to form a magnet alloy having an alloy composition of one of the formulae, by atomic %: SmxFe100-x-vNv, SmxFe100-x-y-vM1yNv and SmxFe100-x-z-vM2zNv wherein M1 is at least one member selected from the group consisting of Hf and Zr; and M2 is at least one member selected from the group consisting of Si, Nb, Ti, Ga, Al, Ta and C; 7≦x≦12, 0.1≦y≦1.5, 0.1≦z≦1.0 and 0.5≦v≦20; the crystal structure is TbCu7 type; and the thickness of the flakes is 10-40 &mgr;m.
    Type: Grant
    Filed: May 29, 2001
    Date of Patent: July 6, 2004
    Assignee: Diado Steel Co., Ltd.
    Inventors: Takahiko Iriyama, Ryo Omatsuzawa, Takayuki Nishio
  • Patent number: 6746545
    Abstract: An R—Fe—B permanent magnet wherein R is Nd or a combination of Nd with a rare earth element is prepared by casting an R—Fe—B alloy, crushing the alloy in an oxygen-free atmosphere of argon, nitrogen or vacuum, effecting comminution, compaction, sintering, aging, and cutting and/or polishing the magnet to give a finished surface. The magnet is then heat treated in an argon, nitrogen or low-pressure vacuum atmosphere having a limited oxygen partial pressure, obtaining a highly oil resistant sintered permanent magnet having corrosion resistance and hydrogen barrier property even in a high pressure hot environment of refrigerant and/or lubricant as encountered in compressors.
    Type: Grant
    Filed: May 30, 2001
    Date of Patent: June 8, 2004
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuo Tamura, Masanobu Shimao, Ryuji Hamada, Takehisa Minowa
  • Patent number: 6709533
    Abstract: This invention aims to provide a manufacturing method of an anisotropic magnet powder from which a bonded magnet with an improved loss of magnetization due to structural changes can be achieved. This is achieved by employing a low-temperature hydrogenation process, high-temperature hydrogenation process and the first evacuation process to an RFeB material (R: rare earth element) to manufacture a hydride powder (RFeBHx); the obtained RFeBHx powder (the precursory anisotropic magnet powder) is subsequently blended with a diffusion powder composed of hydride of dysprosium or the like and a diffusion heat-treatment process and a dehydrogenation process are employed. Through this series of processes, an anisotropic magnet powder with a great coercivity and a great degree of anisotropy can be achieved.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: March 23, 2004
    Assignee: Aichi Steel Corporation
    Inventors: Yoshinobu Honkura, Norihiko Hamada, Chisato Mishima
  • Publication number: 20040007291
    Abstract: 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: Application
    Filed: June 5, 2003
    Publication date: January 15, 2004
    Inventors: Richard Wood, Richard Lathlaen, William C. Beckham
  • Patent number: 6623541
    Abstract: A sintered rare earth magnet consisting essentially of 20-30% by weight of R (wherein R is Sm or a mixture of Sm and another rare earth element), 10-45% by weight of Fe, 1-10% by weight of Cu, 0.5-5% by weight of Zr, and the balance of Co has on its surface a composite layer containing Sm2O3 and/or CoFe2O4 in Co or Co and Fe. The magnet is resistant to hydrogen embrittlement.
    Type: Grant
    Filed: July 30, 2001
    Date of Patent: September 23, 2003
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuaki Sakaki, Masanobu Shimao, Hajime Nakamura, Takehisa Minowa
  • Publication number: 20030172995
    Abstract: Permanent magnets in which the ferromagnetic phase is matched with the grain boundary phase, and permanent magnets in which magnetocrystalline anisotropy in the vicinity of the outermost shell of the major phase is equivalent in intensity to that in the inside to suppress nucleation of the reverse magnetic domain, more specifically having a magnetocrystalline anisotropy not less than one-half the magnetocrystalline anisotropy of the interiors of the ferromagnetic grains, are disclosed.
    Type: Application
    Filed: September 27, 2002
    Publication date: September 18, 2003
    Applicant: Sumitomo Special Metals Co., Ltd.
    Inventors: Ken Makita, Osamu Yamashita
  • Publication number: 20030136471
    Abstract: 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: Application
    Filed: October 8, 2002
    Publication date: July 24, 2003
    Applicant: SUMITOMO SPECIAL METALS CO., LTD.
    Inventors: Atsushi Kikugawa, Fumiaki Kikui
  • Patent number: 6596101
    Abstract: Preferred embodiments of the invention provide new nanostructured materials and methods for preparing nanostructured materials having increased tensile strength and ductility, increased hardness, and very fine grain sizes making such materials useful for a variety of applications such as rotors, electric generators, magnetic bearings, aerospace and many other structural and nonstructural applications. The preferred nanostructured materials have a tensile yield strength from at least about 1.9 to about 2.3 GPa and a tensile ductility from at least 1%. Preferred embodiments of the invention also provide a method of making a nanostructured material comprising melting a metallic material, solidifying the material, deforming the material, forming a plurality of dislocation cell structures, annealing the deformed material at a temperature from about 0.30 to about 0.70 of its absolute melting temperature, and cooling the material.
    Type: Grant
    Filed: October 3, 2001
    Date of Patent: July 22, 2003
    Assignee: Johns Hopkins University
    Inventors: Timothy P. Weihs, Robert Cammarata, Chia-Ling Chien, Changhe Shang
  • Patent number: 6588092
    Abstract: Method for producing a magnetic head of a pair of magnetic core halves combined with a nonmagnetic layer therebetween including forming a winding window in at least one of a pair of generally flat oxide magnetic plates, forming at least one underlying layer on each oxide magnetic plate, forming a metal magnetic thin film on the underlying layer containing magnetic crystalline particles having average volume Va and average surface area Sa fulfilling the relationship Sa>about 4.64 Va¾, forming a groove in a body including the oxide magnetic plate, underlying layer and metal magnetic thin film, and combining the body with another body including an oxide magnetic plate and a metal magnetic thin film with a nonmagnetic layer therebetween, where the metal magnetic thin film is formed in such a manner to prevent the oxide magnetic plates from cracking due to internal stress generated in the metal magnetic thin film.
    Type: Grant
    Filed: December 28, 2001
    Date of Patent: July 8, 2003
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Nozomu Matsukawa, Masayoshi Hiramoto, Hiroshi Sakakima, Koichi Osano, Eisuke Sawai
  • Patent number: 6537389
    Abstract: A magnetically soft, moldable composite material include powder grains coated with nonmagnetic thermoplastic compounds or with molecular precursors for ceramics or with intermetallic compounds, the magnetic properties of the magnetically soft composite material being adjustable in that fashion. Also described is a method for manufacturing a magnetically soft, shapable composite material coated in that fashion, which can subsequently be processed into shaped parts.
    Type: Grant
    Filed: August 13, 1999
    Date of Patent: March 25, 2003
    Assignee: Robert Bosch GmbH
    Inventors: Wilfried Aichele, Hans-Peter Koch
  • Publication number: 20030041920
    Abstract: A method for preparing a coated R-T-B magnet wherein a R-T-B magnet having a R2T14B intermetallic compound, wherein R represents al least one of the rare earth elements including Y, T represents Fe or Fe and Co, as a primary phase is subjected to a chemical treatment, characterized in that the R-T-B magnet is treated with a chemical treating solution which has a molar ratio of Mo to P, Mo/P, of 12 to 60, contains a molybdophosphiate ion as a primary component and is adjusted to have a pH of 4.2 to 6. The resultant chemical coating comprises an oxide of Mo and a hydroxide of R. The oxide of Mo consists essentially of amorphous MoO2.
    Type: Application
    Filed: August 12, 2002
    Publication date: March 6, 2003
    Inventors: Hiroyuki Hoshi, Setsuo Ando
  • Patent number: 6491765
    Abstract: The method for manufacturing alloy powder for R—Fe—B type rare earth magnets of the present invention includes a first pulverization step of coarsely pulverizing a material alloy for rare earth magnets and a second pulverization step of finely pulverizing the material alloy. In the first pulverization step, the material alloy is pulverized by a hydrogen pulverization method. In the second pulverization step, easily oxidized super-fine powder (particle size: 1.0 &mgr;m or less) is removed to adjust the particle quantity of the super-fine powder to 10% or less of the particle quantity of the entire powder.
    Type: Grant
    Filed: May 9, 2001
    Date of Patent: December 10, 2002
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Katsumi Okayama, Naoyuki Ishigaki, Shuhei Okumura
  • Patent number: 6485579
    Abstract: The invention concerns a process for the preparation of soft magnetic composite products comprising the steps of providing particles of an iron based soft magnetic material with an electrically insulating layer; optionally mixing the dry powder with a lubricant; compacting the powder and heating the obtained component at an elevated temperature in the presence of water vapour. The invention also comprises the iron powder compact subjected to this treatment.
    Type: Grant
    Filed: January 18, 2000
    Date of Patent: November 26, 2002
    Assignee: Höganäs AB
    Inventors: Magdalena Nillius, Patricia Jansson
  • Patent number: 6468440
    Abstract: Magnet powder has a composition expressed by (R1XR2YBZT100−X−Y−Z)100−QNQ (in formula, R1 is at least one kind of element selected from rare earth elements, R2 is at least one kind of element selected from Zr, Hf and Sc, T is at least one kind of element selected from Fe and Co, and X, Y, Z and Q are numbers satisfying 2 atomic %≦X, 0.01 atomic %≦Y, 4≦X+Y≧20 atomic %, 0≦Z≦10 atomic %, and 0.1≦Q≦20 atomic %, respectively), and TbCu7 crystal phase as a principal phase. In such magnet powder, a ratio of fine particles of which maximum diameter is 22 &mgr;m or less is 20% by weight or less. Alternatively, surface roughness of particles constituting the magnet powder is 5 &mgr;m or less in terms of maximum height Ry provided in JIS B 0601-1994. Accordingly, to such a magnet powder, excellent magnetic properties can be obtained with reproducibility.
    Type: Grant
    Filed: September 22, 2000
    Date of Patent: October 22, 2002
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Shinya Sakurada, Tomohisa Arai, Masami Okamura, Keisuke Hashimoto, Takahiro Hirai
  • Patent number: 6444052
    Abstract: A production method to produce an anisotropic NdFeB based alloy magnet having a high anisotropic ratio and coercivity by a simple procedure. The production method consists of a first hydrogenation process, a second hydrogenation process and a desorption process. The first hydrogenation process at a low temperature produces the hydride that stores hydrogen needed in advance of the phase transformation. After that, the second hydrogenation process at an elevated temperature proceeds smoothly at a moderate reaction rate of the phase transformation and produces the mixture of NdH2, Fe and Fe2 B from the hydride in addition to making the crystallographic orientation of Fe2 B phase consistent with the original R2 Fe14 B matrix phase. Subsequently, the desorption process produces the fine grained microstructure of Nd2 Fe14 BHx with high degrees of alignment of the crystallographic orientation consistent with the original crystallographic orientation of Fe2 B phase.
    Type: Grant
    Filed: October 13, 1999
    Date of Patent: September 3, 2002
    Assignee: Aichi Steel Corporation
    Inventors: Yoshinobu Honkura, Chisato Mishima
  • Publication number: 20020108677
    Abstract: 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: Application
    Filed: August 27, 2001
    Publication date: August 15, 2002
    Inventors: Xiaohui Wang, Longtu Li, Ji Zhou, Zhengxing Yue, Zhenwei Ma, Shuiyuan Su
  • Patent number: 6423156
    Abstract: The invention relates to a process for the coating of electric steel strips with an oxide powder as annealing separator by the application of an aqueous solution which contains mainly MgO and also at least one additive, including a chlorine-containing compound. The characterizing feature of the invention is that the additive added to the aqueous solution is ammonium chloride (NH4Cl or NH4Cl.nH2O).
    Type: Grant
    Filed: June 6, 2000
    Date of Patent: July 23, 2002
    Assignee: EBG Gesellschaft für Elektromagnetische Werkstoffe mbH
    Inventors: Klaus Günther, Heiner Schrapers
  • Patent number: 6416593
    Abstract: A magnetic material has a composition expressed by the following general formula, general formula: {(R1XR21-X)YBZT1-Y-Z}1-QNQ (where, R1 is at least one kind of element selected from rare earth elements, R2 is at least one kind of element selected from Zr, Hf, Ti and Sc, T is at least one kind of element selected from Fe and Co, and X, Y, Z and Q designate numerical values satisfying 0.5≦X<1, 0.05≦Y≦0.2, 0≦Z≦0.1 and 0.1≦Q≦0.2), and includes 5 volume % or more of a Th2Ni17 crystal phase. The magnetic material has a recrystallization texture of which average grain diameter is in the range of from 0.02 to 50 &mgr;m, and is excellent in magnetic property. Such a magnetic material is obtained by giving a HDDR treatment to a mother alloy of which principal phase is a Th2Ni17 crystal phase.
    Type: Grant
    Filed: August 16, 2001
    Date of Patent: July 9, 2002
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Shinya Sakurada, Tomohisa Arai, Masami Okamura, Keisuke Hashimoto, Takahiro Hirai
  • Patent number: 6416594
    Abstract: A heat shrink band steel sheet of the present invention comprises on the basis of percent in weight C: 0.1% or less, Si: 0.1% or less, Mn: 0.1 to 2%, P: 0.15% or less, S: 0.02% or less, sol Al: 0.08% or less, and N: 0.005% or less, or C: 0.005% or less, Si: 0.1% or less, Mn: 0.1 to 2%, P: 0.15% or less, S: 0.02% or less, sol Al: 0.08% or less, N: 0.005% or less, Ti: 0.02 to 0.06%, and B: 0.0003 to 0.005%, wherein the product of a magnetic permeability at the magnetic field of 0.3 Oe after heat shrinking treatment and a thickness (mm) is at least 350. A color CRT having a sufficient magnetic shielding characteristic and a less amount of color deviation can be realized by the steel sheet.
    Type: Grant
    Filed: October 5, 2000
    Date of Patent: July 9, 2002
    Assignee: NKK Corporation
    Inventors: Nobuo Yamagami, Kunikazu Tomita, Yasuyuki Takada, Yoshihiko Oda, Hideki Matsuoka, Tatsuhiko Hiratani, Katsumi Nakajima, Kenji Tahara
  • Patent number: 6406559
    Abstract: A magnetic material essentially consists of a composition represented by general formula: R1XR2YBZNUHVM100-X-Y-Z-C-V (in the formula, R1 denotes at least one kind element selected from rare earth elements, R2 denotes at least one kind element selected from Zr, Hf and Sc, M denotes at least one kind element selected from Fe and Co, X, Y, Z, U and V are numbers satisfying 2 at. %≦X, 0.01 at. %≦Y, 4≦X+Y≦20 at. %, 0≦Z≦10 at. %, 0.1≦U≦18 at. %, 0.01≦V≦10 at. %, respectively), and comprises a TbCu7 type crystal phase as a principal phase. A nitriding treatment to a mother alloy is carried out in a mixed gas of ammonia gas and hydrogen gas of which partial pressure ratio is set in the range of 3<Py/Px when partial pressure of ammonia gas is PX, that of the hydrogen gas is Py.
    Type: Grant
    Filed: July 13, 2001
    Date of Patent: June 18, 2002
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Shinya Sakurada, Takahiro Hirai, Keisuke Hashimoto, Tomohisa Arai
  • Publication number: 20020053372
    Abstract: A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic materials can provide magnets having excellent magnetic properties and 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 on which dimple correcting means is provided. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5 in an inert gas atmosphere (ambient gas) such as helium gas, so that the molten alloy 6 is cooled and then solidified.
    Type: Application
    Filed: May 30, 2001
    Publication date: May 9, 2002
    Inventors: Akira Arai, Hiroshi Kato
  • Patent number: 6375761
    Abstract: A magnetoresistive material with two metallic magnetic phases. The material exhibits the giant magnetoresistance effect (GMR). A first phase of the material includes a matrix of an electrically conductive ferromagnetic transition metal or an alloy thereof. A second precipitate phase exhibits ferromagnetic behavior when precipitated into the matrix and is antiferromagnetically exchange coupled to the first phase. The second precipitate phase can be electrically conductive rare earth pnictide or can be a Heusler alloy. A method of manufacturing magnetoresistive materials according to the present invention employs facing targets magnetron sputtering.
    Type: Grant
    Filed: April 30, 2001
    Date of Patent: April 23, 2002
    Assignee: The Research Foundation of State University of New York
    Inventors: Richard J. Gambino, Taewan Kim