Core (e.g., Compressed Powder) Patents (Class 336/233)
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Publication number: 20090295529Abstract: Core structures that may be used in transformers to improve the number of turns-ratios available. The core structures may include at least three outer legs and a center leg. In operation windings of the transformer may be wrapped around the center leg (e.g., using a bobbin) a fractional number of times, such that the turns-ratio of the transformer may be more finely selected without increasing the number of turns required. Additionally, the outer legs may have different cross-sectional areas, such that even more fractional turns-ratios are available.Type: ApplicationFiled: May 28, 2009Publication date: December 3, 2009Inventor: Arturo Silva
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Patent number: 7626304Abstract: There is provided a stator in which a plurality of divided stators are annularly combined with each other, and each divided stator includes: a divided lamination iron core having teeth portion and a yoke portion, and constructed by laminating electromagnetic steel sheets divided by the teeth unit; insulating bodies provided at the divided lamination iron core; and concentrated winding wound around the divided lamination iron core through the insulating body. In this case, the divided lamination iron core is held by the insulating bodies and the concentrated winding.Type: GrantFiled: July 11, 2006Date of Patent: December 1, 2009Assignee: Panasonic CorporationInventors: Masayuki Morioka, Yasuaki Matsushita, Yoshihiro Kira, Shinya Tamura
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Publication number: 20090273431Abstract: In a continuous flux path transformer core, at least part of the core is implemented in non-grain oriented steel.Type: ApplicationFiled: May 2, 2008Publication date: November 5, 2009Inventor: John Shirley Hurst
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Publication number: 20090267722Abstract: An apparatus includes a magnetic core, a ground node, and one or more vias to provide a connection between the magnetic core and the ground potential. The magnetic core includes a first magnetic layer and a second magnetic layer. In addition, the apparatus may include a conductive pattern. The conductive pattern may be at a third layer between the first and second magnetic layers. The apparatus may be included in inductors, transformers, transmission lines, and other components using ferromagnetic cores or shields. Such components may be integrated on a chip or die.Type: ApplicationFiled: April 29, 2009Publication date: October 29, 2009Inventors: GERHARD SCHROM, DONALD GARDNER, PETER HAZUCHA, FABRICE PAILLET, TANAY KARNIK
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Patent number: 7609140Abstract: There is provided a molded body having high fixing strength between a magnetic mold material and an external electrode. The molded body uses the magnetic mold material comprising at least 65 vol % of magnetic powder and up to 35 vol % of resin and the external electrode that has pits and projections on a surface that makes contact with the magnetic mold material. The external electrode and the magnetic mold material are integrally-molded such that at least a portion of the external electrode is exposed at at least one surface of the molded body. Spacing between the pit and projection of the external electrode is smaller than the maximum particle size of the magnetic powder.Type: GrantFiled: January 14, 2009Date of Patent: October 27, 2009Assignee: Toko, Inc.Inventor: Yoshizumi Fukui
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Patent number: 7608968Abstract: A stator core includes first and second annular dust core pieces. Each of the first and second annular dust core pieces has a plurality of arcuate dust core pieces each integrally having a yoke extending in an arc shape and a tooth projecting in a radial direction of the yoke. The plurality of arcuate dust core pieces are each disposed along a circumferential direction of the yoke and joined together, and the first and second annular dust core pieces are stacked in a height direction and joined together. Thereby, an increase in size of a pressing machine can be suppressed, good magnetic properties can be obtained, and handling can be facilitated.Type: GrantFiled: April 25, 2005Date of Patent: October 27, 2009Assignee: Sumitomo Electric Industries, Ltd.Inventors: Haruhisa Toyoda, Kazuhiro Hirose, Atsushi Sato
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Patent number: 7589609Abstract: A multilayer inductor component has a multilayer part having a plurality of magnetic layers laminated therein and a conductor part arranged within the multilayer part. The magnetic layers are formed from a ferrite material and an additive. The ferrite material contains Fe2O3, NiO, CuO, and ZnO. Fe2O3 is 30 to 45 mol %. NiO is 45 to 58 mol %. CuO is 6 to 10 mol %. ZnO is 0 to 3 mol %. The additive contains CoO. The content of CoO is 0.1 to 2.5 mass % with respect to the ferrite material as a whole. The multilayer inductor component has an impedance peak of 500 ? or greater at an operating frequency of 1 GHz or higher.Type: GrantFiled: May 5, 2008Date of Patent: September 15, 2009Assignee: TDK CorporationInventors: Naoki Sutoh, Takashi Suzuki, Kunio Oda, Yukio Takahashi, Kunihiko Kawasaki, Hiroshi Momoi
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Patent number: 7583173Abstract: A nanocrystallised tape-wound core without a localised airgap, consisting of a nanocrystalline material with the following atomic composition: [Fe1-aNia]100-x-y-z-a-?-?CuxSiyBzNbaM??M??, wherein a?0.3, 0.6?x?1.5, 10?y?17, 5?z?14, 2?a?6, ??7, ??8, M? is at least one of the elements V, Cr, Al and Zn, M? is at least one of the elements C, Ge, P, Ga, Sb, In and Be, with a permeability ? of 200 to 4000, a saturation of more than 1T, an induction range, in which the permeability does not vary by more than 5%, of more than 0.9T, a remanent induction of less than 0.02T and a cut-off frequency higher than 1 MHz, such that ? varies by less than 1% when the core is aged for 100h at more than 100° C., ? varies by less than 5% when the core is coated, ? varies by less than 15% when the temperature is in the range of ?25° C. and +60° C., and by less than 25% when the temperature is in the range of ?40° C. and +120° C., and ? varies in a monotonic and substantially linear manner with a temperature of ?40° C. to +120° C.Type: GrantFiled: October 26, 2005Date of Patent: September 1, 2009Assignee: Imphy AlloysInventors: Thierry Waeckerle, Fabien Simon, Francisco Alves, Thierry Save, Alain Demier
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Patent number: 7579723Abstract: A power magnetic core has a start section and a termination section. In the powder magnetic core, lines of magnetic force are formed from the start section to the termination section. The powder magnetic core comprises a first portion disposed on the shortest magnetic path of the lines of magnetic force that connects the start section and the termination section and having a permeability ?a and a second portion disposed apart from the shortest magnetic path of the lines of magnetic force and having a permeability ?b greater than ?a. With this constitution, a desired magnetic characteristic is achieved, and the iron loss is sufficiently reduced.Type: GrantFiled: December 15, 2004Date of Patent: August 25, 2009Assignees: Sumitomo Electric Industries, Ltd., Toyota Jidosha Kabushiki KaishaInventors: Haruhisa Toyoda, Naoto Igarashi, Hitoshi Oyama, Yasuhiro Endo, Ryoji Mizutani
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Publication number: 20090206975Abstract: Magnet cores pressed using a powder of nanocrystalline or amorphous particles and a pressing additive should be characterised by minimal iron losses. These particles have first surfaces represented by the original strip surfaces and second surfaces represented by surfaces produced in a pulverisation process, the overwhelming majority of these second particle surfaces being smooth cut or fracture surfaces without any plastic deformation, the proportion T of areas of plastic deformation of the second particle surfaces being 0?T?0.5.Type: ApplicationFiled: June 19, 2007Publication date: August 20, 2009Inventors: Dieter Nuetzel, Markus Brunner
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Patent number: 7570145Abstract: A magnetic multi-element alloy film adapted to be used in a high-frequency operation is provided. The magnetic multi-element alloy film is employed to improve a Q factor and an inductance value of a thin film inductor operated in high frequency. The design concept of a multi-element high-entropy alloy is introduced into the magnetic multi-element alloy film. With material characteristics including high randomness, nanometer microcrystalline structure, low coercive magnetic field and high resistivity, the magnetic multi-element alloy film can still have favorable soft magnetism when operated in high frequency.Type: GrantFiled: October 31, 2007Date of Patent: August 4, 2009Assignee: Industrial Technology Research InstituteInventors: Jien-Wei Yeh, Wen-Chen Chang, Chih-Chao Yang, Nai-Wen Cheng
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Publication number: 20090184705Abstract: A magnetic core for a current transformer, and a current transformer and a watt hour meter used thereof, which is preferred the detection of a alternate current with a large asymmetrical waveform and a alternate current which a direct current is superimposed are realized. A magnetic core for a current transformer comprising the composition represented by the general formula: Fe100-x-a-y-cMxCuaM?yX?c (atomic %), wherein M is at least one element selected from Co and Ni, M? is at least one element selected from V, Ti, Zr, Nb, Mo, Hf, Ta, X? is at least one element selected from Si and B, and x, a, y, and c meets the composition of 3?x?50, 0.1?a?3, 1?y?10, 2?c?30, and also 7?y+c?30, and an alloy comprising a crystal grain consisting of at least a part or all of the composition with a mean particle size of less than or equal to 50 nm.Type: ApplicationFiled: March 19, 2007Publication date: July 23, 2009Inventor: Yoshihito Yoshizawa
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Patent number: 7554431Abstract: An induction device having windings of different phases arranged around magnetic core limbs. The magnetic core limbs are connected by at least one body formed from magnetic particles in a matrix of a dielectric material.Type: GrantFiled: October 19, 2005Date of Patent: June 30, 2009Assignee: ABB ABInventors: Mikael Dahlgren, Udo Fromm, Gunnar Russberg, Christian Sasse, Anders Eriksson, Tomas Jonsson, Svante Soderholm
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Patent number: 7541909Abstract: A filter circuit is used to select frequency bands of digital and analog signals over communications channels in a DSL communications system. The filter circuit includes an inductor having a core that consists essentially of an Fe-base amorphous metal alloy. Advantageously, the filter circuit provides as good or better performance than a filter circuit using a Co-base core; but is much less expensive. As such, it provides a low cost, high efficiency solution to communications applications, such as DSL communications systems, and the like.Type: GrantFiled: February 8, 2002Date of Patent: June 2, 2009Assignee: Metglas, Inc.Inventors: Ryusuke Hasegawa, Ronald J. Martis, Seshu V. Tatikola
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Publication number: 20090121820Abstract: Disclosed is a highly heat-resistant core which has a dust core as a base body. A dust core obtained by press-molding magnetic powder particles particles each of which are covered with an insulating film is used as the base body. An inorganic heat-resistant insulating film is formed on at least a part of a surface of the dust core which faces a winding wire.Type: ApplicationFiled: September 8, 2006Publication date: May 14, 2009Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazutaka Tatematsu, Ryoji Mizutani, Yasuhiro Endo
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Publication number: 20090115561Abstract: Generally, a low-profile planar core structure for use in magnetic components and related processes are presented herein. More specifically, the planar core structure provides a relatively large winding area that reduces heat dissipation, reduces leakage inductance, and allows for a low-profile design. The planar core structure has a center core that is elongated along a horizontal axis. Furthermore, conductors may enter and exit the planar core structure without increasing its height.Type: ApplicationFiled: November 6, 2007Publication date: May 7, 2009Inventors: ANTONY BRINLEE, ARTURO SILVA
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Patent number: 7527744Abstract: An NiCuZn-base ferrite of the invention comprises as main components an iron oxide in an amount of 45.0 to 49.0 mol % on Fe2O3 basis, an copper oxide in an amount of 5.0 to 14.0 mol % on CuO basis and a zinc oxide in an amount of 1.0 to 32.0 mol % on ZnO basis with a nickel oxide accounting for the rest mol % on NiO basis. With respect to the main components, a bismuth oxide is contained in an amount of 0.25 exclusive to 0.40% by weight on Bi2O3 basis, and a tin oxide is contained in an amount of 1.00 to 2.50% by weight on SnO2 basis. The invention ensures a leap upward in direct-current bias characteristics.Type: GrantFiled: August 30, 2006Date of Patent: May 5, 2009Assignee: TDK CorporationInventors: Ryuichi Wada, Takuya Aoki, Hiroshi Momoi, Yukio Takahashi, Takahiro Satoh
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Publication number: 20090102589Abstract: An inductor includes a coil and a core. The core covers the coil and includes a plurality of magnetic particles. Each of the magnetic particles includes a nucleus and a first shell enveloping the nucleus. The nucleus and the first shell are formed by different materials with different specific gravities. When the nucleus includes a polymer material, the first shell includes the first magnetic material. When the nucleus includes the first magnetic material, the first shell includes the polymer material.Type: ApplicationFiled: May 5, 2008Publication date: April 23, 2009Inventors: Cheng-Chang LEE, Zong-Ting YUAN, Heng-Chung CHANG, Huang-Kun CHEN, Tai-Kang SHING
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Publication number: 20090095380Abstract: A metallic magnetic material for magnetic element for magnetic element of a choke coil and an SMD choke power coil for accommodating low voltage and high current in a personal computer, graphic card, high frequency power supply, etc, is prepared by baking a powder of Fe—Si—Al alloy sendust, obtained by an atomization process and having an average particle diameter of 10 to 70 ?m, at 600° C. to 1000° C. in air or in an oxidizing atmosphere and mixing the baked sendust with 3 to 45 wt % of a carbonyl iron powder with an average particle diameter of 1 to 10 ?m. The metallic magnetic material for magnetic element according to the present invention is used in a coil-embedded SMD power choke coil having a square or rectangular shape with a height of 1 mm to 7 mm and with a length of one side being 3 mm to 13 mm.Type: ApplicationFiled: November 30, 2007Publication date: April 16, 2009Applicant: SEKISIN INDUSTRY CO., LTD.Inventors: Namio SATO, Yotaro TOYOSHIMA, Katsutoshi YAMAMOTO
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Publication number: 20090066467Abstract: A micromagnetic device including a substrate, and a magnetic core layer formed over the substrate from a magnetic alloy. The magnetic alloy includes iron, cobalt and phosphorous. A content of the cobalt is in a range of 1.8 to 4.5 atomic percent. A content of the phosphorus is in a range of 20.1 to 30 atomic percent. A content of the iron is substantially a remaining proportion of the magnetic alloy.Type: ApplicationFiled: September 10, 2007Publication date: March 12, 2009Inventors: Ashraf W. Lotfi, Trifon M. Liakopoulos, Robert W. Filas
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Publication number: 20090066468Abstract: A power converter including a power train, a controller and a driver. The power train includes a switch that conducts for a duty cycle and provides a regulated output characteristic for the power converter, and a micromagnetic device interposed between the switch and the output of the power converter. The micromagnetic device includes a substrate, and a magnetic core layer formed over the substrate from a magnetic alloy including iron, cobalt and phosphorous. A content of the cobalt is in a range of 1.8 to 4.5 atomic percent. A content of the phosphorus is in a range of 20.1 to 30 atomic percent. A content of the iron is substantially a remaining proportion of the magnetic alloy. The controller provides a signal to control the duty cycle of the switch. The driver provides a drive signal to the switch as a function of the signal from the controller.Type: ApplicationFiled: September 10, 2007Publication date: March 12, 2009Inventors: Ashraf W. Lotfi, Trifon M. Liakopoulos, Robert W. Filas
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Patent number: 7501925Abstract: A magnetic core made of a mixed material including powder of an amorphous soft magnetic iron alloy and about 10% by volume or more of nonmagnetic inorganic powder, the amorphous soft magnetic iron alloy being expressed by the following composition: Fe100-a-b-x-y-z-w-tCOaNibMxPyCzBwSit wherein M is one or two or more elements selected from among Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, and a, b, x, y, z, w and t represent composition ratios satisfying 0 atom %?x?3 atom %, 2 atom %?y?15 atom %, 0 atom %<z?8 atom %, 1 atom %?w?12 atom %, 0.5 atom %?t?8 atom %, 0 atom %?a?20 atom %, 0 atom %?b?5 atom %, and 70 atom %?(100-a-b-x-y-z-w-t)?80 atom %.Type: GrantFiled: September 28, 2007Date of Patent: March 10, 2009Assignee: Alps Electric Co., Ltd.Inventors: Yutaka Naito, Kazuo Aoki, Masatomi Abe, Kazuya Kaneko
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Publication number: 20090045898Abstract: Methods and apparatus according to various aspects of the present invention may be implemented in conjunction with a inductor mount mounting to a mounting surface. The inductor mount may comprise an inductor having a center opening, and a surface area encompassing all of a front face, a back face, an inner surface about the center opening, and an outer edge concentric about the center opening. The inductor mount may further include mounting hardware holding the outer edge of then inductor to the mounting surface. A cooling element moves air into contact with the front face, through the center opening, and around the outer edge of the inductor. In various embodiments, the mounting hardware contacts less that ten percent of the surface area of the inductor.Type: ApplicationFiled: August 22, 2008Publication date: February 19, 2009Inventor: Grant MacLennan
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Publication number: 20090002117Abstract: A coil component is provided, and the coil component for an inductor is deformable dependent on flex of a flexible printed board due to elapse of time when mounted thereon, and has high resistance against dropping impact and has an inductance value. The coil component includes an anisotropic compound magnetic sheet which is layered on at least any one or both of the upper surface and the lower surface of an air core coil formed spirally in a plane and which is composed of flat or needle-shaped soft magnetic metal powder, which has a major axis and a minor axis and is dispersed in a resin material, the major axis of which corresponds to an in-plane direction of the air core coil.Type: ApplicationFiled: June 19, 2008Publication date: January 1, 2009Applicant: SUMIDA CORPORATIONInventor: Mitsugu Kawarai
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Patent number: 7471182Abstract: A means for treating the end faces of a core which is used for an electrical apparatuses and etc., to give insulation extremely superior in effect of improvement of the insulation, corrosion resistance, adhesiveness, heat resistance, and magnetic properties at a low temperature in a short time without cleaning for removing punching oil, annealing, or other pre-treatment; a core having an insulation coating comprised of a dry film of a pure silicone polymer, modified silicone polymer, and/or mixed silicone polymer as a silicone compound on the core end faces and having an average film thickness of at least 0.5 ?m, a breakdown voltage of at least 30V, and a heat resistance in the air of at least 400° C.; and a method of production comprised of forming a core, then dipping it in or spraying it by one or more types of a pure silicone polymer, modified silicone polymer, and/or mixed silicone polymer as an insulation coating.Type: GrantFiled: January 12, 2007Date of Patent: December 30, 2008Assignees: Nippon Steel Corporation, Nittetsu Plant Designing CorporationInventors: Tomoji Kumano, Chikara Kaido, Hiroyasu Fujii, Kazutaka Higashine, Osamu Tanaka, Norikazu Fujii, Kazufumi Hanzawa, Masayoshi Tanaka, Yuji Kubo, Noriko Yamada
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Patent number: 7445852Abstract: A heat treatment was carried out in a pressurized condition on an amorphous metal ribbon containing Fe and Co as main components and being represented by the general formula: (Co(1?c)Fec)100?a?bXaYb. (In the formula, X represents at least one species of element selected from Si, B, C and Ge, Y represents at least one species of element selected from Zr, Nb, Ti, Hf, Ta, W, Cr, Mo, V, Ni, P, Al, Pt, Rh, Ru, Sn, Sb, Cu, Mn and rare earth elements, c, a and b satisfy 0?c?1.0, 10<a?35 and 0?b?30, respectively, and a and b are represented in terms of atomic %.) By carrying out a heat treatment in a pressurized condition in the same manner on a magnetic substrate comprising an amorphous metal ribbon and a heat resistant resin or a laminate of the substrates, not only the magnetic properties but also the mechanical properties and the processability are improved.Type: GrantFiled: July 6, 2004Date of Patent: November 4, 2008Assignee: Mitsui Chemicals, Inc.Inventors: Nobuhiro Maruko, Mitsunobu Yoshida, Hiroshi Watanabe, Takashi Ono, Hidenobu Nogi, Tomoyuki Nakata
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Publication number: 20080231409Abstract: The object of the present invention is to provide a powder core and method for making the same that is equipped with insulative coating having superior heat resistance, with the coating making it possible to adequately restrict the flow of eddy currents between particles. The powder core is equipped with a plurality of compound magnetic particles bonded to each other. Each of said plurality of composite magnetic particles includes: a metal magnetic particle 10; an insulative lower layer coating 20 surrounding a surface 10a of said metal magnetic particle 10; an upper layer coating 30 surrounding said lower layer coating 20 and containing silicon; and dispersed particles 50 containing a metal oxide compound and disposed in said lower layer coating 20 and/or said upper layer coating 30. A mean particle diameter R of the dispersed particles 50 meets the condition 10 nm<R?2 T, where the average thickness of the coating combining the lower layer coating 20 and the upper layer coating 30 is T.Type: ApplicationFiled: January 28, 2005Publication date: September 25, 2008Applicant: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
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Publication number: 20080196795Abstract: The invention relates to a method of producing a strip of nanocrystalline material which is obtained from a wound ribbon that is cast in an amorphous state, having atomic composition [Fe1-a-bCoaNib]100-x-y-z-$g(a)-$g(b)-$g(g)CuxSiyBzNb$g(a)M?$g(b)M$g(g), M? being at least one of elements V, Cr, Al and Zn, and M being at least one of elements C, Ge, P, Ga, Sb, In and Be, with: a $m(F) 0.07 and b $m(F) 0.1, 0.5 $m(F) x $m(F) 1.5 and 2 $m(F) $g(a) $m(F) 5, 10 $m(F) y $m(F) 16.9 and 5 $m(F) z $m(F) 8, $g(b) $m(F) 2 and $g(g) $m(F) 2. According to the invention, the amorphous ribbon is subjected to crystallisation annealing, in which the ribbon undergoes annealing in the unwound state, passing through at least two S-shaped blocks under voltage along an essentially longitudinal axial direction of the ribbon, such that the ribbon is maintained at an annealing temperature of between 530° C. and 700° C. for between 5 and 120 seconds and under axial tensile stress of between 2 and 1000 MPa.Type: ApplicationFiled: May 19, 2006Publication date: August 21, 2008Applicant: IMPHY ALLOYSInventors: Thierry Waeckerle, Thierry Save, Alain Demier
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Publication number: 20080157912Abstract: This invention discloses a monolithic inductor including a body made by compressing a magnetic powder, a coil positioned in the body, and a permanent magnet positioned in the body and in a magnetic circuit formed by applying current to the coil. The monolithic inductor of this invention includes the magnetic body containing the permanent magnet and the coil. The permanent magnet in the magnetic circuit (path of magnetic flux lines) formed by applying current to the coil generates a reverse-bias magnetic field, thereby increasing the operating range of the magnetic body, the saturation current of the magnetic body, and the rated current of the inductor.Type: ApplicationFiled: July 3, 2007Publication date: July 3, 2008Inventors: Mean-Jue Tung, Wen-Song Ko, Yu-Ting Huang, Yen-Ping Wang
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Patent number: 7390449Abstract: A method of manufacturing ceramic bodies comprising the steps of: preparing a ceramic sheet; forming through holes in the ceramic sheet, each of the through hole forming at least one part of the contour of each ceramic bodies; and cutting the ceramic sheet into pieces of ceramic bodies. The ceramic sheet can be a single ceramic sheet or a laminate of ceramic sheets. The method of manufacturing ceramic bodies further comprises a step of forming a recess in the ceramic sheet, or pressure molding or partially removing of the ceramic body, as required. The manufacturing method provides inexpensive production of small ceramic elements having a complicated shape and extremely smooth surfaces with less uneven filling and nonuniform density.Type: GrantFiled: November 6, 2001Date of Patent: June 24, 2008Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Akihiko Ibata, Michio Oba, Toshihiro Yoshizawa
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Publication number: 20080143470Abstract: A coil unit including an annular toroidal core, two coils wound over the toroidal core providing a bifilar winding, a winding-start positioning part, and a winding-end positioning part. The winding-start positioning part is adapted for making contact with a winding-start portion of the coils. The winding-end positioning part is adapted for making contact with a winding-end portion of the coils for regulating the positions of the winding-start portion and the winding-end portion relative to the toroidal core.Type: ApplicationFiled: December 12, 2007Publication date: June 19, 2008Applicant: TDK CORPORATIONInventors: Hiroshi Suzuki, Kazunori Arimitsu, Yutaka Hatakeyama, Hideki Sasaki, Masaru Kumagai
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Patent number: 7378774Abstract: A laminated core having a first number of magnetic poles, the first number being a natural number divided by two, of a rotary electric machine, includes a plurality of arc-shaped unit cores each having a second number of magnetic poles, the second number being a natural number except for an aliquot part of the first number. The unit cores are wound and laminated a predetermined number of times in a circumferential direction into a spiral shape in such a manner that an axial lamination amount of the unit cores is obtained by an equation of X=?*t/360, X being the axial lamination amount, ? being a winding angle of the unit cores, and t being a thickness of the unit core. The unit cores are adjacent to each other in the circumferential direction connected to each other at a part of an outer circumference thereof.Type: GrantFiled: August 25, 2006Date of Patent: May 27, 2008Assignee: Aisin Seiki Kabushiki KaishaInventors: Atsushi Torii, Masafumi Sakuma, Akinori Hoshino, Hiroyuki Yamamoto
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Patent number: 7378036Abstract: A ferrite material of the present invention is configured such that 0.05 to 1.0 wt % of bismuth oxide in terms of Bi2O3, 0.5 to 3.0 wt % of tin oxide in terms of SnO2, and 30 to 5000 wt ppm of chromium oxide in terms of Cr2O3 are added to a predetermined main component mixture composition. Therefore, it is possible to achieve an improvement in DC bias characteristics, an improvement in temperature characteristics of initial magnetic permeability, and an improvement in resistivity and further achieve an improvement in burned body strength, particularly in burned body flexural strength (bending strength).Type: GrantFiled: October 26, 2005Date of Patent: May 27, 2008Assignee: TDK CorporationInventors: Ryuichi Wada, Takuya Aoki, Atsuhito Matsukawa, Kensaku Asakura
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Patent number: 7373715Abstract: A wire-wound type chip coil can take various inductance values while maintaining its outer dimension at a specified fixed value. A chip coil is formed by winding at least two conductive wires regularly in a single layer around a core made of a magnetic material and firmly connecting both ends of each conductive wire to terminal electrodes disposed on respective flanges of the core. This makes it possible to obtain a great current capacity. Furthermore, the inductance decreases because of an increase in the magnetic path length. A great number of different inductance values can be easily obtained by properly selecting parameters including the number of substantially parallel conductive wires, the diameter of each conductive wire, and the number of turns.Type: GrantFiled: February 18, 2005Date of Patent: May 20, 2008Assignee: Murata Manufacturing Co., Ltd.Inventors: Shinya Hirai, Takaomi Toi, Katsuhiko Tsubana, Hiroyuki Yasuzawa
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Publication number: 20080100410Abstract: A soft magnetic alloy powder containing Fe—Ni-based crystal particles is provided as one capable of adequately reducing core loss of a powder magnetic core and achieving satisfactory magnetic characteristics at an effective operating temperature of an element. The present invention provides a soft magnetic alloy powder containing Fe—Ni-based crystal particles containing 45 to 55 mass % Fe and 45 to 55 mass % Ni, relative to a total mass of Fe and Ni, and containing 1 to 12 mass % Co and 1.2 to 6.5 mass % Si, relative to a total mass of Fe, Ni, Co, and Si.Type: ApplicationFiled: October 19, 2007Publication date: May 1, 2008Applicant: TDK CORPORATIONInventors: Hiroshi Tomita, Hideharu Moro, Kesaharu Takatoh, Koyu Enda
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Patent number: 7358844Abstract: A current transformer core has a ratio of the core outside diameter Da to the core inside diameter Di of <1.5, a saturation magnetostriction ?s of =|4| ppm, a circular hysteresis loop with 0.50=Br/Bs=0.85 and an Hcmax=20 mA/cm. The current transformer core is made of a soft magnetic iron alloy in which at least 50% of the alloy structure is occupied by fine-crystalline particles with an average particle size of 100 nm or less, and the iron-based alloy comprises, in essence, one combination.Type: GrantFiled: November 17, 2006Date of Patent: April 15, 2008Assignee: Vacuumschmelze GmbH & Co. KGInventors: Wulf Guenther, Detlef Otte, Joerg Petzold
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Patent number: 7295097Abstract: An electrical energy saving device or a magnetic induction device is adapted to surround a power delivery line. The magnetic induction device applies a magnetic field region to the power delivery line to reduce amperage up to about 25%. The magnetic induction device can be a one-piece or two-piece construction formed from a molded mixture. The mixture can include from about 35 wt % to about 45 wt % of an epoxy resin; from about 30 wt % to about 40 wt % of a polymer; from about 1 wt % to about 4 wt % of dimethyl sulfoxide; from about 4 wt % to about 7 wt % of a transition metal; from about 10 wt % to about 20 wt % of a magnetic material; and from about 1 wt % to about 5 wt % of a catalyst.Type: GrantFiled: July 12, 2005Date of Patent: November 13, 2007Inventor: Jose De Jesus Camarena Villaseñor
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Patent number: 7289013Abstract: A bulk amorphous metal inductive device includes a magnetic core having at least one low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air therein. The component has a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The device has one or more electrical windings and is easily customized for specialized magnetic applications, e.g. for use as a transformer or inductor in power conditioning electronic circuitry employing switch-mode circuit topologies and switching frequencies ranging from 1 kHz to 200 kHz or more. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful at frequencies of 1 kHz or more.Type: GrantFiled: February 14, 2005Date of Patent: October 30, 2007Assignee: Metglas, Inc.Inventors: Nicholas J. Decristofaro, Gordon E. Fish, Ryusuke Hasegawa, Carl E. Kroger, Scott M. Lindquist, Seshu V. Tatikola
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Patent number: 7281315Abstract: An inductor with the characteristic of resisting high current comprising a conductor coil and a magnet envelope, the magnet envelope tightly wraps the periphery of the conductor coil and forms the main body of the inductor, and the two extending parts of the conductor coil extend to outside of the main body of the inductor, forming terminal electrode. As of the manufacturing method, it includes the part of toroid coil and the extending parts composing the conductor coil. After the toroid coil part is winded into rings, the unwinded wire ends form the extending parts. Through magnet envelope die-casting and wrapping the molded magnet core of the conductor coil to form the main body of the inductor, and the extending parts of the conductor coil extend to outside of the main body to form the terminal electrode.Type: GrantFiled: October 20, 2005Date of Patent: October 16, 2007Inventor: Chang Mao Cheng
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Patent number: 7263761Abstract: A high current, low profile inductor includes a conductor coil surrounded by magnetic material to form an inductor body. The inductor coil is formed from a flat plate which is cut into a sine-shaped configuration and then is folded in accordion fashion to create a helical coil.Type: GrantFiled: December 11, 2006Date of Patent: September 4, 2007Assignee: Vishay Dale Electronics, Inc.Inventors: Timothy M. Shafer, Brett W. Jelkin
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Patent number: 7265651Abstract: The invention relates to an inductive component (10) whose soft magnetic core (11) is produced by pouring a casting resin into a mold (1a) filled with a soft magnetic alloy powder and by subsequently hardening the casting resin with the alloy powder in order to form a solid soft magnetic core. Contrary to conventional injection molding methods, this technique prevents the surface insulation of the alloy particles from becoming damaged so that the formation of bulk eddy currents in the resulting soft magnetic cores can be prevented to a large extent. This enables a distinct reduction in the electric loss of the inductive component.Type: GrantFiled: April 5, 2001Date of Patent: September 4, 2007Assignee: Vacuumschmelze GmbH & Co. KGInventor: Markus Brunner
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Patent number: 7257882Abstract: Embodiments of the present invention provide a thin-film coil assembly. The coil assembly includes a substrate, at least two layers of conductive material on top of the substrate, and one layer of insulating material between the two layers of conductive material, wherein the two layers of conductive material are in contact with two interconnects, respectively, which extends substantially vertical to the substrate.Type: GrantFiled: March 22, 2006Date of Patent: August 21, 2007Assignee: International Business Machines CorporationInventors: Alexandra Welzel, Marcus Breuer, Guenther Crolly, Michael Haag, Manfred Jung, Rolf Schaefer
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Patent number: 7235208Abstract: A dust core consists essentially of ferromagnetic powder; and an insulating binder, in which the ferromagnetic powder is dispersed; wherein the insulating binder is a silicone resin comprising a trifunctional alkyl-phenyl silicone resin and optionally containing an inorganic insulator such as an inorganic oxide, carbide or nitride. Preferably the alkyl-phenyl silicone resin is a methyl-phenyl silicone resin and comprises about 20 to 70 mol % of trifunctional groups. The dust core can be produced by pressure-molding a ferromagnetic powder, a lubricant and a trifunctional alkyl-phenyl silicone resin binder and heat treating the molded core at a temperature in the range of about 300 to about 800° C. for a time period in the range of about 20 minutes to about 2 hours in a non-oxidizing atmosphere. The dust core has high magnetic permeability representing the direct current superimposition characteristics, has reduced core loss and has increased mechanical strength.Type: GrantFiled: January 26, 2005Date of Patent: June 26, 2007Assignee: Okuyama International Patent OfficeInventor: Hideharu Moro
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Patent number: 7219416Abstract: The present invention provides a composite magnetic body containing metallic magnetic powder and thermosetting resin and having a packing ratio of the metallic magnetic powder of 65 vol % to 90 vol % and an electrical resistivity of at least 104 ?·cm. When a coil is embedded in this composite magnetic body, a miniature magnetic element can be obtained that has a high inductance value and is excellent in DC bias characteristics.Type: GrantFiled: May 11, 2004Date of Patent: May 22, 2007Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Osamu Inoue, Junichi Kato, Nobuya Matsutani, Hiroshi Fujii, Takeshi Takahashi
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Patent number: 7183890Abstract: An electrical energy saving device or a magnetic induction device is adapted to surround a power delivery line. The magnetic induction device applies a magnetic field region to the power delivery line to reduce amperage up to about 25%. The magnetic induction device can be a one-piece or two-piece construction formed from a molded mixture. The mixture can include from about 35 wt % to about 45 wt % of an epoxy resin; from about 30 wt % to about 40 wt % of a polymer; from about 1 wt % to about 4 wt % of dimethyl sulfoxide; from about 4 wt % to about 7 wt % of a transition metal; from about 10 wt % to about 20 wt % of a magnetic material; and from about 1 wt % to about 5 wt % of a catalyst.Type: GrantFiled: July 12, 2005Date of Patent: February 27, 2007Inventor: Jose De Jesus Camarena Villaseñor
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Patent number: 7173509Abstract: A means for treating the end faces of a core which is used for an electrical apparatuses and etc., to give insulation extremely superior in effect of improvement of the insulation, corrosion resistance, adhesiveness, heat resistance, and magnetic properties at a low temperature in a short time without cleaning for removing punching oil, annealing, or other pre-treatment; a core having an insulation coating comprised of a dry film of a pure silicone polymer, modified silicone polymer, and/or mixed silicone polymer as a silicone compound on the core end faces and having an average film thickness of at least 0.5 ?m, a breakdown voltage of at least 30V, and a heat resistance in the air of at least 400° C.; and a method of production comprised of forming a core, then dipping it in or spraying it by one or more types of a pure silicone polymer, modified silicone polymer, and/or mixed silicone polymer as an insulation coating.Type: GrantFiled: October 4, 2002Date of Patent: February 6, 2007Assignees: Nippon Steel Corporation, Nittetsu Plant Designing CorporationInventors: Tomoji Kumano, Chikara Kaido, Hiroyasu Fujii, Kazutaka Higashine, Osamu Tanaka, Norikazu Fujii, Kazufumi Hanzawa, Masayoshi Tanaka, Yuji Kubo, Noriko Yamada
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Patent number: 7148767Abstract: A bead type noise filter according to the present invention is constituted by a magnetic core 1 formed of Mn—Zn ferrite having its resistivity increased so as to improve a high frequency characteristic, and having its permittivity lowered, and thereby can successfully suppress radiation noises without distorting the waveform of transmission signals. The magnetic core 1 constituting the bead type noise filter is formed of a high resistivity soft magnetic material, is shaped cylindrical, and has at least one through-hole 1a so as to form a closed magnetic path, and the bead type noise filter is attached on a signal line 2 such that the signal line 2 is inserted through the through-hole 1a. The soft magnetic material has a real part of complex relative permittivity ranging from 1,000 up to 20,000 at 1 kHz and 50 or lower at 1 MHz, and has a resistivity of 150 ?m or higher.Type: GrantFiled: September 22, 2003Date of Patent: December 12, 2006Assignee: Minebea Co., Ltd.Inventors: Osamu Kobayashi, Osamu Yamada, Yukio Suzuki, Kiyoshi Ito, Mayuka Shirai
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Patent number: 7145427Abstract: There is provided a common mode choke coil whose impedance value can be easily adjusted by changing the thickness of an insulation layer for impedance value adjustment appropriately. An insulation layer for impedance value adjustment is formed throughout a principal surface of a first magnetic substrate. Coil patterns and insulation layers are alternately formed on that layer. Parts of the insulation layers other than the insulation layer for impedance value adjustment are removed in either or both of a central region surrounded by the coil patterns and a region around the coil patterns. A resin including magnetic powder is provided on the uppermost insulation layer and the regions where the insulation layers have been removed, and a second magnetic substrate is bonded through a bonding layer.Type: GrantFiled: July 20, 2004Date of Patent: December 5, 2006Assignee: TDK CorporationInventors: Makoto Yoshida, Nobuyuki Okuzawa, Tomokazu Ito, Takashi Kudo, Makoto Otomo, Akira Sato
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Patent number: 7118728Abstract: A method for making ferrite powder may include providing ferrite feed materials in a form of particles having different sizes and irregular shapes, and exposing the ferrite feed materials to a plasma to provide a more spherical shape to irregularly shaped particles to thereby make the ferrite powder. An apparatus for making ferrite powder may include a feeder for ferrite feed materials and a plasma generator for exposing the ferrite feed materials to a plasma.Type: GrantFiled: May 7, 2003Date of Patent: October 10, 2006Assignee: Steward Advanced Materials, Inc.Inventors: Henry G. Paris, Danny R. Smith
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Patent number: 7106163Abstract: An isolation transformer core having a coil and a core member made by injection molding a mixture containing 10 to 50±3 volume % of a soft magnetic material and the remainder being an insulating material having an electrical insulating property.Type: GrantFiled: June 26, 2002Date of Patent: September 12, 2006Assignee: The Furukawa Electric Co., Ltd.Inventors: Dongzhi Jin, Fumihiko Abe, Hajime Mochizuki, Hideharu Yonehara