Patents Examined by John Sheehan
  • Patent number: 8328955
    Abstract: A composite magnetic material is manufactured having magnetic properties that can excellently cope with the decreasing size and increasing electric current of magnetic elements, such as choke coils, and can be used in a high frequency range, a dust core using the composite magnetic material, and a method of manufacturing the same. The dust core includes magnetic metal powder and an insulating material, in which the magnetic metal powder has a Vickers hardness (Hv) of 230 ? Hv? 1000, the insulating material has a compressive strength of 10000 kg/cm2 or lower and is in a mechanical collapsed state, and the insulating material in a mechanical collapsed state is interposed in the magnetic metal powder.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: December 11, 2012
    Assignee: Panasonic Corporation
    Inventors: Yuya Wakabayashi, Takeshi Takahashi, Nobuya Matsutani
  • Patent number: 8323422
    Abstract: Provided is a dust core excellent in flux density, iron loss, and mechanical strength. A production process of a dust core according to the invention includes a step of compacting a mixture obtained by mixing an iron-based soft magnetic powder for powder compact having a phosphate conversion coating film on the surface of an iron-based soft magnetic powder with a lubricant to obtain a powder compact, a heat treatment step of heating the resulting powder compact at 550° C. or more but not more than 650° C. in an inert atmosphere, and a heat treatment step of heating the heat-treated powder compact at 420° C. or more but not more than 530° C. in an oxidizing atmosphere.
    Type: Grant
    Filed: November 22, 2011
    Date of Patent: December 4, 2012
    Assignee: Kobe Steel, Ltd.
    Inventors: Takeshi Ohwaki, Hiroyuki Mitani, Hirofumi Hojo, Tomotsuna Kamijo
  • Patent number: 8323725
    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: June 16, 2010
    Date of Patent: December 4, 2012
    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: 8317937
    Abstract: In order to make a sintered R-T-B-M magnet so that R2T14B phases that include a lot of Dy in the surface region of the main phase are distributed over the entire magnet, a region including a heavy rare-earth element RH at a high concentration is formed continuously beforehand at an interface between the crystals of an R2T14B compound that is the main phase of the sintered R-T-B-M magnet and the other phases.
    Type: Grant
    Filed: March 29, 2010
    Date of Patent: November 27, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventor: Futoshi Kuniyoshi
  • Patent number: 8317941
    Abstract: An R-T-B based sintered magnet according to the present invention has a composition including: 27.3 mass % to 29.5 mass % of R; 0.92 mass % to 1 mass % of B; 0.05 mass % to 0.3 mass % of Cu; 0.02 mass % to 0.5 mass % of M; and T as the balance, and has an oxygen content of 0.02 mass % to 0.2 mass %. The main phase of the sintered magnet is an R2T14B type compound. The crystal grain size of the main phase is represented by an equivalent circle diameter of 8 ?m or less. And crystal grains with equivalent circle diameters of 4 ?m or less account for at least 80% of the overall area of the main phase.
    Type: Grant
    Filed: March 30, 2009
    Date of Patent: November 27, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Futoshi Kuniyoshi, Rintaro Ishii
  • Patent number: 8308874
    Abstract: An alloy comprising: a magnetostrictive iron alloy having the formula: FexGayAlz, where x is of from about 65 at % to about 90 at %, y is of from about 5 at % to about 35 at %, and z is of from about 0 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm. An alloy having a saturated magnetostriction of from about at least 150 ppm comprising: a magnetostrictive iron alloy having the formula: FexGayBet, where x is of from about 65 at % to about 90 at %, y is of from about 1 at % to about 35 at %, and t is of from about 1 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm.
    Type: Grant
    Filed: November 29, 2005
    Date of Patent: November 13, 2012
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Arthur E. Clark, Marilyn Wun-Fogle, James B. Restorff, Thomas A. Lograsso, Rick Allen Kellogg
  • Patent number: 8303730
    Abstract: A slab with a predetermined composition is heated at 1280° C. to 1390° C. to make a substance functioning as an inhibitor to be solid-solved (step S1). Next, the slab is hot-rolled to obtain a steel strip (step S2). The steel strip is annealed to form a primary inhibitor in the steel strip (step S3). Next, the steel strip is cold-rolled once or more (step S4). Next, the steel strip is annealed to perform decarburization and to cause primary recrystallization (step S5). Next, nitriding treatment is performed on the steel strip in a mixed gas of hydrogen, nitrogen and ammonia under a state where the steel strip runs, to form a secondary inhibitor in the steel strip (step S6). Next, the steel strip is annealed to induce secondary recrystallization (step S7).
    Type: Grant
    Filed: September 8, 2009
    Date of Patent: November 6, 2012
    Assignee: Nippon Steel Corporation
    Inventors: Tomoji Kumano, Yoshiyuki Ushigami, Shuichi Nakamura, Yohichi Zaizen
  • Patent number: 8303732
    Abstract: A rare earth magnet having a composition represented by RTB wherein R denotes a rare earth element, T a transition metal and B boron, the magnet being composed of magnet powder constituted by crystalline particles. The particles of the magnetic powder have a ratio of a short diameter being 10 ?m or more to a long diameter is 0.5 or less. An element Rm having a magnetic anisotropy higher than that of the rare earth element is contained in the surface and inside of the magnet constituted by the magnet powder in an approximately constant concentration. An oxy-fluoride and carbon are present at boundaries of the particles of the magnet powder.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: November 6, 2012
    Assignee: Hitachi, Ltd.
    Inventors: Hiroyuki Suzuki, Takao Imagawa, Yuichi Satsu, Matahiro Komuro
  • Patent number: 8298351
    Abstract: A rare earth sintered magnet consists essentially of 26-36 wt % R, 0.5-1.5 wt % B, 0.1-2.0 wt % Ni, 0.1-3.0 wt % Si, 0.05-1.0 wt % Cu, 0.05-4.0 wt % M, and the balance of T and incidental impurities wherein R is a rare earth element, T is Fe or Fe and Co, M is selected from Ga, Zr, Nb, Hf, Ta, W, Mo, Al, V, Cr, Ti, Ag, Mn, Ge, Sn, Bi, Pb, and Zn. Simultaneous addition of Ni, Si, and Cu ensures magnetic properties and corrosion resistance.
    Type: Grant
    Filed: May 9, 2011
    Date of Patent: October 30, 2012
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuya Fukui, Takahiro Hashimoto
  • Patent number: 8298352
    Abstract: A magnet core (1) made of a composite of platelet-shaped particles of a thickness D and a binder has a particularly linear relative permeability curve over a pre-magnetised constant field. For this purpose, the platelet-shaped particles (5) are provided with an amorphous volume matrix (8), wherein areas (9) with a crystalline structure having a thickness d of 0.04*D?d?0.25*D and covering a proportion x of x?0.1 of the surface (6, 7) of the particle (5) are embedded on the surface (6, 7) of the particle (5).
    Type: Grant
    Filed: July 23, 2008
    Date of Patent: October 30, 2012
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventor: Markus Brunner
  • Patent number: 8293030
    Abstract: The present invention relates to new intermetallic compounds having a crystalline structure of Ni3Sn2 type for the magnetic refrigeration, their use and a process for preparing the same. The present invention further relates to new magnetocaloric compositions for the magnetic refrigeration and their use.
    Type: Grant
    Filed: March 31, 2008
    Date of Patent: October 23, 2012
    Assignee: Universite de Lorraine
    Inventor: Thomas Mazet
  • Patent number: 8287664
    Abstract: A magnet core is required to be particularly dense, made of alloys produced in a rapid solidification process and have a minimal coercitive field strength. To achieve these aims, a coarse-grain powder fraction is first produced from an amorphous strip of a soft magnetic alloy. In addition, at least one fine-grain powder fraction is produced from a nanocrystalline strip of a soft magnetic alloy. The particle fractions are then mixed to produce a multi-modal powder, wherein the particles of the coarse-grain particle fraction have an amorphous structure and the particles of the fine-grain powder fraction have a nanocrystalline structure. The multi-modal powder is then pressed to produce a magnet core.
    Type: Grant
    Filed: July 11, 2007
    Date of Patent: October 16, 2012
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventor: Markus Brunner
  • Patent number: 8287665
    Abstract: A soft magnetic alloy contains P, B, and Cu as essential components. As a preferred example, an Fe-based alloy contains Fe of 70 atomic % or more, B of 5 atomic % to 25 atomic %, Cu of 1.5 atomic % or less (excluding zero), and P of 10 atomic or less (excluding zero).
    Type: Grant
    Filed: March 19, 2008
    Date of Patent: October 16, 2012
    Assignees: NEC Tokin Corporation, Tohoku University
    Inventors: Akiri Urata, Hiroyuki Matsumoto, Akihiro Makino
  • Patent number: 8287661
    Abstract: A method for producing a sintered R-T-B based magnet includes the steps of: providing R-T-B based alloy powders A and B so that the R-T-B based alloy powder B has a particle size D50 that is smaller by at least 1.0 ?m than that of the R-T-B based alloy powder A and that there is a difference ?RH of at least 4 mass % between the higher content of a heavy rare-earth element RH in the R-T-B based alloy powder B and the lower content of the heavy rare-earth element RH in the R-T-B based alloy powder A; mixing these two R-T-B based alloy powders A and B together; compacting the mixed R-T-B based alloy powder to obtain a compact with a predetermined shape; and sintering the compact.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: October 16, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Rintaro Ishii, Futoshi Kuniyoshi
  • Patent number: 8287666
    Abstract: A magnetic alloy having a composition represented by the general formula of Fe100-x-yCuxBy (atomic %), wherein x and y are numbers meeting the conditions of 0.1?x?3, and 10?y?20, or the general formula of Fe100-x-y-zCuxByXz (atomic %), wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 0.1?x?3, 10?y?20, 0<z?10, and 10<y+z?24), the magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more.
    Type: Grant
    Filed: December 2, 2010
    Date of Patent: October 16, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Motoki Ohta, Yoshihito Yoshizawa
  • Patent number: 8282745
    Abstract: An Fe-based soft magnetic alloy includes: Fe; and a component R, wherein the component R contains at least one of P, C, B, and Si, there is a temperature difference of equal to or greater than 20° C. between a precipitation temperature of an ?-Fe crystal phase and a precipitation temperature of an Fe compound, the Fe-based soft magnetic alloy is formed of a mixed-phase structure in which an amorphous phase and the ?-Fe crystal phase are mixed, and a diameter of a crystallite of the ?-Fe crystal phase is equal to or smaller than 50 nm, and a volume fraction of the ?-Fe crystal phase to the total is equal to or lower than 40%. In addition, the composition formula is represented by Fe100?x?uJxRu, a component J contains at least one of Cr, Co, Ni, and Nb, and 0 at %?x?6 at %, 17 at %?u?25 at %, and 17 at %?x+u?27.1 at % are satisfied.
    Type: Grant
    Filed: July 11, 2011
    Date of Patent: October 9, 2012
    Assignee: Alps Green Devices Co., Ltd.
    Inventors: Keiko Tsuchiya, Hisato Koshiba, Jun Okamoto, Takao Mizushima
  • Patent number: 8277578
    Abstract: A rare earth permanent magnet is prepared by disposing a powdered metal alloy containing at least 70 vol % of an intermetallic compound phase on a sintered body of R—Fe—B system, and heating the sintered body having the powder disposed on its surface below the sintering temperature of the sintered body in vacuum or in an inert gas for diffusion treatment. The advantages include efficient productivity, excellent magnetic performance, a minimal or zero amount of Tb or Dy used, an increased coercive force, and a minimized decline of remanence.
    Type: Grant
    Filed: October 27, 2010
    Date of Patent: October 2, 2012
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hiroaki Nagata, Tadao Nomura, Takehisa Minowa
  • Patent number: 8277679
    Abstract: The object of the present invention is to provide a composite magnetic material having well-balanced magnetic properties and chemical properties, and a magnetic element using thereof. Concretely, the present provides the composite magnetic material comprising a binder and a magnetic powder contains followings: Mn not less than 0.25 wt % and not larger than 3 wt %, Si not less than 1 wt % and not larger than 7 wt %, Cr not less than 2 wt % and not larger than 8 wt %, and the rest of Fe and inevitable impurities with respect to the total weight of a magnetic powder material, and a ratio of powder particles having the major/minor axis is not less than 2 is not larger than 5% of the total powder particles.
    Type: Grant
    Filed: February 10, 2011
    Date of Patent: October 2, 2012
    Assignee: Sumida Corporation
    Inventors: Akihiko Nakamura, Keisuke Watanabe
  • Patent number: 8277573
    Abstract: A process for the production of a grain oriented magnetic strip, made of steel containing 2.3 to 5.0% of silicon, obtained by producing a hot-rolled sheet containing a distribution of second phases capable of controlling the secondary recrystallization by means of a two-step hot-rolling with an intermediate annealing, and by changing it into the final product.
    Type: Grant
    Filed: April 18, 2008
    Date of Patent: October 2, 2012
    Assignee: Centro Sviluppo Materiali S.p.A.
    Inventors: Giuseppe Abbruzzese, Stefano Cicale', Stefano Fortunati
  • Patent number: 8277575
    Abstract: The invention relates to inorganic intermetallic compounds having a PMR effect (combined GMR/CMR effect), which are characterized in that they contain at least two elements per formula unit and have a field sensitivity of less than 10% per 0.1 T at temperatures greater than 290 K. The invention also relates to composites consisting of these compounds, to a method for the production thereof and to their use, in particular, as magnetic field sensors or in the domain of spin electronics.
    Type: Grant
    Filed: February 19, 2010
    Date of Patent: October 2, 2012
    Assignee: International Business Machines Corporation
    Inventor: Claudia Felser