Patents Examined by John P Sheehan
  • Method for making Fe-based amorphous metal powders and method for making soft magnetic core using the same
    Patent number: 7172660
    Abstract: A method for making an amorphous soft magnetic core using Fe-based amorphous metal powders is provided. The amorphous soft magnetic powders are obtained by crushing amorphous ribbons produced using a rapid solidification process (RSP). The magnetic core is obtained by performing a preliminary thermal treatment of amorphous metal ribbons made of Fe-based amorphous metal alloy using RSP, crushing the amorphous metal ribbons to thereby obtain amorphous metal powders, classifying the amorphous metal powders to then be mixed into a distribution of powder particles having an optimal uniform composition, mixing the mixed amorphous metal powders with a binder, forming a core, and annealing the formed core to then coat the core with an insulating resin.
    Type: Grant
    Filed: October 14, 2003
    Date of Patent: February 6, 2007
    Assignee: Amosense Co., Ltd.
    Inventors: Yong Sul Song, Jae Hwa Hong, Hie Jin Kim
  • Method for producing quenched R-T-B—C alloy magnet
    Patent number: 7172659
    Abstract: The present invention is a production method of an R-T-B—C rare earth alloy (R is at least one element selected from the group consisting of rare earth elements and yttrium, T is a transition metal including iron as a main component, B is boron, and C is carbon). An R-T-B bonded magnet containing a resin component, or an R-T-B sintered magnet with a resin film formed on the surface thereof is prepared, and a solvent alloy containing a rare earth element R and a transition metal element T is prepared. Thereafter, the R-T-B bonded magnet is molten together with the solvent alloy. In this way, a rare earth alloy can be recovered from a spent bonded magnet or a defective one generated in a production process stage, and a rapidly quenched alloy magnet can be obtained. As a result, magnet powder is recovered from the R-T-B magnet, and the recycling of a magnet including a resin component can be realized.
    Type: Grant
    Filed: June 24, 2002
    Date of Patent: February 6, 2007
    Assignee: Neomax Co., Ltd.
    Inventors: Hiroyuki Tomizawa, Koji Nakahara, Yuji Kaneko
  • Ni-based superalloy having high oxidation resistance and gas turbine part
    Patent number: 7169241
    Abstract: A Ni-based alloy hardened with the ?? phase, which is able to exhibit not only superior strength at high temperatures, but also excellent hot corrosion resistance and oxidation resistance at high temperatures in spite of containing no Re or reducing the amount of Re. The Ni-based superalloy contains, by weight, C: 0.01 to 0.5%, B: 0.01 to 0.04%, Hf: 0.1 to 2.5%, Co: 0.8 to 15%, Ta: more than 0% but less than 8.5%, Cr: 1.5 to 16%, Mo: more than 0% but less than 1.0%, W: 5 to 14%, Ti: 0.1 to 4.75%, Al: 2.5 to 7%, Nb: more than 0% but less than 4%, V: 0 to less than 1.0%, Zr: 0 to less than 0.1%, Re: 0 to less than 9%, at least one of platinum group elements: 0 to less than 0.5% in total, at least one of rare earth elements: 0 to less than 0.1% in total, and the rest being Ni except for unavoidable impurities.
    Type: Grant
    Filed: March 19, 2004
    Date of Patent: January 30, 2007
    Assignee: Hitachi, Ltd.
    Inventors: Hideki Tamaki, Akira Yoshinari, Akira Okayama, Tsuyoshi Takano, Hiroyuki Doi
  • Welding material, gas turbine blade or nozzle and a method of repairing a gas turbine blade or nozzle
    Patent number: 7165325
    Abstract: A welding material composition, which is a nickel based super alloy having ?? phase and chromium carbides precipitated. The composition comprising 18 to 25% by weight of Co, 15 to 20% by weight of Cr, 1.5 to 5.5% by weight of Al, 5 to 14% by weight of W, 0.05 to 0.15% by weight of C, 0 to 0.02% by weight of B, 0 to 1% by weight of at least one of Ta, Nb, Ti, Mo, Re and Fe, 0 to 0.5% by weight of at least one of V, Zr, rare earth elements and Y, 0 to 1% by weight of Mn, 0 to 0.5% by weight of Si, and the balance being Ni.
    Type: Grant
    Filed: August 7, 2003
    Date of Patent: January 23, 2007
    Assignee: Hitachi, Ltd.
    Inventors: Shinya Imano, Hiroyuki Doi, Kunihiro Ichikawa, Hideaki Ishii
  • Cast single crystal alloy component with improved low angle boundary tolerance
    Patent number: 7166176
    Abstract: A nickel-based single crystal gas turbine component (30) having a low angle boundary (34) with improved material properties resulting from retained gamma/gamma prime eutectic phase at the low angle boundary. The coarse eutectic phase nodules roughen the grain boundary, reduce the slip distance and disperse concentrated planar slip in the vicinity of the boundary. As a result, the allowable angle of misorientation at the boundary may be increased to greater than 6° for the most highly stressed or critical areas of the component, thereby reducing the amount of scrap material and lowering the cost of manufacturing of a single crystal gas turbine component.
    Type: Grant
    Filed: June 4, 2003
    Date of Patent: January 23, 2007
    Assignee: Siemens Power Generation, Inc.
    Inventors: Maurice Gell, Allister William James
  • Longitudinal magnetic field compacting method and device for manufacturing rare earth magnets
    Patent number: 7166171
    Abstract: Disclosed is a longitudinal magnetic field compacting method and device for manufacturing a neodymium (Nd) based rare earth magnet in the shape of a butterfly for use in VCM of HDD or DVD, a disk or coin for use in coreless motors, and a block for use in linear motors, characterized in that a longitudinal compacting process is performed under a pulse magnetic field for orientation of rare earth powders in the direction of an applied magnetic field. Further, a compacted body of the rare earth powders has the same shape as end products, thus no additional processing cost, thereby lowering manufacturing costs. In addition, the rare earth powders can be subjected to an aligning process and a longitudinal compacting process at the same time under the high pulse magnetic field of 50–70 kOe, whereby the resulting rare earth magnet can have excellent magnetic properties of 42–50 MGOe.
    Type: Grant
    Filed: July 16, 2003
    Date of Patent: January 23, 2007
    Assignee: Jahwa Electronics Co., Ltd.
    Inventor: Dong-Hwan Kim
  • Method of simultaneously initializing two antiferromagnetic layers in a magnetic sensor
    Patent number: 7166173
    Abstract: Magnetic tunnel junction (MTJ) and charge perpendicular-to-plane (CPP) magnetic sensors are disclosed which have a first antiferromagnetic layer for pinning the magnetization direction in a pinned layer and a second antiferromagnetic layer for providing bias stabilization of a free layer. The two antiferromagnetic layers may be formed from the same material and using a spin-flop effect may be initialized simulataneously. A disk drive using these sensors is disclosed.
    Type: Grant
    Filed: October 24, 2003
    Date of Patent: January 23, 2007
    Assignee: Hitachi Global Storage Technologies Netherlands B.V.
    Inventor: Robert S. Beach
  • Method of preparing micro-structured powder for bonded magnets having high coercivity and magnet powder prepared by the same
    Patent number: 7163591
    Abstract: Disclosed is a method of preparing a micro-structured powder for bonded magnets having high coercivity, which is advantageous in terms of low preparation costs by recycling magnet scraps, simplified mass production, minimal environmental contamination by such a recycling process, and the preparation of stable anisotropic powders having high coercivity. Further, a magnet powder prepared by the above method is provided. The current method is characterized in that R—Fe—B type anisotropic sintered magnets or scraps thereof are crushed to prepare 50–500 ?m sized magnet powders, which are then mixed with 1–10 wt % of rare earth fluoride (RF3) powders and thermally treated at high temperatures (500–1100° C.) in a vacuum or an inert gas, to cause the change of matrix-near surface and grain boundary of the powders.
    Type: Grant
    Filed: December 12, 2003
    Date of Patent: January 16, 2007
    Assignee: Jahwa Electronics Co., Ltd.
    Inventors: Andrew S. Kim, Seok Namkung, Dong-Hwan Kim
  • Steel sheet for tension mask, manufacturing method of steel sheet for tension mask, tension mask and cathode ray tube
    Patent number: 7163592
    Abstract: A steel sheet for a tension mask excellent in the shielding properties from geomagnetism consists essentially of lower than 0.1% by weight of C, lower than 0.2% by weight of Si, 0.4 to 2% by weight of Mn, not higher than 0.1% by weight of P, not higher than 0.03% by weight of S, not higher than 0.01% by weight of sol. Al, 0.003 to 0.02% by weight of N and the balance of Fe, and has an anhysteretic magnetic permeability of 5,000 or higher.
    Type: Grant
    Filed: July 2, 2003
    Date of Patent: January 16, 2007
    Assignee: JFE Steel Corporation
    Inventors: Hideki Matsuoka, Yasushi Tanaka, Reiko Sugihara, Tatsuhiko Hiratani, Kenichiro Takayanagi, Masamichi Okada, Hiroaki Kato
  • Method of making rapidly solidified alloy for magnet
    Patent number: 7160398
    Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.
    Type: Grant
    Filed: June 27, 2003
    Date of Patent: January 9, 2007
    Assignee: Neomax Co., Ltd.
    Inventor: Hirokazu Kanekiyo
  • Method for producing anode for rechargeable battery
    Patent number: 7160502
    Abstract: The present invention relates to a method for readily producing an anode for rechargeable batteries having conflicting properties in good balance, including the corrosion resistance and the activities such as the initial activity and the high rate discharge performance, and having excellent recyclability. The method includes the steps of mixing and molding anode materials containing an electrically conductive material and at least two kinds of AB5 type hydrogen storage alloys, wherein said alloys have substantially single phase structures and the same composition, wherein each of the alloys have an average crystal long axis diameter of 30 to 350 ?m, and wherein the alloys have different ratios (D1/D2) of the average crystal long axis diameter (D1) to the average short axis diameter (D2).
    Type: Grant
    Filed: April 9, 2002
    Date of Patent: January 9, 2007
    Assignee: Santoku Corporation
    Inventors: Kiyofumi Takamaru, Hideaki Ikeda, Koji Tatsumi
  • Corrosion-resistant rare earth element magnet
    Patent number: 7156928
    Abstract: A corrosion resistant rare earth magnet is characterized by comprising a rare earth permanent magnet represented by R-T-M-B wherein R is at least one rare earth element inclusive of Y, T is Fe or Fe and Co, M is at least one element selected from among Ti, Nb, Al, V, Mn, Sn, Ca, Mg, Pb, Sb, Zn, Si, Zr, Cr, Ni, Cu, Ga, Mo, W, and Ta, the contents of the respective elements are 5 wt %?R?40 wt %, 50 wt %?T?90 wt %, 0 wt %?M?8 wt %, and 0.2 wt %?B?8 wt %, and a coating on a surface of the permanent magnet comprising a silicone resin, a flake metal fine powder, and a complexing agent.
    Type: Grant
    Filed: November 14, 2002
    Date of Patent: January 2, 2007
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Ryuji Hamada, Takehisa Minowa
  • Method of separating admixed contaminants from superalloy metal powder
    Patent number: 7153377
    Abstract: A method is provided for separating superalloy metal powder from contaminants, such as process-produced contaminants, by enhancing the magnetic properties thereof in a carburizing atmosphere followed by magnetic separation of the contaminants from the superalloy metal powder to thereby enhance the concentration of the contaminants. Heating or mechanical agitation or both are employed to resist agglomeration of the metal powder before magnetic separation thereof from the contaminants. Certain preferred times and temperatures are disclosed.
    Type: Grant
    Filed: February 2, 2004
    Date of Patent: December 26, 2006
    Assignee: R. J. Lee Group, Inc.
    Inventors: Charles E. Spangler, Jr., William J. Murphy
  • Rare earth magnet, method for manufacturing the same, and motor using rare earth magnet
    Patent number: 7147686
    Abstract: A rare earth magnet comprises rare earth magnet particles and a rare earth oxide being present between the rare earth magnet particles. The rare earth oxide is represented by a following general formula (I): R2O3??(I) where R is any one of terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: December 12, 2006
    Assignee: Nissan Motor Co., Ltd.
    Inventors: Tetsurou Tayu, Hideaki Ono, Munekatsu Shimada, Makoto Kano
  • Highly quenchable Fe-based rare earth materials for ferrite replacement
    Patent number: 7144463
    Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.
    Type: Grant
    Filed: September 6, 2005
    Date of Patent: December 5, 2006
    Assignee: Magnequench, Inc.
    Inventors: Zhongmin Chen, Benjamin R. Smith, Bao-Min Ma, James W. Herchenroeder
  • Rare earth magnet and method for manufacturing the same
    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
  • Rare earth magnet and method for producing the magnet
    Patent number: 7138017
    Abstract: A method of making an alloy powder for an R—Fe—B-type rare earth magnet includes the steps of preparing a material alloy that is to be used for forming the R—Fe—B-type rare earth magnet and that has a chilled structure that constitutes about 2 volume percent to about 20 volume percent of the material alloy, coarsely pulverizing the material alloy for the R—Fe—B-type rare earth magnet by utilizing a hydrogen occlusion phenomenon to obtain a coarsely pulverized powder, finely pulverizing the coarsely pulverized powder and removing at least some of fine powder particles having particle sizes of about 1.0 ?m or less from the finely pulverized powder, thereby reducing the volume fraction of the fine powder particles with the particle sizes of about 1.0 ?m or less, and covering the surface of remaining ones of the powder particles with a lubricant after the step of removing has been performed.
    Type: Grant
    Filed: August 21, 2003
    Date of Patent: November 21, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Yuji Kaneko, Junichiro Baba, Katsuya Taniguchi
  • Method for producing magnetostrictive element and sintering method
    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
  • Magnetic material manufacturing method, ribbon-shaped magnetic materials, powdered magnetic material and bonded magnets
    Patent number: 7138070
    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: Grant
    Filed: May 27, 2003
    Date of Patent: November 21, 2006
    Assignee: Seiko Epson Corporation
    Inventors: Akira Arai, Hiroshi Kato
  • Method of making grain-oriented magnetic steel sheet having low iron loss
    Patent number: RE39482
    Abstract: Grain-oriented magnetic steel sheet made by the method-including hot rolling and final finish annealing, wherein (1) the O content in the steel slab is limited to up to about 30 ppm; (2) for the entire steel sheet having final thickness including an oxide film before final finish annealing, from among impurities, the Al content is limited to up to about 100 wtppm, and the respective contents of B, V, Nb, Se, S, P, and N, to up to about 50 wtppm each; and (3) during final finish annealing, the N content in the steel is, at least in the temperature region of from about 850 to 950° C., limited within the range of from about 6 to 80 wtppm.
    Type: Grant
    Filed: October 3, 2002
    Date of Patent: February 6, 2007
    Assignee: JFE Steel Corporation
    Inventors: Yasuyuki Hayakawa, Mitsumasa Kurosawa, Michiro Komatsubara