Iron Base (i.e., Ferrous) Patents (Class 148/306)
  • Patent number: 10065244
    Abstract: The present invention discloses a method for fabricating a porous spherical iron-based alloy powder, a powder thereof and a sintered body thereof. The method comprises steps: mixing an iron oxide powder and an alloying powder to form a mixed powder; spray-granulating the mixed powder to form a spherical spray-granulated powder; and placing the spherical spray-granulated powder in a reducing environment and heating it to a temperature of lower than 700° C. to obtain a porous spherical iron-based alloy powder having high flowability, high compressibility, superior sinterability and low cost.
    Type: Grant
    Filed: April 18, 2016
    Date of Patent: September 4, 2018
    Assignee: Taiwan Powder Technologies Co., Ltd.
    Inventors: Kuen-Shyang Hwang, Ming-Wei Wu, Yang-Liang Fan
  • Patent number: 10011886
    Abstract: A grain-oriented electrical steel sheet to which electron beam irradiation is applied, has a film and a thickness of t (mm), wherein no rust is produced on a surface of the steel sheet after a humidity cabinet test lasting 48 hours at a temperature of 50° C. in an atmosphere of 98% humidity, and iron loss W17/50 after the electron beam irradiation is reduced by at least (?500 t2+200 t?6.5) % of the iron loss W17/50 before the electron beam irradiation and is (5 t2?2 t+1.065) W/kg or less.
    Type: Grant
    Filed: September 28, 2012
    Date of Patent: July 3, 2018
    Assignee: JFE Steel Corporation
    Inventors: Shigehiro Takajo, Hiroi Yamaguchi, Takeshi Omura, Hirotaka Inoue, Seiji Okabe
  • Patent number: 10010935
    Abstract: The present invention provides iron powder for dust cores that has excellent compressibility and low iron loss after formation. In the iron powder for dust cores, Si content is 0.01 mass % or less, apparent density is 3.8 g/cm3 or more, the ratio of iron powder particles with a particle size of 45 ?m or less is 10 mass % or less, the ratio of iron powder particles with a particle size of over 180 ?m and 250 ?m or less is less than 30 mass %, the ratio of iron powder particles with a particle size of over 250 ?m is 10 mass % or less, and the Vickers hardness (test force: 0.245 N) of a powder cross-section is 80 Hv or less.
    Type: Grant
    Filed: December 2, 2013
    Date of Patent: July 3, 2018
    Assignee: JFE STEEL CORPORATION
    Inventors: Takuya Takashita, Naomichi Nakamura
  • Patent number: 9818520
    Abstract: The invention provides a nanocomposite magnet, which has achieved high coercive force and high residual magnetization. The magnet is a non-ferromagnetic phase that is intercalated between a hard magnetic phase with a rare-earth magnet composition and a soft magnetic phase, wherein the non-ferromagnetic phase reacts with neither the hard nor soft magnetic phase. A hard magnetic phase contains Nd2Fe14B, a soft magnetic phase contains Fe or Fe2Co, and a non-ferromagnetic phase contains Ta. The thickness of the non-ferromagnetic phase containing Ta is 5 nm or less, and the thickness of the soft magnetic phase containing Fe or Fe2Co is 20 nm or less. Nd, or Pr, or an alloy of Nd and any one of Cu, Ag, Al, Ga, and Pr, or an alloy of Pr and any one of Cu, Ag, Al, and Ga is diffused into a grain boundary phase of the hard magnetic phase of Nd2Fe14B.
    Type: Grant
    Filed: December 27, 2012
    Date of Patent: November 14, 2017
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, NATIONAL INSTITUTE FOR MATERIALS SCIENCE
    Inventors: Hidefumi Kishimoto, Noritsugu Sakuma, Masao Yano, Weibin Cui, Yukiko Takahashi, Kazuhiro Hono
  • Patent number: 9589723
    Abstract: A process for the manufacture of magnetic ceramic is provided including the steps of: die compacting a powder composition into a compacted body, the composition including a mixture of soft magnetic, iron or iron-based powder, core particles of which are surrounded by an electrically insulating, inorganic coating an amount of 1 to 35% by weight of the composition; and heating and pressing the compacted body in an atmosphere to a temperature and a pressure below the decomposition temperature and pressure of the magnetic, iron or iron-based powder.
    Type: Grant
    Filed: January 27, 2014
    Date of Patent: March 7, 2017
    Assignee: INSTYTUT NISKICH TEMPERATUR I BADAN STRUKTURALNYCH
    Inventors: Karen Oganisian, Wieslaw Strek, Andrzej Vogt, Pawel Gluchowski
  • Patent number: 9500720
    Abstract: A semi-hard magnetic material that is formed with equal to or more than 5.0% but less than 13.0% of Ni by mass, equal to or more than 0.5% but equal to or less than 4.0% of Mn by mass, more than 0% but equal to or less than 3.0% of Al by mass, more than 0% but equal to or less than 1.0% of Ti by mass and a remainder of Fe and an impurity, that has a coercivity of 1000 to 2400 A/m and that has a residual magnetic flux density of 1.3 T or more. A method of manufacturing the above semi-hard magnetic material wherein the material is a thin plate having a thickness of 0.030 to 0.30 mm and, after a cold rolling, performing an aging treatment on the thin plate at a temperature of 520° C. to 680° C.
    Type: Grant
    Filed: August 17, 2012
    Date of Patent: November 22, 2016
    Assignee: HITACHI METALS, LTD.
    Inventors: Masaru Fujiyoshi, Shin-ichiro Yokoyama
  • Publication number: 20150115749
    Abstract: A magnetic component having intermixed first and second regions, and a method of preparing that magnetic component are disclosed. The first region includes a magnetic phase and the second region includes a non-magnetic phase. The method includes mechanically masking pre-selected sections of a surface portion of the component by using a nitrogen stop-off material and heat-treating the component in a nitrogen-rich atmosphere at a temperature greater than about 900° C. Both the first and second regions are substantially free of carbon, or contain only limited amounts of carbon; and the second region includes greater than about 0.1 weight % of nitrogen.
    Type: Application
    Filed: October 31, 2013
    Publication date: April 30, 2015
    Applicant: General Electric Company
    Inventors: Laura Cerully Dial, Richard DiDomizio, Francis Johnson
  • Publication number: 20150059932
    Abstract: A grain-oriented magnetic steel sheet includes grooves each of which extends in a direction intersecting a transportation direction, the grooves being formed at predetermined pitches PL in the transportation direction by laser beam irradiation, in which a relationship between a standard deviation value D and the pitch PL satisfies the following expression (1), the standard deviation value D being a standard deviation of distances between a linear approximation line, which is obtained from a center line of each of the grooves in a groove width direction by a least-squares method, and respective positions on the center line, and an average angle formed between tangent lines of the respective positions on the center line and a direction perpendicular to the transportation direction is more than 0° to 30°. [Expression 1] 0.
    Type: Application
    Filed: April 24, 2013
    Publication date: March 5, 2015
    Inventors: Koji Hirano, Satoshi Arai, Hideyuki Hamamura, Hirofumi Imai
  • Publication number: 20150034211
    Abstract: Disclosed is a grain-oriented electrical steel sheet exhibiting low hysteresis loss and low coercive force, in which an increase in hysteresis loss due to laser irradiation or electron beam irradiation, which has been a conventional concern, is effectively inhibited. The grain-oriented electrical steel sheet has closure domain regions (X) formed to divide the magnetic domains in a rolling direction, from one end to the other in the width direction of the steel sheet, provided that Expression (1) is satisfied: ?(500t?80)×s+230?w??(500t?80)×s+330??Expression (1), where t represents a sheet thickness (mm); w represents a smaller one of the widths (?m) of the regions measured on the front and rear surfaces of the steel sheet, respectively, by using a Bitter method; and s represents an average number of the regions present within one crystal grain.
    Type: Application
    Filed: December 21, 2012
    Publication date: February 5, 2015
    Inventors: Shigehiro Takajo, Seiji Okabe
  • Publication number: 20150017056
    Abstract: Disclosed herein are a soft magnetic metal powder having a pearlite lamellar structure in which ferrite structures and cementite structures are repeated, a method for preparing the same, and an electronic component including the same as a core material. According to the present invention, the soft magnetic metal powder having the pearlite lamellar structure in which the ferrite structures and the cementite structures are repeated may be easily prepared, and an eddy current loss may be easily decreased without changing the existing molding process, such that the soft magnetic metal powder may be used as a core material of various electronic components such as an inductor, a motor, an actuator, a sensor, a transformer, and a reactor, requiring soft magnetic properties.
    Type: Application
    Filed: July 10, 2014
    Publication date: January 15, 2015
    Inventors: Hak Kwan KIM, Sang Kyun KWON, Sung Jae LEE, Sung Yong AN
  • Publication number: 20150013849
    Abstract: A grain-oriented electrical steel sheet produces reduced noise when worked into a transformer, by setting length d of each plastic strain region in the widthwise direction of the steel sheet to 0.05 mm or more and 0.4 mm or less, and a ratio (?d/?w) of a total ?d of the length d to a total ?w of application interval w of each of the above plastic strain regions to 0.2 or more and 0.6 or less.
    Type: Application
    Filed: February 8, 2013
    Publication date: January 15, 2015
    Inventors: Seiji Okabe, Shigehiro Takajo, Takashi Kawano
  • Publication number: 20140352849
    Abstract: The present invention proposes a method that can reduce the noise generated by a transformer core and the like when formed by laminations of a grain-oriented electrical steel sheet in which core loss has been reduced by a magnetic domain refinement process. In this steel sheet, linear distortion extending with an orientation in which an angle formed with a direction perpendicular to the rolling direction of the steel sheet is an angle of 30° or less is periodic in the direction of rolling of the steel sheet, core loss (W17/50) is 0.720 W/kg or less, and magnetic flux density (B8) is 1.930 T. The volume of the closure domain arising in the distortion part is 1.00-3.00% of the total magnetic domain volume within the steel sheet.
    Type: Application
    Filed: December 27, 2012
    Publication date: December 4, 2014
    Applicant: JFE STEEL CORPORATION
    Inventors: Ryuichi Suehiro, Hiroi Yamaguchi, Seiji Okabe, Hirotaka Inoue, Shigehiro Takajo
  • Publication number: 20140338792
    Abstract: A grain-oriented electrical steel sheet allows for manufacture of a transformer that exhibits, when the steel sheet is applied to an iron core thereof, extremely low iron loss and extremely low noise properties, makes highly efficient use of energy, and can be used in various environments. The grain-oriented electrical steel sheet has a strain distribution in regions where closure domains are formed, when observed in a cross section in the rolling direction, with a maximum tensile strain in a sheet thickness direction being 0.45% or less, and with a maximum tensile strain t (%) and a maximum compressive strain c (%) in the rolling direction satisfying Expression (1): t+0.06?t+c?0.35??(1).
    Type: Application
    Filed: December 28, 2012
    Publication date: November 20, 2014
    Applicant: JFE Steel Corporation
    Inventors: Shigehiro Takajo, Ryuichi Suehiro, Hiroi Yamaguchi
  • Patent number: 8871035
    Abstract: A process for producing grain oriented magnetic sheets by subjecting a steel slab ?100 mm, containing 2.5-3.5% si, to the following operations: optional first heating, to a temperature T1?1250° C.; first rough hot-rolling at T2 between 900 and 1200° C., the reduction ratio (% Rid) being at least 80% in the absence of a subsequent heating or, in the presence of a subsequent heating to T3?1300° C., at least 60% determined by % Rid=80?(T3?T2)/5; second finishing hot-rolling at T4<1300° C. to a rolled-section thickness of 1.5 3.0 mm; cold-rolling, in one or more stages with optional intermediate annealing and with a cold reduction ratio ?60% applied in the last stage; primary recrystallization annealing, optionally in a decarburizing atmosphere; second recrystallization annealing.
    Type: Grant
    Filed: November 18, 2009
    Date of Patent: October 28, 2014
    Assignee: Centro Sviluppo Materiali S.p.A.
    Inventors: Stefano Fortunati, Giuseppe Abbruzzese, Stefano Cicale′
  • Publication number: 20140290434
    Abstract: A process for producing an ordered martensitic iron nitride powder that is suitable for use as a permanent magnetic material is provided. The process includes fabricating an iron alloy powder having a desired composition and uniformity; nitriding the iron alloy powder by contacting the material with a nitrogen source in a fluidized bed reactor to produce a nitride iron powder; transforming the nitride iron powder to a disordered martensitic phase; annealing the disordered martensitic phase to an ordered martensitic phase; and separating the ordered martensitic phase from the iron nitride powder to yield an ordered martensitic iron nitride powder.
    Type: Application
    Filed: June 13, 2014
    Publication date: October 2, 2014
    Inventor: David Matthiesen
  • Patent number: 8845957
    Abstract: A method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: (a) first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, (b) creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4), and (c) second compaction of the particles (S5) provided with the surface coating, such that the hollow spaces are reduced in size or eliminated.
    Type: Grant
    Filed: April 27, 2009
    Date of Patent: September 30, 2014
    Assignees: ETO Magnetic GmbH, Kennametal Europe GmbH
    Inventors: Paul Guempel, Stefan Glaeser, Beat Hofer
  • Publication number: 20140251500
    Abstract: New magnetic materials containing cerium, iron, and small additions of a third element are disclosed. These materials comprise compounds Ce(Fe12?xMx) where x=1-4, having the ThMn12 tetragonal crystal structure (space group I4/mmm, #139). Compounds with M=B, Al, Si, P, S, Sc, Co, Ni, Zn, Ga, Ge, Zr, Nb, Hf, Ta, and W are identified theoretically, and one class of compounds based on M=Si has been synthesized. The Si cognates are characterized by large magnetic moments (4?Ms greater than 1.27 Tesla) and high Curie temperatures (264?Tc?305° C.). The Ce(Fe12?xMx) compound may contain one or more of Ti, V, Cr, and Mo in combination with an M element. Further enhancement in Tc is obtained by nitriding the Ce compounds through heat treatment in N2 gas while retaining the ThMn12 tetragonal crystal structure; for example CeFe10Si2N1.29 has Tc=426° C.
    Type: Application
    Filed: March 6, 2013
    Publication date: September 11, 2014
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: CHEN ZHOU, FREDERICK E. PINKERTON, JAN F. HERBST
  • Patent number: 8797137
    Abstract: Provided is a soft magnetic powder used for obtaining a dust core having a low hysteresis loss, in particular, in a high temperature range. A soft magnetic powder includes an aggregate of composite magnetic particles, each including a soft magnetic particle containing Fe, Si, and Al, and an insulating coating film disposed on the surface thereof, and satisfies the expressions (1) and (2) below: Expression (1) . . . 27?2.5a+b?29 and Expression (2) . . . 6?b?9, where a represents the Si content (mass %) and b represents the Al content (mass %). The soft magnetic powder is capable of reducing the hysteresis loss, in a high-temperature environment, of a dust core obtained using the soft magnetic powder.
    Type: Grant
    Filed: May 17, 2011
    Date of Patent: August 5, 2014
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Asako Watanabe, Toru Maeda
  • Patent number: 8784995
    Abstract: A grain oriented electrical steel sheet has linear grooves for magnetic domain refinement formed on a surface thereof and may reduce iron loss by using these linear grooves, where the proportion of those linear grooves having crystal grains directly beneath themselves, each crystal grain having an orientation deviating from the Goss orientation by 10° or more and a grain size of 5 ?m or more, is controlled to 20% or less, and secondary recrystallized grains are controlled to have an average ? angle of 2.0° or less, and each secondary recrystallized grain having a grain size of 10 mm or more is controlled to have an average ?-angle variation of 1° to 4°.
    Type: Grant
    Filed: September 9, 2011
    Date of Patent: July 22, 2014
    Assignee: JFE Steel Corporation
    Inventors: Takeshi Omura, Hirotaka Inoue, Hiroi Yamaguchi, Seiji Okabe, Yasuyuki Hayakawa
  • Patent number: 8741075
    Abstract: A method of producing a hot press-formed member having good corrosion resistance comprises subjecting a zinc-based plated steel sheet to heat treatment by heating to a temperature region of 600-750° C. at a rate of temperature increase up to 600° C. of at most 50° C. per second followed by cooling to 550° C. or below to form a steel blank which has a zinc oxide layer in its uppermost surface portion and below it a zinc-iron alloy phase having an Fe content of at least 25 mass %. This steel blank is heated to a temperature of at least its Ac3 point, then press formed immediately at a temperature of at least its Ac3 point, and then rapidly cooled. The hot press-formed member has a surface region with zinc oxide and iron-zinc solid solution phases and not containing an intermetallic compound phase or a pure zinc phase.
    Type: Grant
    Filed: June 26, 2012
    Date of Patent: June 3, 2014
    Assignees: Nippon Steel & Sumitomo Metal Corporation, Toyoda Iron Works Co., Ltd.
    Inventors: Kazuhito Imai, Masanobu Ichikawa
  • Patent number: 8734658
    Abstract: A resist film is formed on a cold-rolled steel sheet so as to fabricate a groove by etching. At this point, a steel sheet exposed portion where a portion of the steel sheet is exposed is formed in the resist film, and the steel sheet exposed portion has a first region oriented in a sheet width direction, and a plurality of second regions starting from the first region, widths of the first region and the second regions being 20 ?m to 100 ?m, and a distance from an end portion of one of the second regions to an end portion of another of the second regions adjacent thereto being 60 ?m to 570 ?m.
    Type: Grant
    Filed: June 3, 2011
    Date of Patent: May 27, 2014
    Assignee: Nippon Steel & Sumitomo Metal Corporation
    Inventors: Keiji Iwata, Yasuhiro Kikuchi
  • Patent number: 8641835
    Abstract: An iron alloy according to the present invention comprises: Al in an amount of from 3 to 5.5%; Mn in an amount from 0.2 to 6%; and the balance being iron (Fe), and inevitable impurities and/or a modifying element; when the entirety is taken as 100%. Since a high damping factor is obtainable at a low-strain amplitude, this iron alloy demonstrates a stable damping property even in a high-temperature region. Moreover, since the alloying elements are Al and Mn alone, and since their contents are less, the iron alloy according to the present invention is low in cost.
    Type: Grant
    Filed: September 8, 2009
    Date of Patent: February 4, 2014
    Assignee: Kabushiki Kaisha Toyota Jidoshokki
    Inventors: Keita Yamana, Motoharu Tanizawa, Masanori Harata, Kyoichi Kinoshita
  • Publication number: 20140001398
    Abstract: The present invention relates to ferromagnetic particles capable of exhibiting a high purity and excellent magnetic properties from the industrial viewpoints and a process for producing the ferromagnetic particles, and also provides an anisotropic magnet, a bonded magnet and a compacted magnet which are obtained by using the ferromagnetic particles.
    Type: Application
    Filed: January 19, 2012
    Publication date: January 2, 2014
    Applicant: TOHOKU UNIVERSITY
    Inventors: Migaku Takahashi, Tomoyuki Ogawa, Yasunobu Ogata, Naoya Kobayashi, Chammika Ruwan Polwatta Gallage, Kaori Kohara
  • Publication number: 20130314198
    Abstract: A rapidly quenched Fe-based soft-magnetic alloy ribbon having wave-like undulations on a free surface, the wave-like undulations having transverse troughs arranged at substantially constant intervals in a longitudinal direction, and the troughs having an average amplitude D of 20 mm or less, is produced by a method comprising (a) keeping a transverse temperature distribution in a melt nozzle within ±15° C. to have as small a temperature distribution as possible in a melt paddle of the alloy, and (b) forming numerous fine linear scratches on a cooling roll surface by a wire brush, thereby providing a ground surface of the cooling roll with an arithmetical mean (average) roughness Ra of 0.1-1 ?m and a maximum roughness depth Rmax of 0.5-10 ?m.
    Type: Application
    Filed: January 27, 2012
    Publication date: November 28, 2013
    Applicant: HITACHI METALS, LTD.
    Inventors: Yoshihito Yoshizawa, Motoki Ohta, Naoki Ito
  • Patent number: 8591669
    Abstract: The present disclosure is directed to a method of shaping a starting material of polycrystalline Fe—Ga alloy sheet of varying texture or crystal orientation. The method includes texturing the surface of the Fe—Ga alloy sheet to re-orient polycrystalline Fe—Ga crystals of the polycrystalline Fe—Ga alloy sheet to increase the uniformity of the crystal orientation of the Fe—Ga alloy sheet. The texturing step includes: initially deforming the Fe—Ga alloy sheet by hot rolling; subsequently deforming the previously hot rolled Fe—Ga alloy sheet by warm rolling; and annealing the previously warm rolled Fe—Ga alloy sheet. The method provides an alloy having a saturation magnetostriction potential greater than 60 ppm in applied fields of between 200-600 Oersted. During the annealing step H2S gas is added to introduce sulfur for promoting surface-energy-induced selective growth of {110} grain. The annealing step is performed in an atmosphere of argon gas.
    Type: Grant
    Filed: November 23, 2005
    Date of Patent: November 26, 2013
    Assignee: University of Maryland
    Inventors: Suok Min Na, Alison Behre Flatau
  • Publication number: 20130306744
    Abstract: A high coercivity bias piece for making acousto-magnetic labels is made of an alloy strip with 10-14% weight percent Mn, less than 7% weight percent of one or more other transitional metals, with the balance Fe, after cold rolling to final gage, going through a final aging heat treatment at below 590 C, longer than 5 minutes. The strip thickness is 0.065-0.18 mm with coercivity measured by direct current method being 56-90 Oe. The method of making the high coercivity bias piece is to cold roll the strip to 0.07-0.15 mm with aging temperature at 450-570 C, for 0.5-20 hours to form a magnetic strip with coercivity of 60-85 Oe, followed by cutting the strip to required size. This high coercivity bias piece is manufactured without expensive Co and Ni materials, showing that a low cost Fe-(10-14% weight percent Mn) based alloy can be used to make high coercivity bias.
    Type: Application
    Filed: May 18, 2012
    Publication date: November 21, 2013
    Inventor: Lin Li
  • Publication number: 20130206283
    Abstract: A grain oriented electrical steel sheet has thermal strain introduced thereinto in a dotted-line arrangement in which strain-imparted areas are lined in a direction that crosses a rolling direction of the steel sheet, wherein the strain-imparted areas introduced in the dotted-line arrangement have a size from 0.10 mm or more to 0.50 mm or less and an interval between the adjacent strain-imparted areas is from 0.10 mm or more to 0.60 mm or less.
    Type: Application
    Filed: August 5, 2011
    Publication date: August 15, 2013
    Applicant: JFE STEEL CORPORATION
    Inventors: Hirotaka Inoue, Hiroi Yamaguchi, Seiji Okabe, Takeshi Omura
  • Publication number: 20130160901
    Abstract: A grain oriented electrical steel sheet has linear grooves for magnetic domain refinement formed on a surface thereof and may reduce iron loss by using these linear grooves, where the proportion of those linear grooves having crystal grains directly beneath themselves, each crystal grain having an orientation deviating from the Goss orientation by 10° or more and a grain size of 5 ?m or more, is controlled to 20% or less, and secondary recrystallized grains are controlled to have an average ? angle of 2.0° or less, and each secondary recrystallized grain having a grain size of 10 mm or more is controlled to have an average ?-angle variation of 1° to 4°.
    Type: Application
    Filed: September 9, 2011
    Publication date: June 27, 2013
    Applicant: JFE Steel Corporation
    Inventors: Takeshi Omura, Hirotaka Inoue, Hiroi Yamaguchi, Seiji Okabe, Yasuyuki Hayakawa
  • Publication number: 20130118654
    Abstract: A silicon steel sheet (1) containing Si is cold-rolled. Next, a decarburization annealing (3) of the silicon steel sheet (1) is performed so as to cause a primary recrystallization. Next, the silicon steel sheet (1) is coiled so as to obtain a steel sheet coil (31). Next, an annealing (6) of the steel sheet coil (31) is performed through batch processing so as to cause a secondary recrystallization. Next, the steel sheet coil (31) is uncoiled and flattened. Between the cold-rolling and the obtaining the steel sheet coil (31), a laser beam is irradiated a plurality of times at predetermined intervals on a surface of the silicon steel sheet (1) from one end to the other end of the silicon steel sheet (1) along a sheet width direction (2). When the secondary recrystallization is caused, grain boundaries passing from a front surface to a rear surface of the silicon steel sheet (1) along paths of the laser beams are generated.
    Type: Application
    Filed: July 28, 2010
    Publication date: May 16, 2013
    Inventors: Tatsuhiko Sakai, Koji Hirano, Satoshi Arai, Yoshiyuki Ushigami
  • Patent number: 8409707
    Abstract: The invention relates to an iron-based soft magnetic powder for a dust core, wherein a film comprising Fe and Co, a phosphoric acid-based chemical conversion film and a silicone resin film are formed in this order on the surface of an iron-based soft magnetic powder, and to a dust core obtained by molding the iron-based soft magnetic powder for a dust core. The invention also relates to an iron-based soft magnetic powder for a dust core formed by coating the surface of an iron-based soft magnetic powder with an insulating film, wherein the powder has a particle diameter of from 45 ?m to 180 ?m, the insulating film is composed of two layers in which a lower layer composed of a phosphoric acid-based chemical conversion film and an upper layer composed of a silicone resin film, and each of the films has a thickness of from 100 nm to 280 nm, and to a dust core obtained by molding the iron-based soft magnetic powder for a dust core.
    Type: Grant
    Filed: July 2, 2008
    Date of Patent: April 2, 2013
    Assignee: Kobe Steel, Ltd.
    Inventors: Hiroyuki Mitani, Nobuaki Akagi, Hirofumi Houjou
  • Patent number: 8398879
    Abstract: A powder mixture, which contains a soft magnetic powder and an insulating powder lubricant in an amount of 0.1% by mass or more relative to the soft magnetic powder, is formed by compacting at a compacting pressure of 800 MPa or less, thereby obtaining a powder compact that has a space factor of the soft magnetic powder of 93% or more. The powder compact can be used as a soft magnetic powdered core. The soft magnetic powdered core has a specific resistance or 10,000 ??cm or more. A powder of a metal soap such as barium stearate or lithium stearate is used as the insulating powder lubricant.
    Type: Grant
    Filed: July 8, 2010
    Date of Patent: March 19, 2013
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Kohei Muramatsu, Chio Ishihara, Masaki Yanaka
  • Patent number: 8372218
    Abstract: Magnet cores pressed using a powder of nanocrystalline or amorphous particles and a pressing additive should be characterized by minimal iron losses. These particles have first surfaces represented by the original strip surfaces and second surfaces represented by surfaces produced in a pulverization process, the overwhelming majority of these second particle surfaces being smooth cut or fracture surfaces without any plastic deformation, the proportion T of areas of plastic deformation of the second particle surfaces being 0?T?0.5.
    Type: Grant
    Filed: June 19, 2007
    Date of Patent: February 12, 2013
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventors: Dieter Nuetzel, Markus Brunner
  • Patent number: 8366837
    Abstract: The invention can provide a dust core that can counteract a large electric current, achieve an increase in frequency and miniaturization, and achieve an improvement in voltage resistance, and a magnetic element using the same. The dust core of the invention is a dust core including metallic magnetic powder, an inorganic insulating material, and a thermosetting resin, in which the metallic magnetic powder has a Vickers hardness (Hv) in a range of 230?Hv?1000, the inorganic insulating material has a compressive strength of 10000 kg/cm2 or lower and is in a mechanical collapse state, and the inorganic insulating material in a mechanical collapse state and the thermosetting resin are interposed between the metallic magnetic powder particles.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: February 5, 2013
    Assignee: Panasonic Corporation
    Inventors: Yuya Wakabayashi, Takeshi Takahashi, Nobuya Matsutani
  • Patent number: 8337637
    Abstract: A method for ordering a disordered alloy includes: simultaneously ion bombarding and annealing a disordered alloy to transform the disordered alloy from a disordered crystalline state to an ordered crystalline state. A method for making a perpendicular magnetic recording medium which includes an ordered alloy layer is also disclosed.
    Type: Grant
    Filed: December 7, 2009
    Date of Patent: December 25, 2012
    Assignee: National Taiwan University
    Inventors: Fu-Te Yuan, An-Cheng Sun, Jen-Hwa Hsu, Ching-Ray Chang
  • Patent number: 8337638
    Abstract: A powder for a dust core comprising a silicon-containing layer formed within a depth of less than 0.15 D from the surface of the surface layer of a soft magnetic metal powder having a particle diameter D and a method for producing the same are provided.
    Type: Grant
    Filed: April 17, 2009
    Date of Patent: December 25, 2012
    Assignees: Toyota Jidosha Kabushiki Kaisha, Fine Sinter Co., Ltd
    Inventors: Yusuke Oishi, Eisuke Hoshina, Toshiya Yamaguchi, Kazuhiro Kawashima
  • Patent number: 8328955
    Abstract: A composite magnetic material is manufactured having magnetic properties that can excellently cope with the decreasing size and increasing electric current of magnetic elements, such as choke coils, and can be used in a high frequency range, a dust core using the composite magnetic material, and a method of manufacturing the same. The dust core includes magnetic metal powder and an insulating material, in which the magnetic metal powder has a Vickers hardness (Hv) of 230 ? Hv? 1000, the insulating material has a compressive strength of 10000 kg/cm2 or lower and is in a mechanical collapsed state, and the insulating material in a mechanical collapsed state is interposed in the magnetic metal powder.
    Type: Grant
    Filed: January 14, 2010
    Date of Patent: December 11, 2012
    Assignee: Panasonic Corporation
    Inventors: Yuya Wakabayashi, Takeshi Takahashi, Nobuya Matsutani
  • Patent number: 8323422
    Abstract: Provided is a dust core excellent in flux density, iron loss, and mechanical strength. A production process of a dust core according to the invention includes a step of compacting a mixture obtained by mixing an iron-based soft magnetic powder for powder compact having a phosphate conversion coating film on the surface of an iron-based soft magnetic powder with a lubricant to obtain a powder compact, a heat treatment step of heating the resulting powder compact at 550° C. or more but not more than 650° C. in an inert atmosphere, and a heat treatment step of heating the heat-treated powder compact at 420° C. or more but not more than 530° C. in an oxidizing atmosphere.
    Type: Grant
    Filed: November 22, 2011
    Date of Patent: December 4, 2012
    Assignee: Kobe Steel, Ltd.
    Inventors: Takeshi Ohwaki, Hiroyuki Mitani, Hirofumi Hojo, Tomotsuna Kamijo
  • Patent number: 8323725
    Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.
    Type: Grant
    Filed: June 16, 2010
    Date of Patent: December 4, 2012
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Patent number: 8308874
    Abstract: An alloy comprising: a magnetostrictive iron alloy having the formula: FexGayAlz, where x is of from about 65 at % to about 90 at %, y is of from about 5 at % to about 35 at %, and z is of from about 0 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm. An alloy having a saturated magnetostriction of from about at least 150 ppm comprising: a magnetostrictive iron alloy having the formula: FexGayBet, where x is of from about 65 at % to about 90 at %, y is of from about 1 at % to about 35 at %, and t is of from about 1 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm.
    Type: Grant
    Filed: November 29, 2005
    Date of Patent: November 13, 2012
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Arthur E. Clark, Marilyn Wun-Fogle, James B. Restorff, Thomas A. Lograsso, Rick Allen Kellogg
  • Patent number: 8298352
    Abstract: A magnet core (1) made of a composite of platelet-shaped particles of a thickness D and a binder has a particularly linear relative permeability curve over a pre-magnetised constant field. For this purpose, the platelet-shaped particles (5) are provided with an amorphous volume matrix (8), wherein areas (9) with a crystalline structure having a thickness d of 0.04*D?d?0.25*D and covering a proportion x of x?0.1 of the surface (6, 7) of the particle (5) are embedded on the surface (6, 7) of the particle (5).
    Type: Grant
    Filed: July 23, 2008
    Date of Patent: October 30, 2012
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventor: Markus Brunner
  • Patent number: 8287664
    Abstract: A magnet core is required to be particularly dense, made of alloys produced in a rapid solidification process and have a minimal coercitive field strength. To achieve these aims, a coarse-grain powder fraction is first produced from an amorphous strip of a soft magnetic alloy. In addition, at least one fine-grain powder fraction is produced from a nanocrystalline strip of a soft magnetic alloy. The particle fractions are then mixed to produce a multi-modal powder, wherein the particles of the coarse-grain particle fraction have an amorphous structure and the particles of the fine-grain powder fraction have a nanocrystalline structure. The multi-modal powder is then pressed to produce a magnet core.
    Type: Grant
    Filed: July 11, 2007
    Date of Patent: October 16, 2012
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventor: Markus Brunner
  • Patent number: 8287666
    Abstract: A magnetic alloy having a composition represented by the general formula of Fe100-x-yCuxBy (atomic %), wherein x and y are numbers meeting the conditions of 0.1?x?3, and 10?y?20, or the general formula of Fe100-x-y-zCuxByXz (atomic %), wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 0.1?x?3, 10?y?20, 0<z?10, and 10<y+z?24), the magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more.
    Type: Grant
    Filed: December 2, 2010
    Date of Patent: October 16, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Motoki Ohta, Yoshihito Yoshizawa
  • Patent number: 8287665
    Abstract: 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: Grant
    Filed: March 19, 2008
    Date of Patent: October 16, 2012
    Assignees: NEC Tokin Corporation, Tohoku University
    Inventors: Akiri Urata, Hiroyuki Matsumoto, Akihiro Makino
  • Patent number: 8277575
    Abstract: The invention relates to inorganic intermetallic compounds having a PMR effect (combined GMR/CMR effect), which are characterized in that they contain at least two elements per formula unit and have a field sensitivity of less than 10% per 0.1 T at temperatures greater than 290 K. The invention also relates to composites consisting of these compounds, to a method for the production thereof and to their use, in particular, as magnetic field sensors or in the domain of spin electronics.
    Type: Grant
    Filed: February 19, 2010
    Date of Patent: October 2, 2012
    Assignee: International Business Machines Corporation
    Inventor: Claudia Felser
  • Patent number: 8252124
    Abstract: The present invention provides a powder magnetic core low in the loss and high in the saturation magnetic flux density and a method for manufacturing the same. More specifically, the present invention provides a powder magnetic core that comprises a soft magnetic metal powder having an average particle size (D50) of 0.5 to 5 ?m, a half width of diffraction peak in a <110> direction of ?-Fe as measured by X-ray powder diffraction of 0.2 to 5.0°, and an Fe content of 97.0% by mass or more, the core having an oxygen content of 2.0% by mass or more.
    Type: Grant
    Filed: March 11, 2011
    Date of Patent: August 28, 2012
    Assignee: TDK Corporation
    Inventors: Masahito Koeda, Tomofumi Kuroda, Tomokazu Ishikura, Akihiro Harada, Hiroyuki Ono, Osamu Kido, Satoko Ueda
  • Patent number: 8216393
    Abstract: A powder composite core is to be particularly dense and strong while being produced from soft magnetic alloys. In particular, the expansion of the heat-treated core is to be avoided. To produce this core, a strip of a soft magnetic alloy is first comminuted to form particles. The particles are mixed with a first binder having a curing temperature T1,cure and a decomposition temperature T1,decompose and a second binder having a curing temperature T2,cure and a decomposition temperature T2,decompose, wherein T1,cure<T2,cure?T1,decompose<T2,decompose. The mix is pressed to produce a magnet core while the first binder is cured. The magnet core is then subjected to a heat treatment accompanied by the curing of the second binder at a heat treatment temperature TAnneal>T2,cure.
    Type: Grant
    Filed: July 11, 2007
    Date of Patent: July 10, 2012
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventors: Markus Brunner, Georg Werner Reppel
  • Patent number: 8187394
    Abstract: A powder magnetic core is provided for operating at high frequencies that is obtained by pressure forming an iron-based magnetic powder covered with an insulation film, which has a specific resistance more than 1000, preferably more than 2000, and most preferably more than 3000 ??m, and a saturation magnetic flux density B above 1.5, preferably above 1.7, and most preferably above 1.9 (T). A method for the preparation of such cores as well as a powder which is suitable for the preparation also are provided.
    Type: Grant
    Filed: December 6, 2007
    Date of Patent: May 29, 2012
    Assignee: Hoganas AB
    Inventors: Zhou Ye, Björn Skårman
  • Patent number: 8182620
    Abstract: A magnetic alloy having a composition represented by the general formula of Fe100-x-yCuxBy(atomic %), wherein x and y are numbers meeting the conditions of 0.1?x?3, and 10?y?20, or the general formula of Fe100-x-y-zCuxByXz(atomic %), wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 0.1?x?3, 10?y?20, 0<z?10, and 10<y+z?24), the magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more.
    Type: Grant
    Filed: July 19, 2010
    Date of Patent: May 22, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Motoki Ohta, Yoshihito Yoshizawa
  • Patent number: 8177923
    Abstract: A magnetic alloy having a composition represented by the general formula of Fe100-x-yCuxBy (atomic %), wherein x and y are numbers meeting the conditions of 0.1?x?3, and 10?y?20, or the general formula of Fe100-x-y-zCuxByXz (atomic %), wherein X is at least one element selected from the group consisting of Si, S, C, P, Al, Ge, Ga and Be, and x, y and z are numbers meeting the conditions of 0.1?x?3, 10?y?20, 0<z?10, and 10<y+z?24), the magnetic alloy having a structure containing crystal grains having an average diameter of 60 nm or less in an amorphous matrix, and a saturation magnetic flux density of 1.7 T or more.
    Type: Grant
    Filed: September 19, 2006
    Date of Patent: May 15, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Motoki Ohta, Yoshihito Yoshizawa
  • Patent number: 8172956
    Abstract: A sintered soft magnetic powder molded body having a composition containing Fe, 44 to 50% by mass of Ni and 2 to 6% by mass of Si, or a composition containing Fe and 2 to 6% by mass of Si, wherein the Si is unevenly distributed among particles, is provided.
    Type: Grant
    Filed: May 14, 2008
    Date of Patent: May 8, 2012
    Assignee: Mitsubishi Steel Mfg. Co., Ltd.
    Inventors: Kenichi Unoki, Shoichi Yamasaki, Yuji Soda, Masakatsu Fukuda