Particulate Material Patents (Class 148/105)
  • Patent number: 10594184
    Abstract: The stator includes a stator core having a first tooth and a second tooth adjacent to each other, a coil having a first winding portion wound around the first tooth and a second winding portion wound around the second tooth, a resin chip disposed in in a gap between the first winding portion and the second winding portion, and a molding resin covering the stator core, the coil, and the resin chip.
    Type: Grant
    Filed: December 16, 2015
    Date of Patent: March 17, 2020
    Assignee: Mitsubishi Electric Corporation
    Inventors: Hiroki Aso, Tomoaki Oikawa, Mineo Yamamoto, Hiroyuki Ishii, Junichiro Oya, Yuto Urabe
  • Patent number: 10586646
    Abstract: A magnetic core has a high initial permeability and a small core loss, reducing a core loss at high frequencies; and a coil component including the same. This magnetic core is formed by binding a plurality of Fe-based alloy particles containing Al via an oxide layer containing an Fe oxide. In an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, a peak intensity ratio (P1/P2) of peak intensity P1 of a diffraction peak derived from the Fe oxide having a corundum structure appearing in the vicinity of 2?=33.2° to peak intensity P2 of a diffraction peak derived from the Fe-based alloy having a bcc structure appearing in the vicinity of 2?=44.7° is 0.010 or less (excluding 0). A superlattice peak intensity of an Fe3Al ordered structure is at most a noise level within a range of 2?=20° to 40°.
    Type: Grant
    Filed: September 15, 2017
    Date of Patent: March 10, 2020
    Assignee: HITACHI METALS, LTD.
    Inventors: Toshio Mihara, Tetsuroh Katoh, Kazunori Nishimura, Shin Noguchi
  • Patent number: 10468174
    Abstract: Provided are a magnetic core having a high initial permeability and a coil component including the same. The magnetic core has an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, wherein a peak intensity ratio (P1/P2) of a peak intensity P1 of a diffraction peak of an Fe oxide having a corundum structure appearing in a vicinity of 2?=33.2° to a peak intensity P2 of a diffraction peak of the Fe-based alloy having a bcc structure appearing in a vicinity of 2?=44.7° is 0.015 or less; and in the X-ray diffraction spectrum, a peak intensity ratio (P3/P2) of a peak intensity P3 of a superlattice peak of an Fe3Al ordered structure appearing in a vicinity of 2?=26.6° to the peak intensity P2 is 0.015 or more and 0.050 or less.
    Type: Grant
    Filed: September 15, 2017
    Date of Patent: November 5, 2019
    Assignee: HITACHI METALS, LTD.
    Inventors: Toshio Mihara, Tetsuroh Katoh, Kazunori Nishimura, Shin Noguchi
  • Patent number: 10204651
    Abstract: The magnetic recording medium includes a support and a magnetic layer containing a magnetic powder. The magnetic powder includes at least either of a magnetic particle containing a cubic ferrite and a magnetic particle containing an ?-phase iron oxide. The magnetic powder has a mean particle size of 10 nm or more and 14 nm or less, the magnetic powder has a mean aspect ratio of 0.75 or more and 1.25 or less, and the magnetic layer has a ten-point mean roughness Rz of 35 nm or less.
    Type: Grant
    Filed: April 10, 2015
    Date of Patent: February 12, 2019
    Assignee: Sony Corporation
    Inventors: Eiji Nakashio, Minoru Yamaga, Masaru Terakawa, Yoichi Kanemaki, Katsunori Maeshima, Jun Hashimoto
  • Patent number: 10186357
    Abstract: An R-T-B based sintered magnet including a main phase composed of an R2T14B (wherein, R is at least one selected from the group consisting of Y, Ce, La, Pr, Nd, Sm, Eu and Gd; and T is one or more transition metal elements with Fe as necessity) structure, wherein the R-T-B based sintered magnet has a grain boundary phase containing Ce, Fe and Co, and the cross-section area ratio of the grain boundary phase containing Ce, Fe and Co in a unit cross-section area is 1.0% or more and 5.0% or less.
    Type: Grant
    Filed: April 15, 2016
    Date of Patent: January 22, 2019
    Assignee: TDK CORPORATION
    Inventor: Atsushi Tada
  • Patent number: 10186875
    Abstract: The present invention relates to a coil type unit for wireless power transmission, a wireless power transmission device, an electronic device, and a manufacturing method of a coil type unit for wireless power transmission. A coil type unit for wireless power transmission according to the present invention includes a coil pattern having a wiring pattern shape; a magnetic portion having the coil pattern attached to one surface thereof and a conductive pattern formed thereon; an insulating adhesive portion interposed between the magnetic portion having the conductive pattern formed thereon and the coil pattern to bond the magnetic portion and the coil pattern to each other while insulating the coil pattern and the conductive pattern from each other; and a conductive via for electrically connecting both ends of the coil pattern and the conductive pattern.
    Type: Grant
    Filed: August 18, 2014
    Date of Patent: January 22, 2019
    Assignee: Samsung Electro-Mechanics Co., Ltd.
    Inventors: Seung Wook Park, No Il Park, Doo Sung Jung, Jang Su Kim, Chang Bae Lee
  • Patent number: 10166529
    Abstract: A process for the production of coating graphene, and other carbon allotropes, onto carbon-coated magnetic nanoparticles while maintaining high magnetic moment and adsorption properties is disclosed.
    Type: Grant
    Filed: March 17, 2014
    Date of Patent: January 1, 2019
    Assignee: Honda Motor Co., Ltd.
    Inventor: Avetik Harutyunyan
  • Patent number: 10148001
    Abstract: There is disclosed a mobile terminal including a first case comprising a battery loading portion, a battery loaded in the battery loading portion, a second case coupled to the first case and configured to cover the battery, a coil antenna module arranged between the second case and the battery, and a controller electrically connected to the coil antenna module and configured to transmit and receive a signal or receive an electric power, wherein the coil antenna module includes an insulating sheet, a first coil arranged in a surface of the insulating sheet, a second coil arranged in the first coil, a third coil arranged in the second coil, and a magnetic sheet disposed on the surface of the insulating sheet, and ends of the first, second and third coils are arranged in the surface of the insulating sheet or dividedly arranged in both surfaces of the insulating sheet.
    Type: Grant
    Filed: July 13, 2017
    Date of Patent: December 4, 2018
    Assignee: LG ELECTRONICS INC.
    Inventors: Kiwon Han, Youngtae Kim, Gwanghoon Lee
  • Patent number: 10085370
    Abstract: A method for producing a magnetic resonant frequency (MRF) absorber and apparatus for an MRF absorber are described herein. The method comprises processing a high permeability material such as permalloy comprising 80% nickel, 18% iron, 2% molybdenum to create a specific geometric form factor such as a flake, sphere, or rod. The geometric form factor may then be encapsulated in an insulating matrix. The insulating matrix may be a Potassium Silicate (SiO3K2). The insulated flake, sphere, or rod form factor may be introduced to a powder coating process. The insulated flake, sphere, or rod form factor may then be mixed with a polymeric coating powder at a weight ratio based on a desired performance for absorbing electromagnetic interference (EMI).
    Type: Grant
    Filed: March 17, 2014
    Date of Patent: September 25, 2018
    Assignee: Flextronics AP, LLC.
    Inventor: Peter Suorsa
  • Patent number: 9892833
    Abstract: A magnetic powder includes magnetic metal particles, a first insulating layer disposed on a surface of each magnetic metal particle and containing silicon (Si) and oxygen (O), and a second insulating layer disposed on the first insulating layer and containing phosphorus (P). A coil electronic component includes a body in which a coil part is disposed, and external electrodes connected to the coil part. The body of the coil electronic component contains the magnetic powder.
    Type: Grant
    Filed: May 9, 2016
    Date of Patent: February 13, 2018
    Assignee: SAMSUNG ELECTRO-MECHANICS CO., LTD.
    Inventor: Dong Jin Jeong
  • Patent number: 9847169
    Abstract: A production method includes producing a rare-earth magnet precursor (S?) by performing first hot working in which, in two side surfaces of a sintered body, which are parallel to a pressing direction and are opposite to each other, one side surface is brought to a constrained state to suppress deformation, and the other side surface is brought to an unconstrained state to permit deformation; and producing a rare-earth magnet by performing second hot working in which, in two side surfaces (S?1, S?2) of the rare-earth magnet precursor (S?), which are parallel to the pressing direction, a side surface (S?2), which is in the unconstrained state in the first hot working, is brought to the constrained state to suppress deformation, and a side surface (S?1), which is in the constrained state in the first hot working, is brought to the unconstrained state to permit deformation.
    Type: Grant
    Filed: March 31, 2014
    Date of Patent: December 19, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akira Kano, Dai Kobuchi, Eisuke Hoshina, Osamu Yamashita, Noritaka Miyamoto
  • Patent number: 9820418
    Abstract: A tangible device such as a credit card shaped device that includes at least one waffler carved therein. A bottom stabilizing material in the shape of a film or sheet is placed within the waffler. A nano-scaled metal in powdered form that is ferromagnetic in nanoscale, such as gold, is then added above the bottom stabilizing film. A ferromagnetic powder in nanoscale is added to the nano-scaled metal and a top stabilizing film is placed thereon. Ceramic powder is then used to further stabilize the composition and finally all the components are sealed within the waffler. The nano-scaled metals can be affixed to the stabilizing films using atomic layer deposition. The present invention is used to neutralize the electromagnetic contamination emitted from a plurality of electronic devices by organizing the polarity of the spin of the element particles within their radiation.
    Type: Grant
    Filed: March 24, 2016
    Date of Patent: November 14, 2017
    Inventor: Jose Machado
  • Patent number: 9818519
    Abstract: Provided is soft magnetic powder used to manufacture a dust core having good mechanical strength and superior formability while iron loss is reduced. The soft magnetic powder for dust cores according to the invention is soft magnetic mixed powder that includes pure iron powder and soft magnetic iron-base alloy powder, wherein the proportion of the soft magnetic iron-base alloy powder in the mixture is 5 to 60 mass %, the ratio of the modes of the particle size distributions of the soft magnetic iron-base alloy powder and the pure iron powder ((the mode of the particle size distribution of the soft magnetic iron-base alloy powder)/(the mode of the particle size distribution of the pure iron powder)) is 0.9 or more and less than 5, and the ratio Rover/Runder is 1.
    Type: Grant
    Filed: September 19, 2013
    Date of Patent: November 14, 2017
    Assignee: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Takeo Miyamura, Hiroyuki Mitani
  • Patent number: 9761928
    Abstract: There is disclosed a mobile terminal including a first case comprising a battery loading portion, a battery loaded in the battery loading portion, a second case coupled to the first case and configured to cover the battery, a coil antenna module arranged between the second case and the battery, and a controller electrically connected to the coil antenna module and configured to transmit and receive a signal or receive an electric power, wherein the coil antenna module includes an insulating sheet, a first coil arranged in a surface of the insulating sheet, a second coil arranged in the first coil, a third coil arranged in the second coil, and a magnetic sheet disposed on the surface of the insulating sheet, and ends of the first, second and third coils are arranged in the surface of the insulating sheet or dividedly arranged in both surfaces of the insulating sheet.
    Type: Grant
    Filed: November 25, 2015
    Date of Patent: September 12, 2017
    Assignee: LG ELECTRONICS INC.
    Inventors: Kiwon Han, Youngtae Kim, Gwanghoon Lee
  • Patent number: 9725789
    Abstract: Provided are an apparatus for manufacturing a compound powder, a method of manufacturing an iron-boron compound powder by using the apparatus, a boron alloy powder mixture, a method of manufacturing the boron alloy powder mixture, a combined powder structure, a method of manufacturing the combined powder structure, a steel pipe, and a method of manufacturing the steel pipe The method of manufacturing the boron alloy powder mixture includes: preparing a mixed powder including a boron iron alloy powder and a target powder; heat-treating the mixed powder to boronize at least a portion of the target powder and de-boronize at least a portion of the boron iron alloy powder, thereby de-boronizing the boron iron alloy powder to reduce the melting point of the boron iron alloy powder.
    Type: Grant
    Filed: June 8, 2012
    Date of Patent: August 8, 2017
    Assignee: KMT CO., LTD.
    Inventors: Kee-Seok Nam, Jung-Dae Kwon, Jong-Joo Rha, Hee-Chan Ahn, Tae-Su Lim
  • Patent number: 9631253
    Abstract: The present invention refers to an effective method for minimizing the problems of iron ore pellet degradation by weathering during their stockpiling, i.e., by providing an appropriate method for improving the state of the art with regard to iron ore pellet resistance related just to the hydration process of the slag phase. Thus, in order to minimize hydration in the slag phase, stabilizers are introduced into the mixture used to produce iron ore pellets prior to being heat-treated.
    Type: Grant
    Filed: December 16, 2014
    Date of Patent: April 25, 2017
    Assignee: VALE S.A.
    Inventors: Maria Beatriz Harmendani Vieira, Marcus Eduardo Emrich Botelho
  • Patent number: 9472328
    Abstract: Disclosed is an iron-based soft magnetic powder for dust core use, which includes an iron-based soft magnetic matrix powder and a phosphate conversion coating on a surface of the matrix powder. The phosphate conversion coating contains nickel element and has an aluminum content of equal to or less than that in the matrix powder. The iron-based soft magnetic powder has such excellent heat resistance as to maintain electrical insulation at satisfactory level even after subjected to a high-temperature heat treatment.
    Type: Grant
    Filed: June 15, 2012
    Date of Patent: October 18, 2016
    Assignee: Kobe Steel, Ltd.
    Inventors: Mamoru Hosokawa, Wataru Urushihara, Takeshi Ohwaki, Tomotsuna Kamijo, Hirofumi Hojo
  • Patent number: 9467205
    Abstract: A method for wireless power transmission includes obtaining, via a Q-value circuit, first and second voltages at respective first and second nodes of a resonance circuit. The first and second voltages are effective to determine if foreign matter is present in a space affecting wireless power transmission. The method includes controlling a switching section between the Q-value circuit and the resonance circuit such that at least a part of the electric power transmission process occurs at a different time than when the first and second voltages are obtained.
    Type: Grant
    Filed: July 18, 2012
    Date of Patent: October 11, 2016
    Assignee: Sony Corporation
    Inventors: Hiroaki Nakano, Takaaki Hashiguchi, Shinichi Fukuda, Kenichi Fujimaki
  • Patent number: 9461240
    Abstract: According to one embodiment, a magnetoresistive memory device includes a first magnetic layer, a second magnetic layer, a nonmagnetic layer provided between the first magnetic layer and the second magnetic layer, and a third magnetic layer provided on a side of the first or second magnetic layer opposite to the nonmagnetic layer. The third magnetic layer has a multilayer film having an artificial lattice structure, and the third magnetic layer is partly microcrystalline or amorphous.
    Type: Grant
    Filed: July 30, 2015
    Date of Patent: October 4, 2016
    Assignee: KABUSHIKI KAISHA TOSHIBA
    Inventors: Kazuya Sawada, Toshihiko Nagase, Youngmin Eeh, Koji Ueda, Daisuke Watanabe, Makoto Nagamine
  • Patent number: 9383125
    Abstract: Magnetic materials, having: a composition represented by a general formula: (R1?yXy)x(Fe1?aMa)100?x where, R is at least one of element selected from the group consisting of La, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Ho, Er, Tm, Yb and Y, X is at least one of element selected from the group consisting of Ti, Zr and Hf, M is at least one of element selected from the group consisting of V, Cr, Mn, Ni, Cu, Zn, Nb, Mo, Ta, W, Al, Si, Ga and Ge, x is a value satisfying 4?x?20 atomic %, y is a value satisfying 0.01?y?0.9, and a is a value satisfying 0?a?0.2, wherein the magnetic material includes a Th2Ni17 crystal phase or a TbCu7 crystal phase as a main phase, that are useful for magnetic refrigeration.
    Type: Grant
    Filed: January 6, 2014
    Date of Patent: July 5, 2016
    Assignee: KABUSHIKI KAISHA TOSHIBA
    Inventors: Shinya Sakurada, Akiko Saito, Tadahiko Kobayashi, Hideyuki Tsuji
  • Patent number: 9314843
    Abstract: The present invention provides a powder for a magnet which can form a rare earth magnet having excellent magnetic characteristics and which has excellent moldability, a method for producing the powder for a magnet, a powder compact, and a rare earth-iron-boron-based alloy material.
    Type: Grant
    Filed: April 13, 2011
    Date of Patent: April 19, 2016
    Assignee: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Toru Maeda, Asako Watanabe
  • Patent number: 9293244
    Abstract: A magnetic material constituted by a grain compact 1 obtained by shaping metal grains 11 and then heat-treating them in an oxidizing ambience, wherein the metal grains 11 are made of a Fe—Cr—Si alloy and their FeMetal/(FeMetal+FeOxide) ratio as measured before shaping by XPS, with respect to the sum of integral values at the peaks of 709.6 eV, 710.7 eV and 710.9 eV, or FeOxide, and peak integral value at 706.9 eV, or FeMetal, is 0.2 or more.
    Type: Grant
    Filed: July 11, 2012
    Date of Patent: March 22, 2016
    Assignee: TAIYO YUDEN CO., LTD.
    Inventors: Hitoshi Matsuura, Hideki Ogawa, Atsushi Tanada, Kiyoshi Tanaka, Kenji Otake
  • Patent number: 9245676
    Abstract: Provided are a soft magnetic alloy powder, a compact made from the soft magnetic alloy powder, a powder magnetic core including the compact, and a magnetic element including the powder magnetic core. The soft magnetic alloy powder contains Fe—Ni-based particles containing 38% to 48% by mass Ni, 1.0% to 15% by mass Co, and 1.2% to 10% by mass Si relative to the total mass of Fe, Ni, Co, and Si, the remainder being Fe. The Fe—Ni-based particles have an average size of more than 1 ?m to less than 10 ?m.
    Type: Grant
    Filed: November 28, 2012
    Date of Patent: January 26, 2016
    Assignee: TDK CORPORATION
    Inventors: Masahito Koeda, Yoshihiro Shinkai, Tomofumi Kuroda
  • Patent number: 9196403
    Abstract: The present invention provides a powder for a magnetic member being excellent in moldability and difficult to oxidize, a powder compact produced from the powder, and a magnetic member suitable for a raw material of a magnetic member such as a rare earth magnet. A powder for a magnetic member includes magnetic particles 1 which constitute the powder for a magnetic member and each of which is composed of less than 40% by volume of a hydrogen compound 3 of a rare earth element, and the balance composed of an iron-containing material 2 which contains iron and an iron-boron alloy containing iron and boron. The hydrogen compound 3 of a rare earth element is dispersed in a phase of the iron-containing material 2. An antioxidant layer 4 having a low-oxygen permeability coefficient is provided on the surface of each of the magnetic particles 1.
    Type: Grant
    Filed: May 10, 2011
    Date of Patent: November 24, 2015
    Assignee: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Toru Maeda, Asako Watanabe
  • Patent number: 9090964
    Abstract: Methods of forming cobalt films utilizing a cobalt precursor comprising an additive are described. Those methods may include adding an additive to a cobalt precursor, wherein the cobalt precursor is located in an ampoule that is coupled with a deposition tool, and then forming a cobalt film using the cobalt precursor comprising the additive. Non-volatile decomposition products of the cobalt precursor are solubilized in the ampoule.
    Type: Grant
    Filed: December 19, 2013
    Date of Patent: July 28, 2015
    Assignee: Intel Corporation
    Inventors: James M. Blackwell, Daniel B. Bergstrom, Scott B. Clendenning, Patricio E. Romero
  • Patent number: 9067284
    Abstract: Recycled Nd—Fe—B sintered magnets. One of the recycled Nd—Fe—B sintered magnets includes a composition of WaRbAc, where waste material W comprises material from a waste Nd—Fe—B sintered magnet, rare earth material R comprises at least one of: Nd or Pr, and elemental additives A comprises at least one of: Nd, Pr, Dy, Co, Cu, or Fe, and indices a, b, and c indicate atomic percentages of the corresponding compositions or elements and the atomic percentages of the rare earth material R and the elemental additives A have values satisfying Nd[0.1-19 at. %*s(Nd), x]Pr[0.1-19 at. %*s(Pr), y]Dy[0.1-19 at. %*s(Dy), z]Co[0 at. %, d]Cu[0 at. %, e]Fe[0 at. %, f] where [m,n] means a range from minimum m and maximum n, s(t) is the atomic percent of element t in starting composition, x=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), y=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), z=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), d=3 at. %-[81,99.9] at. %*s(Co), e=0.3 at. %-[81,99.9] at. %*s(Cu), and f=77 at. %-[81,99.9] at.
    Type: Grant
    Filed: July 31, 2014
    Date of Patent: June 30, 2015
    Assignee: Urban Mining Technology Company, LLC
    Inventors: Miha Zakotnik, Peter Afiuny, Scott Dunn, Catalina Oana Tudor
  • Patent number: 8999075
    Abstract: A composite magnetic material manufactured by mixing a metal magnetic powder with an insulating binder to produce a mixed powder, press-molding the mixed powder to produce a molded product, and heat-treating the molded product in an oxidizing atmosphere at not lower than 80° C. and not higher than 400° C. to form an oxide film on a surface of the molded product. The metal magnetic powder includes Si, Fe, and component A, and the composition thereof satisfies 5.5%?Si?9.5%, 10%?Si+component A?13.5%, and the remainder is Fe, where % denotes weight %. The component A includes at least one of Ni, Al, Ti, and Mg.
    Type: Grant
    Filed: June 28, 2011
    Date of Patent: April 7, 2015
    Assignee: Panasonic Intellectual Property Management Co., Ltd.
    Inventors: Nobuya Matsutani, Takeshi Takahashi
  • Patent number: 8979973
    Abstract: A method and a device for recovering hydrogen pulverized powder of a raw-material alloy for rare-earth magnets capable of lowering a possibility that hydrogen pulverized powder after hydrogen was pulverized remains in a recovery chamber and capable of enhancing magnetic properties by reducing an amount of oxygen of an obtained rare-earth magnet, a processing container 50 is carried into a recovery chamber 40 from a processing chamber through a carry-in port after inert gas was introduced into the recovery chamber 40 by inert gas introducing means 12, the raw-material alloy for rare-earth magnets in the processing container 50 is discharged into the recovery chamber 40 after the pressure in the recovery chamber 40 was reduced by evacuating means 33 and thereafter, inert gas is introduced into the recovery chamber 40 by inert gas introducing means 12, and the raw-material alloy for rare-earth magnets is recovered into the recovery container 50 from an discharge port 40a after a pressure in the recovery chamber
    Type: Grant
    Filed: July 7, 2010
    Date of Patent: March 17, 2015
    Assignee: Hitachi Metals, Ltd.
    Inventors: Shoji Nakayama, Kazuhiro Sonoda, Jyunichi Sanai
  • Patent number: 8974608
    Abstract: A powder magnetic core with improved high frequency magnetic characteristics and reduced eddy current loss is manufactured by a manufacturing method including the steps of (a) providing coated soft magnetic particles which are particles composed of soft magnetic material which each have been coated with an insulating coating, and insulator particles; (b) forming a magnetic layer by press molding the coated soft magnetic particles in a mold assembly; (c) forming an insulator layer on the magnetic layer by press molding the insulator particles in the mold assembly; and (d) repeating the steps (b) and (c) to fabricate a laminate of alternating magnetic layers and insulator layers and provide the powder magnetic core.
    Type: Grant
    Filed: April 16, 2008
    Date of Patent: March 10, 2015
    Assignee: Fuji Electric Co., Ltd.
    Inventors: Takayuki Hirose, Masaharu Edo, Akira Sato
  • Patent number: 8932517
    Abstract: A process for production of a packed soft magnetic component, comprises the steps of:—preparing a rotational mold, consisting of at least one mold cavity connected to a driven rotational axle, arranging a coil in the mold, filling the at least one mold cavity with a binder and a soft magnetic, metallic material in the form of a powder,—driving the axle for rotation of said at least one mold, whereby the soft magnetic, metallic material is packed by centrifugal forces to one side of said at least one mold cavity, mixed with the binder, thus forming a component comprising a soft magnetic composite with a coil embedded therein.
    Type: Grant
    Filed: October 16, 2008
    Date of Patent: January 13, 2015
    Assignee: Magnetic Components Sweden AB
    Inventor: Mats Alaküla
  • Patent number: 8911530
    Abstract: In a manufacturing method of magnetic alloy powder including an alloy of Fe and Ni, a precursor made of powdered chloride expressed as FeCl2·2H2O·NiCl2·2H2O is prepared, and the precursor is reduced by heating with calcium hydride to form the, magnetic alloy powder having a coercivity of greater than or equal to 40 kA/m.
    Type: Grant
    Filed: January 21, 2013
    Date of Patent: December 16, 2014
    Assignee: Denso Corporation
    Inventor: Yasushi Hayashi
  • Publication number: 20140326363
    Abstract: The present invention provides R-T-B-based rare earth magnet particles comprising no expensive rare resources such as Dy and having an excellent coercive force which can be produced by HDDR treatment without any additional steps. The present invention relates to R-T-B-based rare earth magnet particles comprising crystal grains comprising a magnetic phase of R2T14B, and a grain boundary phase, in which the grain boundary phase has a composition comprising R in an amount of not less than 13.5 atom % and not more than 35.0 atom % and Al in an amount of not less than 1.0 atom % and not more than 7.0 atom %. The R-T-B-based rare earth magnet particles can be obtained by controlling heat treatment conditions in the DR step of the HDDR treatment in the course of subjecting a raw material alloy to the HDDR treatment.
    Type: Application
    Filed: August 30, 2012
    Publication date: November 6, 2014
    Applicant: TODA KOGYO CORP.
    Inventors: Nobuhiro Katayama, Hirofumi Kawasaki, Koichiro Morimoto
  • Patent number: 8852314
    Abstract: A magnetic powder for magnetic recording medium comprises acicular particles constituted primarily of Fe, wherein the powder contains Co in an amount such that the Co/Fe ratio is 50 at. % or less and the Co is contained in a manner such that the surface portion has a higher concentration than the core portion of the particles, and upon subjecting the magnetic powder for magnetic recording medium to TG measurement, the powder exhibits at least two oxidation starting points: a low-temperature side oxidation starting point and a high-temperature side oxidation starting point. The magnetic powder achieves improved resistance to oxidation without sacrificing magnetic characteristics.
    Type: Grant
    Filed: March 3, 2011
    Date of Patent: October 7, 2014
    Assignee: Dowa Electronics Materials Co., Ltd.
    Inventors: Shinichi Konno, Kenichi Inoue, Toshihiko Ueyama, Kenji Masada, Shinya Sasaki
  • Publication number: 20140266525
    Abstract: An object of the present invention is to enhance a coercive force of magnetic particles by promoting formation of a continuous R-rich grain boundary phase in a crystal grain boundary of a magnetic phase of the particles, and to thereby obtain R-T-B-based rare earth magnet particles further having a high residual magnetic flux density. The present invention relates to production of R-T-B-based rare earth magnet particles capable of exhibiting a high coercive force even when a content of Al therein is reduced, and a high residual magnetic flux density, in which formation of an R-rich grain boundary phase therein can be promoted by heat-treating Al-containing R-T-B-based rare earth magnet particles obtained by HDDR treatment in vacuum or in an Ar atmosphere at a temperature of not lower than 670° C. and not higher than 820° C. for a period of not less than 30 min and not more than 300 min.
    Type: Application
    Filed: March 12, 2014
    Publication date: September 18, 2014
    Applicant: TODA KOGYO CORP.
    Inventors: Nobuhiro KATAYAMA, Hirofumi KAWASAKI, Koichiro MORIMOTO
  • Patent number: 8808468
    Abstract: The invention relates to a Fe—Si—La alloy having the atomic composition: (La1-a-a?MmaTRa?)1[(Fe1-b-b?CObMb?)1-x(Si1-cXc)x]13(CdNeH1-d-e)y(R)z(I)f Mm representing a mixture of lanthanum, cerium, neodymium and praseodynium in the weight proportion of 22 to 26% La, 48 to 53% Ce, 17 to 20% Nd and 5 to 7% Pr, the said mixture possibly comprising up to 1% by weight of impurities, TR representing one or more elements of the rare earth family other than lanthanum, M representing one or more type d transition elements of the 3d, 4d and 5d layers X representing a metalloid element selected from Ge, Al, B, Ga and In R representing one or more elements selected from Al, Ca, Mg, K and Na, I representing one or two elements selected from O and S, with: 0?a<0.5 and 0?a?<0.2 0?b?0.2 and 0?b?<0.4 0?c?0.5 and 0?d?1 0?e?1 and f?0.1 0.09?x?0.13 and 0.002?y?4 0.0001?z?0.01 the subscripts b, d, e, x and y being such that the alloy further satisfies the following condition: 6.143b(13(1?x))+4.437y[1?0.
    Type: Grant
    Filed: December 15, 2008
    Date of Patent: August 19, 2014
    Assignee: Aperam Alloys Imphy
    Inventors: Thierry Waeckerle, Herve Fraisse, Mohamed Balli, Patricia De Rango, Daniel Fruchart, Damien Gignoux, Salvatore Miraglia, Mariana Rosca, Miguel Jose Artigas Alava
  • Patent number: 8771436
    Abstract: An electronic device including a magnetic body and a wire is provided. The magnetic body has a first magnetic powder and a second magnetic powder mixed with the first magnetic powder. The Vicker's Hardness of the first magnetic powder is greater than that of the second magnetic powder and the mean particle diameter of the first magnetic powder is greater than that of the second magnetic powder.
    Type: Grant
    Filed: July 30, 2012
    Date of Patent: July 8, 2014
    Assignee: Cyntec Co., Ltd.
    Inventors: Wen-Hsiung Liao, Roger Hsieh, Hideo Ikuta, Yueh-Lang Chen
  • Patent number: 8734714
    Abstract: 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 separation means for separating the rare earth particulate material from the assembly, and a collection means 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: Grant
    Filed: June 27, 2011
    Date of Patent: May 27, 2014
    Assignee: The University of Birmingham
    Inventors: Ivor Rex Harris, Andrew Williams, Allan Walton, John Speight
  • Patent number: 8695210
    Abstract: A method for preparing the magnet includes the steps of: (a) providing a sintered Nd base magnet block having surfaces and a magnetization direction, (b) coating the surfaces of the magnet block excluding the surface perpendicular to the magnetization direction with a Dy or Tb oxide powder, a Dy or Tb fluoride powder, or a Dy or Tb-containing alloy powder, (c) treating the coated block at a high temperature for causing Dy or Tb to diffuse into the block, and (d) cutting the block in a plane perpendicular to the magnetization direction into a magnet segment having a coercive force distribution on the cut section that the coercive force is high at the periphery and lower toward the inside and a constant coercive force distribution in the magnetization direction.
    Type: Grant
    Filed: November 27, 2009
    Date of Patent: April 15, 2014
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Koji Miyata, Takehisa Minowa, Hajime Nakamura, Koichi Hirota, Masakatsu Honshima
  • Patent number: 8557330
    Abstract: A manufacturing method of a soft magnetic material has a step of preparing a metal magnetic particle containing iron as the main component, and a step of forming an insulating film surrounding the surface of the metal magnetic particle. The step of forming the insulating film includes a step of mixing and stirring the metal magnetic particle, aluminum alkoxide, silicon alkoxide, and phosphoric acid.
    Type: Grant
    Filed: March 1, 2012
    Date of Patent: October 15, 2013
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Seiji Ishitani, Hiroko Morii, Kazuyuki Hayashi
  • Publication number: 20130265128
    Abstract: R-T-B-based rare earth magnet particles are produced by an HDDR treatment which comprises a first stage HD step of heating particles of a raw material alloy having a composition of R, B and Co in an inert atmosphere or in a vacuum atmosphere and then replacing the atmosphere with a hydrogen-containing gas atmosphere in which the raw material alloy particles are held in the same temperature range and a second stage HD step of heating a material obtained in the first stage HD step in which the material is held in the hydrogen-containing gas atmosphere.
    Type: Application
    Filed: March 15, 2013
    Publication date: October 10, 2013
    Applicant: TODA KOGYO CORP.
    Inventors: Nobuhiro KATAYAMA, Hirofumi KAWASAKI, Koichiro MORIMOTO
  • Patent number: 8518190
    Abstract: An electronic device including a magnetic body and a wire is provided. The magnetic body has a first magnetic powder and a second magnetic powder mixed with the first magnetic powder. The Vicker's Hardness of the first magnetic powder is greater than that of the second magnetic powder and the mean particle diameter of the first magnetic powder is greater than that of the second magnetic powder.
    Type: Grant
    Filed: February 10, 2010
    Date of Patent: August 27, 2013
    Assignee: Cyntec Co., Ltd.
    Inventors: Wen-Hsiung Liao, Roger Hsieh, Hideo Ikuta, Yueh-Lang Chen
  • Patent number: 8357222
    Abstract: A metal magnetic powder for a magnetic recording medium is provided whose particles have a metal magnetic phase, composed mainly of Fe or Fe plus Co, and an oxide layer, wherein the average major axis length of the powder particles is 10-50 nm, the average particle volume including the oxide layer is 5,000 nm3 or less, the atomic ratio (R+Al+Si)/(Fe+Co) calculated using the content values (at. %) of the elements contained in the powder particles is 20% or less, where R is rare earth element (Y being treated as a rare earth element). The metal magnetic powder is obtained by using a complexing agent and a reducing agent to elute nonmagnetic constituents after firing. The metal magnetic powder exhibits a large saturation magnetization as for its particle volume while maintaining weatherability comparable to the conventional level and is suitable for a coated-type magnetic recording medium.
    Type: Grant
    Filed: November 23, 2010
    Date of Patent: January 22, 2013
    Assignee: DOWA Electronics Materials Co., Ltd.
    Inventors: Takayuki Yoshida, Masatoshi Nakayama, Ryota Igarashi
  • Patent number: 8337638
    Abstract: A powder for a dust core comprising a silicon-containing layer formed within a depth of less than 0.15 D from the surface of the surface layer of a soft magnetic metal powder having a particle diameter D and a method for producing the same are provided.
    Type: Grant
    Filed: April 17, 2009
    Date of Patent: December 25, 2012
    Assignees: Toyota Jidosha Kabushiki Kaisha, Fine Sinter Co., Ltd
    Inventors: Yusuke Oishi, Eisuke Hoshina, Toshiya Yamaguchi, Kazuhiro Kawashima
  • Patent number: 8337637
    Abstract: A method for ordering a disordered alloy includes: simultaneously ion bombarding and annealing a disordered alloy to transform the disordered alloy from a disordered crystalline state to an ordered crystalline state. A method for making a perpendicular magnetic recording medium which includes an ordered alloy layer is also disclosed.
    Type: Grant
    Filed: December 7, 2009
    Date of Patent: December 25, 2012
    Assignee: National Taiwan University
    Inventors: Fu-Te Yuan, An-Cheng Sun, Jen-Hwa Hsu, Ching-Ray Chang
  • 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: 8313834
    Abstract: To provide a core for reactor capable of reducing the eddy current loss and improving the direct current superposition characteristics, a manufacturing method thereof, and a reactor. A core for reactor M is obtained by press molding metallic magnetic particles coated with an insulating coated film, and the metallic magnetic particles have the following compositions: (1) the mean particle size is 1 ?m or more and 70 ?m or less; (2) the variation coefficient Cv which is a ratio (?/?) of the standard deviation (?) of the particle size and the mean particle size (?) is 0.40 or less; and (3) the degree of circularity is 0.8 or more and 1.0 or less. On the outside of the insulating coated film, at least one of a heat-resistance imparting protective film and a flexible protective film is further provided as a outer coated film.
    Type: Grant
    Filed: September 10, 2008
    Date of Patent: November 20, 2012
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Atsushi Sato, Toru Maeda
  • Patent number: 8236087
    Abstract: The present invention relates to an iron-base powder for a powder core, wherein when cross-sections of at least 50 iron-base powders are observed and a crystal grain size distribution containing at least a maximum crystal grain size is determined by measuring a crystal grain size of each iron-base powder, 70% or more of the measured crystal grains are a crystal grain having a crystal grain size of 50 ?m or more. According to the iron-base powder of the invention, a coercivity of the powder core can be made small and a hysteresis loss can be reduced.
    Type: Grant
    Filed: September 11, 2007
    Date of Patent: August 7, 2012
    Assignees: Kobe Steel, Ltd., Hitachi Powdered Metals Co., Ltd.
    Inventors: Hiroyuki Mitani, Nobuaki Akagi, Hirofumi Houjou, Chio Ishihara, Makoto Iwakiri, Sohei Yamada, Yasukuni Mochimizo
  • Patent number: 8226779
    Abstract: A manufacturing method of a magnetic core includes a first step of applying a treatment liquid for forming an insulating film to iron powder; a second step of heat-treating the iron powder to which the treatment liquid has been applied, at a temperature higher than 350 degrees; a third step of compacting the heat-treated iron powder to form a magnetic core; and a forth step of heat-treating the magnetic core at a temperature ranging from 600 degrees to 800 degrees.
    Type: Grant
    Filed: April 9, 2008
    Date of Patent: July 24, 2012
    Assignee: Hitachi, Ltd.
    Inventors: Takao Imagawa, Yuichi Satsu, Matahiro Komuro, Hiroyuki Suzuki
  • Patent number: 8153256
    Abstract: The soft magnetic material includes a plurality of composite magnetic particles having a metal magnetic particle and an insulating film surrounding the surface of the metal magnetic particle. The metal magnetic particle contains iron as the main component. The insulating film contains aluminum, silicon, phosphorus, and oxygen. The insulating film satisfies the relationship 0.4?MAl/(MAl+MSi)?0.9 and the relationship of 0.25?(MAl+MSi)/MP?1.0 in the case that molar amount of aluminum contained in the insulating film is represented by MAl, the sum of the molar amount of aluminum contained in the insulating film and the molar amount of silicon contained in the insulating film is represented by (MAl+MSi), and the molar amount of phosphorus contained in the insulating film is represented by MP.
    Type: Grant
    Filed: November 22, 2006
    Date of Patent: April 10, 2012
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Seiji Ishitani, Hiroko Morii, Kazuyuki Hayashi