公开(公告)号：US06534564B2

公开(公告)日：2003-03-18

申请号：US09865082

申请日：2001-05-24

申请人： Francis G. Hanejko ,  Sydney Luk ,  Kalathur S. V. L. Narasimhan

发明人： Francis G. Hanejko ,  Sydney Luk ,  Kalathur S. V. L. Narasimhan

IPC分类号： B22C100

CPC分类号： B22F1/0059 ,  B22F2998/10 ,  B22F2999/00 ,  B22F3/02 ,  B22F2003/248 ,  B22F2202/15 ,  B22F2203/01

摘要： A method is provided for compacting metal-based powder compositions containing at least one thermoplastic material at temperatures below the glass transition temperature or melting temperature of the thermoplastic material to form a metal-based component. Preferably, compaction is carried out at temperatures ranging from ambient to about 55° C. The method of the present invention is particularly useful for making magnetic core components. The present invention also provides metal-based powder compositions useful for cold compaction. The metal based powder compositions contain metal-based particles containing no iron phosphate layer; a thermoplastic material selected from polyetherimides, polyphenylene ethers, polyethersulfones, polycarbonates, polyethylene glycol, polyvinyl acetate, polyvinyl alcohol or combinations thereof, and an oligomer of a polyamide.

摘要翻译： 提供了一种用于在低于热塑性材料的玻璃化转变温度或熔融温度的温度下压制含有至少一种热塑性材料的金属基粉末组合物以形成金属基组分的方法。 优选地，在环境温度至约55℃的温度下进行压实。本发明的方法对于制造磁芯组件特别有用。 本发明还提供了用于冷压缩的金属基粉末组合物。 金属粉末组合物含有不含铁磷酸盐层的金属类颗粒; 选自聚醚酰亚胺，聚苯醚，聚醚砜，聚碳酸酯，聚乙二醇，聚乙酸乙烯酯，聚乙烯醇或其组合的热塑性材料和聚酰胺的低聚物。

公开(公告)号：US06395687B1

公开(公告)日：2002-05-28

申请号：US09866013

申请日：2001-05-24

申请人： Francis G. Hanejko

发明人： Francis G. Hanejko

IPC分类号： B22F100

CPC分类号： B22F1/0059 ,  B22F3/02 ,  B22F2003/026 ,  C10M149/18 ,  C10M2217/044 ,  C10M2217/045 ,  C10N2240/00 ,  C10N2240/22 ,  C10N2240/30 ,  C10N2240/50 ,  C10N2240/52 ,  C10N2240/54 ,  C10N2240/56 ,  C10N2240/58 ,  C10N2240/60 ,  C10N2240/66

摘要： A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.

摘要翻译： 提供了一种用于润滑模腔的方法，其包括将含有高熔点聚合物蜡润滑剂的润滑剂组合物施加到模腔的壁。 优选地，润滑剂是在使用过程中熔融温度大于模具壁的温度的聚酰胺润滑剂。 本发明还提供了一种制造压实金属部件的方法，包括将润滑剂组合物施加到模腔的内壁，将金属基粉末组合物引入模腔中; 并在足以从金属粉末组合物形成压实部件的压力下压实粉末组合物。

公开(公告)号：US5063011A

公开(公告)日：1991-11-05

申请号：US365186

申请日：1989-06-12

申请人： Howard Rutz ,  Francis G. Hanejko

发明人： Howard Rutz ,  Francis G. Hanejko

IPC分类号： B22F1/00 ,  C22C33/02 ,  H01F1/20 ,  H01F1/26 ,  H01F3/08 ,  H01F41/02

CPC分类号： H01F41/0246 ,  B22F1/0059 ,  C22C33/0228 ,  H01F1/24 ,  H01F1/26 ,  H01F3/08 ,  Y10S264/58 ,  Y10T428/2998

摘要： Methods of doubly coating iron particles. The methods comprise treating the iron particles with phosphoric acid to form a layer of hydrated iron phosphate at the surfaces of the iron particles. The particles are heated in an inert atmosphere at a temperature and for a time sufficient to convert the hydrated layer to an iron phosphate layer. The particles are then coated with a termoplastic material to provide a coating of thermoplastic material substantially uniformly circumferentially surrounding the iron phosphate layer. Doubly-coated iron particles provided in accordance with this invention are generally useful for forming magnetic components and cores for use in high frequency switching applications.

摘要翻译： 双重涂覆铁粒子的方法。 所述方法包括用磷酸处理铁颗粒以在铁颗粒的表面形成一层水合磷酸铁。 颗粒在惰性气氛中在足以将水合层转化为磷酸铁层的温度和时间下加热。 然后用活性材料涂覆颗粒，以提供基本均匀地围绕磷酸铁层的热塑性材料的涂层。 根据本发明提供的双重涂覆的铁颗粒通常可用于形成用于高频开关应用的磁性部件和芯体。

公开(公告)号：US4499048A

公开(公告)日：1985-02-12

申请号：US469100

申请日：1983-02-23

申请人： Francis G. Hanejko

发明人： Francis G. Hanejko

IPC分类号： B22F3/15 ,  B22F3/00

CPC分类号： B22F3/156 ,  B22F3/15 ,  B22F2998/00

摘要： A method of consolidating a metallic body is disclosed. The method comprises the steps of forming an article of manufacture from powdered metal; sintering the article of manufacture so as to increase the strength thereof; coating the article with a sacrificial layer of ceramic; providing a bed of heated, generally spheroidal ceramic particles; compacting the coated article of manufacture embedded in the heated bed under pressure to thereby consolidate the article into a dense, desired shape; and, removing said sacrificial coating such that the surface of the article remains substantially free of process-related imperfections.

摘要翻译： 公开了一种固结金属体的方法。 该方法包括从金属粉末形成制品的步骤; 烧结制品以提高其强度; 用陶瓷的牺牲层涂覆制品; 提供加热的，通常为球形陶瓷颗粒的床; 在加压床中压制嵌入加热床中的涂覆制品，从而将制品固结成致密的期望形状; 并且去除所述牺牲涂层，使得制品的表面基本上没有与工艺有关的缺陷。

公开(公告)号：US20110239823A1

公开(公告)日：2011-10-06

申请号：US13074045

申请日：2011-03-29

申请人： Kalathur S. Narasimhan ,  Francis G. Hanejko

发明人： Kalathur S. Narasimhan ,  Francis G. Hanejko

IPC分类号： B32B15/02 ,  B22F1/00 ,  C22C38/00 ,  B22F3/12 ,  B32B5/16 ,  H01F1/01

CPC分类号： H01F1/06 ,  B22F1/02 ,  B22F3/24 ,  B22F2998/10 ,  H01F1/24 ,  H01F1/33 ,  H01F41/0246 ,  Y10T428/2991 ,  B22F3/18

摘要： The present invention is directed to electrically conductive compacted metal parts fabricated using powder metallurgy methods. The iron-based powders of the invention are coated with magnetic or pre-magnetic materials.

摘要翻译： 本发明涉及使用粉末冶金方法制造的导电压实金属部件。 本发明的铁基粉末涂覆有磁性或预磁性材料。

公开(公告)号：US06635122B2

公开(公告)日：2003-10-21

申请号：US09970423

申请日：2001-10-03

申请人： Francis G. Hanejko ,  George Ellis

发明人： Francis G. Hanejko ,  George Ellis

IPC分类号： C23C2207

CPC分类号： C23C26/00 ,  B22F1/02 ,  B22F2998/10 ,  B22F2999/00 ,  H01F1/26 ,  H01F41/0246 ,  Y10T428/2998 ,  B22F1/0096 ,  B22F1/0085

摘要： Methods of making and using annealable insulated metal-based powder particles are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.

公开(公告)号：US06372348B1

公开(公告)日：2002-04-16

申请号：US09198311

申请日：1998-11-23

申请人： Francis G. Hanejko ,  George Ellis

发明人： Francis G. Hanejko ,  George Ellis

IPC分类号： B32B516

CPC分类号： C23C26/00 ,  B22F1/02 ,  B22F2998/10 ,  B22F2999/00 ,  H01F1/26 ,  H01F41/0246 ,  Y10T428/2998 ,  B22F1/0096 ,  B22F1/0085

摘要： Annealable insulated metal-based powder particles and methods of preparing and using the same are provided. The insulated metal-based powder particles are formed from metal-based core particles that are coated with an annealable insulating material. The annealable insulating material has at least one inorganic compound and at least one organic polymeric resin. The inorganic compound in the insulating material forms a nonporous insulating layer surrounding the metal-based core particles upon heating. The organic polymeric resin preferably aids in dispersing or binding the inorganic compound to the metal-based core particles prior to annealing. The insulated metal-based powder particles produced can be formed into core components that can be annealed to improve the magnetic performance of the core component. The core components produced are particularly useful under AC operating conditions of 500 Hz or lower.

摘要翻译： 提供了可弹性绝缘的金属基粉末颗粒及其制备和使用方法。 绝缘金属粉末颗粒由涂有可退火绝缘材料的金属基颗粒形成。 可退火的绝缘材料具有至少一种无机化合物和至少一种有机聚合物树脂。 绝缘材料中的无机化合物在加热时形成围绕金属基核颗粒的无孔绝缘层。 有机聚合物树脂优选在退火之前有助于将无机化合物分散或结合到金属基核颗粒上。 可以将所制造的绝缘金属粉末颗粒形成为能够进行退火以提高核心部件的磁性能的核心部件。 所生产的核心组件在500Hz或更低的AC工作条件下特别有用。

公开(公告)号：US4499049A

公开(公告)日：1985-02-12

申请号：US469101

申请日：1983-02-23

申请人： Francis G. Hanejko

发明人： Francis G. Hanejko

IPC分类号： B22F3/14 ,  B22F3/15 ,  B22F3/16 ,  C04B35/645 ,  B22F3/00

CPC分类号： B22F3/15

摘要： A method of consolidating a metallic or ceramic body is disclosed. The method comprises the steps of forming an article of manufacture from powdered metal; sintering the article of manufacture so as to increase the strength thereof; providing a bed of heated, generally spheroidal ceramic particles which have been coated with a thermally stable lubricant; and compacting the article of manufacture embedded in the heated bed under pressure to thereby consolidate the article into a dense, desired shape.

摘要翻译： 公开了一种固结金属或陶瓷体的方法。 该方法包括从金属粉末形成制品的步骤; 烧结制品以提高其强度; 提供已经涂覆有热稳定润滑剂的加热的，通常为球形的陶瓷颗粒床; 并且在压力下将嵌入在加热床中的制品压实，从而将制品固结成致密的期望形状。

公开(公告)号：US08703046B2

公开(公告)日：2014-04-22

申请号：US13334622

申请日：2011-12-22

申请人： Francis G. Hanejko

发明人： Francis G. Hanejko

IPC分类号： B22F1/00

CPC分类号： B22F3/12 ,  B22F1/0059 ,  B22F1/02 ,  B22F3/02 ,  B22F2001/0066 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/0207 ,  Y10T428/2991 ,  Y10T428/2993 ,  Y10T428/2998 ,  B22F3/10 ,  B22F1/0088

摘要： Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.

摘要翻译： 提供了制备高密度压实组分的方法，其增加了冶金粉末组合物的润滑性，同时降低了压实组分的总体有机含量。 制备具有高密度的高密度压实组分的方法包括以下步骤：提供具有至少部分涂覆有金属磷酸盐层的颗粒的冶金粉末组合物，并且在至少约5tsi的压力下压制模具中的冶金粉末组合物 。 冶金粉末组合物包含贱金属粉末，任选的合金粉末和颗粒状内部润滑剂。 金属磷酸盐至少部分地涂覆基础金属粉末，任选的合金粉末或两者。 金属磷酸盐涂层增加了冶金粉末的润滑性，而不需要大量的有机材料，例如润滑剂和粘合剂。

公开(公告)号：US20120219451A1

公开(公告)日：2012-08-30

申请号：US13334622

申请日：2011-12-22

申请人： Francis G. Hanejko

发明人： Francis G. Hanejko

IPC分类号： B22F3/12 ,  B32B15/02 ,  B22F1/02 ,  B32B5/16 ,  B05D7/00 ,  B22F3/02

CPC分类号： B22F3/12 ,  B22F1/0059 ,  B22F1/02 ,  B22F3/02 ,  B22F2001/0066 ,  B22F2998/10 ,  B22F2999/00 ,  C22C33/0207 ,  Y10T428/2991 ,  Y10T428/2993 ,  Y10T428/2998 ,  B22F3/10 ,  B22F1/0088

摘要： Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.

摘要翻译： 提供了制备高密度压实组分的方法，其增加了冶金粉末组合物的润滑性，同时降低了压实组分的总体有机含量。 制备具有高密度的高密度压实组分的方法包括以下步骤：提供具有至少部分涂覆有金属磷酸盐层的颗粒的冶金粉末组合物，并且在至少约5tsi的压力下压制模具中的冶金粉末组合物 。 冶金粉末组合物包含贱金属粉末，任选的合金粉末和颗粒状内部润滑剂。 金属磷酸盐至少部分地涂覆基础金属粉末，任选的合金粉末或两者。 金属磷酸盐涂层增加了冶金粉末的润滑性，而不需要大量的有机材料，例如润滑剂和粘合剂。