Boron Containing Patents (Class 148/302)
  • Patent number: 11823824
    Abstract: The present disclosure includes a main phase comprising an R2T14B compound, and a grain boundary phase. The atom number ratio of B to T in this R-T-B sintered magnet is less than the atom number ratio of B to T in the stoichiometric composition of the R2T14B compound, and the relationships 26.0 mass %?([Nd]+[Pr]+[Ce]+[Dy]+[Tb])?(9×[O]+12×[C])?27.5 mass %, 0.15 mass %?[O]?0.30 mass %, and 0.05 mass %<[Tb]?0.35 mass % are satisfied, where [Nd] is the Nd content (mass %), [Pr] is the Pr content (mass %), [Ce] is the Ce content (mass %), [Dy] is the Dy content (mass %), [O] is the O content (mass %), and [C] is the C content (mass %). Tb concentration and/or the Dy concentration gradually decreases from the magnet surface toward the magnet interior, at least in part.
    Type: Grant
    Filed: September 17, 2021
    Date of Patent: November 21, 2023
    Assignee: PROTERIAL, LTD.
    Inventor: Futoshi Kuniyoshi
  • Patent number: 11783974
    Abstract: A soft magnetic alloy comprising a main component having a compositional formula of ((Fe(1?(?+?))X1?X2?)(1?(a+b+c))MaBbCrc)1?dCd, and a sub component including P, S and Ti, wherein X1 is selected from the group Co and Ni, X2 is selected from the group Al, Mn, Ag, Zn, Sn, As, Sb, Bi and rare earth elements, “M” is selected from the group Nb, Hf, Zr, Ta, Mo, W and V, 0.030?a?0.14, 0.005?b?0.20, 0<c?0.040, 0?d?0.040, ??0, ??0, and 0??+??0.50 are satisfied, when soft magnetic alloy is 100 wt %, P is 0.001 to 0.050 wt %, S is 0.001 to 0.050 wt %, and Ti is 0.001 to 0.080 wt %, and when a value obtained by dividing P by S is P/S, then P/S satisfies 0.10?P/S?10.
    Type: Grant
    Filed: January 26, 2018
    Date of Patent: October 10, 2023
    Assignee: TDK CORPORATION
    Inventors: Akihiro Harada, Hiroyuki Matsumoto, Kenji Horino, Kazuhiro Yoshidome, Akito Hasegawa, Hajime Amano, Kensuke Ara, Seigo Tokoro
  • Patent number: 11783973
    Abstract: An R-T-B based permanent magnet in which R is a rare earth element, T is Fe or a combination of Fe and Co, B is boron, and further includes M. The R-T-B based permanent magnet includes main phase grains consisting of R2T14B phase. M at least includes Ga and Zr. The R-T-B based permanent magnet further includes C and O. R content is 29.0 mass % to 33.0 mass %, B content is 0.85 mass % to 1.05 mass %, Ga content is 0.30 mass % to 1.20 mass %, 0 content is 0.03 mass % to 0.20 mass %, and C content is 0.03 mass % to 0.30 mass %. Further, the R-T-B based permanent magnet satisfies 3.48m(B)?2.67?m(Zr)?3.48m(B)?1.87 in which m(B) (mass %) is B content and m(Zr) (mass %) is Zr content.
    Type: Grant
    Filed: March 4, 2019
    Date of Patent: October 10, 2023
    Assignee: TDK CORPORATION
    Inventors: Hidetake Kitaoka, Makoto Iwasaki
  • Patent number: 11676748
    Abstract: A method of producing anisotropic magnetic powders comprising obtaining a precipitate containing an element R, iron and lanthanum from a solution including R, iron and lanthanum, wherein R is at least one selected from the group consisting of Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm and Lu; obtaining an oxide containing R, iron and lanthanum from the precipitate; treating the oxide with a reducing gas to obtain a partial oxide; obtaining alloy particles by reduction diffusion of the partial oxide at a temperature in the range of 920° C. to 1200° C.; and nitriding the alloy particles to produce an anisotropic magnetic powder represented by the following general formula: Rv-xFe(100-v-w-z)NwLaxWz, where 3?v?x?30, 5?w?15, 0.08?x?0.3, and 0?z?2.5.
    Type: Grant
    Filed: December 22, 2016
    Date of Patent: June 13, 2023
    Assignee: NICHIA CORPORATION
    Inventor: Hisashi Maehara
  • Patent number: 11491545
    Abstract: A method of preparing magnetic powder includes preparing iron powder by a reduction reaction of iron oxide; preparing magnetic powder by heat-treating a molded article prepared by pressure-molding a mixture containing the iron powder, neodymium oxide, boron and calcium at a pressure of 22 MPa or more; and coating an organic fluoride on a surface of the magnetic powder.
    Type: Grant
    Filed: August 14, 2019
    Date of Patent: November 8, 2022
    Inventors: Ikjin Choi, Soon Jae Kwon, Ingyu Kim, Hyounsoo Uh
  • Patent number: 11410804
    Abstract: A permanent magnet 2 includes Nd, Fe, and B, the permanent magnet 2 contains a plurality of main phase grains; and grain boundaries positioned between the main phase grains, the main phase grains include Nd, Fe, and B, at least a portion of the grain boundaries contains an R?—O—C phase, the R?—O—C phase includes a rare earth element R?, O, and C, the concentration of each of R?, O, and C in the R?—O—C phase is higher compared to the main phase grains, the permanent magnet 2 comprises a surface layer portion 21 and a central portion 22, the surface layer portion 21 is positioned on the surface side of the permanent magnet 2, the central portion 22 is positioned on the inner side of the permanent magnet 2, the proportion of the area of the R?—O—C phase occupying in a cross-section of the surface layer portion 21 is S1 %, the proportion of the area of the R?—O—C phase occupying in a cross-section of the central portion 22 is S2%, and S1 is higher than S2.
    Type: Grant
    Filed: March 14, 2020
    Date of Patent: August 9, 2022
    Assignee: TDK Corporation
    Inventor: Masashi Miwa
  • Patent number: 11309485
    Abstract: A magnetostrictive material includes a FeGaSm alloy that is represented by Expression (1), Fe(100-x-y)GaxSmy??(1) (in Expression (1), x and y are respectively a content rate (at. %) of Ga and a content rate (at. %) of Sm, and satisfy that y?0.35x?4.2, y??x+20.1, and y??0.1x+2.1).
    Type: Grant
    Filed: February 13, 2019
    Date of Patent: April 19, 2022
    Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.
    Inventors: Takehiro Tanaka, Kazuki Sakai, Taichi Nakamura, Ryou Kuwabara
  • Patent number: 11174537
    Abstract: A sintered R-T-B based magnet includes a main phase crystal grain and a grain boundary phase, in which R: not less than 27.5 mass % and not more than 35.0 mass % (R always includes at least Nd and Pr); B: not less than 0.80 mass % and not more than 1.05 mass %; Ga: not less than 0.05 mass % and not more than 1.0 mass %; M: not more than 2 mass % (where M is at least one of Cu, Al, Nb, and Zr); and a balance T (where T is Fe, or Fe and Co) and impurities. At 300-?m depth from the magnet surface, a Pr/Nd ratio in a central portion of a main phase crystal grain is lower than 1, and a Pr/Nd ratio in an intergranular grain boundary is higher than 1. The Ga concentration gradually decreases in a portion of the magnet from the surface toward the interior.
    Type: Grant
    Filed: August 14, 2017
    Date of Patent: November 16, 2021
    Assignee: HITACHI METALS, LTD.
    Inventor: Futoshi Kuniyoshi
  • Patent number: 11177069
    Abstract: A sintered R-T-B based magnet work contains R: 27.5 to 35.0 mass % (R is at least one rare-earth element which always includes Nd), B: 0.80 to 0.99 mass %, Ga: 0 to 0.8 mass %, M: 0 to 2 mass % (M is at least one of Cu, Al, Nb and Zr), and a balance T (T is at least one transition metal element which always includes Fe, with 10% or less of Fe replaceable by Co). [T]/55.85>14[B]/10.8 is satisfied where [T] is the T content (mass %) and [B] is the B content (mass %). At least a portion of a Pr—Ga alloy is in contact with a portion of the sintered magnet work surface, and a first heat treatment is performed at a temperature between 600° C. and 950° C. A second heat treatment is performed at a temperature lower than the temperature of the first heat treatment and between 450° C. and 750° C.
    Type: Grant
    Filed: July 20, 2016
    Date of Patent: November 16, 2021
    Assignee: HITACHI METALS, LTD.
    Inventor: Futoshi Kuniyoshi
  • Patent number: 11104982
    Abstract: An Fe-based nanocrystalline alloy is represented by Composition Formula, (Fe(1-a)M1a)100-b-c-d-e-gM2bBcPdCueM3g, where M1 is at least one element selected from Co and Ni, M2 is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, and Mn, M3 is at least one element selected from the group consisting of C, Si, Al, Ga, and Ge, and 0?a?0.5, 2?b?3, 9?c?11, 1?d?2, 0.6?e?1.5, and 9?g?11.
    Type: Grant
    Filed: June 14, 2018
    Date of Patent: August 31, 2021
    Assignee: SAMSUNG ELECTRO-MECHANICS CO., LTD.
    Inventors: Sang Kyun Kwon, Han Wool Ryu, Chang Ryul Jung, Jong Ho Chung, Jong Suk Jeong, Chui Min Sim
  • Patent number: 11065685
    Abstract: A slinger, or slinger ring, for a melt spinning apparatus has a cylindrical, mechanically shaped main element that is composed of a refractory metal or a refractory metal-based alloy and has a circumferential surface running in a tangential direction. The circumferential surface is delimited in the axial direction by two end faces. A degree of deformation in the radial direction is greater than the degree of deformation in the axial direction.
    Type: Grant
    Filed: June 12, 2018
    Date of Patent: July 20, 2021
    Assignee: Plansee SE
    Inventors: Thomas Huber, Katrin Knittl, Wolfram Knabl, Wolfgang Simader
  • Patent number: 11062827
    Abstract: A method of making a rare earth magnet containing zero heavy rare earth elements includes a step of mixing the fine grain powder with the lubricant having a weight content of at least 0.03 wt. % and no greater than 0.2 wt. % for a period of between 1 and 2 hours. The step of pulverizing is further defined as jet milling the alloy powder with the lubricant using a carrier gas of argon or nitrogen. The method further includes a step of controlling oxygen content during the steps of melting, forming, disintegrating, mixing, pulverizing, molding, and sintering whereby the impurities including Carbon (C), Oxygen (O), and Nitrogen (N) satisfies 1.2C+0.6O+N?2800 ppm. A rare earth magnet composition including C, O, and N whereby C, O, and N satisfies 1.2C+0.6O+N?2800 ppm and has zero heavy rare earth elements.
    Type: Grant
    Filed: January 9, 2017
    Date of Patent: July 13, 2021
    Assignee: YANTAI SHOUGANG MAGNETIC MATERIALS INC.
    Inventors: Kaihong Ding, Zhongjie Peng, Guohai Wang, Xiulei Chen
  • Patent number: 11024448
    Abstract: An alloy for R-T-B-based rare earth sintered magnets which contains R which is a rare earth element; T which is a transition metal essentially containing Fe; a metallic element M containing one or more metals selected from Al, Ga and Cu; B and inevitable impurities, in which R accounts for 13 at % to 15 at %, B accounts for 4.5 at % to 6.2 at %, M accounts for 0.1 at % to 2.4 at %, T accounts for balance, a proportion of Dy in all rare earth elements is in a range of 0 at % to 65 at %, and the following Formula 1 is satisfied, 0.0049Dy+0.34?B/TRE?0.0049Dy+0.36??Formula 1 wherein Dy represents a concentration (at %) of a Dy element, B represents a concentration (at %) of a boron element, and TRE represents a concentration (at %) of all the rare earth elements.
    Type: Grant
    Filed: July 25, 2016
    Date of Patent: June 1, 2021
    Assignee: TDK CORPORATION
    Inventors: Kenichiro Nakajima, Takashi Yamazaki
  • Patent number: 11007677
    Abstract: A mold for forming a wind turbine blade comprising first and second mold surfaces including a flange portion having an opening therein, wherein the first and second mold surfaces are configured for relative movement therebetween from an open position to a closed position. The opening of the first flange portion is aligned with the opening of the second flange portion when in the closed position, and a first magnet is disposed within the opening in the opening of the first mold surface, and a second magnet is disposed within the opening of the second mold surface.
    Type: Grant
    Filed: August 8, 2018
    Date of Patent: May 18, 2021
    Assignee: TPI Composites, Inc.
    Inventors: Jim Hannan, Andrew McDonald
  • Patent number: 10978226
    Abstract: A sintered Nd—Fe—B magnet comprising at least one light rare earth element having a weight content between 31 wt. % and 35 wt. %, at least one heavy rare earth element having a weight content of no more than 0.2 wt. %, B having a weight content between 0.95 wt. % and 1.2 wt. %, at least one additive including Ti and having a weight content between 1.31 wt. % and 7.2 wt. %, Fe as a balance, and impurities including C, O, and N. Ti has a weight content between 0.3 wt. % and 1 wt. % and forms a Titanium-Iron-Boron phase with Fe and Boron B and being present in the sintered Nd—Fe—B magnet between 0.86 vol. % and 2.85 vol. %. The C, O, and N satisfy 630 ppm?1.2C+0.6O+N?3680 ppm. The sintered Nd—Fe—B magnet has a squareness factor of at least 0.95.
    Type: Grant
    Filed: May 5, 2017
    Date of Patent: April 13, 2021
    Assignee: YANTAI SHOUGANG MAGNETIC MATERIALS INC.
    Inventors: Kaihong Ding, Zhongjie Peng, Guohai Wang, Xiulei Chen
  • Patent number: 10971289
    Abstract: Disclosed in the present invention is a composite R—Fe—B based rare-earth sintered magnet comprising Pr and W, wherein the rare-earth sintered magnet comprises an R2Fe14B type main phase, and R is a rare-earth element comprising at least Pr, wherein the raw material components therein comprise more than or equal to 2 wt % of Pr and 0.0005 wt %-0.03 wt % of W; and the rare-earth sintered magnet is made through a process comprising the following steps: preparing molten liquid of the raw material components into a rapidly quenched alloy; grinding the rapidly quenched alloy into fine powder; obtaining a shaped body from the fine powder by using a magnetic field; and sintering the shaped body. By adding a trace amount of W into the rare-earth sintered magnet, the heat resistance and thermal demagnetization performance of the Pr-containing magnet are improved.
    Type: Grant
    Filed: September 23, 2016
    Date of Patent: April 6, 2021
    Assignees: XIAMEN TUNGSTEN CO., LTD., Fujian Changting Golden Dragon Rare-Earth Co., Ltd
    Inventor: Hiroshi Nagata
  • Patent number: 10964464
    Abstract: The present invention aims to provide a novel magnet, whose surface's insulating property can be increased, and a motor using the same. The present invention provides a magnet comprising a magnet element containing a rare earth element R, a transition metal element T and boron B, and a phosphate layer including manganese-containing phosphate, wherein the phosphate layer is provided on the surface of the magnet element, and the thickness of the phosphate layer is 0.5 ?m or more.
    Type: Grant
    Filed: November 19, 2018
    Date of Patent: March 30, 2021
    Assignee: TDK CORPORATION
    Inventor: Nobuo Takagi
  • Patent number: 10950373
    Abstract: An R-TM-B hot-pressed and deformed magnet (here, R represents a rare earth metal selected from the group consisting of Nd, Dy, Pr, Tb, Ho, Sm, Sc, Y, La, Ce, Pm, Eu, Gd, Er, Tm, Yb, Lu, and a combination thereof, and TM represents a transition metal) of the present invention comprises flat type anisotropic magnetized crystal grains and a nonmagnetic alloy distributed in a boundary surface between the crystal grains, and thus the magnet of the present invention has an excellent magnetic shielding effect as compared with an existing permanent magnet since the crystal gains can be completely enclosed in the nonmagnetic alloy, so that a hot-pressed and deformed magnet with enhanced coercive force can be manufactured through a more economical process.
    Type: Grant
    Filed: December 8, 2014
    Date of Patent: March 16, 2021
    Assignee: LG ELECTRONICS INC.
    Inventors: Seok Namkung, Deokhai Park, Namseok Kang
  • Patent number: 10892076
    Abstract: A rare earth magnet includes a main phase, a grain boundary phase present around the main phase and an intermediate phase interposed between the main phase and the grain boundary phase, and has an overall composition that is represented by the formula ((Ce(1-x)Lax)(1-y)R1y)pT(100-p-q-r)BqM1r?(R21-zM2z)s (where, R1 and R2 are rare earth elements other than Ce and La, T is at least one selected from among Fe, Ni, and Co, M1 is an element having a small amount that does not influence magnetic characteristics, and M2 is an alloy element for which a melting point of R21-zM2z is lower than a melting point of R2). A total concentration of Ce and La is higher in the main phase than in the intermediate phase, and a concentration of R2 is higher in the intermediate phase than in the main phase.
    Type: Grant
    Filed: December 5, 2017
    Date of Patent: January 12, 2021
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Masaaki Ito, Noritsugu Sakuma, Tetsuya Shoji, Hidefumi Kishimoto, Masao Yano
  • Patent number: 10825592
    Abstract: It is an object of the present disclosure to produce a soft magnetic material having high saturation magnetization by heat-treating a Fe-based amorphous alloy, without needing the control of the atmosphere. The present disclosure provides a method for producing a soft magnetic material, including heat treating a Fe-based amorphous alloy in a state in which the alloy is wrapped with a sheet comprising one or more substances having a standard Gibbs energy of formation of an oxide thereof that is larger in a negative direction than Fe, to form a crystal phase.
    Type: Grant
    Filed: November 13, 2018
    Date of Patent: November 3, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Kiyotaka Onodera
  • Patent number: 10672546
    Abstract: An R-T-B based permanent magnet includes main phase grains composed of R2T14B type compound. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. The magnet contains at least C, Ga, and M selected from Zr, Ti, and Nb in addition to R, T, and B. B is contained at 0.71 mass % to 0.88 mass %. C is contained at 0.15 mass % to 0.34 mass %. Ga is contained at 0.40 mass % to 1.40 mass %. M is contained at 0.25 mass % to 2.50 mass %. A formula (1) of 0.14?[C]/([B]+[C])?0.30 and a formula (2) of 5.0?[B]+[C]?[M]?5.6 are satisfied, where [B], [C], and [M] are respectively a content of B, C, and M by atom %.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: June 2, 2020
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Takurou Iwasa, Tamotsu Ishiyama
  • Patent number: 10614938
    Abstract: The present invention discloses a W-containing R—Fe—B—Cu serial sintered magnet and quenching alloy. The sintered magnet contains an R2Fe14B-type main phase, the R being at least one rare earth element comprising Nd or Pr; the crystal grain boundary of the rare earth magnet contains a W-rich area above 0.004 at % and below 0.26 at %, and the W-rich area accounts for 2.0 vol %˜11.0 vol % of the sintered magnet. The sintered magnet uses a minor amount of W pinning crystal to segregate the migration of the pinned grain boundary in the crystal grain boundary to effectively prevent abnormal grain growth and obtain significant improvement. The crystal grain boundary of the quenching alloy contains a W-rich area above 0.004 at % and below 0.26 at %, and the W-rich area accounts for at least 50 vol % of the crystal grain boundary.
    Type: Grant
    Filed: May 13, 2019
    Date of Patent: April 7, 2020
    Assignees: XIAMEN TUNGSTEN CO., LTD., Fujian Changting Golden Dragon Rare-Earth Co., Ltd
    Inventors: Hiroshi Nagata, Rong Yu, Qin Lan
  • Patent number: 10604406
    Abstract: A magnet core has a linear B-H loop, a high modulability with alternating current and direct current, a relative permeability of more than 500 but less than 15,000, and a saturation magnetostriction ?s of less than 15 ppm, and is made of a ferromagnetic alloy, at least 50 percent of which consist of fine crystalline parts having an average particle size of 100 nm or less (nanocrystalline alloy) and which is characterized by formula FeaCobNicCudMeSifBgXh, wherein M represents at least one of the elements V, Nb, Ta, Ti, Mo, W, Zr, Cr, Mn, and Hf, a, b, c, d, e, f, g are indicated in atomic percent, X represents the elements P, Ge, C and commercially available impurities, and a, b, c, d, e, f, g, h satisfy the following conditions: 0<=b<=40; 2<c<20; 0.5<=d<=2; 1<=e<=6; 6.5<=f<=18; 5<=g<=14; h<5 atomic percent; 5<=b+c<=45, and a+b+c+d+e+f+g+h=100.
    Type: Grant
    Filed: September 27, 2005
    Date of Patent: March 31, 2020
    Assignee: VACUUMSCHMELZE GMBH & CO. KG
    Inventors: Giselher Herzer, Detlef Otte
  • Patent number: 10529474
    Abstract: To provide a permanent magnet which uses Ce of an abundant resource and has a great magnetic anisotropy in rare earth permanent magnets. To obtain a permanent magnet having a high magnetic anisotropy due to the trivalent Ce state by setting the abundance ratio C3/(C3+C4) in the main phase grains to be 0.1?C3/(C3+C4)?0.5 where C3 denotes the number of trivalent Ce atoms and C4 denotes the number of tetravalent Ce atoms.
    Type: Grant
    Filed: March 10, 2015
    Date of Patent: January 7, 2020
    Assignee: TDK CORPORATION
    Inventors: Shogo Kadota, Kenichi Suzuki, Yuji Umeda, Ryuji Hashimoto, Keiji Takeda
  • Patent number: 10529473
    Abstract: An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 ?m or more and 2.8 ?m or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: January 7, 2020
    Assignee: TDK CORPORATION
    Inventors: Takurou Iwasa, Masashi Miwa
  • Patent number: 10515747
    Abstract: The invention provides an R—Fe—B sintered magnet consisting essentially of 12-17 at % of Nd, Pr and R, 0.1-3 at % of M1, 0.05-0.5 at % of M2, 4.8+2*m to 5.9+2*m at % of B, and the balance of Fe, containing R2(Fe,(Co))14B intermetallic compound as a main phase, and having a core/shell structure that the main phase is covered with a grain boundary phases. The sintered magnet has an average grain size of less than 6 ?m, a crystal orientation of more than 98%, and a degree of magnetization of more than 96%, and exhibits a coercivity of at least 10 kOe despite a low or nil content of Dy, Tb, and Ho.
    Type: Grant
    Filed: March 31, 2016
    Date of Patent: December 24, 2019
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Koichi Hirota, Hiroaki Nagata, Tetsuya Kume, Hajime Nakamura
  • Patent number: 10490324
    Abstract: In an alloy for an R-T-B-based rare earth sintered magnet of the present invention formed of a rare earth element R, a transition metal T containing Fe as a main component, a metal element M containing one or more types of metals selected from Al, Ga, and Cu, and B and inevitable impurities, 13 at % to 16 at % of R is contained, 4.5 at % to 6.2 at % of B is contained, 0.1 at % to 2.4 at % of M is contained, the balance is T and the inevitable impurities, a proportion of Dy in the entire rare earth element is 0 at % to 65 at %, Formula 1 described below is satisfied, a main phase containing R2Fe14B and an alloy grain boundary phase containing more R than the main phase are included, and a distance between the alloy grain boundary phases is greater than or equal to 3 ?m and less than or equal to 11 ?m. 0.30?B/TRE?0.
    Type: Grant
    Filed: December 1, 2016
    Date of Patent: November 26, 2019
    Assignee: TDK CORPORATION
    Inventors: Takashi Yamazaki, Kenichiro Nakajima, Akifumi Muraoka
  • Patent number: 10475561
    Abstract: A method for producing an RFeB system magnet with high coercivity by preventing a coating material from peeling off the surface of a base material during a grain boundary diffusion treatment is provided. A method for producing an RL2Fe14B system magnet which is a sintered magnet or a hot-deformed magnet containing, as the main rare-earth element, a light rare-earth element RL which is at least one of the two elements of Nd and Pr, the method including: applying, to a surface of a base material M of the RL2Fe14B system magnet, a coating material prepared by mixing a silicone grease and an RH-containing powder containing a heavy rare-earth element RH composed of at least one element selected from the group of Dy, Tb and Ho; and heating the base material together with the coating material. Improved coating and base materials adhesion facilitates transfer of RH into base material grain boundaries.
    Type: Grant
    Filed: March 13, 2014
    Date of Patent: November 12, 2019
    Assignees: INTERMETALLICS CO., LTD., DAIDO STEEL CO., LTD.
    Inventors: Masato Sagawa, Shinobu Takagi, Hayato Hashino
  • Patent number: 10468168
    Abstract: Disclosed is a Ho and W-containing rare-earth magnet. The rare-earth magnet comprises a R2Fe14B type principal phase, and comprises the following raw material components: R: 28 wt % to 33 wt %, wherein R is a raw-earth element comprising Nd and Ho, and the content of Ho is 0.3 wt % to 5 wt %; B: 0.8 wt % to 1.3 wt %; W: 0.005 wt % to 0.3 wt %, and the balance of T and inevitable purities, wherein T is an element mainly comprising Fe and/or Co. The rare-earth magnet mainly consists of a W-rich grain boundary phase and a Ho-rich principal phase; crystal grain growth of the Ho-containing magnet in a sintering process is constrained by the trace of W, thereby preventing AGG from occurring on the Ho-containing magnet, and obtaining a magnet with high coercivity and high heat resistance.
    Type: Grant
    Filed: April 4, 2016
    Date of Patent: November 5, 2019
    Assignees: XIAMEN TUNGSTEN CO., LTD., FUJIAN CHANGTING GOLDEN DRAGON RARE-EARTH CO., LTD
    Inventors: Hiroshi Nagata, Jianhong Zhang
  • Patent number: 10453595
    Abstract: A rare earth permanent magnet includes a main phase composed of a main phase particle and a grain boundary present among a plurality of the main phase particles. The grain boundary includes a region whose electric resistance is higher than that of the main phase.
    Type: Grant
    Filed: February 27, 2017
    Date of Patent: October 22, 2019
    Assignee: TDK CORPORATION
    Inventors: Tetsuya Hidaka, Yuki Nagamine, Yoshinori Fujikawa
  • Patent number: 10446306
    Abstract: A method for manufacturing an R-T-B based sintered magnet includes: 1) a step of preparing an R-T-B based sintered magnet material by sintering a molded body, the sintered magnet material having a particular composition and satisfying inequality expressions (1) and (2); 2) a high-temperature heat treatment step of heating the sintered magnet material to a heating temperature of 730° C. to 1,020° C. and then cooling the sintered magnet material to 300° C. at a cooling rate of 5° C./min or more; and 3) a low-temperature heat treatment step of heating the sintered magnet material after the high-temperature heat treatment step to 440° C. to 550° C.: [T]?72.3[B]>0??(1) ([T]?72.3[B])/55.85<13[Ga]/69.72??(2) where [T] is a T content in percent by mass, [B] is a B content in percent by mass, and [Ga] is a Ga content in percent by mass.
    Type: Grant
    Filed: August 31, 2015
    Date of Patent: October 15, 2019
    Assignee: HITACHI METALS, LTD.
    Inventors: Teppei Satoh, Futoshi Kuniyoshi, Rintaro Ishii, Ryouichi Yamagata
  • Patent number: 10388440
    Abstract: An R-T-B based sintered magnet includes R2T14B crystal grains. A grain boundary formed by the two or more adjacent R2T14B crystal grains includes an R—N—O—C concentrated part having higher concentrations of “R”, N, O, and C than those in the R2T14B crystal grains. “R” of the R—N—O—C concentrated part includes Y. A ratio of Y atom to “R” atom in the R—N—O—C concentrated part is 0.65 or more and 1.00 or less. A ratio of O atom to “R” atom in the R—N—O—C concentrated part is more than 0 and 0.20 or less. A ratio of N atom to “R” atom in the R—N—O—C concentrated part is 0.03 or more and 0.15 or less.
    Type: Grant
    Filed: November 4, 2016
    Date of Patent: August 20, 2019
    Assignee: TDK CORPORATION
    Inventor: Atsushi Tada
  • Patent number: 10290408
    Abstract: A NdFeB system sintered magnet produced by the grain boundary diffusion method and has a high coercive force and squareness ratio with only a small decrease in the maximum energy product. A NdFeB system sintered magnet having a base material produced by orienting powder of a NdFeB system alloy and sintering the powder, with Dy and/or Tb (the “Dy and/or Tb” is hereinafter called RH) attached to and diffused from a surface of the base material through the grain boundary inside the base material by a grain boundary diffusion treatment, wherein the difference Cgx?Cx between the RH content Cgx (wt %) in the grain boundary and the RH content Cx (wt %) in main-phase grains which are grains constituting the base material at the same depth within a range from the surface to which RH is attached to a depth of 3 mm is equal to or larger than 3 wt %.
    Type: Grant
    Filed: June 22, 2016
    Date of Patent: May 14, 2019
    Assignee: INTERMETALLICS CO., LTD.
    Inventors: Masato Sagawa, Tetsuhiko Mizoguchi
  • Patent number: 10256015
    Abstract: The present invention provides an R-T-B based sintered magnet having excellent corrosion resistance together with good magnetic properties. The R-T-B based sintered magnet contains R2T14B crystal grains, wherein, an R—Ga—Co—Cu—N concentrated part exists in a grain boundary formed between or among two or more adjacent R2T14B crystal grains, and the concentrations of R, Ga, Co, Cu and N in the R—Ga—Co—Cu—N concentrated part are higher than those in the R2T14B crystal grains respectively.
    Type: Grant
    Filed: August 8, 2014
    Date of Patent: April 9, 2019
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Haruna Nakajima, Isao Kanada
  • Patent number: 10242777
    Abstract: Provided is a sintered magnet that is an R-T-B based sintered magnet having a region having a concentration of at least one heavy rare earth element decreasing from the surface toward the inside, in which the at least one heavy rare earth element includes at least either of Tb or Dy, R includes Nd, T includes Fe, Co, and Cu, there is a grain boundary phase containing at least either of Tb or Dy and Nd between two main phase particles, and a value obtained by subtracting a half value width of a concentration distribution curve of Cu from a half value width of a concentration distribution curve of Tb or Dy in a part including the grain boundary phase is from 10 to 20 nm.
    Type: Grant
    Filed: January 31, 2017
    Date of Patent: March 26, 2019
    Assignee: TDK Corporation
    Inventors: Makoto Iwasaki, Tetsuya Hidaka, Takuma Hayakawa, Ayato Kakoki, Yoshinori Fujikawa, Syota Goto, Haruna Nakajima, Takeshi Masuda, Chikara Ishizaka
  • Patent number: 10115507
    Abstract: The present invention discloses a low-B rare earth magnet. The rare earth magnet contains a main phase of R2T14B and comprises the following raw material components: 13.5 at %˜4.5 at % of R, 5.2 at %˜5.8 at % of B, 0.3 at %˜0.8 at % of Cu, 0.3 at %˜3 at % of Co, and the balance being T and inevitable impurities, the R being at least one rare earth element comprising Nd, and the T being an element mainly comprising Fe. 0.3˜0.8 at % of Cu and an appropriate amount of Co are co-added into the rare earth magnet, so that three Cu-rich phases formed in the grain boundary, and the magnetic effect of the three Cu-rich phases existing in the grain boundary and the solution of the problem of insufficient B in the grain boundary can obviously improve the squareness and heat-resistance of the magnet.
    Type: Grant
    Filed: May 26, 2016
    Date of Patent: October 30, 2018
    Assignee: Xiamen Tungsten Co., Ltd.
    Inventors: Hiroshi Nagata, Rong Yu
  • Patent number: 10116174
    Abstract: A synchronous reluctance electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of packets assembled from anisotropic material are disposed in the slots.
    Type: Grant
    Filed: May 4, 2016
    Date of Patent: October 30, 2018
    Assignee: GM Global Technology Operations LLC
    Inventors: Constantin C. Stancu, Peter J. Savagian, Khwaja M. Rahman, Nitinkumar R. Patel, Robert T. Dawsey
  • Patent number: 10115506
    Abstract: A sintered neodymium-iron-boron magnet, the main components thereof comprising rare-earth elements R, additional elements T, iron Fe and boron B, and having a rare-earth-enriched phase and a main phase of a Nd2Fe14B crystal structure. The sum of the numerical values of the maximum magnetic energy product (BH)max in units of MGOe and the intrinsic coercive force Hcj in units of kOe is not less than 70. The manufacturing method of the sintered neodymium-iron-boron magnet comprises alloy smelting, powder making, powder mixing, press forming, sintering and heat treatment procedures. By controlling the component formulation and optimizing the process conditions, the sintered neodymium-iron-boron magnet is enabled to simultaneously have a high maximum magnetic energy product and a high intrinsic coercive force.
    Type: Grant
    Filed: December 24, 2013
    Date of Patent: October 30, 2018
    Assignees: Beijing Zhong Ke San Huan Hi-Tech Co., LTD., Sanvac (Beijing) Magnetics Co., LTD.
    Inventors: Boping Hu, Yugang Zhao, Jin Zhang, Guoan Chen, Xiaolei Rao, E Niu, Zhian Chen, Guoshun Jin, Jingdong Jia
  • Patent number: 10096413
    Abstract: The present invention is provided with a quenched alloy for rare earth magnet and a manufacturing method of rare earth magnet. It comprises an R2T14B main phase, wherein R is selected from at least one rare earth element including Nd. The average grain diameter of the main phase in the brachyaxis direction is in a range of 10˜15 ?m and the average interval of the Nd rich phase is in a range of 1.0˜3.5 ?m. In the fine powder of the above-mentioned quenched alloy, the number of magnet domains of a single grain decreases. Thus, it is easier for external magnetic field orientation to obtain high performance magnet, and the squareness, coercivity and the thermal resistance of the magnet are sufficiently improved.
    Type: Grant
    Filed: July 30, 2015
    Date of Patent: October 9, 2018
    Assignee: XIAMEN TUNGSTEN CO., LTD.
    Inventor: Hiroshi Nagata
  • Patent number: 10049797
    Abstract: The invention discloses a low-neodymium, non-heavy-rare-earth and high-performance magnet and its preparing method, and belongs to technical field of rare earth permanent magnetic material. The magnet has a chemical formula of [(Nd, Pr)100-x(Ce100-yLay)x]aFe100-a-b-cBbTMc, wherein x, y, a, b and c represent mass percents of corresponding elements respectively, 0?x?40%, 0?y?15%, 29?a?30%, 0.5?b?5%, 0.5?c?5%; and TM is one or more selected from Ga, Co, Cu, Nb and Al elements. A series of grades of magnets can be prepared with rapidly solidified strips of only three components. Component proportioning of magnet can also be directly performed by using mixed rare earth, so that the cost increased by further separation and purification of the rare earth is reduced. During the preparation of magnetic powder with a jet mill, an antioxidant lubricant which is composed of alcohol, gasoline and basic synthetic oil is added.
    Type: Grant
    Filed: December 12, 2012
    Date of Patent: August 14, 2018
    Assignee: CENTRAL IRON AND STEEL RESEARCH INSTITUTE
    Inventors: Minggang Zhu, Jingdai Wang, Wei Li, Haibo Feng, Yikun Fang, Yanfeng Li, Mingge Zhou, Xuchao Wang, Shulin Huang
  • Patent number: 10026532
    Abstract: An R-T-B based sintered magnet includes “R”, “T”, and “B”. “R” represents a rare earth element. “T” represents a metal element other than rare earth elements including at least Fe, Cu, Mn, Al, Co, Ga, and Zr. “B” represents boron or boron and carbon. With respect to 100 mass % of a total mass of the R-T-B based sintered magnet, a content of “R” is 28.0 to 31.5 mass %, a content of Cu is 0.04 to 0.50 mass %, a content of Mn is 0.02 to 0.10 mass %, a content of Al is 0.15 to 0.30 mass %, a content of Co is 0.50 to 3.0 mass %, a content of Ga is 0.08 to 0.30 mass %, a content of Zr is 0.10 to 0.25 mass %, and a content of “B” is 0.85 to 1.0 mass %.
    Type: Grant
    Filed: October 4, 2016
    Date of Patent: July 17, 2018
    Assignee: TDK CORPORATION
    Inventors: Tetsuya Hidaka, Takuma Hayakawa, Makoto Iwasaki, Ayato Kakoki
  • Patent number: 10020100
    Abstract: A method is provided for producing an R-T-B based alloy powder. The method includes providing an alloy powder containing 27.5 to 36.0 mass % of R, where R is at least one among the rare-earth elements and always includes at least one of Nd and Pr, 0.85 to 1.05 mass % of B, 0.1 to 2.5 mass % of element M (Al, Ti, V, Cr, Mn, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, In, Sn, Hf, Ta, W, Pb and/or Bi), and a balance T, where T is Fe or is Fe and Co; and pulverizing the powder by introducing the powder and a pulverization gas in a pulverization chamber. The pulverization includes attrition while circulating the alloy powder with a flow of the pulverization gas in the pulverization chamber. The pulverization gas has a gauge pressure of 0.75 MPa or more, and the residence time is 6 minutes or more.
    Type: Grant
    Filed: March 23, 2015
    Date of Patent: July 10, 2018
    Assignee: HITACHI METALS, LTD.
    Inventor: Rintaro Ishii
  • Patent number: 9997284
    Abstract: A sintered magnet of a preferred embodiment has a composition comprising: R (R is a rare earth element that must contain any one of Nd and Pr.): 29.5 to 33.0 mass %; B: 0.7 to 0.95 mass %; Al: 0.03 to 0.6 mass %; Cu: 0.01 to 1.5 mass %; Co: 3.0 mass % or less (provided that 0 mass % is not included.); Ga: 0.1 to 1.0 mass %; C: 0.05 to 0.3 mass %; O: 0.03 to 0.4 mass %; and Fe and other elements: a balance, and wherein a content of heavy rare earth elements in total is 1.0 mass % or less, and wherein the following relations are satisfied: 0.29<[B]/([Nd]+[Pr])<0.40 and 0.07<([Ga]+[C])/[B]<0.60, where [Nd], [Pr], [B], [C] and [Ga] represent the numbers of atoms of Nd, Pr, B, C and Ga, respectively.
    Type: Grant
    Filed: June 21, 2013
    Date of Patent: June 12, 2018
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Atsushi Fujiwara, Eiji Kato, Taeko Tsubokura, Koji Mitake, Chikara Ishizaka
  • Patent number: 9991035
    Abstract: An R-T-B based sintered magnet includes “R”, “T”, and “B”. “R” represents a rare earth element. “T” represents a metal element other than rare earth elements including at least Fe, Cu, Mn, Al, Co, Ga, and Zr. “B” represents boron or boron and carbon. With respect to 100 mass % of a total mass of the R-T-B based sintered magnet, a content of “R” is 28.0 to 31.5 mass %, a content of Cu is 0.04 to 0.50 mass %, a content of Mn is 0.02 to 0.10 mass %, a content of Al is 0.15 to 0.30 mass %, a content of Co is 0.50 to 3.0 mass %, a content of Ga is 0.08 to 0.30 mass %, a content of Zr is 0.10 to 0.25 mass %, and a content of “B” is 0.85 to 1.0 mass %.
    Type: Grant
    Filed: October 4, 2016
    Date of Patent: June 5, 2018
    Assignee: TDK CORPORATION
    Inventors: Tetsuya Hidaka, Takuma Hayakawa, Makoto Iwasaki, Ayato Kakoki
  • Patent number: 9970087
    Abstract: In the present invention, a permanent magnet with excellent temperature properties and magnetic properties which will not significantly deteriorate can be stably prepared, by using a raw alloy for the R-T-B based permanent magnet in which the rare earth element(s) composed of at least one selected from the group consisting of Y, La and Ce is selected as a predetermined amount of the rare earth element R in the R-T-B based permanent magnet and a proper amount of Ca is contained.
    Type: Grant
    Filed: April 14, 2015
    Date of Patent: May 15, 2018
    Assignee: TDK CORPORATION
    Inventors: Ryuji Hashimoto, Yasushi Enokido, Hironori Wada
  • Patent number: 9973026
    Abstract: Disclosed are a soft magnetic alloy and a wireless charging apparatus including the soft magnetic alloy. The soft magnetic alloy has a chemical formula expressed as Fe100-x-yCuxBy (wherein x ranges from 0.1 at % to 1.7 at % and y ranges from 2.3 at % to 9.6 at %). Without adding any expensive alloying element, only iron (Fe), copper (Cu), and boron (B) are used to obtain a nanocrystalline soft magnetic alloy that has a low coercive force and a high saturation magnetic flux density. The nanocrystalline soft magnetic alloy is applied to a wireless power transmitter and a wireless power receiver. Thereby, it is possible to make a shield member thin and increase a power transmission capacity. The soft magnetic alloy is easily processed into a flake form. The soft magnetic alloy processed in this way is applied to the shield member. Thereby, it is possible to increase permeability in a surface direction.
    Type: Grant
    Filed: July 29, 2015
    Date of Patent: May 15, 2018
    Assignee: LG INNOTEK CO., LTD.
    Inventors: Seok Bae, Ji Yeon Song, Won Ha Moon, Sang Won Lee, Jong Hyuk Lee, Soon Young Hyun
  • Patent number: 9953751
    Abstract: A R-T-B based permanent magnet which not only has equivalent magnetic properties as the existing Nd—Fe—B based permanent magnet as well as light mass but also can be suitably used as a magnet for field system of a permanent magnet synchronous rotating machine. The magnet can be obtained in a case where the composition of the compound for forming the main phase is (R1-x(Y1-zLaz)x)2T14B (R is rare earth element(s) consisting of one or more elements of Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, T is one or more transition metal elements with Fe or Fe and Co as essential elements, 0.0<x?0.5 and 0.0<z?0.5), by making the abundance ratio of Y4f/(Y4f+Y4g) satisfies 0.8?Y4f/(Y4f+Y4g)?1.0 when the Y occupying the 4f site of the tetragonal R2T14B structure is denoted as Y4f and the Y occupying the 4g site is denoted as Y4g.
    Type: Grant
    Filed: February 12, 2014
    Date of Patent: April 24, 2018
    Assignee: TDK CORPORATION
    Inventors: Kenichi Suzuki, Yuji Umeda, Ryuji Hashimoto
  • Patent number: 9922761
    Abstract: A device for transmitting data includes a transmitting coil configured to receive and transmit the data signal and to generate a magnetic field, and a magnetic material provided on one surface of the transmitting coil. A ratio of a residual magnetic flux density and a saturation magnetic flux density of the magnetic material is greater in a direction that the material is magnetized than in a direction the material is not magnetized.
    Type: Grant
    Filed: May 16, 2017
    Date of Patent: March 20, 2018
    Assignee: Samsung Electro-Mechanics Co., Ltd.
    Inventors: Jae Hyuk Jang, Hee Seung Kim, Hyun Jung Lee, Jae Sun Won, Jung Young Cho, Yeong Hwan Song, Young Seung Roh
  • Patent number: 9903009
    Abstract: A rare-earth element including a magnet body containing a rare-earth element, and a protective layer formed on a surface of the magnet body. The protective layer may include a first layer covering the magnet body and containing a rare-earth element, and a second layer covering the first layer and containing substantially no rare-earth element. Another protective layer in accordance may include an inner protective layer and an outer protective layer successively from the magnet body side. The outer protective layer is any of an oxide layer, a resin layer, a metal salt layer, and a layer containing an organic-inorganic hybrid compound.
    Type: Grant
    Filed: January 17, 2012
    Date of Patent: February 27, 2018
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Takeshi Sakamoto, Jun Hagiwara, Masami Mori
  • Patent number: 9837193
    Abstract: This sintered R-T-B based rare-earth magnet includes: R2Fe14B type compound crystal grains, including a light rare-earth element RL (which includes at least one of Nd and Pr) as a major rare-earth element R, as main phases; and a heavy rare-earth element RH (which includes at least one of Dy and Tb). Before its surface region is removed, the sintered R-T-B based rare-earth magnet has no layer including the rare-earth element R at a high concentration in that surface region. The sintered R-T-B based rare-earth magnet has a portion in which coercivity decreases gradually from its surface region toward its core portion. The difference in the amount of TRE between a portion of the sintered R-T-B based rare-earth magnet that reaches a depth of 500 ?m as measured from its surface region toward its core portion and the core portion of the sintered R-T-B based rare-earth magnet is 0.1 through 1.0.
    Type: Grant
    Filed: January 19, 2012
    Date of Patent: December 5, 2017
    Assignee: HITACHI METALS, LTD.
    Inventor: Futoshi Kuniyoshi