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1. 发明授权

US06179894B2 Method of improving compressibility of a powder and articles formed thereby 失效
标题翻译：提高由此形成的粉末和制品的压缩性的方法
公开(公告)号：US06179894B2
公开(公告)日：2001-01-30
申请号：US09450212
申请日：1999-11-29
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： B22F102
CPC分类号： H01F41/0246 , B22F1/025 , H01F1/08 , H01F1/083 , H01F1/22 , H01F1/26 , H01F41/0266
摘要： A method for producing high-density powder metallurgy articles formed of hard powder materials, and particularly hard ferromagnetic materials that yield powder metallurgy magnets exhibiting improved magnetic properties as compared to powder metallurgy magnets formed of pure iron. The method generally entails the use of a powder of a material that is harder than iron, and then encapsulating each particle of the powder with a layer of iron. The powder is then compacted, by which the particles are adhered together to form a powder metallurgy article. As a result of forming a sufficiently thick encapsulating layer of iron on each powder particle, the powder can be compacted to a greater density than would be possible without the encapsulating layer of iron. If a ferromagnetic material is used, the resulting magnetic article is capable of exhibiting magnetic properties superior to a substantially identical pure iron powder metallurgy magnet.
摘要翻译：一种由硬质粉末材料形成的高密度粉末冶金制品的方法，特别是与由纯铁形成的粉末冶金磁体相比，产生显示出改进的磁性能的粉末冶金磁体的特别硬的铁磁材料。该方法通常需要使用比铁更硬的材料的粉末，然后用铁层包封粉末的每个颗粒。然后将粉末压实，通过其将颗粒粘附在一起以形成粉末冶金制品。作为在每个粉末颗粒上形成足够厚的铁包覆层的结果，可以将粉末压实到比没有铁的包封层的情况下更大的密度。如果使用铁磁材料，则所得磁性制品能够表现出优于基本相同的纯铁粉末冶金磁体的磁性能。

2. 发明授权

US06423264B1 Process for forming rotating electromagnets having soft and hard magnetic components 失效
标题翻译：用于形成具有软和硬磁性部件的旋转电磁体的方法
公开(公告)号：US06423264B1
公开(公告)日：2002-07-23
申请号：US09418294
申请日：1999-10-14
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： H01F103
CPC分类号： H02K15/03 , B22F7/06 , B22F2003/033 , H01F7/0268 , H01F41/0266 , Y10T29/4902
摘要： A method of a manufacturing rotating electromagnetic component to have both soft and hard (permanent) magnet regions, in which powder technologies are used to net-shape mold the component. A soft magnet powder material and an insert or powder of a permanent magnet material are compacted to form a rotating electromagnetic body containing soft and hard magnet regions. A partial sintering operation is then performed on the body at a temperature of 1600° F. (about 870° C.) or less, preferably about 1400° F. to 1500° F. (about 760° C. and 830° C.), and most preferably at 1500° F. to at least partially fuse the soft magnet powder materials with the permanent magnet material. The soft powder component of the resulting electromagnetic body is sufficiently fused to exhibit mechanical properties comparable to a fully sintered body (i.e., sintered at 2050° F. (about 1120° C.) or more), but without degrading the magnetic properties of the hard magnet region.
摘要翻译：一种制造旋转电磁部件的方法，其具有软和硬（永久）磁体区域，其中使用粉末技术来对部件进行网状模制。软磁体粉末材料和永磁材料的插入物或粉末被压实以形成包含软和硬磁体区域的旋转电磁体。然后在1600°F（约870℃）或更低，优选约1400°F至1500°F（约760℃和830℃）的温度下对身体进行部分烧结操作。），最优选在1500°F，以使软磁体粉末材料与永磁体材料至少部分地熔合。所得到的电磁体的软质粉末成分被充分熔化，以表现出与完全烧结体相当的机械性能（即，在2050°F（约1120℃）或更高温度下烧结），但不会降低硬磁区。

3. 发明授权

US06224798B1 Method for fabricating powdered metal cores 失效
标题翻译：粉末状金属芯的制造方法
公开(公告)号：US06224798B1
公开(公告)日：2001-05-01
申请号：US09629923
申请日：2000-07-31
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： B29B912
CPC分类号： B29C35/0244 , B01J2/006 , B01J2/16 , B22F1/0059 , B22F2999/00 , B29K2503/06 , H01F1/0578 , H01F1/26 , H01F41/0246 , B22F2202/15
摘要： A method of curing a polymeric binder onto a powdered metal after such polymer has been coated on the powdered metal but before a part is therefrom molded, thereby forming a polymer matrix-powdered metal composite material. The polymer-coated powdered metal may be cured by retaining the polymer-coated powdered metal in a fluidized bed contained within a fluidized bath (e.g. a fluid bed coater/drier apparatus) even after the coating process has terminated. The temperature of the fluidized bath may then be raised, in turn raising the temperature of the fluidized bed, thereby curing the polymer onto the coated powdered metal in situ. By keeping the polymer-coated power metal in constant motion during the curing process, the polymer-coated powdered metal particles do not agglomerate nor otherwise adhere to other coated powdered metal particles.
摘要翻译：在将聚合物涂覆在粉末状金属上之后，但在其部分被模制之前，将聚合物粘合剂固化在粉末金属上的方法，从而形成聚合物基体粉末状金属复合材料。聚合物涂覆的粉末金属可以通过将聚合物涂覆的粉末金属保持在包含在流化床（例如流化床涂布机/干燥器装置）内的流化床中而固化，即使在涂覆过程终止之后。然后可以升高流化浴的温度，从而升高流化床的温度，从而将聚合物原位固化到涂覆的粉末状金属上。通过在固化过程中保持聚合物涂覆的动力金属恒定运动，聚合物涂覆的粉末状金属颗粒不会附聚，也不会粘附到其它涂覆的粉末金属颗粒上。

4. 发明授权

US06651309B2 Method for fabricating a highly-dense powder iron pressed stator core for use in alternating current generators and electric motors 失效
标题翻译：制造用于交流发电机和电动马达的高密度粉末铁压定子铁芯的方法
公开(公告)号：US06651309B2
公开(公告)日：2003-11-25
申请号：US09795201
申请日：2001-02-27
申请人： David Earl Gay , David Allen Score
发明人： David Earl Gay , David Allen Score
IPC分类号： H02K1500
CPC分类号： H02K1/16 , H02K1/02 , H02K15/024 , Y10T29/49009 , Y10T29/49011 , Y10T29/49012 , Y10T29/49071 , Y10T29/49073
摘要： A high-density stator core for use in electrodynamic devices is fabricated by the electromagnetic pressing of an iron-based powder coated with a dielectric material and methods for performing the electromagnetic pressing are disclosed. The stator core includes a yoke portion that may further include a plurality of integral poles extending either radially outward from an outer circumferential surface of the yoke portion or radially inward from an interior circumferential surface of the yoke portion. The stator core is formed as a near-net-shape compact by an electromagnetic pressing process and has an as-formed density of at least about 98% of the theoretical density.
摘要翻译：公开了一种用于电动力装置的高密度定子铁心，其通过电介质材料的铁基粉末的电磁加压制造，并且进行电磁加压的方法。定子铁芯包括轭部，该轭部还可以包括从轭部的外周表面径向向外延伸或从轭部的内周面径向向内延伸的多个整体极。定子铁芯通过电磁压制法形成为近网状压实体，并具有至少约理论密度的约98％的密度。

5. 发明授权

US6156264A Electromagnetic compacting of powder metal for ignition core application 失效
标题翻译：用于点火芯应用的粉末金属的电磁压实
公开(公告)号：US6156264A
公开(公告)日：2000-12-05
申请号：US413678
申请日：1999-10-06
申请人： Ralph Herbert Johnston , David Allen Score , David Earl Gay , Albert Anthony Skinner
发明人： Ralph Herbert Johnston , David Allen Score , David Earl Gay , Albert Anthony Skinner
IPC分类号： B22F3/087 , H01F38/12 , H01F41/02 , B22F1/02
CPC分类号： H01F41/0246 , B22F3/087 , B22F3/1216 , H01F38/12
摘要： Disclosed is a process for producing an AC cylindrical electromagnetic ignition coil core (28) comprising:filling a cylindrical holding container (20) with powdered metal;placing the filled container into an electromagnetic field and compacting, in the radial direction, the powder in the container by subjecting the powder to the electromagnetic field; andrecovering the compacted ignition coil core (28).
摘要翻译：公开了一种用于制造AC圆柱形电磁点火线圈芯（28）的方法，包括：用金属粉末填充圆柱形保持容器（20）; 将填充的容器放置在电磁场中，并通过使粉末受到电磁场而在容器内沿径向压实粉末; 并恢复压实的点火线圈芯（28）。

6. 发明授权

US5722032A AC generator rotor segment 失效
标题翻译：交流发电机转子段
公开(公告)号：US5722032A
公开(公告)日：1998-02-24
申请号：US675311
申请日：1996-07-01
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： B22F7/06 , H01F41/02 , H02K1/02 , H02K15/02 , B22F3/12 , B22F5/08
CPC分类号： H02K15/022 , B21K1/28 , B22F7/06 , H01F41/0246 , H02K1/02
摘要： Method of making pole segment for a Lundell-type AC generator rotor from a mixture of ferromagnetic particles and a fugitive binder where the teeth of the rotor are molded concurrently with the base of the rotor but from a mixture of particles which is different from the mixture used to mold the base. Thereafter the segment is fired to remove the binder and sinter the metal particles together.
摘要翻译：从铁磁颗粒和短暂的粘合剂的混合物制备隆德尔型交流发电机转子的极段的方法，其中转子的齿与转子的基部同时成型，但是与混合物不同的颗粒的混合物用来模制基地。此后，将该段烧制以除去粘合剂并将金属颗粒烧结在一起。

7. 发明授权

US06689183B2 Ferrite powder coating insulating layer for molding a powder metal core 失效
标题翻译：用于成型粉末金属芯的铁氧体粉末涂层绝缘层
公开(公告)号：US06689183B2
公开(公告)日：2004-02-10
申请号：US09757139
申请日：2001-01-09
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： C22C105
CPC分类号： C22C33/0228 , H01F1/33 , H01F41/0246
摘要： A composition of metal powder for powder metallurgy applications comprising an iron-based powder metal admixed with a minority fraction of a ferrite powder having a lesser particle-size distribution. The ferrite particles are associated with an exterior surface of the iron-based particles and, after compression molding by a powder metallurgy technique, are incorporated into the microstructural pores between adjacent particles of iron-based powder. A composite structure formed from the composition of the present invention has an improved overall permeability and overall resistivity. A binder, such as a thermoplastic polyacrylate, may be added to the admixture of iron-based and ferrite powders for promoting the association of the ferrite powder with the iron-based powder.
摘要翻译：用于粉末冶金应用的金属粉末的组合物包括与少量部分具有较小粒度分布的铁氧体粉末混合的铁基粉末金属。铁素体颗粒与铁基颗粒的外表面相关联，并且在通过粉末冶金技术压缩成型之后，并入铁基粉末的相邻颗粒之间的微结构孔中。由本发明的组合物形成的复合结构具有改善的总导磁率和整体电阻率。可以向铁基和铁氧体粉末的混合物中加入粘合剂，例如热塑性聚丙烯酸酯，以促进铁氧体粉末与铁基粉末的结合。

8. 发明授权

US06193903B1 Method of forming high-temperature magnetic articles and articles formed thereby 失效
标题翻译：形成高温磁性制品的方法和由此形成的制品
公开(公告)号：US06193903B1
公开(公告)日：2001-02-27
申请号：US09311714
申请日：1999-05-14
申请人： David Earl Gay , David Allen Score
发明人： David Earl Gay , David Allen Score
IPC分类号： H01F137
CPC分类号： B22F1/02 , H01F1/24 , H01F41/0246
摘要： Ceramic-coated powdered ferromagnetic materials for forming magnetic articles, and which maintain the mechanical and magnetic properties of the articles at high temperatures, such as during annealing to relieve stresses induced during the forming operation. The ceramic coatings are formed by one of several techniques to provide an encapsulating layer on each ferromagnetic particle. The particles are then compacted to form a solid magnetic article, which can be annealed without concern for degrading the ceramic coating.
摘要翻译：用于形成磁性制品的陶瓷涂覆粉状铁磁材料，并且其在高温下保持制品的机械和磁性，例如在退火期间以减轻在成型操作期间引起的应力。陶瓷涂层由几种技术之一形成，以在每个铁磁颗粒上提供封装层。然后将颗粒压实以形成固体磁性制品，其可以在不考虑降解陶瓷涂层的情况下退火。

9. 发明授权

US6136265A Powder metallurgy method and articles formed thereby 失效
标题翻译：由此形成粉末冶金法和制品
公开(公告)号：US6136265A
公开(公告)日：2000-10-24
申请号：US370320
申请日：1999-08-09
申请人： David Earl Gay
发明人： David Earl Gay
IPC分类号： B22F1/00 , H01F1/20 , H01F1/26 , H01F41/02
CPC分类号： H01F41/0246 , B22F1/0059 , H01F1/20 , H01F1/26
摘要： A method of forming a coating on metal particles that can be used to produce powder metallurgy articles, including those for electromagnetic and structural applications. The method is generally a solution-blending process that employs a coating solution that contains a solvent and one or more particulate additives, at least one of which is a polymeric binder that is only partially soluble in the solvent. As a result, only a portion of each binder particle is dissolved in the solvent. Notably, the coating solution is free of a discrete adhesion-promoting (tackifier) additive for adhering the polymeric binder to the metal particles. Instead, each binder particle is sufficiently dissolved in the solvent to promote adhesion of the binder particles to the metal particles during mixing, so that each metal particle is encapsulated with a coating containing the polymeric binder. The particles may then be compacted to bind them together with the coating and form a solid article.
摘要翻译：在可用于生产粉末冶金制品的金属颗粒上形成涂层的方法，包括用于电磁和结构应用的涂层。该方法通常是溶液共混方法，其使用包含溶剂和一种或多种颗粒添加剂的涂布溶液，其中至少一种是仅部分溶于溶剂的聚合物粘合剂。结果，只有一部分粘合剂颗粒溶解在溶剂中。值得注意的是，涂层溶液没有用于将聚合物粘合剂粘附到金属颗粒上的离散粘合促进（增粘剂）添加剂。相反，每个粘合剂颗粒充分地溶解在溶剂中以促进粘合剂颗粒在混合期间粘合到金属颗粒上，使得每个金属颗粒被包含聚合物粘合剂的涂层包封。然后可以将颗粒压实以将其与涂层结合在一起并形成固体制品。

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