Patents Examined by John P Sheehan
  • Rare earth element-iron-boron alloy and magnetically anisotropic permanent magnet powder and method for production thereof
    Patent number: 7550047
    Abstract: A method of making a magnetically anisotropic magnet powder according to the present invention includes the steps of preparing a master alloy by cooling a rare-earth-iron-boron based molten alloy and subjecting the master alloy to an HDDR process. The step of preparing the master alloy includes the step of forming a solidified alloy layer, including a plurality of R2Fe14B-type crystals (where R is at least one element selected from the group consisting of the rare-earth elements and yttrium) in which rare-earth-rich phases are dispersed, by cooling the molten alloy through contact with a cooling member.
    Type: Grant
    Filed: December 18, 2002
    Date of Patent: June 23, 2009
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hiroyuki Tomizawa, Yuji Kaneko
  • Composite material, method for producing same and member using same
    Patent number: 7547412
    Abstract: A composite material is a Mo—Cu based composite material having a Cu content of 30 to 70 weight % and containing a copper pool phase and an Mo—Cu based composite phase. The copper pool phase is contained in an amount of 10-50 weight %. A heat-sink member uses the composite material.
    Type: Grant
    Filed: October 28, 2003
    Date of Patent: June 16, 2009
    Assignee: A.L.M.T. Corporation
    Inventors: Masayuki Itoh, Tadashi Arikawa, Norio Hirayama, Yoshinari Amano, Nobuyuki Saitoh
  • Process for producing, through strip casting, raw alloy for nanocomposite type permanent magnet
    Patent number: 7547365
    Abstract: To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by Fe100-x-y-zRxQyMz (where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %?x<6 at %, 15 at %?y?30 at % and 0 at %?z?7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.
    Type: Grant
    Filed: November 28, 2005
    Date of Patent: June 16, 2009
    Assignee: Hitachi Metals, Ltd.
    Inventors: Ryo Murakami, Hirokazu Kanekiyo, Satoshi Hirosawa
  • Method for producing magnetically active shape memory metal alloy
    Patent number: 7547367
    Abstract: The invention relates to a method for producing magnetically active shape memory metal alloy, said metal alloy containing nickel, manganese and gallium. In the method, the different components of the metal alloy are melted, and the melt is homogenized essentially at the melting temperature; the obtained metal alloy is cast, and the cast metal alloy is subjected to directional solidification at 10-100° C. below the liquidus temperature of said metal alloy.
    Type: Grant
    Filed: July 3, 2003
    Date of Patent: June 16, 2009
    Assignee: Outotec Oyj
    Inventors: Tuija Suortti, Juha Järvi, Pekka Taskinen
  • Method of fabricating pressed components
    Patent number: 7544258
    Abstract: A simpler and less expensive method of fabricating pressed components from sheet steel that can be heat treated while inside the press, whereby the material is heated to above its transformation point Ac3, pressed, and cooled, controlled, to below its crystalline-transformation point. The sheet is unwound from a coil (1), heated to above its transformation point, pressed in a press, and separated.
    Type: Grant
    Filed: May 18, 2004
    Date of Patent: June 9, 2009
    Assignee: ThyssenKrupp Automotive AG
    Inventors: Detleff Steinhöfer, Ralf Kolleck
  • Method of manufacturing magnetic particle, magnetic particle and magnetic recording medium
    Patent number: 7544230
    Abstract: The solution I is spouted from a first nozzle into a mixing chamber as a high-pressure jet stream of not less than 1 MPa and as a turbulent flow having a Reynolds number of not less than 10000 during the flow into the mixing chamber, and the solution II having a lower pressure than the solution I is spouted from a second nozzle into the mixing chamber as an orthogonal flow which intersects the solution I almost at right angles. The two solutions are mixed together and caused to react with each other, with the result that a mixed reaction solution Z containing alloy particles Z is formed.
    Type: Grant
    Filed: March 4, 2004
    Date of Patent: June 9, 2009
    Assignee: FUJIFILM Corporation
    Inventors: Fumiko Shiraishi, Yasunori Ichikawa, Koukichi Waki, Yasushi Hattori
  • Soft magnetic steels excellent in cold forgeability, machinability and magnetic properties, and soft magnetic steel parts excellent in magnetic properties
    Patent number: 7540927
    Abstract: A soft magnetic steel has, on the mass basis, a carbon content of 0.0015% to 0.02%, a manganese content of 0.15% to 0.5%, and a sulfur content of 0.015% to 0.1%, has a ratio Mn/S of 5.7 or more, and contains a single-phase ferrite microstructure as its metallographic structure, in which the density of precipitated FeS grains having a major axis of 0.1 ?m or more is 5000 grains/mm2 or less. This steel ensures excellent magnetic properties with less variation after magnetic annealing, exhibits excellent machinability and cold forgeability during production processes, and can thereby yield a steel part even having a complicated shape and a large size in a high yield.
    Type: Grant
    Filed: July 10, 2006
    Date of Patent: June 2, 2009
    Assignee: Kobe Steel, Ltd.
    Inventor: Masamichi Chiba
  • Continuous process for production of steel part with regions of different ductility
    Patent number: 7540993
    Abstract: The interior of a furnace is partitioned into two longitudinally extending and transversely adjacent zones, and one of the zones is heated to a substantially higher treatment temperature than the other of the zones, which may or may not be heated. A steel workpiece is conveyed longitudinally through the furnace with a region of the workpiece moving exclusively through the one zone and another region of the workpiece moving exclusively through the other of the zones such that the regions are heated to different temperatures. The treatment temperature in one of the zone is above the AC1 point for the workpiece and the temperature in the other of the zones is close to or below the AC1 point for the workpiece.
    Type: Grant
    Filed: December 2, 2003
    Date of Patent: June 2, 2009
    Assignee: Benteler Automobiltechnik GmbH
    Inventors: Patrick Reinhold, Jürgen Krogmeier, Johannes Böke
  • Eglin steel—a low alloy high strength composition
    Patent number: 7537727
    Abstract: The present invention relates to a low alloy, low to medium carbon content, high strength, and high ductility steel composition. The present invention contains relatively low nickel content, yet exhibits high performance characteristics and is manufactured at a substantially lower cost than alloy compositions containing high levels of nickel.
    Type: Grant
    Filed: January 21, 2004
    Date of Patent: May 26, 2009
    Assignee: Ellwood National Forge Company
    Inventors: Morris Dilmore, James D. Ruhlman
  • R-t-b sintered magnet and rare earth alloy
    Patent number: 7534311
    Abstract: A rare-earth sintered magnet according to the present invention, of which the main phase is an R2T14B type compound phase, includes: 27 mass % through 32 mass % of R, which is at least one rare-earth element that is selected from the group consisting of Nd, Pr, Tb, and Dy and that always includes at least one of Nd and Pr; 60 mass % through 73 mass % of T, which is either Fe alone or a mixture of Fe and Co; 0.85 mass % through 0.98 mass % of Q, which is either B alone or a mixture of B and C and which is converted-into B on a number of atoms basis when its mass percentage is calculated; more than 0 mass % through 0.3 mass % of Zr; at most 2.0 mass % of an additive element M, which is at least one element selected from the group consisting of Al, Cu, Ga, In and Sn; and inevitably contained impurities.
    Type: Grant
    Filed: August 10, 2004
    Date of Patent: May 19, 2009
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hiroyuki Tomizawa, Yutaka Matsuura
  • Anti-galling alloy with finely dispersed precipitates
    Patent number: 7531130
    Abstract: The present invention relates to an anti-galling alloy with finely dispersed precipitates, more particularly to an anti-galling alloy comprising Ni, Cr, Sn, Bi, Mo, Fe, Si and Te, in which the matrix has a fine dendritic structure and the Bi-rich precipitates are finely dispersed between the dendritic structure, so that the anti-galling properties are significantly improved, while physicochemical properties such as corrosion resistance and hardness are not deteriorated. The anti-galling alloy of the present invention will greatly contribute to the improvement in life cycle and mechanical precision of a variety of wet machinery parts such as rotor, shaft, valve and mechanical sealing.
    Type: Grant
    Filed: October 2, 2003
    Date of Patent: May 12, 2009
    Assignee: Korea Anti-Galling Metal Co., Ltd.
    Inventors: Heon Phil Ha, Jae-Dong Shim, Kyung Tak Kim
  • Method for manufacturing bonded magnet and method for manufacturing magnetic device having bonded magnet
    Patent number: 7531050
    Abstract: A viscous material (4) is obtained by mixing an alloy magnetic powder, magnetized in advance, with a resin. The viscous material (4) thus obtained is applied to an upper surface of a center magnetic leg of an E-shaped core (2). A coil (3) and an I-shaped core are coupled to the E-shaped core (2). An orientation magnetic field is applied by a permanent magnet (5) while the resin is hardened. As a consequence, a bond magnet is obtained which is formed in tight contact with both of a pair of surfaces defining a magnetic gap between the E-shaped core (2) and the I-shaped core.
    Type: Grant
    Filed: September 19, 2003
    Date of Patent: May 12, 2009
    Assignee: Nec Tokin Corporation
    Inventors: Shigun Oh, Teruhiko Fujiwara, Yasubumi Kikuchi, Takashi Yambe
  • Method for controlling magnetostriction in a free layer of a magnetoresistive sensor
    Patent number: 7524381
    Abstract: A method for controlling magnetostriction in a free layer of a magnetoresistive sensor. A pinned layer structure is deposited and then a spacer layer, preferably Cu is deposited. Oxygen is introduced into the spacer layer. The oxygen can be introduced either during the deposition of the spacer layer or after the spacer layer has been deposited. A free layer structure is then deposited over the spacer layer. A capping layer such as Ta can be deposited over the free layer structure. The sensor is annealed to set the magnetization of the pinned layer. In the process of annealing the sensor the oxygen migrates out of the spacer. After annealing, no significant amount of oxygen is present in either the spacer layer or the free layer structure, and only trace amounts of oxygen are present in the Ta capping layer.
    Type: Grant
    Filed: December 22, 2005
    Date of Patent: April 28, 2009
    Assignee: Hitachi Global Storage Technologies Netherlands B.V.
    Inventors: Ben Long Thai, Dulip Ajantha Welipitiya
  • Cobalt alloys, methods of making cobalt alloys, and implants and articles of manufacture made therefrom
    Patent number: 7520947
    Abstract: Embodiments of the present invention provide methods of processing cobalt alloys including, in weight percent, from 26 to 30 chromium, from 5 to 7 molybdenum, and greater than 50 cobalt, the methods comprises cold working and aging the alloys such that after aging the cobalt alloys have a hardness of at least Rockwell C 50. Other embodiments provide methods of selectively cold working at least one portion of a cobalt alloy, and subsequently aging the alloy, such after aging, the selectively cold worked portions of the alloy have a higher hardness value then portions of the alloy that were not selectively cold worked. The present invention also discloses cobalt alloys, implants, and articles of manufacture made from cobalt alloys within the present invention.
    Type: Grant
    Filed: May 23, 2003
    Date of Patent: April 21, 2009
    Assignee: ATI Properties, Inc.
    Inventors: Richard L. Kennedy, Henry E. Lippard
  • Functionally graded rare earth permanent magnet
    Patent number: 7520941
    Abstract: A functionally graded rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, R2 is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, and the magnet body includes a surface layer having a higher coercive force than in the interior. The invention provides permanent magnets having improved heat resistance.
    Type: Grant
    Filed: January 27, 2006
    Date of Patent: April 21, 2009
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Precipitation-strengthened nickel-iron-chromium alloy and process therefor
    Patent number: 7507306
    Abstract: An Fe—Ni—Cr alloy formulated to contain a strengthening phase that is able to maintain a fine grain structure during forging and high temperature processing of the alloy. The alloy contains a sufficient amount of titanium, zirconium, carbon and nitrogen so that fine titanium and zirconium carbonitride precipitates formed thereby are near their solubility limit in the alloy when molten. In the production of an article from such an alloy by thermomechanical processing, a dispersion of the fine titanium and zirconium carbonitride precipitates form during solidification of the melt and remain present during subsequent elevated processing steps to prohibit austenitic grain growth.
    Type: Grant
    Filed: February 28, 2006
    Date of Patent: March 24, 2009
    Assignee: General Electric Company
    Inventors: Jianqiang Chen, Jon Conrad Schaeffer, Anjilivelil Kuruvilla
  • Method for producing nanocomposite magnet using atomizing method
    Patent number: 7507302
    Abstract: A rare-earth alloy powder is obtained by rapidly cooling a melt of an alloy by an atomization process. The alloy has a composition represented by (Fe1-mTm)100-x-y-zQxRyTizMn, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one of the rare-earth metal elements and yttrium, and M is at least one of Nb, Zr, Mo, Ta and Hf. The mole fractions x, y, z, m and n satisfy 10 at %<x?25 at %, 6 at %?y<10 at %, 0.1 at %?z?12 at %, 0?m?0.5, and 0 at %?n?10 at %, respectively. By adding Ti to the alloy, the nucleation and growth of ?-Fe during the rapid quenching process can be minimized.
    Type: Grant
    Filed: July 19, 2002
    Date of Patent: March 24, 2009
    Assignee: Hitachi Metals, Ltd.
    Inventors: Toshio Miyoshi, Hirokazu Kanekiyo, Satoshi Hirosawa
  • High-strength, high-permeability steel sheet for picture tube band and method of producing the same
    Patent number: 7501029
    Abstract: A high-strength, high-permeability steel sheet for picture tube band comprises, in mass percent, C: 0.003-0.010%, Si: 0.5-1.0%, Mn: 1.0-2.0%, P: 0.04-0.15%, S: not more than 0.02%, Al: not more than 0.030%, N: not more than 0.004% and the balance of Fe and unavoidable impurities, has a chemical composition satisfying C×Mn×P?2.5×10?4, and has a ferrite crystal grain diameter of 10-100 ?m and a yield stress of 300 N/mm2 or higher, and preferably has a specific permeability ?0.35 in a DC magnetic field of 0.35 Oe of 400 or higher. The steel sheet can be produced by regulating the hot-rolling coiling temperature to 600-700° C. and selecting an appropriate combination of the cold rolling reduction ratio and a final annealing temperature in the range of 750-900° C.
    Type: Grant
    Filed: April 12, 2004
    Date of Patent: March 10, 2009
    Assignee: Nisshin Steel Co., Ltd.
    Inventors: Tsunetoshi Suzaki, Kentaro Hirata, Yuichi Higo
  • Hot-rolled steel strip for high strength electric resistance welding pipe and manufacturing method thereof
    Patent number: 7501030
    Abstract: A hot-rolled steel strip having superior low temperature toughness and weldability, which is suitably used as a starting material for high strength electric resistance welding pipe, is provided at a low cost without constructing new production facilities and increasing cost. The hot-rolled steel strip is low carbon steel containing at least one of about 0.5.% or less of Cu, about 0.5% or less of Ni, and about 0.5% or less of Mo, wherein Pcm represented by the following equation (1) is 0.17 or less: Pcm=(% C)+(% Si)/30+((% Mn)+(% Cu))/20+(% Ni)/60+(% Mo)/7+(% V)/10??Equation (1), (where (% M) indicates the content of element M on a mass percent basis), and the balance includes Fe and incidental impurities. In addition, in the entire microstructure, the ratio of bainitic ferrite, which is a primary phase, is controlled to be about 95 percent by volume or more.
    Type: Grant
    Filed: March 24, 2004
    Date of Patent: March 10, 2009
    Assignee: JFE Steel Corporation
    Inventors: Hiroshi Nakata, Nobuyuki Kageyama, Koji Iwata, Tetsuo Shimizu, Chikara Kami
  • Magnetic core using amorphous soft magnetic alloy
    Patent number: 7501925
    Abstract: 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: Grant
    Filed: September 28, 2007
    Date of Patent: March 10, 2009
    Assignee: Alps Electric Co., Ltd.
    Inventors: Yutaka Naito, Kazuo Aoki, Masatomi Abe, Kazuya Kaneko