Permanent Magnet Patents (Class 148/101)
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Patent number: 10068690Abstract: An R-T-B based permanent with the residual magnetic flux density Br2 satisfies the relationship of Br2/Br?0.90, wherein the residual magnetic flux density Br2 is obtained after applying the external magnetic field of Hex and then applying an external magnetic field of 0.95 HcJ. Such a R-T-B based permanent magnet preferably contains main phase grains with a composition of (R11?xR2x)2T14B (R1 is rare earth element(s) composed of one or more elements selected from the group consisting of Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, R2 is element(s) containing at least one selected from the group consisting of Y, La and Ce, T is one or more transition metal elements including Fe or a combination of Fe and Co as essential elements, and 0.2?x?0.7) and thus can be suitably used as a magnet with a variable magnetic force for a variable magnetic flux motor.Type: GrantFiled: March 20, 2015Date of Patent: September 4, 2018Assignee: TDK CORPORATIONInventors: Kenichi Suzuki, Yasushi Enokido
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Patent number: 10068691Abstract: An R-T-B based permanent containing main phase grains with a composition of (R1-xYx)2T14B (R is rare earth element(s) composed of one or more elements selected from the group consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, T is one or more transition metal elements including Fe or a combination of Fe and Co as essential elements, and 0.2?x?0.7), wherein the residual magnetic flux density Br is 1.1 T or more, the coercivity HcJ is 400 kA/m or less, and the ratio Hex/HcJ of the external magnetic field Hex required for obtaining a residual magnetic flux density Br of 0 to the coercivity HcJ is 1.10 or less.Type: GrantFiled: March 18, 2015Date of Patent: September 4, 2018Assignee: TDK CORPORATIONInventor: Kenichi Suzuki
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Patent number: 10062489Abstract: The present invention discloses a rare earth permanent magnet and a method for preparing same. The material of the rare earth permanent magnet has a heavy rare earth element volume diffusion phenomenon at a depth of 5 ?m to 100 ?m from the surface of the magnet to the interior of the magnet along the magnetic field orientation direction, thereby forming a volume diffusion layer region; the volume diffusion layer region is divided into magnet units having a volume of 10*100*5 ?m, and the concentration difference of the heavy rare earth elements of the magnet units at different positions in the volume diffusion layer is below 0.5 at %. The present invention provides a sintered NdFeB magnet of high intrinsic coercive force Hcj on the premise of not influencing the remanence Br and the maximum magnetic energy product (BH)max of products.Type: GrantFiled: May 11, 2017Date of Patent: August 28, 2018Assignee: BEIJING ZHONG KE SAN HUAN HI-TECH CO., LTD.Inventors: Zhi'an Chen, E. Niu, Wei Zhu, Fenghua Chen, Yeqing He, Xiaolei Rao, Boping Hu, Haojie Wang
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Patent number: 10047265Abstract: A rare earth regenerator material particle and a regenerator material particle group having a high long-term reliability, and a superconducting magnet, an examination apparatus, a cryopump and the like using the same are provided. A rare earth regenerator material particle contains a rare earth element as a constituent component, and in the particle, a peak indicating a carbon component is detected in a surface region by an X-ray photoelectron spectroscopy analysis.Type: GrantFiled: April 7, 2015Date of Patent: August 14, 2018Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Katsuhiko Yamada, Keiichi Fuse
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Patent number: 10022796Abstract: A method of making a magnetic material includes a step of providing a first material in the form of a core powder containing Nd, Fe and B. The first material is combined with the second material to form a powder combination. The second material includes a component selected from the group consisting of Dy, Tb, and combinations thereof. The powder combination is encapsulated to form an encapsulated powder combination. A magnetic field is applied to the powder combination during encapsulation and thereafter to align the magnetic dipoles therein. The encapsulated powder combination is isostatically pressed with heat to form the magnetic material.Type: GrantFiled: August 28, 2014Date of Patent: July 17, 2018Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventor: Yucong Wang
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Patent number: 10024583Abstract: Provided is a group of rare-earth regenerator material particles having an average particle size of 0.01 to 3 mm, wherein the proportion of particles having a ratio of a long diameter to a short diameter of 2 or less is 90% or more by number, and the proportion of particles having a depressed portion having a length of 1/10 to ½ of a circumferential length on a particle surface is 30% or more by number. By forming the depressed portion on the surface of the regenerator material particles, it is possible to increase permeability of an operating medium gas and a contact surface area with the operating medium gas.Type: GrantFiled: June 28, 2017Date of Patent: July 17, 2018Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Katsuhiko Yamada, Keiichi Fuse
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Patent number: 10014099Abstract: The present invention discloses a rare earth permanent magnet and a method for preparing same. The material of the rare earth permanent magnet has a heavy rare earth element volume diffusion phenomenon at a depth of 5 ?m to 100 ?m from the surface of the magnet to the interior of the magnet along the magnetic field orientation direction, thereby forming a volume diffusion layer region; the volume diffusion layer region is divided into magnet units having a volume of 10*100*5 ?m, and the concentration difference of the heavy rare earth elements of the magnet units at different positions in the volume diffusion layer is below 0.5 at %. The present invention provides a sintered NdFeB magnet of high intrinsic coercive force Hcj on the premise of not influencing the remanence Br and the maximum magnetic energy product (BH)max of products.Type: GrantFiled: July 20, 2016Date of Patent: July 3, 2018Assignee: BEIJING ZHONG KE SAN HUAN HI-TECH CO., LTD.Inventors: Zhi'an Chen, E. Niu, Wei Zhu, Fenghua Chen, Yeqing He, Xiaolei Rao, Boping Hu, Haojie Wang
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Patent number: 10014107Abstract: There are provided a rare-earth permanent magnet, and a method for manufacturing a rare-earth permanent magnet and a system for manufacturing a rare-earth permanent magnet, capable of achieving improved shape uniformity. Magnet material is milled into magnet powder, and the milled magnet powder is formed into a formed body 40. The formed body 40 is calcined and then sintered using a spark plasma sintering apparatus 45, so that a permanent magnet 1 is manufactured. A die unit 46 included in the spark plasma sintering apparatus 45 that performs spark plasma sintering at least includes in one direction an inflow hole 50 configured to receive inflow of part of the pressurized formed body.Type: GrantFiled: March 8, 2013Date of Patent: July 3, 2018Assignee: NITTO DENKO CORPORATIONInventors: Izumi Ozeki, Katsuya Kume, Toshiaki Okuno, Tomohiro Omure, Takashi Ozaki, Keisuke Taihaku, Takashi Yamamoto
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Patent number: 10002695Abstract: Provided is a method for manufacturing a rare-earth magnet having good workability and capable of manufacturing a rare-earth magnet having low oxygen density. A method for manufacturing a rare-earth magnet includes: a first step of applying or spraying graphite-based lubricant GF on an inner face of a forming die M, and charging magnetic powder MF as a rare-earth magnet material in the forming die M, followed by cold forming, to form a cold-forming compact 10 having a surface on which a graphite-based lubricant coat 12 is formed; a second step of performing hot forming to the cold-forming compact 10 to form a sintered body 20 having a surface on which a graphite-based lubricant coat 22 is formed; and a third step of, in order to give the sintered body 20 anisotropy, performing hot deformation processing to the sintered body 20 to form the rare-earth magnet 30.Type: GrantFiled: August 19, 2015Date of Patent: June 19, 2018Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki Haga, Tomonori Inuzuka, Yuya Ikeda
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Patent number: 9978487Abstract: An article for magnetic heat exchange includes a functionally-graded monolithic sintered working component including La1-aRa(Fe1-x-yTyMx)13HzCb with a NaZn13-type structure. M is one or more of the elements from the group consisting of Si and Al, T is one or more of the elements from the group consisting of Mn, Co, Ni, Ti, V and Cr and R is one or more of the elements from the group consisting of Ce, Nd, Y and Pr. A content of the one or more elements T and R, if present, a C content, if present, and a content of M varies in a working direction of the working component and provides a functionally-graded Curie temperature. The functionally-graded Curie temperature monotonically decreases or monotonically increases in the working direction of the working component.Type: GrantFiled: August 17, 2011Date of Patent: May 22, 2018Assignee: VACUUMSCHMELZE GMBH & CO. KGInventors: Matthias Katter, Alexander Barcza, Volker Zellmann
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Patent number: 9972435Abstract: Disclosed is a method for manufacturing an R-T-B based sintered magnet, which includes the steps of: preparing an R-T-B based sintered magnet material; and performing a heat treatment by heating the R-T-B based sintered magnet material at a temperature of 450° C. or higher and 470° C. or lower for 4 hours or more and 12 hours or less, wherein the R-T-B based sintered magnet material is represented by the formula of: uRwBxGayCuzAlqM (100?u?w?x?y?z?q) T, the content of RH is 5% or less by mass in the R-T-B based sintered magnet, 29.5?u?32.0, 0.86?w?0.93, 0.2?x?1.0, 0.3?y?1.0, 0.05?z?0.5, 0?q?0.1, and a relationship of p<0 is satisfied when p=[B]/10.811×14?[Fe]/55.847?[Co]/58.933.Type: GrantFiled: March 25, 2015Date of Patent: May 15, 2018Assignee: HITACHI METALS, LTD.Inventor: Noriyuki Nozawa
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Patent number: 9963769Abstract: Provided in one embodiment is a method of selective microstructural transformation, comprising: providing a part comprising a bulk amorphous alloy; heating selectively a portion of the part to a first temperature such that at least some of the portion is transformed into a crystalline phase; and processing the transformed portion.Type: GrantFiled: July 5, 2012Date of Patent: May 8, 2018Assignee: Apple Inc.Inventors: Christopher D. Prest, Matthew S. Scott, Stephen P. Zadesky, Dermot J. Stratton, Joseph C. Poole
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Patent number: 9947445Abstract: A R-T-B based permanent magnet which has equivalent magnetic properties as the existing Nd—Fe—B based permanent magnet and light mass but also can be suitably used as a magnet for field system of a permanent magnet synchronous rotating machine. The magnet can be obtained in a case where the composition of the compound for forming the main phase is (R1?x(Y1?zCez)x)2T14B (R is rare earth element(s) consisting of one or more elements selected from La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, Y is yttrium, Ce is cerium, T is one or more transition metal elements with Fe or Fe and Co as essential element(s), B is boron, 0.0<x?0.5 and 0.0?z?0.5), by making the abundance ratio of Y4f/(Y4f+Y4g) in relation to the Y occupying the 4f site of the tetragonal R2T14B structure (i.e., Y4f) and the Y occupying the 4g site (i.e., Y4g) satisfies 0.8?Y4f/(Y4f+Y4g)?1.0.Type: GrantFiled: January 17, 2014Date of Patent: April 17, 2018Assignee: TDK CORPORATIONInventors: Kenichi Suzuki, Kyung-Ku Choi, Ryuji Hashimoto
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Patent number: 9920406Abstract: A method for manufacturing a high-performance NdFeB rare earth permanent magnetic device which is made of an R—Fe—Co—B-M strip casting alloy, a micro-crystal HR—Fe alloy fiber, and TmGn compound micro-powder, includes steps of: manufacturing the R—Fe—Co—B-M strip casting alloy, manufacturing the micro-crystal HR—Fe alloy fiber, providing hydrogen decrepitating, pre-mixing, powdering with jet milling, post-mixing, providing magnetic field pressing, sintering and ageing, wherein after a sintered NdFeB permanent magnet is manufactured, machining and surface-treating the sintered NdFeB permanent magnet for forming a rare earth permanent device.Type: GrantFiled: May 11, 2015Date of Patent: March 20, 2018Assignee: SHENYANG GENERAL MAGNETIC CO., LTDInventor: Baoyu Sun
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Patent number: 9905362Abstract: A method for manufacturing a rare-earth magnet, through hot deformation processing, having a high degree of orientation at the entire area thereof and high remanence, without increasing processing cost including a step of press-forming powder as a rare-earth magnetic material to form a compact S; and a step of performing hot deformation processing to the compact S, thus manufacturing the rare-earth magnet C. The hot deformation processing includes two steps of extruding and upsetting. The extruding is to place a compact S in a die Da, and apply pressure to the compact S? in a heated state with an extrusion punch PD so as to reduce the thickness for extrusion to prepare the rare-earth magnet intermediary body S? having a sheet form, and the upsetting is to apply pressure to the rare-earth magnet intermediary body S? in the thickness direction to reduce the thickness, thus manufacturing the rare-earth magnet C.Type: GrantFiled: October 17, 2013Date of Patent: February 27, 2018Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Daisuke Ichigozaki, Noritaka Miyamoto, Tetsuya Shoji, Yuya Ikeda, Akira Manabe
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Patent number: 9865382Abstract: Provided are raw material alloy flakes for a rare earth sintered magnet and a method for producing the same. The alloy flakes have a roll-cooled face, and (1) contain at least one R selected from rare earth metal elements including Y, B, and the balance M including iron, at a particular ratio; (2) as observed in a micrograph at a magnification of 100× of its roll-cooled face, have not less than 5 crystals each of which is a dendrite grown radially from a point of crystal nucleation, and crosses a line segment corresponding to 880 ?m; and (3) as observed in a micrograph at a magnification of 200× of its section taken generally perpendicularly to its roll-cooled face, have an average distance between R-rich phases of not less than 1 ?m and less than 10 ?m.Type: GrantFiled: July 30, 2012Date of Patent: January 9, 2018Assignee: SANTOKU CORPORATIONInventors: Shinya Tabata, Kazumasa Shintani, Takuya Onimura
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Patent number: 9862030Abstract: Provided are alloy flakes for rare earth sintered magnet, which achieve a high rare earth component yield after pulverization with respect to before pulverization and a uniform particle size after pulverization, and a method for producing such alloy at high energy efficiency in an industrial scale. The method includes (A) preparing an alloy melt containing R composed of at least one element selected from rare earth metal elements including Y, B, and the balance M composed of Fe, or of Fe and at least one element selected from transition metal elements other than Fe, Si, and C, (B) rapidly cooling/solidifying the alloy melt to not lower than 700° C. and not higher than 1000° C. by strip casting with a cooling roll, and (C) heating and maintaining, in a particular temperature range, alloy flakes separated from the roll by rapid cooling and solidifying in step (B) before the flakes are cooled to not higher than 500° C., to obtain alloy flakes having a composition of 27.0 to 33.0 mass % R, 0.90 to 1.Type: GrantFiled: July 1, 2011Date of Patent: January 9, 2018Assignee: SANTOKU CORPORATIONInventors: Takuya Onimura, Shinya Tabata
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Patent number: 9865673Abstract: An on-chip magnetic structure includes a magnetic material comprising cobalt in a range from about 80 to about 90 atomic % (at. %) based on the total number of atoms of the magnetic material, tungsten in a range from about 4 to about 9 at. % based on the total number of atoms of the magnetic material, phosphorous in a range from about 7 to about 15 at. % based on the total number of atoms of the magnetic material, and palladium substantially dispersed throughout the magnetic material.Type: GrantFiled: March 24, 2015Date of Patent: January 9, 2018Assignee: INTERNATIONAL BUSINESS MACHINES CORPORATIONInventors: Hariklia Deligianni, William J. Gallagher, Andrew J. Kellock, Eugene J. O'Sullivan, Lubomyr T. Romankiw, Naigang Wang
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Patent number: 9837207Abstract: A method for producing a NdFeB system sintered magnet. The method includes: a hydrogen pulverization process, in which coarse powder of a NdFeB system alloy is prepared by coarsely pulverizing a lump of NdFeB system alloy by making this lump occlude hydrogen; a fine pulverization process, in which fine powder is prepared by performing fine pulverization for further pulverizing the coarse powder; a filling process, in which the fine powder is put into a filling container; an orienting process, in which the fine powder in the filling container is oriented; and a sintering process, in which the fine powder after the orienting process is sintered as held in the filling container. The processes from hydrogen pulverization through orienting are performed with neither dehydrogenation heating nor evacuation each for desorbing hydrogen occluded in the hydrogen pulverization process. The processes from hydrogen pulverization through sintering are performed in an oxygen-free atmosphere.Type: GrantFiled: June 27, 2013Date of Patent: December 5, 2017Assignee: INTERMETALLICS CO., LTD.Inventors: Masato Sagawa, Tetsuhiko Mizoguchi, Yasuhiro Une
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Patent number: 9818514Abstract: Nanocomposite magnetic materials, methods of manufacturing nanocomposite magnetic materials, and magnetic devices and systems using these nanocomposite magnetic materials are described. A nanocomposite magnetic material can be formed using an electro-infiltration process where nanomaterials (synthesized with tailored size, shape, magnetic properties, and surface chemistries) are infiltrated by electroplated magnetic metals after consolidating the nanomaterials into porous microstructures on planar substrates. The nanomaterials may be considered the inclusion phase, and the magnetic metals may be considered the matrix phase of the multi-phase nanocomposite.Type: GrantFiled: July 25, 2014Date of Patent: November 14, 2017Assignee: University of Florida Research Foundation, IncorporatedInventors: David P. Arnold, Jennifer S. Andrew
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Patent number: 9818521Abstract: There is provided a compression-bonded magnet with a case, which can realize high magnetic properties, high corrosion resistance and high durability strength even at low cost.Type: GrantFiled: December 10, 2014Date of Patent: November 14, 2017Assignee: NTN CORPORATIONInventors: Shinji Miyazaki, Takuji Harano, Tatsuo Nakajima
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Patent number: 9805850Abstract: A NdFeB permanent magnet is provided and includes Nd of about 25 to 30 wt %, Dy of about 0.5 to 6 wt %, Tb of about 0.2 to 2 wt %, Cu of about 0.1 to 0.5 wt %, B of about 0.8 to 2 wt %, a balance of Fe and other inevitable impurities. In addition, a method for producing the permanent magnet is provided.Type: GrantFiled: July 16, 2014Date of Patent: October 31, 2017Assignee: Hyundai Motor CompanyInventors: Kun Min Park, Jae Ryung Lee, Shin Gyu Kim, Hyung Ju Lee
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Patent number: 9774220Abstract: The present invention provides an R-T-B based permanent magnet, comprising: a main phase which is composed of the structure of R2T14B (R is at least one element selected from Y, La, Ce, Pr, Nd, Sm, Eu and Gd, and T is one or more transition metal elements having Fe or a combination of Fe and Co as necessary); and a grain boundary phase which is composed of CexM1-x (M is at least one element selected from Mg, Al, Si, Ti, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Y, Zr, Nb, Mo, Ag, In, Sn, La, Pr, Nd, Sm, Eu, Gd, Hf, Ta, W and Bi, and x is within the range of 0.20?x?0.55), and the cross-sectional ratio Atre of the grain boundary phase to the whole magnet structure is within the range of 0.03<Atre<0.07.Type: GrantFiled: April 3, 2015Date of Patent: September 26, 2017Assignee: TDK CORPORATIONInventors: Daisuke Tanaka, Yasushi Enokido
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Patent number: 9732406Abstract: Provided is a magnetic refrigeration material represented by the formula La1-fREf(Fe1-a-b-c-d-eSiaCobXcYdZe)13 (RE: at least one of rare earth elements including Sc and Y and excluding La; X: Ga and/or Al; Y: at least one of Ge, Sn, B, and C; Z: at least one of Ti, V, Cr, Mn, Ni, Cu, Zn, and Zr; 0.03?a?0.17, 0.003?b?0.06, 0.02?c?0.10, 0?d?0.04, 0?e?0.04, 0?f?0.50), and having an average crystal grain size of not smaller than 0.01 ?m and not larger than 3 ?m, a Curie temperature of not lower than 250 K, and the maximum (??Smax) of magnetic entropy change (??SM) when subjected to a field change up to 2 Tesla is not less than 5 J/kgK.Type: GrantFiled: June 22, 2012Date of Patent: August 15, 2017Assignee: SANTOKU CORPORATIONInventor: Toshio Irie
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Patent number: 9714458Abstract: The embodiments provide a high-performance permanent magnet. The permanent magnet includes a sintered body having a composition expressed by a composition formula RpFeqMrCutCo100-p-q-r-t, with carbon in a range from 50 mass ppm to 1500 mass ppm. The sintered body also includes a metallic structure. The metallic structure includes a main phase having a Th2Zn17 crystal phase, and a secondary phase having a carbide phase of the M element of the composition formula. A ratio (I2/I1) of a maximum intensity I2 of a diffraction peak at an angle 2? in a range from 37.5 degrees to 38.5 degrees to a maximum intensity I1 of a diffraction peak at the angle 2? in a range from 32.5 degrees to 33.5 degrees is greater than 25 but no greater than 80 in an X-ray diffraction pattern obtained by applying an X-ray diffraction measuring method to the sintered body.Type: GrantFiled: March 11, 2015Date of Patent: July 25, 2017Assignee: KABUSHIKI KAISHA TOSHIBAInventors: Yosuke Horiuchi, Shinya Sakurada, Masaya Hagiwara, Tsuyoshi Kobayashi, Tadahiko Kobayashi, Naoyuki Sanada
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Patent number: 9715956Abstract: The magnet has a composition expressed by RpFeqMrCutCo100-p-q-r-t. The magnet has a metallic structure including a main phase having a Th2Zn17 crystal phase. The main phase has crystal grains. 5% or less of the crystal grains having a grain diameter equal to or smaller than 10 ?m, 40% or less of the crystal grains having crystal orientation perpendicular to (001) plane of the Th2Zn17 crystal phase in a direction deviated 30 degrees or more relative to an axis of easy magnetization.Type: GrantFiled: March 11, 2015Date of Patent: July 25, 2017Assignee: KABUSHIKI KAISHA TOSHIBAInventors: Yosuke Horiuchi, Shinya Sakurada, Masaya Hagiwara, Tsuyoshi Kobayashi, Tadahiko Kobayashi
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Patent number: 9672980Abstract: The present invention discloses an R-T-B-M-C sintered magnet and a method for manufacturing the R-T-B-M-C sintered magnet from an R-T-B-M-C alloy powder including the lubricant. The present invention also discloses an apparatus for manufacturing the R-T-B-M-C sintered magnet from the R-T-B-M-C alloy powder including the lubricant. The apparatus includes an alloy powder feeding mechanism for distributing the R-T-B-M-C alloy powder including the lubricant, a filling mechanism including a mold for receiving the R-T-B-M-C alloy powder including the lubricant, a press mechanism for compressing the R-T-B-M-C alloy powder including the lubricant and a stacking mechanism for storing the mold including the R-T-B-M-C alloy powder including the lubricant.Type: GrantFiled: January 29, 2014Date of Patent: June 6, 2017Assignee: YANTAI SHOUGANG MAGNETIC MATERIALS INC.Inventors: Zhongjie Peng, Xiaotong Liu, Shengli Cui, Kaihong Ding
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Patent number: 9663843Abstract: The present invention discloses a method for recovering rare earth particulate material from an assembly comprising a rare earth magnet and comprises the steps of exposing the assembly to hydrogen gas to effect hydrogen decrepitation of the rare earth magnet to produce a rare earth particulate material, and separating the rare earth particulate material from the rest of the assembly. The invention also resides in an apparatus for separating rare earth particulate material from an assembly comprising a rare earth magnet. The apparatus comprises a reaction vessel having an opening which can be closed to form a gas-tight seal, a separator for separating the rare earth particulate material from the assembly, and a collector for collecting the rare earth particulate material. The reaction vessel is connected to a vacuum pump and a gas control system, and the gas control system controls the supply of hydrogen gas to the reaction vessel.Type: GrantFiled: May 31, 2013Date of Patent: May 30, 2017Assignee: The University of BirminghamInventors: Ivor Rex Harris, Allan Walton, John D. Speight
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Patent number: 9649691Abstract: When a ribbon is cast by heating raw materials to prepare a molten R-T-B-based alloy and supplying the molten alloy to a chill roll to solidify the molten alloy, the temperature of the molten alloy is adjusted in accordance with at least one of the arithmetic mean roughness Ra and the mean spacing of profile irregularities Sm of the surface of the chill roll, thereby controlling the spacing between adjacent R-rich phases in a crystal structure of resulting alloy flakes to a desired value. This makes it possible to inhibit variations in the crystal structure of the resulting alloy flakes that may occur due to wear of the chill roll. In adjusting the temperature of the molten alloy in accordance with at least one of the arithmetic mean roughness Ra and the mean spacing of profile irregularities Sm, it is preferred that the molten alloy temperature be adjusted using the equation: ?t=?7×(|?Ra|×|?Sm|)0.5/? where ?t is an amount of adjustment of the molten alloy temperature (° C.Type: GrantFiled: January 23, 2013Date of Patent: May 16, 2017Assignee: SANTOKU CORPORATIONInventor: Hideo Sasaki
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Patent number: 9651522Abstract: The invention relates to a method of analyzing a plurality of ferromagnetic particles (1). The method comprises the following steps: a) aligning the particles (1) of this plurality in such a manner that each of the particles is oriented substantially in the same direction; b) fixing the particles (1) of said plurality in the alignment; c) exposing the internal regions of the particles (1) as aligned in this way; d) determining the nature of each of the particles and grouping the particles by category as a function of their natures; and e) in each category, determining the metallurgical structure and the chemical composition of one or more of the particles.Type: GrantFiled: April 1, 2011Date of Patent: May 16, 2017Assignee: SNECMAInventor: Fabrice Colladon
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Patent number: 9633769Abstract: Provided is a magnetic refrigeration material which has a Curie temperature near room temperature or higher, and provides refrigeration performance well over that of conventional materials when subjected to a field change up to 2 Tesla, which is assumed to be achievable with a permanent magnet. The magnetic refrigeration material is of a composition represented by the formula La1-fREf(Fe1-a-b-c-d-eSiaCObXcYdZe)13 (RE: at least one of rare earth elements including Sc and Y and excluding La; X: Ga and/or Al; Y: at least one of Ge, Sn, B, and C; Z: at least one of Ti, V, Cr, Mn, Ni, Cu, Zn, and Zr; 0.03?a?0.17, 0.003?b?0.06, 0.02?c?0.10, 0?d?0.04, 0?e?0.04, 0?f?0.50), and has Tc of not lower than 220 K and not higher than 276 K, and the maximum (??Smax) of magnetic entropy change (??SM) of the material when subjected to a field change up to 2 Tesla is not less than 5 J/kgK.Type: GrantFiled: March 14, 2012Date of Patent: April 25, 2017Assignee: SANTOKU CORPORATIONInventors: Hiroaki Takata, Toshio Irie
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Patent number: 9589714Abstract: Disclosed is a sintered NdFeB magnet having high coercivity (HcJ) a high maximum energy product ((BH)max) and a high squareness ratio (SQ) even when the sintered magnet has a thickness of 5 mm or more. The sintered NdFeB magnet is produced by diffusing Dy and/or Tb in grain boundaries in a base material of the sintered NdFeB magnet by a grain boundary diffusion process. The sintered NdFeB magnet is characterized in that the amount of rare earth in a metallic state in the base material is between 12.7 and 16.0% in atomic ratio, a rare earth-rich phase continues from the surface of the base material to a depth of 2.5 mm from the surface at the grain boundaries of the base material, and the grain boundaries in which RH has been diffused by the grain boundary diffusion process reach a depth of 2.5 mm from the surface.Type: GrantFiled: July 9, 2010Date of Patent: March 7, 2017Assignee: INTERMETALLICS CO., LTD.Inventor: Masato Sagawa
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Permanent magnet and method for manufacturing the same, and motor and power generator using the same
Patent number: 9583243Abstract: In an embodiment, a permanent magnet includes a composition of R (FepMqCur(Co1-sAs)1-p-q-r)z (R: rare earth element, M: Ti, Zr, Hf, A: Ni, V, Cr, Mn, Al, Si, Ga, Nb, Ta, W, 0.05?p 0.6, 0.005?q?0.1, 0.01?r?0.15, 0?s?0.2, 4?z?9). The permanent magnet includes a two-phase structure of a Th2Zn17 crystal phase and a copper-rich phase. An average interval between the copper-rich phases in a cross section including a crystal c axis of the Th2Zn17 crystal phase is in a range of over 120 nm and less than 500 nm.Type: GrantFiled: March 15, 2011Date of Patent: February 28, 2017Assignee: KABUSHIKI KAISHA TOSHIBAInventors: Yosuke Horiuchi, Shinya Sakurada, Keiko Okamoto, Masaya Hagiwara -
Patent number: 9558885Abstract: An object of the present invention is to provide a method for producing a surface-modified rare earth metal-based sintered magnet having extremely excellent corrosion resistance even in an environment with fluctuating temperature and humidity and also having excellent magnetic characteristics. The method for producing a surface-modified rare earth metal-based sintered magnet of the present invention as a means for achieving the object is characterized by comprising a step of subjecting a rare earth metal-based sintered magnet to a heat treatment at 200° C. to 600° C. in an atmosphere having an oxygen partial pressure of 1×103 Pa to 1×105 Pa and a water vapor partial pressure of 45 Pa or less with the ratio between the oxygen partial pressure and the water vapor partial pressure (oxygen partial pressure/water vapor partial pressure) being 450 to 20000.Type: GrantFiled: June 29, 2011Date of Patent: January 31, 2017Assignee: HITACHI METALS, LTD.Inventors: Mahoro Fujihara, Koshi Yoshimura
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Patent number: 9558874Abstract: Disclosed is a sintered NdFeB magnet having high coercivity (HcJ) a high maximum energy product ((BH)max) and a high squareness ratio (SQ) even when the sintered magnet has a thickness of 5 mm or more. The sintered NdFeB magnet is produced by diffusing Dy and/or Tb in grain boundaries in a base material of the sintered NdFeB magnet by a grain boundary diffusion process. The sintered NdFeB magnet is characterized in that the amount of rare earth in a metallic state in the base material is between 12.7 and 16.0% in atomic ratio, a rare earth-rich phase continues from the surface of the base material to a depth of 2.5 mm from the surface at the grain boundaries of the base material, and the grain boundaries in which RH has been diffused by the grain boundary diffusion process reach a depth of 2.5 mm from the surface.Type: GrantFiled: July 9, 2010Date of Patent: January 31, 2017Assignee: INTERMETALLICS CO., LTD.Inventor: Masato Sagawa
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Patent number: 9548444Abstract: Memory cells including cell cores having free regions are disclosed. The free regions exhibit a strain that affects a magnetization orientation within the cell core. A stressor structure may exert a stress upon at least a portion of the cell core to effect the strain state of the free region. Also disclosed are semiconductor device structures and systems including such memory cells as well as methods for forming such memory cells.Type: GrantFiled: April 13, 2015Date of Patent: January 17, 2017Assignee: Micron Technology, Inc.Inventors: Gurtej S. Sandhu, Wayne I. Kinney
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Patent number: 9531223Abstract: The stack of laminations consists of punched laminations (5), which are bonded together by an adhesive agent. The adhesive agent is composed of an adhesive (4) and an initiator (15), which consists of methacrylates, derivative imines and methacrylic esters. The completely cured adhesive bond has long-term resistance when exposed to a temperature of at least over 80° C. The adhesive (4) is applied over the full surface area and in a contacting manner to one side of the lamination (5) and the initiator (15) is applied to the same side and/or to the other side of the lamination (5). The initiator (15) reacts with the adhesive (4) when contact is made and establishes the adhesive connection between laminations (5) lying against one another. The adhesive agent may, however, also be an adhesive (4) that cures by itself when heat is applied.Type: GrantFiled: March 13, 2013Date of Patent: December 27, 2016Assignee: Kienle + Spiess GmbHInventors: Daniel Blocher, Steffen Bauer, Andras Bardos
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Patent number: 9490053Abstract: A R-T-B based permanent magnet which not only has equivalent magnetic properties as the existing Nd—Fe—B based permanent magnet but also has a high adhesive strength and which can be suitably used as a magnet for field system of a permanent magnet synchronous rotating machine. The magnet can be obtained in a case where the composition of the compound for forming the main phase is (R1-x(Ce1-zYz)x)2T14B (R is rare earth element(s) consisting of one or more elements selected from La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, T is one or more transition metal elements with Fe or Fe and Co as essential element(s), 0.0<x?0.5 and 0.0?z?0.5), by making the abundance ratio of Ce4f/(Ce4f+Ce4g) satisfies 0.8?Ce4f/(Ce4f+Ce4g)?1.0 when the Ce occupying the 4f site of the tetragonal R2T14B structure is denoted Ce4f and the Ce occupying the 4g site is denoted as Ce4g.Type: GrantFiled: February 12, 2014Date of Patent: November 8, 2016Assignee: TDK CORPORATIONInventors: Kenichi Suzuki, Kyung-Ku Choi, Ryuji Hashimoto
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Patent number: 9484151Abstract: A method for producing a sintered R-T-B based magnet includes providing at least one sintered R-T-B based magnet material (where R is a rare-earth element and T is Fe or Fe and Co); providing RH diffusion sources that include a heavy rare-earth element RH (which is Dy and/or Tb) and 30 to 80 mass % of Fe and that have a particle size between 53 ?m and 5600 ?m; arranging the magnet material and the RH diffusion sources in a process vessel so that some of the RH diffusion sources are in contact with the magnet material; performing an RH diffusion process by heat treating in an inert ambient at a pressure of 5000 Pa or less and at a temperature of 800° C. to 1000° C.; and separating the RH diffusion sources from the magnet material.Type: GrantFiled: January 19, 2012Date of Patent: November 1, 2016Assignee: HITACHI METALS, LTD.Inventor: Futoshi Kuniyoshi
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Patent number: 9427804Abstract: In the method for producing a high-performance neodymium-iron-boron rare earth permanent magnetic material of the present invention, the degree of alignment of the magnet can be improved by preparing the pre-sintered alloy material, the particle size of the powder ground by the jet mill can be refined and the fine powder in the filter of the jet mill can be mixed with the powder collected by the cyclone collector by controlling the oxygen content of the jet mill and adding the nanoscale oxide fine powder. The present invention can significantly improve the utilization ratio of the material and the performance of the magnet, save the use of the rare earth, and especially the heavy rare earth, thereby protecting the scare resources.Type: GrantFiled: October 9, 2013Date of Patent: August 30, 2016Assignee: China North Magnetic & Electronic Technology Co., LTDInventor: Haotian Sun
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Patent number: 9418779Abstract: A scalable process is detailed for forming bulk quantities of high-purity ?-MnBi phase materials suitable for fabrication of MnBi based permanent magnets.Type: GrantFiled: October 22, 2013Date of Patent: August 16, 2016Assignee: BATTELLE MEMORIAL INSTITUTEInventors: Jung Pyung Choi, Curt A. Lavender, Guosheng Li, Jun Cui
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Patent number: 9415444Abstract: A method for producing a sintered R-T-B based magnet includes the steps of: providing a sintered R-T-B based magnet body 1; providing an RH diffusion source 2 including a metal or an alloy of a heavy rare-earth element RH (which is at least one of Dy an Tb); loading the sintered magnet body 1 and the RH diffusion source 2 into a processing chamber 3 so that the magnet body 1 and the diffusion source 2 are movable relative to each other and brought close to, or in contact with, each other; and performing an RH diffusion process by conducting a heat treatment on the sintered R-T-B based magnet body 1 and the RH diffusion source 2 at a temperature of 500° C. to 850° C. for at least 10 minutes while moving the magnet body 1 and the diffusion source 2 either continuously or discontinuously in the processing chamber 3.Type: GrantFiled: July 12, 2010Date of Patent: August 16, 2016Assignee: HITACHI METALS, LTD.Inventor: Futoshi Kuniyoshi
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Patent number: 9385363Abstract: A method of producing a composite active material having an active material and a coat layer containing an ion conductive oxide and formed on a surface of the active material, including: applied film forming step of forming an applied film by applying a coating liquid for coat layer, containing an alkoxide compound as a raw material of the ion conductive oxide, on a surface of the active material under an atmosphere of lower dew-point temperature than dew-point temperature where the active material deteriorates; hydrolysis promoting step of promoting hydrolysis of the alkoxide compound by exposing the applied film under an atmosphere of higher dew-point temperature than dew-point temperature in the applied film forming step; and heat-treating step of forming the coat layer by heat-treating the applied film after the hydrolysis promoting step.Type: GrantFiled: December 27, 2012Date of Patent: July 5, 2016Assignee: Toyota Jidosha Kabushiki KaishaInventors: Nariaki Miki, Takayuki Uchiyama
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Patent number: 9373432Abstract: The purpose of the present invention is to provide an alcoholic solvent, in which FeCo-based particles becoming a soft magnet are improved, for enhancing properties of a magnetic material using no heavy rare earth elements, and is to provide a sintered magnet produced by using it.Type: GrantFiled: November 15, 2012Date of Patent: June 21, 2016Assignee: Hitachi Chemical Company, Ltd.Inventors: Nobuo Abe, Yuichi Satsu, Matahiro Komuro, Takayuki Kanda
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Patent number: 9365049Abstract: An improved print head for use by a magnetic printer consists of multiple flat metal layers that form a flat metal inductor coil about a hole having a first diameter on a first side of the print head and having a second diameter smaller than the first diameter on a second side of the print head.Type: GrantFiled: September 29, 2015Date of Patent: June 14, 2016Assignee: Correlated Magnetics Research, LLCInventor: Larry W. Fullerton
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Patent number: 9368276Abstract: A method for producing a sintered R-T-B based magnet includes the steps of: providing a sintered R-T-B based magnet body 1; providing an RH diffusion source including a heavy rare-earth element RH (which is at least one of Dy and Tb) and 30 mass % to 80 mass % of Fe; loading the sintered R-T-B based magnet body 1 and the RH diffusion source 2 into a processing chamber 3 so that the magnet body 1 and the diffusion source 2 are movable relative to each other and are readily brought close to, or in contact with, each other; and performing an RH diffusion process in which the sintered magnet body 1 and the RH diffusion source 2 are heated to a processing temperature of more than 850° C. through 1000° C. while being moved either continuously or discontinuously in the processing chamber.Type: GrantFiled: July 12, 2011Date of Patent: June 14, 2016Assignee: HITACHI METALS, LTD.Inventor: Futoshi Kuniyoshi
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Patent number: 9275795Abstract: An object of the present invention is to provide an R—Fe—B based sintered magnet having on a surface thereof a chemical conversion film with higher corrosion resistance than a conventional chemical conversion film such as a phosphate film, and a method for producing the same. The corrosion-resistant magnet of the present invention as a means for achieving the object is characterized by comprising a chemical conversion film containing at least Zr, Nd, fluorine, and oxygen as constituent elements and not containing phosphorus directly on a surface of an R—Fe—B based sintered magnet, wherein R is a rare-earth element including at least Nd.Type: GrantFiled: November 25, 2013Date of Patent: March 1, 2016Assignee: HITACHI METALS, LTD.Inventors: Toshinobu Niinae, Koshi Yoshimura, Koji Kamiyama
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Patent number: 9230721Abstract: A method of preparing R—Fe—B-based rare earth magnetic powder for a bonded magnet and magnetic powder prepared thereby, and a method of manufacturing a bonded magnet using magnetic powder and a bonded magnet manufactured thereby. Further, a method of preparing R—Fe—B-based rare earth magnetic powder having improved magnetic properties including grinding rare earth sintered magnet products as a raw material, performing a hydrogenation process where a ground product is charged into a furnace, and the furnace is then filled with hydrogen and a temperature of the furnace is increased, performing a disproportionation process where the temperature of the furnace is further increased in the same hydrogen atmosphere above, performing a desorption process where hydrogen is exhausted from an inside of the furnace, and performing a recombination process where hydrogen in the inside of the furnace is exhausted, and magnetic powder prepared thereby, and a method of manufacturing a bonded magnet.Type: GrantFiled: July 1, 2011Date of Patent: January 5, 2016Assignee: Korea Institute of Machinery and MaterialsInventors: Ji-Hun Yu, Dongwon Lee, Junggoo Lee
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Patent number: 9225212Abstract: A method of manufacturing a bonded-magnet rotor according to the invention includes forming step and arranging step. The forming step is by forming a bonded-magnet formed body. The arranging step includes: integrating an inside-diameter holding jig, a rotor core, and a rotor-core presser jig; arranging the bonded-magnet formed bodies on the outside periphery of the inside-diameter holding jig; and arranging an outside-diameter-holding magnet-pressure-welding jig to support outside peripheral faces of the bonded-magnet formed bodies. The method further includes steps of: deforming the bonded-magnet formed bodies to fit with the outside peripheral dimension of the rotor core by pressing and transferring the bonded-magnet formed bodies to the rotor core with a forming jig; mutually joining end portions of adjacent ones of the bonded-magnet formed bodies; and integrating the bonded-magnet formed bodies with the rotor core by compressing the bonded-magnet formed bodies.Type: GrantFiled: March 23, 2012Date of Patent: December 29, 2015Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventor: Hiroki Asai
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Patent number: 9096917Abstract: A composite material combining—a precious metal or an alloy containing a precious metal—and a boron-based ceramic having a melting point greater than that of said precious metal and a density at most equal to 4 g/cm3.Type: GrantFiled: March 8, 2011Date of Patent: August 4, 2015Assignee: HUBLOT SA, GENÈVEInventors: Senad Hasanovic, Andreas Mortensen, Ludger Weber, Reza Tavangar