Particulate Material Patents (Class 148/105)
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Patent number: 8734714Abstract: 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: GrantFiled: June 27, 2011Date of Patent: May 27, 2014Assignee: The University of BirminghamInventors: Ivor Rex Harris, Andrew Williams, Allan Walton, John Speight
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Patent number: 8695210Abstract: 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: GrantFiled: November 27, 2009Date of Patent: April 15, 2014Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Koji Miyata, Takehisa Minowa, Hajime Nakamura, Koichi Hirota, Masakatsu Honshima
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Patent number: 8557330Abstract: 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: GrantFiled: March 1, 2012Date of Patent: October 15, 2013Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Seiji Ishitani, Hiroko Morii, Kazuyuki Hayashi
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Publication number: 20130265128Abstract: 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: ApplicationFiled: March 15, 2013Publication date: October 10, 2013Applicant: TODA KOGYO CORP.Inventors: Nobuhiro KATAYAMA, Hirofumi KAWASAKI, Koichiro MORIMOTO
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Patent number: 8518190Abstract: 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: GrantFiled: February 10, 2010Date of Patent: August 27, 2013Assignee: Cyntec Co., Ltd.Inventors: Wen-Hsiung Liao, Roger Hsieh, Hideo Ikuta, Yueh-Lang Chen
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Patent number: 8357222Abstract: 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: GrantFiled: November 23, 2010Date of Patent: January 22, 2013Assignee: DOWA Electronics Materials Co., Ltd.Inventors: Takayuki Yoshida, Masatoshi Nakayama, Ryota Igarashi
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Patent number: 8337638Abstract: 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: GrantFiled: April 17, 2009Date of Patent: December 25, 2012Assignees: Toyota Jidosha Kabushiki Kaisha, Fine Sinter Co., LtdInventors: Yusuke Oishi, Eisuke Hoshina, Toshiya Yamaguchi, Kazuhiro Kawashima
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Patent number: 8337637Abstract: 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: GrantFiled: December 7, 2009Date of Patent: December 25, 2012Assignee: National Taiwan UniversityInventors: Fu-Te Yuan, An-Cheng Sun, Jen-Hwa Hsu, Ching-Ray Chang
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Patent number: 8323725Abstract: 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: GrantFiled: June 16, 2010Date of Patent: December 4, 2012Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
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Patent number: 8317937Abstract: 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: GrantFiled: March 29, 2010Date of Patent: November 27, 2012Assignee: Hitachi Metals, Ltd.Inventor: Futoshi Kuniyoshi
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Patent number: 8313834Abstract: 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: GrantFiled: September 10, 2008Date of Patent: November 20, 2012Assignee: Sumitomo Electric Industries, Ltd.Inventors: Atsushi Sato, Toru Maeda
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Patent number: 8236087Abstract: 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: GrantFiled: September 11, 2007Date of Patent: August 7, 2012Assignees: Kobe Steel, Ltd., Hitachi Powdered Metals Co., Ltd.Inventors: Hiroyuki Mitani, Nobuaki Akagi, Hirofumi Houjou, Chio Ishihara, Makoto Iwakiri, Sohei Yamada, Yasukuni Mochimizo
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Patent number: 8226779Abstract: 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: GrantFiled: April 9, 2008Date of Patent: July 24, 2012Assignee: Hitachi, Ltd.Inventors: Takao Imagawa, Yuichi Satsu, Matahiro Komuro, Hiroyuki Suzuki
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Patent number: 8153256Abstract: 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: GrantFiled: November 22, 2006Date of Patent: April 10, 2012Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Seiji Ishitani, Hiroko Morii, Kazuyuki Hayashi
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Patent number: 8128757Abstract: There is provided a method of manufacturing a permanent magnet having extremely high orientation by arranging such that the crystal fractures of alloy raw meal powder having more equal crystal orientational relationship are combined in magnetic field. In this invention, alloy raw meal powder is filled into a cavity and, while agitating the alloy raw meal powder inside the cavity, is oriented in the magnetic field. This oriented body is then compression molded in the magnetic field into a predetermined shape.Type: GrantFiled: November 19, 2007Date of Patent: March 6, 2012Assignee: Ulvac, Inc.Inventors: Hiroshi Nagata, Yoshinori Shingaki
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Patent number: 8075838Abstract: A compression molding which is high in both dimensional accuracy and mechanical strength is difficult to manufacture by a powder molding process. Especially, a molding including a soft magnetic material with high soft magnetic properties is difficult to manufacture. A composite metal molding according to the present invention includes metal particles and the carbide of a resin intervening among the particles. It is manufactured by coating metal particles with a resin, molding the prepared molding material under pressure into a predetermined shape, and heating the prepared pressurized preform to calcine the resin and weld mutually the particles. The carbide of the resin has a weight ratio of 0.001 to 2% to the metal particles when the particles have their proportion expressed as 100. The particles have a weld ratio of 10 to 80%. The particles preferably contain a soft magnetic material and the resin is preferably a furan resin.Type: GrantFiled: July 16, 2010Date of Patent: December 13, 2011Assignee: Canon Denshi Kabushiki KaishaInventors: Junji Hamana, Isamu Kawada, Naoaki Maruyama
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Patent number: 8048191Abstract: The present invention provides a compound powder for making magnetic powder cores, a kind of magnetic powder core, and a process for making them. Said compound powder is a mixture composing of powder A and powder B, the content of powder A is 50-96 wt % and the content of powder B is 4-50 wt %, wherein powder A is at least one selected from iron powder, Fe—Si powder, Fe—Si—Al powder, Fe-based nanocrystalline powder, Fe-based amorphous powder, Fe—Ni powder and Fe—Ni—Mo powder; powder B bears different requirement characteristics from powder A and is at least one selected from iron powder, Fe—Si powder, Fe—Si—Al powder, Fe-based nanocrystalline powder, Fe-based amorphous powder, Fe—Ni powder and Fe—Ni—Mo powder. Said powder B adopts Fe-based amorphous soft magnetic powder with good insulation property as insulating agent and thus core loss of magnetic powder core decreases.Type: GrantFiled: December 14, 2006Date of Patent: November 1, 2011Assignees: Advanced Technology & Material Co., Ltd., Central Iron & Steel Research InstituteInventors: Zhichao Lu, Deren Li, Shaoxiong Zhou, Caowei Lu, Feng Guo, Jianliang Li, Jun Wang, Tongchun Zhao, Liang Zhang
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Patent number: 8038808Abstract: A flat soft magnetic material to be used for a noise-suppressing magnetic sheet, wherein the 50% particle size D50 (?m), coercive force Hc (A/m) and bulk density BD (Mg/m3) of the flat soft magnetic material satisfy the following formula (1). D50/(HC×BD)?1.Type: GrantFiled: April 20, 2009Date of Patent: October 18, 2011Assignee: TDK CorporationInventors: Atsuhito Matsukawa, Katsuhiko Wakayama, Hideharu Moru, Naoyoshi Sato, Yoshihito Hirai, Toshihisa Murayoshi
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Patent number: 7976643Abstract: A nanocomposite magnet containing an Fe particle in the grain boundary of an Nd2Fe14B compound particle is produced by mixing a dispersion of the Nd2Fe14B compound particle in a solvent containing a surface-active agent and a dispersion of the Fe particle in a solvent containing a surface-active agent, and then supporting the Fe particle on the surface of the Nd2Fe14B compound particle by stirring the mixture of the dispersions while adding an amphiphilic solvent, and then performing the drying and the drying and the sintering.Type: GrantFiled: November 27, 2007Date of Patent: July 12, 2011Assignee: Toyota Jidosha Kabushiki KaishaInventors: Noritsugu Sakuma, Tetsuya Shoji
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Patent number: 7972448Abstract: Disclosed herein is a method for the production of an anisotropic magnetic powder or a magnet produced from said powder, wherein a hydrogenating and dehydrogenating method is applied to the starting material in order to produce the powder. An anisotropic oriented magnetic material, more particularly magnetic scrap metal, is advantageously used as starting material so that the complicated use of a molten mass with isotropic distribution of the c axes of the hard metal crystals is not required. The result is an anisotropic material having a fine grain structure and a crystallographic orientation matching a TMXB phase formed during hydrogenation.Type: GrantFiled: November 27, 2003Date of Patent: July 5, 2011Assignee: Vacuumschmelze GmbH & Co. KGInventor: Georg Werner Reppel
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Patent number: 7931756Abstract: A method of making a rare-earth alloy granulated powder according to the present invention includes the steps of: preparing a rare-earth alloy powder; generating remnant magnetization in the powder; and granulating the powder by utilizing agglomeration force produced by the remnant magnetization of the powder. Since the agglomeration force produced by the remnant magnetization is utilized, the addition of a granulating agent may be omitted.Type: GrantFiled: October 5, 2009Date of Patent: April 26, 2011Assignee: Hitachi Metals, Ltd.Inventors: Futoshi Kuniyoshi, Tomoiku Otani
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Patent number: 7854878Abstract: A method including providing Au-doped Co nanoparticles. The nanoparticles include a combination of non-ferromagnetic nanoparticles and weakly ferromagnetic nanoparticles. The nanoparticles each have an exterior surface. The surfaces of the nanoparticles are functionalized with 7-(5-uracil-ylcarbamoyl)heptanoic acid. A polymer is provided having a general formula including a uracil group. A dispersion is formed by agitating a solution of the nanoparticles. The solution is spin cast into a film. The film is heated under vacuum at a first temperature, TFM, resulting in inducing ferromagnetism in the non-ferromagnetic nanoparticles and converting the non-ferromagnetic nanoparticles to ferromagnetic nanoparticles, and resulting in enhancing ferromagnetism in the weakly ferromagnetic nanoparticles. The nanoparticles are aligned such that magnetic easy axes of the nanoparticles are oriented by applying a magnetic field to the dispersion while at a second temperature less than TFM.Type: GrantFiled: January 23, 2007Date of Patent: December 21, 2010Assignee: International Business Machines CorporationInventors: James Lupton Hedrick, Delia Jane Milliron, Alshakim Nelson, Russell Clayton Pratt
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Publication number: 20100212455Abstract: An iron-based soft magnetic powder for dust core having a high magnetic flux density, maintaining high electric insulation even after annealing, and more excellent in the mechanical strength in which a coating film having a phosphate conversion coating film is formed on the surface thereof and the peak height for the absorption of hydroxyl groups formed at 3700 cm?1 to 2500 cm?1 is 0.04 or more being indicated by absorbance when the coating film is analyzed by infrared diffuse reflectance spectroscopy.Type: ApplicationFiled: December 29, 2009Publication date: August 26, 2010Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel Ltd)Inventors: Takeshi OHWAKI, Hiroyuki Mitani, Hirofumi Hojo, Kasumi Yanagisawa, Nobuaki Akagi
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Patent number: 7767035Abstract: A metallic magnetic material for magnetic element for magnetic element of a choke coil and an SMD choke power coil for accommodating low voltage and high current in a personal computer, graphic card, high frequency power supply, etc, is prepared by baking a powder of Fe—Si—Al alloy sendust, obtained by an atomization process and having an average particle diameter of 10 to 70 ?m, at 600° C. to 1000° C. in air or in an oxidizing atmosphere and mixing the baked sendust with 3 to 45 wt % of a carbonyl iron powder with an average particle diameter of 1 to 10 ?m. The metallic magnetic material for magnetic element according to the present invention is used in a coil-embedded SMD power choke coil having a square or rectangular shape with a height of 1 mm to 7 mm and with a length of one side being 3 mm to 13 mm.Type: GrantFiled: November 30, 2007Date of Patent: August 3, 2010Assignee: Sekisin Industry Co., Ltd.Inventors: Namio Sato, Yotaro Toyoshima, Katsutoshi Yamamoto
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Patent number: 7718082Abstract: The invention concerns a powder metallurgical composition containing, preferably a coarse, soft magnetic iron or iron-based powder, wherein the particles are surrounded by an insulating inorganic coating and as lubricant at least one non-drying oil or liquid having a crystalline melting point below 25° C., a viscosity (?) at 40° C. above 15 mPas and wherein said viscosity is temperature dependent according to the following formula: 10 log ?=k/T+C wherein the slope k is above 800 T is in Kelvin and C is a constant in an amount between 0.05 and 0.4% by weight of the composition.Type: GrantFiled: June 21, 2005Date of Patent: May 18, 2010Assignee: Höganäs ABInventors: Hilmar Vidarsson, Paul Skoglund, Björn Sk{dot over (a)}rman
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Publication number: 20100097171Abstract: A soft magnetic alloy contains P, B, and Cu as essential components. As a preferred example, an Fe-based alloy contains Fe of 70 atomic % or more, B of 5 atomic % to 25 atomic %, Cu of 1.5 atomic % or less (excluding zero), and P of 10 atomic or less (excluding zero).Type: ApplicationFiled: March 19, 2008Publication date: April 22, 2010Inventors: Akiri Urata, Hiroyuki Matsumoto, Akihiro Makino
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Patent number: 7691323Abstract: A rare-earth alloy ingot is produced by melting an alloy composed of 20-30 wt % of a rare-earth constituent which is Sm alone or at least 50 wt % Sm in combination with at least one other rare-earth element, 10-45 wt % of Fe, 1-10 wt % of Cu and 0.5-5 wt % of Zr, with the balance being Co, and quenching the molten alloy in a strip casting process. The strip-cast alloy ingot has a content of 1-200 ?m size equiaxed crystal grains of at least 20 vol % and a thickness of 0.05-3 mm. Rare-earth sintered magnets made from such alloys exhibit excellent magnetic properties and can be manufactured under a broad optimal temperature range during sintering and solution treatment.Type: GrantFiled: March 7, 2008Date of Patent: April 6, 2010Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Kazuaki Sakaki, Koji Sato, Takahiro Hashimoto, Hajime Nakamura, Takehisa Minowa
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Patent number: 7632360Abstract: A rare earth magnet powder has a chemical composition which includes R: 5 to 20% (wherein, R represents one or two or more rare earth elements being inclusive of Y but exclusive of Dy and Tb), one or two of Dy and Tb: 0.01 to 10%, and B: 3 to 20%, with the balance comprising Fe and inevitable impurities; and an average particle diameter of 10 to 1,000 ?m, wherein 70% or more of the entire surface of the rare earth magnet powder is covered with a layer being rich in the content of one or two of Dy and Tb and having a thickness of 0.05 to 50 ?m.Type: GrantFiled: May 13, 2004Date of Patent: December 15, 2009Assignee: Nissan Motor Co., Ltd.Inventors: Katsuhiko Mori, Ryoji Nakayama, Hideaki Ono, Takae Ono, legal representative, Tetsurou Tayu, Munekatsu Shimada, Makoto Kano, Yoshio Kawashita
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Patent number: 7608158Abstract: The present invention includes particle compositions and methods of fabrication that prevent agglomeration, thereby maintaining particle size and/or shape. Particles of the present invention were prepared after embedding chemically disordered metal-containing particles in at least one salt to form a dispersion. The dispersion of particles in salt was treated to temperatures of at least about 500 degrees Centigrade for several hours. Particles were easily recovered from the dispersion and did not agglomerate. The particles were also absent contaminating salts after performing simple washing and/or rinsing steps. Structural, compositional and/or magnetic characterizations of the metal-containing particles confirmed that they had not agglomerated. When particles with an fcc structure formed a dispersion with at least one salt, the method yielded the formation of particles having an fct structure with high magnetic anisotropy and without a substantial change in size and/or shape.Type: GrantFiled: March 13, 2006Date of Patent: October 27, 2009Assignee: Board of Regents, the University of Texas SystemInventor: J. Ping Liu
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Patent number: 7608153Abstract: A rare earth magnet includes rare earth magnet particles; and amorphous and/or crystalline terbium oxide present at the boundary of the rare earth magnet particles and represented by the formula: TbOn, wherein 1.5<n?2. The rare earth magnet prevents decrease eddy current effectively.Type: GrantFiled: December 21, 2004Date of Patent: October 27, 2009Assignee: Nissan Motor Co., Ltd.Inventors: Tetsurou Tayu, Hideaki Ono, Takae Ono, legal representative, Yoshio Kawashita, Makoto Kano, Munekatsu Shimada
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Patent number: 7553793Abstract: A method for recovering a catalyst for a fuel cell includes a collection step in which a catalyst is collected by attracting, using a magnetic force, a magnetic material contained in at least one of the catalyst and a carrier on which the catalyst is supported. A system for recovering a catalyst for a fuel cell includes a collection device that attracts, using a magnetic force, a magnetic material contained in at least one of a catalyst and a carrier on which the catalyst is supported.Type: GrantFiled: September 20, 2006Date of Patent: June 30, 2009Assignee: Toyota Jidosha Kabushiki KaishaInventor: Kazuhiro Taniwaki
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Patent number: 7470308Abstract: In a method of producing magnetic particles which includes the steps of preparing alloy particles capable of forming a CuAu or Cu3Au hard magnetic ordered alloy phase and of forming magnetic particles for forming CuAu or Cu3Au magnetic particles, a plurality of solutions L1 and L2 for preparing the alloy particles are passed in a thin-plate laminar flow and diffused in the direction perpendicular to the flow direction at the contact interface of the solutions L1 and L2 in a mixing channel by using a microreactor, whereby a uniform mixing reaction is conducted in a short time.Type: GrantFiled: February 10, 2005Date of Patent: December 30, 2008Assignee: FUJIFILM CorporationInventors: Fumiko Shiraishi, Seiji Sugiyama, Koukichi Waki, Yasunori Ichikawa, Tomohide Ueyama, Yasushi Hattori
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Publication number: 20080257716Abstract: A film is formed at a high rate on the surface of an iron-boron-rare-earth-metal magnet having a given shape, while effectively using dysprosium or terbium as a film-forming material. Thus, productivity is improved and a permanent magnet can be produced at low cost. A permanent magnet is produced through a film formation step in which a film of dysprosium is formed on the surface of an iron-boron-rare-earth-metal magnet of a given shape and a diffusion step in which the magnet coated is subjected to a heat treatment at a given temperature to cause the dysprosium deposited on the surface to diffuse into the grain boundary phase of the magnet.Type: ApplicationFiled: March 14, 2006Publication date: October 23, 2008Inventors: Hiroshi Nagata, Yoshinori Shingaki
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Publication number: 20080152939Abstract: The present invention relates to magnetic beads suitable for, for example, isolation of proteins, cells, and viruses and also for diagnostic applications and cell cultivation. The magnetic beads are composite beads with an inner core of metal particles, which are coated with an inert synthetic polymer and these are then enclosed in a hydrophilic porous polymer, preferably agarose. This provides porous biocompatible beads without metal leakage. The beads may be used for cell cultivation or for chromatography. When the beads are used for chromatography the agarose layer is preferably provided with ligands having affinity for selected biomolecules.Type: ApplicationFiled: April 13, 2006Publication date: June 26, 2008Applicant: GE Healthcare Bio-Sciences ABInventors: Mathias Alterman, Andreas Axen, Gunnar Glad, Dag Lindstrom, Ulrika Meyer, Nils Norrman, Tobias E. Soderman
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Patent number: 7390567Abstract: A soft magnetic compact which is produced by using soft magnetic composite powder in which the surface of magnetic powder is covered with an electrical insulating material containing at least an inorganic insulating material, and a resin material is fusion-bonded to the surface of the inorganic insulating material so as to partially cover the surface of the soft magnetic powder. Accordingly, it is possible to ensure an electrical insulating property between pieces of soft magnetic material powder to secure a good magnetic characteristics and to easily mold a compact.Type: GrantFiled: April 22, 2004Date of Patent: June 24, 2008Assignee: Nippon Kagaku Yakin Co., Ltd.Inventors: Kiyotaka Matsukawa, Kozo Ishihara, Ikuo Uemoto, Masafumi Taniguchi
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Patent number: 7371271Abstract: An object of the present invention is to provide a composite soft magnetic sintered material that has high density, high mechanical strength and high relative magnetic permeability at high frequencies and, in order to achieve this object, the present invention provides a method of producing the composite soft magnetic sintered material, which comprises mixing a composite soft magnetic powder, that consists of iron powder, Fe—Si based soft magnetic iron alloy powder, Fe—Al based soft magnetic iron alloy powder, Fe—Si—Al based soft magnetic iron alloy powder, Fe—Cr based soft magnetic iron alloy powder or nickel-based soft magnetic alloy powder (hereinafter these powders are referred to as soft magnetic metal powder) of which particles arc coated with a ferrite layer which has a spinel structure, with 0.05 to 1.Type: GrantFiled: March 29, 2002Date of Patent: May 13, 2008Assignee: Mitsubishi Materials PMG CorporationInventors: Kazunori Igarashi, Ryoji Nakayama, Koichiro Morimoto, Muneaki Watanabe
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Publication number: 20080041496Abstract: A method of producing a soft magnetic material includes the steps of preparing soft magnetic powder containing a plurality of soft magnetic particles etching the soft magnetic powder to remove surfaces of the soft magnetic particles and, after the etching step, heat-treating the soft magnetic powder in a finely divided state at a temperature of not less than 400° C. and not more than 900° C. By this method configured as above, desired magnetic characteristics can be obtained.Type: ApplicationFiled: March 29, 2005Publication date: February 21, 2008Inventors: Toru Maeda, Naoto Igarashi, Kazuhiro Hirose, Haruhisa Toyoda
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Patent number: 7273405Abstract: A method of producing a sintered rare earth magnetic alloy wafer comprises a step of using a cutter to slice a wafer of a thickness of not greater than 3 mm from a sintered rare earth magnetic alloy having ferromagnetic crystal grains surrounded by a more readily grindable grain boundary phase and a step of surface-grinding at least one cut surface of the obtained wafer with a grindstone to form at a surface layer thereof flat ferromagnetic crystal grain cross-sections lying parallel to the wafer planar surface. The method enables high-yield production of a sintered rare earth magnetic alloy wafer having flat surfaces.Type: GrantFiled: September 16, 2005Date of Patent: September 25, 2007Assignee: Dowa Mining Co., Ltd.Inventors: Kiyoshi Yamada, Hirofumi Takei, Masami Kamada, Toshinori Eba
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Patent number: 7270718Abstract: The invention provides a method for manufacturing a soft magnetic powder material covered by oxide layers at surfaces of the powder, by using a soft magnetic alloy powder containing a soft magnetic powder material and a second element such as Si having an oxidizing reactivity higher than iron, and heating the soft magnetic alloy powder in an atmosphere of a weak oxidizing gas by mixing a weak oxidizing gas in an inert gas, and oxidizing selectively the second element at surface layers of the powder while restraining an oxidation of iron to form thin oxide layers with high electrical resistance.Type: GrantFiled: November 19, 2004Date of Patent: September 18, 2007Assignee: DENSO CorporationInventors: Yoshiaki Nishijima, Yurio Nomura, Kouichi Yamaguchi, Yuuichi Ishikawa, Hidekazu Hayama
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Publication number: 20070144614Abstract: The present invention provides a compound powder for making magnetic powder cores, a kind of magnetic powder core, and a process for making them. Said compound powder is a mixture composing of powder A and powder B, the content of powder A is 50-96 wt % and the content of powder B is 4-50 wt %, wherein powder A is at least one selected from iron powder, Fe—Si powder, Fe—Si—Al powder, Fe-based nanocrystalline powder, Fe-based amorphous powder, Fe—Ni powder and Fe—Ni—Mo powder; powder B bears different requirement characteristics from powder A and is at least one selected from iron powder, Fe—Si powder, Fe—Si—Al powder, Fe-based nanocrystalline powder, Fe-based amorphous powder, Fe—Ni powder and Fe—Ni—Mo powder. Said powder B adopts Fe-based amorphous soft magnetic powder with good insulation property as insulating agent and thus core loss of magnetic powder core decreases.Type: ApplicationFiled: December 14, 2006Publication date: June 28, 2007Inventors: Zhichao Lu, Deren Li, Shaoxiong Zhou, Caowei Lu, Feng Guo, Jianliang Li, Jun Wang, Tongchun Zhao, Liang Zhang
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Patent number: 7179337Abstract: The invention provides a method for preparing a soft magnetic material which meets demands for low iron loss, high density, high strength and high productivity. The method comprises a surface oxidation step of forming oxide films on the surfaces of a soft magnetic powder, a step of preparing a molding compound of the soft magnetic powder by mixing a soft magnetic powder and a binder with a predetermined blending ratio, a press molding step of press-molding the molding compound of the soft magnetic powder into a predetermined shape, and a sintering step of sintering the press-molded soft magnetic powder to produce a soft magnetic material, wherein a millimeter wave sintering apparatus or a discharge plasma sintering apparatus is used as a heating means in the surface oxidation step or in the sintering step.Type: GrantFiled: October 17, 2003Date of Patent: February 20, 2007Assignee: Denso CorporationInventors: Yasuyoshi Suzuki, Yurio Nomura, Yoshiaki Nishijima, Shoji Miyake, Yukio Makino, Teppei Satoh
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Patent number: 7175717Abstract: A method for making a nano-scale amorphous soft magnetic powders obtained by thermally processing and crystallizing amorphous ribbons produced using a rapid solidification process (RSP) and crushing the same. The amorphous soft magnetic core having an excellent high-frequency characteristic is obtained by performing a preliminary thermal treatment of Fe-based amorphous metal ribbons produced by using RSP to then be converted into nano-scale grain metal ribbons, crushing the metal ribbons to thereby obtain nano-scale grain metal powders, classifying the nano-scale grain metal powders to then be mixed into a distribution of powder particles having an optimal uniform composition, mixing the mixed powder with a binder, and then forming a core, and annealing the formed core to then coat the core with an insulating resin.Type: GrantFiled: October 14, 2003Date of Patent: February 13, 2007Assignee: Amosense Co., Ltd.Inventors: Yong Sul Song, Hie Jin Kim
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Patent number: 7172642Abstract: Magnetic metal particles containing iron as a main component, comprising cobalt in an amount of usually 20 to 50 atm %, calculated as Co, based on whole Fe, aluminum in an amount of usually 3 to 15 atm %, calculated as Al, based on whole Fe and a rare earth element in an amount of usually 3 to 20 atm %, calculated as rare earth element, based on whole Fe, and having an average major axis diameter of usually 0.02 to 0.065 ?m, preferably from 0.02 to less than 0.05 ?m, a coercive force of usually 159.2 to 222.9 kA/m (2,000 to 2,800 Oe), a soluble Na content of usually not more than 30 ppm, a soluble Ca content of usually not more than 100 ppm, and an oxidation stability ??s of usually not more than 10%.Type: GrantFiled: November 27, 2002Date of Patent: February 6, 2007Assignee: Toda Kogyo CorporationInventors: Akinori Yamamoto, Yasutaka Ota, Haruki Kurokawa, Masaaki Maekawa
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Patent number: 7172660Abstract: A method for making an amorphous soft magnetic core using Fe-based amorphous metal powders is provided. The amorphous soft magnetic powders are obtained by crushing amorphous ribbons produced using a rapid solidification process (RSP). The magnetic core is obtained by performing a preliminary thermal treatment of amorphous metal ribbons made of Fe-based amorphous metal alloy using RSP, crushing the amorphous metal ribbons to thereby obtain amorphous metal powders, classifying the amorphous metal powders to then be mixed into a distribution of powder particles having an optimal uniform composition, mixing the mixed amorphous metal powders with a binder, forming a core, and annealing the formed core to then coat the core with an insulating resin.Type: GrantFiled: October 14, 2003Date of Patent: February 6, 2007Assignee: Amosense Co., Ltd.Inventors: Yong Sul Song, Jae Hwa Hong, Hie Jin Kim
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Patent number: 7166172Abstract: A ferromagnetic iron alloy powder for a magnetic recording medium is composed of acicular iron-base particles of an average major axis length (X) of not less than 20 nm and not greater than 80 nm and have oxygen content of not less than 15 wt % and coercive force (Hc) of not less than [0.0036 X3?1.1 X2+110 X?1390 (Oe)] (where X is average major axis length expressed in nm). The ferromagnetic iron alloy powder is obtained by reacting metal powder composed of acicular iron-base particles having an average major axis length of not less than 20 nm and not greater than 80 nm with pure water in substantial absence of oxygen to form a metal oxide film on the particle surfaces. Optionally, the particles can be reacted with a weak oxidizing gas by a wet or dry method.Type: GrantFiled: December 3, 2004Date of Patent: January 23, 2007Assignee: Dowa Mining Co., Ltd.Inventors: Kazuyuki Matsumoto, Kimitaka Sato, Takatoshi Fujino, Kenichi Inoue
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Patent number: 7144463Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.Type: GrantFiled: September 6, 2005Date of Patent: December 5, 2006Assignee: Magnequench, Inc.Inventors: Zhongmin Chen, Benjamin R. Smith, Bao-Min Ma, James W. Herchenroeder
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Patent number: 7144642Abstract: A ferrite magnet obtained by adding a ferrite having a hexagonal W-type magnetoplumbite structure to a ferrite having a hexagonal M-type magnetoplumbite structure, in which a portion of Sr, Ba, Pb or Ca is replaced with at least one element that is selected from the group consisting of the rare-earth elements (including Y) and Bi and that always includes La, during the fine pulverization process thereof. By adding a small amount of the element such as Co, Ni, Mn or Zn to the ferrite already having the hexagonal M-type magnetoplumbite structure during the fine pulverization process thereof, the magnetic properties can be improved.Type: GrantFiled: February 6, 2002Date of Patent: December 5, 2006Assignee: Neomax Co., Ltd.Inventors: Etsushi Oda, Seiichi Hosokawa, Sachio Toyota
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Patent number: 7138018Abstract: A method for manufacturing an anisotropic magnet powder includes a high-temperature hydrogenation process of holding an RFeB-based alloy containing rare earth elements (R), B and Fe as main ingredients in a treating atmosphere under a first treating pressure (P1) of which a hydrogen partial pressure ranges from 10 to 100 kPa and at a first treating temperature (T1) which ranges from 953 to 1133 K, a structure stabilization process of holding the RFeB-based alloy after the high-temperature hydrogenation process under a second treating pressure (P2) of which a hydrogen partial pressure is 10 or more and at a second treating temperature (T2) which ranges from 1033 to 1213 K such that the condition T2>T1 or P2>P1 is satisfied, a controlled evacuation process of holding the RFeB-based alloy after the structure stabilization process in a treating atmosphere under a third treating pressure (P3) of which a hydrogen partial pressure ranges from 0.Type: GrantFiled: January 15, 2004Date of Patent: November 21, 2006Assignee: Aichi Steel CorporationInventors: Yoshinobu Honkura, Norihiko Hamada, Chisato Mishima
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Patent number: 7029769Abstract: An insulation film whose requisite constituent elements are first elements and a second element. The first elements include B, P, O and Fe. The second element can generate cations whose hexa-coordinated ion radius, defined by Shannon, R. D., is 0.073 nm or more, and which are bivalent or more. Since the second element having a large ion radius is incorporated into network formers made from the first elements, it is possible to improve the heat resistance of the insulation film.Type: GrantFiled: March 18, 2003Date of Patent: April 18, 2006Assignees: Kabushiki Kaisha Toyota Chuo Kenkyusho, Toyota Jidosha Kabushiki Kaisha, Finesinter Co., Ltd.Inventors: Shin Tajima, Takeshi Hattori, Mikio Kondoh, Kiyoshi Higashiyama, Hidefumi Kishimoto, Masaki Sugiyama, Tadayoshi Kikko
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Patent number: RE40524Abstract: The magnet powder-resin compound particles substantially composed of rare earth magnet powder and a binder resin are in such a round shape that a ratio of the longitudinal size a to the transverse size b (a/b) is more than 1.00 and 3 or less, and that an average particle size defined by (a/b)/2 is 50-300 ?m. They are produced by charging a mixture of rare earth magnet powder and a binder resin into an extruder equipped with nozzle orifices each having a diameter of 300 ?m or less; extruding the mixture while blending under pressure though the nozzle orifices to form substantially cylindrical, fine pellets; and rounding the pellets by rotation.Type: GrantFiled: July 20, 2004Date of Patent: September 30, 2008Assignee: Hitachi Metals, Ltd.Inventors: Katsunori Iwasaki, Kazunori Tabaru