Patents Examined by John P Sheehan
  • Patent number: 7785424
    Abstract: Magnetic powder contained in a resin composition for use in injection molding is coated with an insulating material, and a soft magnetic green compact or a hard magnetic green compact is insert molded into the resin composition. Increased magnetic flux destiny, reduced size, a simplified shape, and/or increased filling density can be achieved in a core part of an electric instrument.
    Type: Grant
    Filed: August 23, 2005
    Date of Patent: August 31, 2010
    Assignee: Nippon Kagaku Yakin Co., Ltd.
    Inventors: Kiyotaka Matsukawa, Kozo Ishihara, Kazuo Ishikawa, Tomohiro Toyoda, Toshikazu Tanaka
  • Patent number: 7780826
    Abstract: There is disclosed a method for producing a Cr-doped FeCoB based target material that can be used efficiently in magnetron sputtering processes and has a low magnetic permeability. In the method for producing the target material, there are firstly provided raw-materials of two or more kinds of FeCoB based alloy powders which are different in composition from each other, wherein at least one of the FeCoB based alloy powders comprises Fe and Co in a total amount of 60 atom % or more such that Fe:Co atomic ratio is within a range of 70:30 to 40:60, and comprises Cr in an amount which is from 15 to 25 atom % greater than B. Then, the two or more kinds of the FeCoB based alloy powder are mixed and consolidated to form a target material.
    Type: Grant
    Filed: August 14, 2007
    Date of Patent: August 24, 2010
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Toshiyuki Sawada, Akihiko Yanagitani
  • Patent number: 7772529
    Abstract: Methods and systems for improving permalloy sensitivity. One or more permalloy sensing components can be configured upon a substrate, and one or more conductors are located above a portion of the permalloy sensing component of interest. A current can then be initiated through the conductor. The substrate can then be heated such that the current creates a magnetic field that modifies the anisotropy of the portion of the permalloy sensing component of interest, thereby providing selective anisotropy and improving permalloy sensitivity thereof.
    Type: Grant
    Filed: March 10, 2005
    Date of Patent: August 10, 2010
    Assignee: Honeywell International Inc.
    Inventor: Perry A. Holman
  • Patent number: 7771546
    Abstract: An object of the present invention is to solve the problem in hot workability caused by Cu aggregation and provide semi-hard magnetic materials having good magnetic properties, bias materials for magnetic markers, magnetic markers and production methods of bias materials for magnetic markers. The present invention provides a semi-hard magnetic material including 2.0%?Cu?10.0% and 0.1%?Nb?5.0% by mass %, the balance being Fe and inevitable impurities, and having a microstructure in which Cu phase and an intermetallic compound of Fe and Nb are dispersed. The semi-hard magnetic material of the present invention is suitable as bias materials for magnetic markers. Furthermore, the bias materials for magnetic markers can be formed by disposing bias materials for magnetic markers mentioned above so that a bias magnetic field may be applied to a magnetostrictive element for a magnetic marker.
    Type: Grant
    Filed: March 28, 2008
    Date of Patent: August 10, 2010
    Assignee: Hitachi Metals, Ltd.
    Inventors: Noriyuki Nakaoka, Shinichiroh Yokoyama, Yoshiyuki Fujihara
  • Patent number: 7767035
    Abstract: 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: Grant
    Filed: November 30, 2007
    Date of Patent: August 3, 2010
    Assignee: Sekisin Industry Co., Ltd.
    Inventors: Namio Sato, Yotaro Toyoshima, Katsutoshi Yamamoto
  • Patent number: 7767034
    Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.
    Type: Grant
    Filed: September 29, 2005
    Date of Patent: August 3, 2010
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Patent number: 7763122
    Abstract: The invention relates to a non-oriented electrical steel sheet, widely used as an iron core in electric devices, and to a method of manufacturing the same. The non-oriented electrical sheet includes 0.004 wt. % or less C; 1.0-3.5 wt. % Si; 0.02 wt. % or less P; 0.001 wt. % or less S; 0.2˜2.5 wt. % Al; 0.003 wt. % or less N; 0.004 wt. % or less Ti; Mn, in which the amount thereof is represented by the following formula (1): 0.10+100×S(wt. %)?Mn(wt. %)?0.21+200×S(wt. %)—(1); a balance of iron; and inevitable impurities.
    Type: Grant
    Filed: December 18, 2006
    Date of Patent: July 27, 2010
    Assignee: POSCO Co., Ltd.
    Inventors: Byung-Keun Bae, Jae-Kwan Kim
  • Patent number: 7763120
    Abstract: The present invention provides a method of production of grain-oriented electrical steel sheet greatly reducing the Watt loss of the grain-oriented electrical steel sheet and making the magnetostriction as small as possible, that is, a method of production of grain-oriented electrical steel sheet with small magnetostriction by improving the magnetic properties by irradiation by a finely focused laser beam comprising using a power modulated laser controlled in maximum power density to 1×102 to 1×104 W/mm2 to optimize the amount of strain given by laser irradiation in both the sheet width direction and rolling direction and, in particular, to make the modulation duty 70% to less than 100%.
    Type: Grant
    Filed: March 28, 2007
    Date of Patent: July 27, 2010
    Assignee: Nippon Steel Corporation
    Inventors: Tatsuhiko Sakai, Hideyuki Hamamura
  • Patent number: 7758706
    Abstract: A method for producing a dust core compact includes the steps of forming a compact component by pressure-forming a soft magnetic powder having an average particle diameter Da under a pressure Pa, and forming a compact by pressure-forming a soft magnetic powder having an average particle diameter Db and the compact component under a pressure Pb. Average particle diameters Da and Db of the soft magnetic powders satisfy relationship Da/Db?2, and pressures Pa and Pb applied during the pressure-forming satisfy relationship Pa/Pb?½. With this structure, a method for producing a dust core compact exhibiting a high strength and capable of being fabricated even when it has a complex shape, and the dust core compact can be provided.
    Type: Grant
    Filed: September 16, 2005
    Date of Patent: July 20, 2010
    Assignees: Sumitomo Electric Industries, Ltd., Toyota Jidosha Kabushiki Kaisha
    Inventors: Kazuhiro Hirose, Haruhisa Toyoda, Atsushi Sato, Takao Nishioka, Yasuhiro Endo, Ryoji Mizutani, Kazutaka Tatematsu, Kenji Harada
  • Patent number: 7754027
    Abstract: A method for manufacturing a sputtering target includes the steps of: providing a highly pure matrix material containing a magnetic metal, and a highly pure precious metal ingot material; cleaning the surfaces of the matrix material and the precious metal ingot; vacuum melting the matrix material and the precious metal ingot to obtain a molten alloy; pouring the molten alloy in a mold having a cooling system while maintaining a surface of the molten alloy at a molten state by arc heating until the pouring is finished, thereby forming the molten alloy into a cast blank; hot working the cast blank; and annealing the cast blank after the hot working.
    Type: Grant
    Filed: August 27, 2007
    Date of Patent: July 13, 2010
    Assignee: China Steel Corporation
    Inventors: Rong-Zhi Chen, Jye-Long Lee, In-Ting Hong, Jui-Tung Chang, Pa-Tsui Sze
  • Patent number: 7744702
    Abstract: 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: Grant
    Filed: October 19, 2007
    Date of Patent: June 29, 2010
    Assignee: TDK Corporation
    Inventors: Hiroshi Tomita, Hideharu Moro, Kesaharu Takatoh, Koyu Enda
  • Patent number: 7740714
    Abstract: A radially anisotropic magnet is prepared by furnishing a cylindrical magnet-compacting mold comprising a die, a core, and top and bottom punches, packing a magnet powder in the mold cavity, applying a magnetic field across the magnet powder, and forcing the top and bottom punches to compress the magnet powder for compacting the magnet powder by a horizontal magnetic field vertical compacting process. The top punch is divided into segments so that the magnet powder may be partially compressed; in the step of compacting the magnet powder packed in the mold cavity by a horizontal magnetic field vertical compacting process, the magnet powder is partially compressed by the segments of the top punch cooperating with the bottom punch for thereby consolidating the partially compressed zones of magnet powder to a density from 1.
    Type: Grant
    Filed: November 29, 2006
    Date of Patent: June 22, 2010
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Koji Sati, Mitsuo Kitagawa, Takehisa Minowa
  • Patent number: 7740716
    Abstract: The present invention provides a technique to improve an adhesion strength between a magnet main body and a protective film. The rare earth sintered magnet of the present invention comprises a magnet main body of a sintered body containing a rare earth element and a protective film formed on the magnet main body, wherein the ratio of a 10-point average surface roughness Rz of the magnet main body on which the protective film is formed to a mean grain size D50 in the magnet main body (Rz/D50 ratio) is kept in a range from 0.20 to 10.00, inclusive. This gives the rare earth sintered magnet which is coated with the protective film having a high adhesion strength of 100 N/m or more and exhibits high corrosion resistance.
    Type: Grant
    Filed: November 17, 2005
    Date of Patent: June 22, 2010
    Assignee: TDK Corporation
    Inventors: Yasushi Enokido, Gouichi Nishizawa, Chikara Ishizaka
  • Patent number: 7740715
    Abstract: An R-T-B based sintered magnet according to the present invention has a composition comprising: 12 at % to 15 at % of a rare-earth element R; 5.0 at % to 8.0 at % of boron B; 0.1 at % to at % of Al; 0.02 at % to less than 0.2 at % of Mn; and a transition metal T as the balance. The rare-earth element R is at least one element selected from the rare-earth elements, including Y (yttrium), and includes at least one of Nd and Pr. The transition element T includes Fe as its main element.
    Type: Grant
    Filed: September 16, 2009
    Date of Patent: June 22, 2010
    Assignee: Hitachi Metals, Ltd.
    Inventor: Hiroyuki Tomizawa
  • Patent number: 7736444
    Abstract: Grain oriented electrical steel is made in a manner that the grains are selectively grown to obtain a crystal structure known as cube-on-edge and the grains are largely aligned in the rolling direction. Selection of chemistry and process route along with thin slab continuous casting enables the production of Grain oriented electrical steel such that less energy is consumed in the process, certain process steps can be combined, yield is better and the product can be manufactured within a wider process control tolerance.
    Type: Grant
    Filed: April 16, 2007
    Date of Patent: June 15, 2010
    Assignee: Silicon Steel Technology, Inc.
    Inventors: Vladimir Pavlovich Shumilov, Alexandr G. Shalimov, Leonard Mironov, Urij Christiakov
  • Patent number: 7722726
    Abstract: The invention provides a method for producing alloy flakes for rare earth sintered magnets, which makes uniform the intervals, size, orientation, and shape of the R-rich region and the dendrites of the 2-14-1 phase, which inhibits formation of chill, and which produces flakes that are pulverized into powder of a uniform particle size in the pulverization step in the production of a rare earth sintered magnet, and that are pulverized into powder compactable into a product with a controlled shrink ratio, and alloy flakes for a rare earth sintered magnet obtained by the method, and a rare earth sintered magnet having excellent magnetic properties.
    Type: Grant
    Filed: March 31, 2005
    Date of Patent: May 25, 2010
    Assignee: Santoku Corporation
    Inventors: Kazumasa Shintani, Ryo Murakami, Kazuhiko Yamamoto
  • Patent number: 7718898
    Abstract: A precursor for manufacturing a Nb3Sn superconducting wire according to the present invention includes a mono-element wire including a Sn or Sn-based alloy core disposed at the, a Cu or Cu-based alloy matrix and a plurality of Nb or Nb-based alloy filaments surrounding the Sn or Sn-based alloy core, and a diffusion barrier layer and a stabilizing copper layer surrounding the Cu or Cu-based alloy matrix. In a final shape after a reduction process, the average diameter of the Nb or Nb-based alloy filaments is set to 5 ?m to 30 ?m, and the average distance between the Sn or Sn-based alloy core and the Nb or Nb-based alloy filaments nearest the Sn or Sn-based alloy core is set to 100 ?m or less.
    Type: Grant
    Filed: February 7, 2007
    Date of Patent: May 18, 2010
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Hiroyuki Kato, Takayuki Miyatake, Takayoshi Miyazaki, Kyoji Zaitsu
  • Patent number: 7713364
    Abstract: A manganese alloy sputtering target characterized in that oxygen is 1000 ppm or less, sulfur is 200 ppm or less and a forged texture is provided, and a method for producing a forged manganese alloy target stably by eliminating the drawbacks of manganese alloy that it is susceptible to cracking and has a low rupture strength. A manganese alloy sputtering target which can form a thin film exhibiting high characteristics and high corrosion resistance while suppressing generation of nodules or particles is thereby obtained.
    Type: Grant
    Filed: March 19, 2007
    Date of Patent: May 11, 2010
    Assignee: Nippon Mining & Metals Co., Ltd.
    Inventor: Yuichiro Nakamura
  • Patent number: 7713360
    Abstract: It is an object of the present invention to provide a permanent magnet which is observed as a uniform structure without microstructures, but shows a pinning type initial magnetization curve. There is provided a rare earth permanent magnet comprising a magnetic intermetallic compound comprising R, T, N and an unavoidable impurity, wherein R is one or more rare earth elements comprising Y, T is two or more transition metal elements and comprises principally Fe and Co; wherein the magnetic intermetallic compound has an T/R atomic ratio of 6 to 14; a magnetocrystalline anisotropy energy of at least 1 MJ/m3; a Curie point of at least 100° C.; average particle diameter of at least 3 ?m; and a substantially uniform structure; wherein the rare earth permanent magnet has a structure that gives a pinning-type initial magnetization curve; and wherein the magnetic intermetallic compound has a Th2Zn17-type structure, and the like.
    Type: Grant
    Filed: February 22, 2005
    Date of Patent: May 11, 2010
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventor: Ken Ohashi
  • Patent number: 7695574
    Abstract: A method for producing an RE-containing alloy represented by formula R(T1?xAx)13?y (wherein R represents Ce, etc.; T represents Fe, etc.; and A represents Al, etc; 0.05?x?0.2; and ?1?y?1) including a melting step of melting alloy raw materials at 1,200 to 1,800° C.; and a solidification step of rapidly quenching the molten metal produced through the above step, to thereby form the first RE-containing alloy, wherein the solidification step is performed at a cooling rate of 102 to 104° C./second, as measured at least within a range of the temperature of the molten metal to 900° C.; and an RE-containing alloy, which is represented by a compositional formula of RrTtAa (wherein R and A represent the same meaning as above, T represents Fe, etc.; 5.0 at. %?r?6.8 at. %, 73.8 at. %?t?88.7 at. %, and 4.6 at. %?a?19.4 at. %) and has an alloy microstructure containing an NaZn13-type crystal structure in an amount of at least 85 mass % and ?-Fe in an amount of 5-15 mass % inclusive.
    Type: Grant
    Filed: October 22, 2003
    Date of Patent: April 13, 2010
    Assignee: Showda Denko K.K.
    Inventor: Kenichiro Nakajima