Particulate Material Patents (Class 148/105)
  • Patent number: 6929757
    Abstract: A magnetorheological fluid containing magnetorheological particles which are resistant to oxidation having regions rich in diffused nitrogen located therein and a method for producing such magnetorheological fluid.
    Type: Grant
    Filed: August 25, 2003
    Date of Patent: August 16, 2005
    Assignee: General Motors Corporation
    Inventors: John C. Ulicny, Yang T. Cheng
  • Publication number: 20040261905
    Abstract: The present invention relates to a method of producing a magnetic particle including forming a layer containing an alloy particle that can form CuAu type or Cu3Au type hard magnetic order alloy phase on a support, oxidizing the layer, and annealing the layer in non-oxidizing atmosphere. The invention also relates to a method of producing a magnetic particle including producing an alloy particle that can form hard magnetic order alloy phase, oxidizing the alloy particle, and annealing the particle in non-oxidizing atmosphere, and a magnetic particle produced by the foregoing production method. Further, the invention relates to a magnetic recording medium comprising a magnetic layer containing a magnetic particle and a method of producing a magnetic recording medium including forming a layer containing an alloy that can form the foregoing hard magnetic order alloy phase, oxidizing the layer, and annealing the layer in non-oxidizing atmosphere.
    Type: Application
    Filed: July 22, 2004
    Publication date: December 30, 2004
    Applicant: FUJI PHOTO FILM CO., LTD.
    Inventors: Yasushi Hattori, Koukichi Waki, Keizo Ogawa
  • Publication number: 20040261906
    Abstract: The present invention relates to a method of producing a magnetic particle including forming a layer containing an alloy particle that can form CuAu type or Cu3Au type hard magnetic order alloy phase on a support, oxidizing the layer, and annealing the layer in non-oxidizing atmosphere. The invention also relates to a method of producing a magnetic particle including producing an alloy particle that can form hard magnetic order alloy phase, oxidizing the alloy particle, and annealing the particle in non-oxidizing atmosphere, and a magnetic particle produced by the foregoing production method. Further, the invention relates to a magnetic recording medium comprising a magnetic layer containing a magnetic particle and a method of producing a magnetic recording medium including forming a layer containing an alloy that can form the foregoing hard magnetic order alloy phase, oxidizing the layer, and annealing the layer in non-oxidizing atmosphere.
    Type: Application
    Filed: July 22, 2004
    Publication date: December 30, 2004
    Applicant: FUJI PHOTO FILM CO., LTD.
    Inventors: Yasushi Hattori, Koukichi Waki, Keizo Ogawa
  • Publication number: 20040244872
    Abstract: A press machine 10 includes a die 12 with a through hole 12a that defines a cavity, a first press surface 14a and a second press surface 16a for pressing a magnetic powder 18 loaded in the cavity, and magnetic field generating means for applying an aligning magnetic field to the magnetic powder 18 in the cavity. At least one of the first and second press surfaces 14a and 16a has a region made of a material having a Vickers hardness that is higher than 200 but equal to or lower than 450. In pressing the powder under the aligning magnetic field, the press machine 10 minimizes the disturbance in the orientation of the powder.
    Type: Application
    Filed: March 23, 2004
    Publication date: December 9, 2004
    Inventors: Tsutomu Harada, Takashi Tajiri
  • Patent number: 6827758
    Abstract: A method for manufacturing magnetic metal powder is provided. In the method, a powdered magnetic metal oxide is supplied to a heat treatment furnace with a carrier gas composed of a reducing gas. The heat treatment furnace is maintained at temperatures above a reducing action starting temperature for the powdered magnetic metal oxide and above a melting point of the magnetic metal in the powder. The powdered magnetic metal oxide is subject to a reducing process, and then magnetic metal particles, the resultant reduced product, is melted to form a melt. The melt is re-crystallized in a succeeding cooling step, to obtain single crystal magnetic metal power in substantially spherical form.
    Type: Grant
    Filed: May 29, 2002
    Date of Patent: December 7, 2004
    Assignee: TDK Corporation
    Inventors: Minoru Takaya, Yoshiaki Akachi, Hisashi Kobuke, Hiroyuki Uematsu
  • Publication number: 20040238072
    Abstract: A bitumen film containing magnetic powder is heated prior to magnetization to a temperature enabling the magnetic powder particles to be oriented according to the effect of the magnetic field. The bitumen film is sufficiently cooled after magnetization in order to preserve said magnetization, whereby the orientation, whereby the orientation of the magnetic powder particles, which is adjusted during magnetization, is maintained.
    Type: Application
    Filed: July 21, 2004
    Publication date: December 2, 2004
    Inventors: Josef Polak, Christoph Freist, Gerd Mannebach, Ernst Hotz, Joachim Oster
  • Publication number: 20040231751
    Abstract: Rare earth alloy powder having an oxygen content of 50 to 4000 wt. ppm and a nitrogen content of 150 to 1500 wt. ppm is compacted by dry pressing to produce a compact. The compact is impregnated with an oil agent and then sintered. The sintering process includes a first step of retaining the compact at a temperature of 700° C. to less than 1000° C. for a period of time of 10 to 420 minutes and a second step of permitting proceeding of sintering at a temperature of 1000° C. to 1200° C. The average crystal grain size of the rare earth magnet after the sintering is controlled to be 3 &mgr;m to 9 &mgr;m.
    Type: Application
    Filed: June 22, 2004
    Publication date: November 25, 2004
    Applicant: SUMITOMO SPECIAL METALS CO., LTD.
    Inventors: Futoshi Kuniyoshi, Hitoshi Morimoto
  • Patent number: 6821357
    Abstract: Permanent magnets in which the ferromagnetic phase is matched with the grain boundary phase, and permanent magnets in which magnetocrystalline anisotropy in the vicinity of the outermost shell of the major phase is equivalent in intensity to that in the inside to suppress nucleation of the reverse magnetic domain, more specifically having a magnetocrystalline anisotropy not less than one-half the magnetocrystalline anisotropy of the interiors of the ferromagnetic grains, are disclosed.
    Type: Grant
    Filed: September 27, 2002
    Date of Patent: November 23, 2004
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Ken Makita, Osamu Yamashita
  • Publication number: 20040216811
    Abstract: A powder for forming a R—Fe—B bonded magnet, wherein an R compound, such as an R oxide, an R carbide, an R nitride or an R hydride, which is contained in a raw material powder such as a super rapidly cooled powder or a hydrogen treated powder (HDDR powder) and reacts with water vapor to change into R(OH)3, has been converted to a R hydroxide R(OH)3 being stable in the air by subjecting the raw material powder to a heat treatment in an atmosphere of a pressured water vapor. The powder for forming an R—Fe—B bonded magnet is free from the generation of a white powder in the surface of or inside a bonded magnet formed from the powder and accordingly, is free from the occurrence or cracking, chipping, swelling or the like in the bonded magnet caused by volume expansion of a white powder.
    Type: Application
    Filed: June 2, 2004
    Publication date: November 4, 2004
    Inventor: Takashi Ikegami
  • Patent number: 6808807
    Abstract: A coated ferromagnetic particle comprises a ferromagnetic core and a coating. The coating comprises a residue resulting from a thermal treatment of a coating material comprising a polymer selected from the group consisting of polyorganosiloxanes, polyorganosilanes, and mixtures thereof. A composite magnetic article comprises a compacted and annealed article of a desired shape. The composite magnetic article comprises a plurality of coated ferromagnetic articles. Each coated ferromagnetic particle comprises a ferromagnetic core and a coating. The coating comprises a residue resulting from a thermal treatment of a coating material comprising a polymer selected from the group consisting of polyorganosiloxanes, polyorganosilanes, and mixtures thereof.
    Type: Grant
    Filed: June 14, 2002
    Date of Patent: October 26, 2004
    Assignee: General Electric Company
    Inventors: Krishnamurthy Anand, Gerald Burt Kliman, Luana Emiliana Iorio, Suchismita Sanyal, Amitabh Verma, Kanchan Kumari, Srinidhi Sampath
  • Publication number: 20040206423
    Abstract: A method for producing a compact of rare earth alloy powder of the present invention includes: a powder-filling step of filling rare earth allow powder in a cavity formed by inserting a lower punch into a through hall of a die of a powder compacting machine; and a compression step of pressing the rare earth alloy powder while applying a magnetic field, the steps being repeated a plurality of times. When the (n+1)th (n is an integer equal to or more than 1) stage compression step is to be carried out, the top surface of a compact produced in the n-th stage compression step is placed at a position above the bottom surface of a magnetic portion of a die.
    Type: Application
    Filed: May 12, 2004
    Publication date: October 21, 2004
    Applicant: SUMITOMO SPECIAL METALS CO., LTD.
    Inventors: Tsutomu Harada, Hitoshi Morimoto, Atsuo Tanaka
  • Publication number: 20040194856
    Abstract: A rare-earth alloy powder is obtained by rapidly cooling a melt of an alloy by an atomization process. The alloy has a composition represented by (Fe1-mTm)100-x-y-zQxRyTizMn, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one of the rare-earth metal elements and yttrium, and M is at least one of Nb, Zr, Mo, Ta and Hf. The mole fractions x, y, z, m and n satisfy 10 at %<x≦25 at %, 6 at %≦y<10 at %, 0.1 at %≦z≦12 at %, 0≦m≦0.5, and 0 at %≦n≦10 at %, respectively. By adding Ti to the alloy, the nucleation and growth of &agr;-Fe during the rapid quenching process can be minimized.
    Type: Application
    Filed: January 16, 2004
    Publication date: October 7, 2004
    Inventors: Toshio Miyoshi, Hirokazu Kanekiyo, Satoshi Hirosawa
  • Publication number: 20040194855
    Abstract: The magnetic material for magnetic refrigeration according to the present invention has an NaZn13-type crystalline structure and comprises iron (Fe) as a principal element (more specifically, Fe is substituted for the position of “Zn”) and hydrogen (H) in an amount of 2 to 18 atomic % based on all constitutional elements. Preferably, the magnetic material for magnetic refrigeration preferably contains 61 to 87 atomic % of Fe, 4 to 18 atomic % of a total amount of Si and Al, 5 to 7 atomic % of La. The magnetic material for magnetic refrigeration exhibits a large entropy change in a room temperature region and no thermal hysteresis in a magnetic phase transition. Therefore, when a magnetic refrigeration cycle is configured using the magnetic material for magnetic refrigeration, a stable operation can be performed.
    Type: Application
    Filed: April 1, 2003
    Publication date: October 7, 2004
    Inventors: Kazuaki Fukamichi, Asaya Fujita, Yoshiaki Iijima, Akiko Saito, Tadahiko Kobayashi, Masashi Sahashi
  • Publication number: 20040187963
    Abstract: A rare earth magnet to be used in a motor. The rare earth magnet comprises rare earth magnet particles.
    Type: Application
    Filed: March 26, 2004
    Publication date: September 30, 2004
    Applicant: NISSAN MOTOR CO. LTD.
    Inventors: Tetsurou Tayu, Hideaki Ono, Takae Ono, Makoto Kano, Munekatsu Shimada, Yoshio Kawashita, Takeshi Yamauchi
  • Patent number: 6783798
    Abstract: Thin, flexible composite materials, which are magnetic or magnetizable and processes for producing and using the materials. The composite material contains a laminate formed from a mixture of magnetic or magnetizable particles, binder particles (and optionally active particles), applied to and fused and/or coalesced with a first substrate. The composite preferably contains an additional second substrate fused to and/or coalesced with, the laminate on the side of the laminate opposite that of the first substrate.
    Type: Grant
    Filed: June 6, 2003
    Date of Patent: August 31, 2004
    Assignee: Koslow Technologies Corporation
    Inventor: Evan E. Koslow
  • Patent number: 6780255
    Abstract: A magnetic powder of an Sm—Fe—N alloy, which has a mean particle diameter of 0.5 to 10 &mgr;m, and either an average acicularity of 75% or above or an average sphericity of 78% or above. The powder exhibits an extremely high residual magnetization and an extremely high coercive force, since particles characterized by the above acicularity or sphericity have particle diameters approximately equal to that of the single domain particle and nearly spherical particle shapes. The powder can be produced by preparing an Sm—Fe oxide by firing a coprecipitate corresponding to the oxide, mixing the obtained oxide with metallic calcium and subjecting the mixture to reduction/diffusion and nitriding successively.
    Type: Grant
    Filed: November 13, 2001
    Date of Patent: August 24, 2004
    Assignee: Nichia Chemical Industries, Ltd.
    Inventors: Yohsiyuki Kawano, Michiya Kume, Keiji Ichinomiya
  • Publication number: 20040161600
    Abstract: 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: Application
    Filed: April 6, 2004
    Publication date: August 19, 2004
    Inventors: Kazunori Igarashi, Ryoji Nakayama, Koichiro Morimoto, Muneaki Watanabe
  • Publication number: 20040149354
    Abstract: The method for producing a granulated powder of the present invention includes the steps of: preparing an R—Fe—B alloy powder; and granulating the alloy powder using at least one kind of granulating agent selected from normal paraffins, isoparaffins and depolymerized oligomers, to prepare a granulated powder. The produced R—Fe—B alloy granulated powder is excellent in flowability and compactibility as well as in binder removability.
    Type: Application
    Filed: March 29, 2004
    Publication date: August 5, 2004
    Inventors: Futoshi Kuniyoshi, Yuji Kaneko, Akihito Tsujimoto, Kazunari Shimauchi, Kazuo Tanaka, Kiyofumi Suzuki
  • Patent number: 6770242
    Abstract: Permanent magnet for voice coil actuator motors used to actuate head-arm assemblies in small form disk drives are produced from a dispersion of prealloyed rare earth magnetic particles in a thermoplastic binder. Upon shaping of green parts the magnetic axis of the particles is aligned with the field lines of a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better than tolerances and 100% material utilization are claimed.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: August 3, 2004
    Inventors: Romain L. Billiet, Hanh T. Nguyen
  • Publication number: 20040144450
    Abstract: Disclosed is an isotropic SmFeN powdery magnet material for producing resin-bonded magnets.
    Type: Application
    Filed: January 20, 2004
    Publication date: July 29, 2004
    Inventors: Takahiko Iriyama, Ryo Omatsuzawa, Takayuki Nishio
  • Publication number: 20040144449
    Abstract: A Nd—Fe—B type anisotropic exchange spring magnet is produced by a method of obtaining powder of a Nd—Fe—B type rare earth magnet alloy which comprises hard magnetic phases and soft magnetic phases wherein a minimum width of the soft magnetic phases is smaller than or equal to 1 &mgr;m and a minimum distance between the soft magnetic phases is greater than or equal to 0.1 &mgr;m, obtaining a compressed powder body by compressing the powder, and obtaining the Nd—Fe—B type anisotropic exchange spring magnet by sintering the compressed powder body using a discharge plasma sintering unit.
    Type: Application
    Filed: November 12, 2003
    Publication date: July 29, 2004
    Inventors: Munekatsu Shimada, Hideaki Ono, Takae Ono, Makoto Kano, Tetsurou Tayu
  • Publication number: 20040134565
    Abstract: A process of forming a hard-soft phase, exchange-coupled, magnetic nanocomposite includes forming a dispersion of magnetic nanoparticles, separating the magnetic nanoparticles from a solvent of the dispersion so as to allow self-assembly of the magnetic nanoparticles, and removing a coating from the nanoparticles, which are disposed in a self-assembled, locally-ordered nanostructure.
    Type: Application
    Filed: January 13, 2003
    Publication date: July 15, 2004
    Applicant: International Business Machines Corporation
    Inventors: Shouheng Sun, Hao Zeng
  • Publication number: 20040134566
    Abstract: A manufacturing method of a soft magnetic green compact includes mixing a magnetic powder including an iron system powder and a mixed powder including a resin powder, compressively molding the magnetic powder and the mixed powder in a mold by a powder metallurgic method in a mold to form a green compact, and applying thermal treatment to the green compact. The resin powder includes a lubrication function and a binding function. A composition amount of the resin powder assumes 0.10-3.00 weight percent relative to the total weight before the molding and assumes 0.01-0.
    Type: Application
    Filed: October 21, 2003
    Publication date: July 15, 2004
    Applicant: AISIN SEIKI KABUSHIKI KAISHA
    Inventors: Yoshiharu Iyoda, Naoki Kamiya, Ichiro Arita, Kota Maruyama
  • Publication number: 20040099341
    Abstract: Disclosed herein is a magnetic powder which can provide magnets having excellent magnetic properties and having excellent reliability especially excellent heat stability. The magnetic powder is composed of an alloy composition represented by Rx(Fe1-aCOa)100-x-y-zByMz(where R is at least one kind of rare-earth element excepting Dy, M is at least one kind of element selected from Ti, Cr, Nb, V, Mo, Hf, W, Mn, Zr and Dy, x is 7.1-9.9 at %, y is 4.6-8.0 at %, z is 0.1-3.0 at %, and a is 0-0.
    Type: Application
    Filed: November 21, 2003
    Publication date: May 27, 2004
    Inventors: Akira Arai, Hiroshi Kato
  • Publication number: 20040084112
    Abstract: Ferromagnetic particles with a high-temperature and thermally stable insulating coating are described. The ferromagnetic particles are first coated with a thin layer of a high permeability metal (nickel) by an electroless plating process. The deposited metal layer is then oxidized by controlling the time and temperature while heating the coated particles in an oxygen atmosphere. This process develops a thin and uniform layer of metal oxide on the ferromagnetic particles. The controlled oxidation of the coating helps encapsulate the particles with a thermally stable and electrically non-conducting layer. These particles can then be compacted and then annealed above 500 degrees Celsius to relieve the stresses introduced in the shaping, thereby obtaining articles with a high permeability and low magnetic loss.
    Type: Application
    Filed: November 5, 2002
    Publication date: May 6, 2004
    Applicant: General Electric Company
    Inventors: Amitabh Verma, Luana Emiliana Iorio, K. Anand, Srinidhi Sampath, Kanchan Kumari, Geetha Karavoor
  • Publication number: 20040074564
    Abstract: Inductive component (10; 20; 30) having at least one coil (12; 22; 32) and a magnetically soft core (11; 21; 31) made from a ferromagnetic powder composite in which the ferromagnetic powder composite shows an alloy powder mixture made from alloy powders having formanisotropic as well as formisotropic powder particles and a casting resin.
    Type: Application
    Filed: November 7, 2003
    Publication date: April 22, 2004
    Inventor: Markus Brunner
  • Patent number: 6720094
    Abstract: Secondary agglomerates of magnetic metal particles containing primary particles having an average major axial diameter of 0.05 to 0.25 &mgr;m, said secondary agglomerates having an average particle diameter of 300 to 800 &mgr;m, an upper limit of particle diameter of 2,000 &mgr;m and a repose angle of 38 to 45°. The secondary agglomerates exhibit not only excellent handing property due to high storage efficiency, high transport efficiency and good flowability thereof, but also excellent kneading property when kneaded with various binder resins and organic solvents in a kneader, and excellent dilution-dispersibility when diluted with an additional amount of the organic solvent, upon the production of coating-type magnetic recording media, so as to more improve a surface smoothness and squareness of a magnetic coating film obtained therefrom, and a process for producing such secondary agglomerates of magnetic metal particles for magnetic recording.
    Type: Grant
    Filed: June 12, 2001
    Date of Patent: April 13, 2004
    Assignee: Toda Kogyo Corporation
    Inventors: Kenji Okinaka, Masayuki Uegami
  • Patent number: 6709533
    Abstract: This invention aims to provide a manufacturing method of an anisotropic magnet powder from which a bonded magnet with an improved loss of magnetization due to structural changes can be achieved. This is achieved by employing a low-temperature hydrogenation process, high-temperature hydrogenation process and the first evacuation process to an RFeB material (R: rare earth element) to manufacture a hydride powder (RFeBHx); the obtained RFeBHx powder (the precursory anisotropic magnet powder) is subsequently blended with a diffusion powder composed of hydride of dysprosium or the like and a diffusion heat-treatment process and a dehydrogenation process are employed. Through this series of processes, an anisotropic magnet powder with a great coercivity and a great degree of anisotropy can be achieved.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: March 23, 2004
    Assignee: Aichi Steel Corporation
    Inventors: Yoshinobu Honkura, Norihiko Hamada, Chisato Mishima
  • Publication number: 20040050454
    Abstract: A blended powder including a first powder containing an R2T14B phase as a main phase, and a second powder containing an R2T17 phase at 25 wt % or more of the whole is prepared. Herein, R is at least one element selected from the group consisting of all rare-earth elements and Y (yttrium), T is at least one element selected from the group consisting of all transition elements, and Q is at least one element selected from the group consisting of B (boron) and C (carbon). The blended powder is sintered, so as to manufacture a permanent magnet having a structure in which a rare-earth element included in the second powder is concentrated in a grain surgace region of a main phase.
    Type: Application
    Filed: July 30, 2003
    Publication date: March 18, 2004
    Inventors: Takao Sekino, Yuji Kaneko
  • Publication number: 20040050455
    Abstract: A method of making an alloy powder for an R—Fe—B—type rare earth magnet includes the steps of preparing a material alloy that is to be used for forming the R—Fe—B—type rare earth magnet and that has a chilled structure that constitutes about 2 volume percent to about 20 volume percent of the material alloy, coarsely pulverizing the material alloy for the R—Fe—B—type rare earth magnet by utilizing a hydrogen occlusion phenomenon to obtain a coarsely pulverized powder, finely pulverizing the coarsely pulverized powder and removing at least some of fine powder particles having particle sizes of about 1.0 &mgr;m or less from the finely pulverized powder, thereby reducing the volume fraction of the fine powder particles with the particle sizes of about 1.0 &mgr;m or less, and covering the surface of remaining ones of the powder particles with a lubricant after the step of removing has been performed.
    Type: Application
    Filed: August 21, 2003
    Publication date: March 18, 2004
    Applicant: Sumitomo Special Metals Co., Ltd.
    Inventors: Yuji Kaneko, Junichiro Baba, Katsuya Taniguchi
  • Publication number: 20040020563
    Abstract: A method of making a sintered body for a rare earth magnet includes the steps of (a) preparing a first coarse powder by coarsely pulverizing a rare earth alloy sintered body by a hydrogen pulverization process, (b) preparing a first fine powder by finely pulverizing the first coarse powder, (c) preparing a second fine powder by pulverizing an alloy block of a rare earth alloy material, and (d) sintering a mixed powder including the first and second fine powders. The first and second fine powders each includes a main phase represented by (LR1-xHRx)2T14A, where T is Fe and/or at least one non-Fe transition metal element; A is boron and/or carbon; LR is at least one light rare earth element; HR is at least one heavy rare earth element; and 0≦x<1.
    Type: Application
    Filed: March 20, 2003
    Publication date: February 5, 2004
    Inventors: Koki Tokuhara, Hitoshi Morimoto
  • Patent number: 6682813
    Abstract: Magnetic acicular alloy particles containing iron as a main component according to the present invention, have an average major axial diameter of 0.05 to 0.2 &mgr;m, and pH values of water suspensions of said magnetic acicular alloy particles containing iron as a main component, which satisfies the formula: (pH value of water suspension treated by A method)−(pH value of water suspension treated by B method)<0 Such magnetic acicular alloy particles containing iron as a main component exhibit an excellent dispersibility in a vehicle, especially such a vehicle composed of a binder resin having a polar group such as —SO3M (wherein M is H, Na or K), —COOH or the like, and in which an orientation and a packing density in coating film are improved.
    Type: Grant
    Filed: July 17, 2002
    Date of Patent: January 27, 2004
    Assignee: Toda Kogyo Corporation
    Inventors: Kohji Mori, Yasutaka Ota
  • Patent number: 6676730
    Abstract: The present invention relates to a method of producing Nd—Fe—B based nanophase powder, or more particularly, to a method of producing Nd2Fe14B phase powder of 1 &mgr;m or less, having Nd2Fe14B crystal grains of 50 nm or less, which comprises the following steps of: producing a precursor powder having a mixture of elements of Nd, Fe and B by means of spray-drying a mixed aqueous solution comprising Nd metal salt, Fe metal salt, and boric acid; producing an oxide composite powder by means of desaltation of said powder; reducing the composite oxide powder, and ball-milling of said composite powder comprising Nd oxides and &agr;-Fe; producing a mixed powder of Nd2Fe14B/CaO phase by mixing Ca to said composite powder after milling; and removing CaO by washing said composite powder with water, followed by drying.
    Type: Grant
    Filed: May 23, 2001
    Date of Patent: January 13, 2004
    Assignee: Korea Institute of Machinery and Materials
    Inventors: Byung Kee Kim, Chul Jin Choi, Xing Long Dong
  • Publication number: 20040000356
    Abstract: An apparatus for subjecting a rare earth alloy block to a hydrogenation process includes a casing, gas inlet and outlet ports, a member arranged to produce a gaseous flow, and a windbreak plate. The casing defines an inner space for receiving a container. The container includes an upper opening and stores the rare earth alloy block therein. A hydrogen gas and an inert gas are introduced into the inner space through the gas inlet port, and are exhausted from the inner space through the gas outlet port. The gaseous flow is produced by a fan, for example, in the inner space. The windbreak plate is disposed upstream with respect to the gaseous flow that has been produced inside the inner space. Also, the windbreak plate reduces a flow rate of the gaseous flow that has been produced near the upper opening of the container.
    Type: Application
    Filed: March 20, 2003
    Publication date: January 1, 2004
    Inventors: Akihito Tsujimoto, Katsumi Okayama, Shinji Kidowaki, Tadayoshi Muneto
  • Publication number: 20030230362
    Abstract: 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: Application
    Filed: March 18, 2003
    Publication date: December 18, 2003
    Applicants: 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
  • Publication number: 20030221749
    Abstract: Magnetic materials having a coercivity not less than about 1000 Oersted are prepared in a single step procedure. A molten mixture of a desired composition having a relatively high boron content is cooled at a rate slower than about 105 degrees Celsius per second. Preferably, the molten mixture is cooled by depositing it on a chilled surface such that it forms a layer between about 120 and about 300, and preferably between about 120 and about 150, microns thick.
    Type: Application
    Filed: February 24, 2003
    Publication date: December 4, 2003
    Applicant: Pioneer Metals and Technology, Inc.
    Inventor: John Keem
  • Publication number: 20030213532
    Abstract: A method of manufacturing magnetic powder is disclosed. This method can provide magnetic powder from which a bonded magnet having excellent magnetic properties and reliability can be manufactured. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5. The cooling roll 5 is constructed from a roll base 51 and a circumferential surface 53 in which gas flow passages 54 for expelling gas are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas flow passages 54. The magnetic powder is obtained by milling thus formed melt spun ribbon 8.
    Type: Application
    Filed: February 25, 2003
    Publication date: November 20, 2003
    Inventors: Akira Arai, Hiroshi Kato
  • Publication number: 20030205294
    Abstract: A compact is produced from an alloy powder for R—Fe—B type rare earth magnets including particles having a size in a range of about 2.0 &mgr;m to about 5.0 &mgr;m as measured by a light scattering method using a Fraunhofer forward scattering in a proportion of approximately 45 vol. % or more and particles having a size larger than about 10 &mgr;m in a proportion of less than about 1 vol. %. The compact is then sintered to obtain a R—Fe—B type rare earth magnet having an average crystal grain size in a range of about 5 &mgr;m to about 7.5 &mgr;m, and an oxygen concentration in a range of about 2.2 at. % to about 3.0 at. %.
    Type: Application
    Filed: May 29, 2003
    Publication date: November 6, 2003
    Applicant: Sumitomo Special Metals Co., Ltd.
    Inventors: Shigeru Takaki, Ken Makita
  • Patent number: 6638367
    Abstract: The objects of the present invention are to provide a method of producing highly weather-resistant iron-based magnet powder containing a rare-earth element, particularly characterized by high coercive force in a practically important humid atmosphere, highly weather-resistant magnet powder produced by the same method, resin composition containing the same powder for bonded magnets, and bonded magnet containing the same powder. The present invention provides a method of producing a magnet powder by crushing an iron-based magnet powder containing a rare-earth element in an organic solvent, wherein phosphoric acid is added to the solvent in which the powder is crushed.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: October 28, 2003
    Assignee: Sumitomo Metal Mining Co., Ltd.
    Inventors: Kenji Ohmori, Toshiyuki Osako, Kayo Hashiguchi, Kouichi Yokosawa
  • Publication number: 20030196730
    Abstract: Permanent magnets, devices including permanent magnets and methods for manufacture are described with the permanent magnet comprising, for example: iron-boron-rare earth alloy particulate having an intrinsic coercive force of at least about 1591 kiloamperes/meter (about 20 kiloOersteds) and a residual magnetization of at least about 0.8 tesla (about 8 kiloGauss), wherein the rare earth content comprises praseodymium, a light rare earth element selected from the group consisting of cerium, lanthanum, yttrium and mixtures thereof, and balance neodymium; and a binder bonding the particulate.
    Type: Application
    Filed: May 12, 2003
    Publication date: October 23, 2003
    Inventors: Ralph James Carl, Gerald Burt Kliman, Juliana Chiang Shei, Mark Gilbert Benz, Judson Sloan Marte
  • Patent number: 6635120
    Abstract: A sintered rare earth magnet is produced by finely pulverizing a coarse rare earth magnet alloy powder to an average particle size of 1-10 &mgr;m in a non-oxidizing atmosphere; introducing the resultant fine rare earth magnet alloy powder into a non-oxidizing liquid comprising at least one oil selected from the group consisting of mineral oils, synthetic oils and vegetable oils, and at least one lubricant selected from the group consisting of esters of aliphatic acids and monovalent alcohols, esters of polybasic acids and monovalent alcohols, esters of aliphatic acids and polyvalent alcohols and their derivatives to prepare a slurry; molding the slurry; degreasing the resultant green body; sintering the degreased green body; and then heat-treating the green body.
    Type: Grant
    Filed: September 14, 2001
    Date of Patent: October 21, 2003
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hisato Tokoro, Kimio Uchida
  • Publication number: 20030178103
    Abstract: A method for producing rare earth sintered magnets includes the steps of pressing and compacting an alloy powder for the rare earth sintered magnets, thereby preparing a plurality of green compacts, arranging the green compacts on a receiving plane in a direction in which a projection area of each of the green compacts onto the receiving plane is not maximized, and heating the green compacts, thereby sintering the green compacts and obtaining a plurality of sintered bodies.
    Type: Application
    Filed: March 21, 2003
    Publication date: September 25, 2003
    Inventors: Daisuke Harimoto, Yuji Kaneko, Akira Nakamura
  • Publication number: 20030172996
    Abstract: 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: Application
    Filed: March 5, 2003
    Publication date: September 18, 2003
    Inventors: Kazuyuki Matsumoto, Kimitaka Sato, Takatoshi Fujino, Kenichi Inoue
  • Publication number: 20030172997
    Abstract: Disclosed herein is a method of manufacturing a magnetic material which can provide a bonded magnet having excellent magnetic properties and having excellent reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 in which gas expelling grooves 54 are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 6 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas expelling grooves 54.
    Type: Application
    Filed: March 10, 2003
    Publication date: September 18, 2003
    Inventors: Akira Arai, Hiroshi Kato
  • Patent number: 6610415
    Abstract: Thin, flexible composite materials, which are magnetic or magnetizable and processes for producing and using the materials. The composite material contains a laminate formed from a mixture of magnetic or magnetizable particles, binder particles (and optionally active particles), applied to and fused and/or coalesced with a first substrate. The composite preferably contains an additional second substrate fused to and/or coalesced with, the laminate on the side of the laminate opposite that of the first substrate.
    Type: Grant
    Filed: October 26, 2001
    Date of Patent: August 26, 2003
    Assignee: Koslow Technologies Corporation
    Inventor: Evan E. Koslow
  • Publication number: 20030150523
    Abstract: A powder core is obtained by compaction-forming magnetic powder. The magnetic powder is an alloy comprising 1-10 wt % Si, 0.1-1.0 wt % O, and balance Fe. An insulator comprising SiO2 and MgO as main components is interposed between powder particles having a particle size of 150 &mgr;m or less.
    Type: Application
    Filed: January 17, 2002
    Publication date: August 14, 2003
    Applicant: NEC TOKIN CORPORATION
    Inventors: Teruhiko Fujiwara, Masayoshi Ishii, Yoshitaka Saito
  • Patent number: 6599465
    Abstract: According to the inventive method for producing a composite part (4), a support body (1) is produced from a powder with a ferrous alloy base using powder metallurgy. A magnet body (2) which is based on an alloy that is rich in rare earths is applied to the support body (1) and both are then sintered in a furnace (1), whereby a solid joint is formed between the support body (1) and the magnet body (2).
    Type: Grant
    Filed: December 21, 2001
    Date of Patent: July 29, 2003
    Assignee: Vacuumschemlze GmbH
    Inventors: Georg-Werner Reppel, Volker Zellmann
  • Publication number: 20030136469
    Abstract: Permanent magnets in which the ferromagnetic phase is matched with the grain boundary phase, and permanent magnets in which magnetocrystalline anisotropy in the vicinity of the outermost shell of the major phase is equivalent in intensity to that in the inside to suppress nucleation of the reverse magnetic domain, more specifically having a magnetocrystalline anisotropy not less than one-half the magnetocrystalline anisotropy of the interiors of the ferromagnetic grains, are disclosed.
    Type: Application
    Filed: September 27, 2002
    Publication date: July 24, 2003
    Applicant: Sumitomo Special Metals Co., Ltd.
    Inventors: Ken Makita, Osamu Yamashita
  • Patent number: 6591483
    Abstract: A method is provided for depositing a spatially fine pattern of magnets on a substrate. The substrate can be fabricated from any number of materials, such as plastics, metals or ceramics. When sufficiently magnetized, the magnets will provide a magnetic field that can be sensed by a magnetic proximity sensor, to determine the position of the magnets. The magnets can be arranged in a plurality of patterns, including radial or linear arrangements. The ability to arrange these magnets in varying patterns provides a wide capability of magnetic sensing applications.
    Type: Grant
    Filed: April 4, 2000
    Date of Patent: July 15, 2003
    Assignee: The Cherry Corporation
    Inventor: Nicholas W. Kay
  • Publication number: 20030118467
    Abstract: A radial anisotropic sintered magnet formed into a cylindrical shape includes a portion oriented in directions tilted at an angle of 30° or more from radial directions, the portion being contained in the magnet at a volume ratio in a range of 2% or more and 50% or less, and a portion oriented in radial directions or in directions tilted at an angle less than 30° from radial directions, the portion being the rest of the total volume of the magnet. The radial anisotropic sintered magnet has excellent magnet characteristics without occurrence of cracks in the steps of sintering and cooling for aging, even if the magnet has a shape of a small ratio between an inner diameter and an outer diameter.
    Type: Application
    Filed: October 31, 2002
    Publication date: June 26, 2003
    Inventors: Koji Sato, Mitsuo Kawabata, Takehisa Minowa