Patents Examined by Xiaowei Su
  • Patent number: 11450479
    Abstract: An alloy having a formula FeaCobNicCudMeSifBgXh is provided. M is at least one of V, Nb, Ta, Ti, Mo, W, Zr, Cr, Mn and Hf; a, b, c, d, e, f, g are in at. %; X denotes impurities and optional elements P, Ge and C; and a, b, c, d, e, f, g, h satisfy the following: 0?b?4, 0?c<4, 0.5?d?2, 2.5?e?3.5, 14.5?f?16, 6?g?7, h<0.5, and 1?(b+c)?4.5, where a+b+c+d+e+f+g=100. The alloy has a nanocrystalline microstructure, a saturation magnetostriction of |?s|?1 ppm, a hysteresis loop with a central linear part, and a permeability (?) of 10,000 to 15,000.
    Type: Grant
    Filed: March 2, 2020
    Date of Patent: September 20, 2022
    Assignee: VACUUMSCHMELZE GMBH & CO. KG
    Inventors: Giselher Herzer, Viktoria Budinsky, Christian Polak
  • Patent number: 11450459
    Abstract: A soft magnetic powder contains Fe in a proportion of 45.0 mass % or more and 52.0 mass % or less, Co in a proportion of 47.0 mass % or more and 52.0 mass % or less, V in a proportion of 0.030 mass % or more and less than 2.0 mass %, and Si in a proportion of 0.10 mass % or more, wherein the sum of the content of V and the content of Si is 2.5 mass % or less, and the soft magnetic powder has a specific surface area of 0.15 m2/g or more and 0.80 m2/g or less.
    Type: Grant
    Filed: March 28, 2019
    Date of Patent: September 20, 2022
    Inventor: Takayuki Murai
  • Patent number: 11441213
    Abstract: A soft magnetic alloy ribbon having high corrosion resistance and good magnetic properties is obtained. The soft magnetic alloy ribbon contains Fe and M. M is at least one selected from the group consisting of Nb, Ta, W, Zr, Hf, Mo, Cr, and Ti, and a part of M is included in oxides. A maximum point of a concentration of at least one of M included in the oxides is present in a region within 20 nm from the surface, when a concentration distribution of an element contained in the soft magnetic alloy ribbon is measured from a surface toward an interior of the soft magnetic alloy ribbon in a thickness direction.
    Type: Grant
    Filed: November 19, 2020
    Date of Patent: September 13, 2022
    Assignee: TDK CORPORATION
    Inventors: Takuya Tsukahara, Isao Nakahata, Kazuhiro Yoshidome, Hiroyuki Matsumoto
  • Patent number: 11441212
    Abstract: Provided is alloyed steel powder having excellent fluidity, formability, and compressibility without containing Ni, Cr, or Si. The alloyed steel powder includes iron-based alloy containing Mo, in which Mo content is 0.4 mass % to 1.8 mass %, a weight-based median size D50 is 40 ?m or more, and among particles contained in the alloyed steel powder, those particles having an equivalent circular diameter of 50 ?m to 200 ?m have a number average of solidity of 0.70 to 0.86, the solidity being defined as (particle cross-sectional area/envelope-inside area).
    Type: Grant
    Filed: November 30, 2018
    Date of Patent: September 13, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Takuya Takashita, Akio Kobayashi, Naomichi Nakamura
  • Patent number: 11427896
    Abstract: A soft magnetic alloy thin strip which has high saturation magnetic flux density and low coercivity, which enables a core with high space factor and high saturation magnetic flux density. A soft magnetic alloy thin strip including a main component that has a composition formula (Fe(1?(?+?))X1?X2?)(1?(a+b+c+d+e+f))MaBbPcSidCeSf. In the formula, X1, X2 and M are selected from a specific element group; 0?a?0.140, 0.020?b?0.200, 0?c?0.150, 0?d?0.090, 0?e?0.030, 0?f?0.030, ??0, ??0, and 0??+??0.50; and at least one of a, c and d is larger than 0. The strip has a structure that is composed of an Fe-based nanocrystal; and the surface roughness of a release surface satisfies 0.85?Rae/Rac?1.25 (wherein Rac is the average of arithmetic mean roughnesses in the central portion, and Rae is the average in the edge portion).
    Type: Grant
    Filed: December 3, 2018
    Date of Patent: August 30, 2022
    Assignee: TDK CORPORATION
    Inventors: Akito Hasegawa, Hironobu Kumaoka, Kazuhiro Yoshidome, Hiroyuki Matsumoto, Kenji Horino, Isao Nakahata
  • Patent number: 11424055
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Grant
    Filed: September 25, 2019
    Date of Patent: August 23, 2022
    Assignee: NICHIA CORPORATION
    Inventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
  • Patent number: 11417462
    Abstract: A method of forming an annealed magnet includes positioning a magnetizing array ring concentrically with a ring of bulk magnetic material to form an assembly, the magnetizing array ring having a magnetic field defining directions for orienting grains of the ring of bulk magnetic material, placing the assembly in a furnace, and operating the furnace to anneal the ring of bulk magnetic material and grow the grains in the directions. A magnetic array assembly includes a furnace; and an assembly including (i) a ring of bulk magnetic material having grains and (ii) a magnetizing array ring concentric with the ring of bulk magnetic material, and having a magnetic field defining directions for orienting the grains during growth thereof in a presence of heat from the furnace.
    Type: Grant
    Filed: May 17, 2019
    Date of Patent: August 16, 2022
    Assignee: Ford Global Technologies LLC
    Inventors: Michael W. Degner, Wanfeng Li, Franco Leonardi
  • Patent number: 11410804
    Abstract: A permanent magnet 2 includes Nd, Fe, and B, the permanent magnet 2 contains a plurality of main phase grains; and grain boundaries positioned between the main phase grains, the main phase grains include Nd, Fe, and B, at least a portion of the grain boundaries contains an R?—O—C phase, the R?—O—C phase includes a rare earth element R?, O, and C, the concentration of each of R?, O, and C in the R?—O—C phase is higher compared to the main phase grains, the permanent magnet 2 comprises a surface layer portion 21 and a central portion 22, the surface layer portion 21 is positioned on the surface side of the permanent magnet 2, the central portion 22 is positioned on the inner side of the permanent magnet 2, the proportion of the area of the R?—O—C phase occupying in a cross-section of the surface layer portion 21 is S1 %, the proportion of the area of the R?—O—C phase occupying in a cross-section of the central portion 22 is S2%, and S1 is higher than S2.
    Type: Grant
    Filed: March 14, 2020
    Date of Patent: August 9, 2022
    Assignee: TDK Corporation
    Inventor: Masashi Miwa
  • Patent number: 11410805
    Abstract: An R—Fe—B base sintered magnet is provided comprising a main phase containing an HR rich phase of (R?,HR)2(Fe,(Co))14B wherein R? is an element selected from yttrium and rare earth elements exclusive of Dy, Tb and Ho, and essentially contains Nd, and HR is an element selected from Dy, Tb and Ho, and a grain boundary phase containing a (R?,HR)—Fe(Co)-M1 phase in the form of an amorphous phase and/or nanocrystalline phase, the (R?,HR)—Fe(Co)-M1 phase consisting essentially of 25-35 at % of (R?,HR), 2-8 at % of M1 which is at least one element selected from Si, Al, Mn, Ni, Cu, Zn, Ga, Ge, Pd, Ag, Cd, In, Sn, Sb, Pt, Au, Hg, Pb, and Bi, up to 8 at % of Co, and the balance of Fe. The HR rich phase has a higher HR content than the HR content of the main phase at its center. The magnet produces a high coercivity despite a low content of Dy, Tb and Ho.
    Type: Grant
    Filed: June 5, 2020
    Date of Patent: August 9, 2022
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Tetsuya Ohashi, Tetsuya Kume, Koichi Hirota, Hajime Nakamura
  • Patent number: 11404207
    Abstract: A method for manufacturing an R-T-B permanent magnet comprises a diffusion step of adhering a diffusing material to the surface of a magnet base material and heating the magnet base material with the diffusing material adhered thereto, wherein the magnet base material comprises rare-earth elements R, transition metal elements T and boron B; at least some of R are Nd; at least some of T are Fe; the diffusing material comprises a first component, a second component and a third component; the first component is at least one of a simple substance of Tb and a simple substance of Dy; the second component comprises a metal comprising at least one of Nd and Pr and not comprising Tb and Dy; and the third component is at least one selected from the group consisting of a simple substance of Cu, an alloy comprising Cu, and a compound of Cu.
    Type: Grant
    Filed: November 27, 2019
    Date of Patent: August 2, 2022
    Assignee: TDK Corporation
    Inventors: Taeko Tsubokura, Takeshi Masuda, Taku Murase
  • Patent number: 11404187
    Abstract: A magnetic material is expressed by a composition formula 1: (R1-xYx)aMbTcZnd. R is at least one element selected from the group consisting of rare-earth elements, M is Fe or Fe and Co, T is at least one element selected from the group consisting of Ti, V, Nb, Ta, Mo, and W, x is a number satisfying 0.01?x?0.8, a is a number satisfying 4?a?20 atomic percent, b is a number satisfying b=100?a?c?d atomic percent, c is a number satisfying 0<c<7 atomic percent, and d is a number satisfying 0.01?d?7 atomic percent. The magnetic material includes: a main phase having a ThMn12 crystal phase; and a sub phase containing 50 atomic percent or more of Zn.
    Type: Grant
    Filed: February 25, 2019
    Date of Patent: August 2, 2022
    Assignee: KABUSHIKI KAISHA TOSHIBA
    Inventors: Masaya Hagiwara, Shinya Sakurada, Keiko Okamoto
  • Patent number: 11383296
    Abstract: Systems and methods are disclosed for using magnetic fields (e.g., changing magnetic fields) to control metal flow conditions during casting (e.g., casting of an ingot, billet, or slab). The magnetic fields can be introduced using rotating permanent magnets or electromagnets. The magnetic fields can be used to induce movement of the molten metal in a desired direction, such as in a rotating pattern around the surface of the molten sump. The magnetic fields can be used to induce metal flow conditions in the molten sump to increase homogeneity in the molten sump and resultant ingot.
    Type: Grant
    Filed: August 30, 2019
    Date of Patent: July 12, 2022
    Assignee: Novelis, Inc.
    Inventors: Samuel R. Wagstaff, Wayne J. Fenton, Robert B. Wagstaff, Milan Felberbaum, Todd F. Bischoff, Tina J. Kosmicki
  • Patent number: 11384422
    Abstract: The present invention provides a method for producing a magnetic nanoparticle-coated laminate material. The method comprises coating a pair of opposed surfaces of a plurality of steel or iron/cobalt (Fe/Co) alloy film portions with a magnetic nanoparticle-containing coating. Each magnetic nanoparticle comprises a core and a shell covering at least a portion of the core. The shell and core are made of different materials selected from one or more of: iron, cobalt, nickel; and/or alloys comprising two or more of: iron, cobalt and/or nickel; and/or magnetic rare earth metals; and/or diamagnetic transition metals. The method further comprises stacking the coated film portions on top of each other such that a or each coated surface of each film portion is located adjacent a further coated surface of an adjacent film portion; and compressing the stacked coated film portions together to form a nanoparticle-coated laminate material.
    Type: Grant
    Filed: November 27, 2017
    Date of Patent: July 12, 2022
    Assignee: Magnetic Laminates Ltd.
    Inventors: Patrick William John Kinmont, Robert Davidson Binns, Christopher Robin Binns
  • Patent number: 11377705
    Abstract: A grain-oriented electrical steel sheet includes a steel layer and an insulation coating arranged in directly contact with the steel layer thereon. The steel layer includes, as a chemical composition, by mass %, 2.9 to 4.0% of Si, 2.0 to 4.0% of Mn, 0 to 0.20% of Sn, and 0 to 0.20% of Sb. In the steel layer, a silicon content and a manganese content expressed in mass % satisfy 1.2%?Si?0.5×Mn?2.0%, and a tin content and an antimony content expressed in mass % satisfy 0.005%?Sn+Sb?0.20%.
    Type: Grant
    Filed: February 18, 2020
    Date of Patent: July 5, 2022
    Assignee: NIPPON STEEL CORPORATION
    Inventors: Hiroyoshi Yashiki, Kenichi Murakami, Nobusato Morishige, Hirotoshi Tada, Yoshiaki Natori
  • Patent number: 11365460
    Abstract: A high-carbon cold rolled steel sheet having a specified chemical composition, and a method for manufacturing the same. The method includes forming a hot rolled steel sheet, performing cooling at an average cooling rate of 30° C./s or more and 70° C./s or less through a temperature range of a finish rolling end temperature to 660° C., coiling a hot rolled steel sheet at a temperature of 500° C. or more and 660° C. or less, and, optionally, pickling the coiled hot rolled steel sheet, and then performing a first box-annealing of holding at an annealing temperature in a temperature range of 650 to 720° C., then performing cold rolling at a rolling reduction ratio of 20 to 50%, and then performing a second box-annealing of holding at an annealing temperature in a temperature range of 650 to 720° C.
    Type: Grant
    Filed: February 20, 2019
    Date of Patent: June 21, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Yuka Miyamoto, Yoichiro Matsui, Shogo Sato, Takeshi Yokota
  • Patent number: 11351613
    Abstract: Elements formed from magnetic materials and their methods of manufacture are presented. Magnetic materials include a magnetic alloy material, such as, for example, an Fe—Co alloy material (e.g., the Fe—Co—V alloy Hiperco-50®). The magnetic alloy materials may comprise a powdered material suitable for use in additive manufacturing techniques, such as, for example direct energy deposition or laser powder bed fusion. Manufacturing techniques include the use of variable deposition time and energy to control the magnetic and structural properties of the materials by altering the microstructure and residual stresses within the material. Manufacturing techniques also include post deposition processing, such as, for example, machining and heat treating. Heat treating may include a multi-step process during which the material is heated, held and then cooled in a series of controlled steps such that a specific history of stored internal energy is created within the material.
    Type: Grant
    Filed: June 3, 2019
    Date of Patent: June 7, 2022
    Assignee: California Institute of Technology
    Inventors: Samad A. Firdosy, Robert P. Dillon, Ryan W. Conversano, John Paul C. Borgonia, Andrew A. Shapiro-Scharlotta, Bryan W. McEnerney, Adam Herrmann
  • Patent number: 11342099
    Abstract: Disclosed is a surface modification technique for permanent magnetic materials. First, a sintered Nd—Fe—B magnet is immersed in a chlorine-containing solution to corrode its surface after the sintered Nd—Fe—B magnet is ground, polished and cleaned, so that atomic vacancies or gaps are produced at the grain boundaries in the surface layer of the corroded sintered Nd—Fe—B magnet; then, compound nanopowders coated on the surface of the sintered Nd—Fe—B magnet are implanted into the grain boundaries by laser shock peening to obtain a gradient nanostructure layer along the depth direction; at the same time, the surface nanocrystallization of the sintered Nd—Fe—B magnet and a residual compressive stress layer are induced by laser shock peening which remarkably improves the corrosion resistance of the sintered Nd—Fe—B magnet.
    Type: Grant
    Filed: August 6, 2018
    Date of Patent: May 24, 2022
    Inventors: Kaiyu Luo, Changyu Wang, Fang Wang, Yefang Yin, Xiaohong Xu, Jinzhong Lu
  • Patent number: 11331721
    Abstract: Provided are a new, highly magnetically stable magnetic material which has higher saturation magnetization than ferrite-based magnetic materials, and with which problems of eddy current loss and the like can be solved due to higher electric resistivity than that of existing metal-based magnetic materials, and a method for manufacturing the same. A magnetic material powder is obtained by reducing in hydrogen Ni-ferrite nanoparticies obtained by wet synthesis and causing grain growth, while simultaneously causing nanodispersion of an ?-(Fe, Ni) phase and an Ni-enriched phase by means of a phase dissociation phenomenon due to disproportional reaction. The powder is sintered to obtain a solid magnetic material.
    Type: Grant
    Filed: February 23, 2018
    Date of Patent: May 17, 2022
    Assignee: NATIONAL INSTITUTE OF ADVANCED INDUSTRIAL SCIENCE AND TECHNOLOGY
    Inventors: Shinpei Yamamoto, Nobuyoshi Imaoka, Kimihiro Ozaki
  • Patent number: 11335482
    Abstract: The present disclosure discloses a high-temperature-stability permanent magnet material and an application thereof. The microstructure of the permanent magnet material comprises a first magnetic phase and a second magnetic phase; the first magnetic phase is a magnetic phase with uniaxial anisotropy, and the second magnetic phase is a magnetic phase with spin reorientation transition; and the first magnetic phase and the second magnetic phase are isolated from each other; and the absolute value of the temperature coefficient of saturation magnetization intensity of the first magnetic phase is less than 0.02%/° C. By means of the permanent magnet material comprising the first magnetic phase and the second magnetic phase, a positive temperature coefficient of coercivity can be obtained, so that obtaining a low temperature coefficient of coercivity can be targeted, regular and universal.
    Type: Grant
    Filed: September 6, 2019
    Date of Patent: May 17, 2022
    Assignee: NINGBO INSTITUTE OF MATERIALS TECHNOLOGY AND ENGINEERING, CHINESE ACADEMY OF SCIENCES
    Inventors: Lei Liu, Zhuang Liu, Aru Yan, Xin Zhang, Yingli Sun, Dong Li
  • Patent number: 11335483
    Abstract: The present invention provides a magnet structure comprising a first magnet, a second magnet, and an intermediate layer joining the first magnet and the second magnet. In the magnet structure, each of the first magnet and the second magnet is a permanent magnet comprising a rare earth element R, a transition metal element T, and boron B. In addition, the rare earth element R comprises: a light rare earth element RL comprising at least Nd; and a heavy rare earth element RH, and the transition metal element T comprises Fe, Co, and Cu. Further, the intermediate layer comprises: an RL oxide phase comprising an oxide of the light rare earth element RL; and an RL—Co—Cu phase comprising the light rare element RL, Co, and Cu.
    Type: Grant
    Filed: October 15, 2018
    Date of Patent: May 17, 2022
    Assignee: TDK Corporation
    Inventors: Taeko Tsubokura, Takeshi Masuda, Toshihiro Kuroshima