Abstract: A method for making ferrite powder may include providing ferrite feed materials in a form of particles, such as having different sizes and irregular shapes. The method may further include exposing the ferrite feed materials to a low velocity oxygen-fueled (LVOF) flame spray. This may provide a more spherical shape to irregularly shaped particles to thereby make the ferrite powder. An apparatus for making ferrite powder may include a feeder for ferrite feed materials and a LVOF flame spray system for exposing the ferrite feed materials to the flame spray.

Abstract: A common mode choke may include a generally rectangular body including bottom and top ferrite portions, at least one pair of laterally spaced apart interior conductors between the bottom and top ferrite portions and extending between the first and second ends of the generally rectangular body, and a dielectric material layer between the bottom and top ferrite portions. Moreover, the dielectric material layer may also extend laterally between the at least one pair of interior conductors and may also at least partially encapsulate the at least one pair of interior conductors at portions thereof opposite at least one of the bottom and top ferrite portions. The choke may also include end conductors on the opposite ends of the generally rectangular body and connected to the interior conductors. A compact footprint is provided for the common mode choke while maintaining a high level of electrical performance.

Abstract: A method for making ferrite powder may include providing ferrite feed materials in a form of particles having different sizes and irregular shapes, and exposing the ferrite feed materials to a plasma to provide a more spherical shape to irregularly shaped particles to thereby make the ferrite powder. An apparatus for making ferrite powder may include a feeder for ferrite feed materials and a plasma generator for exposing the ferrite feed materials to a plasma.

Abstract: A filter device may include a plurality of ferrite filters laminated together in vertically stacked relation, where each ferrite filter may include a pair of ferrite layers laminated together in vertically stacked relation and a lateral conductor extending therebetween. The filter device may also include at least one vertical conductor connecting the lateral conductors together in series. Moreover, at least some of the ferrite filters may have different operating characteristics. In particular, the different operating characteristics may be different impedance versus frequency characteristics to thereby broaden an attenuation frequency band of the filter device.

Abstract: A method for making a radiation absorbing material (RAM) coating may include providing an iron-silicon alloy powder, forming the iron-silicon alloy powder into flakes, and passivating the flakes. The method may further include selecting passivated flakes having a desired size, and combining the selected passivated flakes with a carrier to provide the RAM coating. The coating may be applied to a substrate to impart the radiation absorbing property thereto.

Abstract: A filter device may include a plurality of ferrite filters laminated together in vertically stacked relation, where each ferrite filter may include a pair of ferrite layers laminated together in vertically stacked relation and a lateral conductor extending therebetween. The filter device may also include at least one vertical conductor connecting the lateral conductors together in series. Moreover, at least some of the ferrite filters may have different operating characteristics. In particular, the different operating characteristics may be different impedance versus frequency characteristics to thereby broaden an attenuation frequency band of the filter device.

Abstract: A method for making ferrite powder may include providing ferrite feed materials in a form of particles having different sizes and irregular shapes, and exposing the ferrite feed materials to a plasma to provide a more spherical shape to irregularly shaped particles to thereby make the ferrite powder. An apparatus for making ferrite powder may include a feeder for ferrite feed materials and a plasma generator for exposing the ferrite feed materials to a plasma.

Abstract: A method for making a radiation absorbing material (RAM) coating may include providing an iron-silicon alloy powder, forming the iron-silicon alloy powder into flakes, and passivating the flakes. The method may further include selecting passivated flakes having a desired size, and combining the selected passivated flakes with a carrier to provide the RAM coating. The coating may be applied to a substrate to impart the radiation absorbing property thereto.

Abstract: A method treats an article and more specifically an aircraft surface in order to prevent icing and to provide a coating that emits very low volatile organic compounds (VOC) during application and setting. Icing on critical aircraft surfaces creates dangerous conditions that impair the stability of the aircraft. The specific areas are referred to as “cold-soak” conditions and some areas on the “leading edges” of the wings. The invention eliminates icing on these surfaces. Ice will not form on the surface of certain polymer coatings with low surface energy such as Teflon. This is a consequence of the high contact angle between the water droplet and the surface that establishes a non-wetting surface. The invention implements such coatings and a deposition process. The coating may be used for other objects such as automobiles, consumer products, such as refrigerators, stoves, etc.

Abstract: The method may include joining together a bottom layer, a top layer and at least one intermediate layer therebetween, with the bottom and top layers including a non-magnetic material, and the at least one intermediate layer including a non-magnetic material. The method may also include dividing the joined together layers into a plurality of closed-shape cores each having at least one magnetic flux gap therein provided by the non-magnetic material. The closed-shape cores may be toroidal, for example. The method may also include winding at least one conductor on each closed-shape core to form the inductors. In some embodiments the joined together layers may be divided into a plurality of strips. The method may also include punching each strip to form a plurality of closed shape cores, with toroidal core having at least one magnetic flux gap therein provided by the non-magnetic material.

Abstract: A toroidal inductor includes a toroidal core including magnetic material and having at least one magnetic flux gap therein, and at least one conductor wound on the core. The magnetic flux gap may include a non-magnetic material having a substantially uniform thickness between respective adjacent magnetic material portions. In some embodiments, the non-magnetic material may have a shrinkage factor during sintering substantially equal to a shrinkage factor of the magnetic material. For example, the magnetic material may include ferrite, and the non-magnetic material may include alumina or zinc ferrite. In some embodiments, the flux gap may be provided by an air gap. The substantially uniform thickness of the at least one magnetic flux gap is readily and accurately produced in accordance with associated manufacturing aspects of the invention.

Abstract: Composite materials having improved fracture toughness are formed by dispersing ductile inclusions in a less ductile matrix. The matrices may be formed from metals, such as high-strength aluminum alloys or ceramics. Bonding should be present between the inclusions and the matrix so that cracks in the composite material must pass through the inclusions.

Abstract: A metallurgical method including cooling molten aluminum particles and consolidating resulting solidified particles into a multiparticle body, wherein the improvement comprises the provision of greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.Aluminum containing greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.