Patent US4776980A successfully refreshed from Google Patents.
US4776980A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Inductor insert compositions and methods
Assignee: Individual
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Filing: 1987-10-30
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Granted: 1988-10-11
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Expires: 2007-10-30
Abstract
Abstract Disclosed are compositions useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer binder selected from the group consisting of epoxies, flourocarbon, hot melt adhesives, and mixtures thereof; wherein said iron powder has a specific surface area of less than about 0.25 m 2 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 500 KHz. Blocks and inserts made from such compositions, as well as methods of manufacturing such inserts, are also disclosed.
Inventors
- 👤 Robert S. Ruffini
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 05:09
CPC Classifications
C; C08; C08K; C08K3/00; C08K3/02; C08K3/08; H; H01; H01F; H01F1/00; H01F1/01; H01F1/03; H01F1/12; H01F1/14; H01F1/20; H01F1/22; H01F1/24; H01F1/26; H05; H05B; H05B6/00; H05B6/02; H05B6/36; H05B6/365
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
44 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer binder;
Claim 2
Dependent Claim
44 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer binder;
Claim 3
Dependent Claim
28 words
wherein said iron powder has a specific surface area of less than about 0.25 m 2 /g and a carbon content of less than about 0.01 percent; and
Claim 4
Dependent Claim
28 words
wherein said iron powder has a specific surface area of less than about 0.25 m 2 /g and a carbon content of less than about 0.01 percent; and
Claim 5
Dependent Claim
40 words
wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 500 KHz.
Claim 6
Dependent Claim
40 words
wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 500 KHz.
Claim 7
Dependent Claim
25 words
A composition according to claim 1 wherein the polymer binder is selected from the group consisting of flourocarbons, epoxies, hot melt adhesives, and mixtures thereof.
Claim 8
Dependent Claim
13 words
A composition according to claim 1 wherein the polymer binder is an epoxy.
Claim 9
Dependent Claim
15 words
A composition according to claim 1 wherein the polymer binder is a hot nelt adhesive.
Claim 10
Dependent Claim
13 words
A composition according to claim 1 wherein the polymer binder is a flourocarbon.
Claim 11
Dependent Claim
15 words
A composition according to claim 5 wherein the polymer binder is a fluorinated ethylene propylene.
Claim 12
Dependent Claim
12 words
A composition according to claim 1 wherein the binder is a nylon.
Claim 13
Dependent Claim
17 words
A composition according to claim 1 which additionally comprises about 0.1 to about 1 percent acid phosphate.
Claim 14
Dependent Claim
13 words
A composition according to claim 1 wherein said iron powder is substantially disc-shaped.
Claim 15
Dependent Claim
27 words
A composition according to claim 1 wherein said pressed iron powder has a hydrogen loss of less than about 0.30 percent prior to addition to the composition.
Claim 16
Dependent Claim
25 words
A composition according to claim 1 wherein the iron powder has an average particle size in the range of about 40 to about 150 um.
Claim 17
Dependent Claim
22 words
A composition according to claim 11 wherein the iron powder has an average particle size of about 40 to about 70 um.
Claim 18
Dependent Claim
19 words
An insert for an inductor of the like manufactured by pressing and curing a composition according to claim 1.
Claim 19
Dependent Claim
113 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer epoxy resin binder; wherein said iron powder has a specific surface area of less than about 0.25 2 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz.
Claim 20
Dependent Claim
113 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer epoxy resin binder; wherein said iron powder has a specific surface area of less than about 0.25 2 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz.
Claim 21
Dependent Claim
112 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating flourocarbon polymer binder; wherein said iron powder has a specific surface area of less than about 0.25 2 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz.
Claim 22
Dependent Claim
112 words
A composition useful in fabricating blocks or inserts for inductors comprising: (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating flourocarbon polymer binder; wherein said iron powder has a specific surface area of less than about 0.25 2 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz.
Claim 23
Independent Claim
76 words
A method of preparing a block or insert for conductors comprising: (a) preparing a premix comprising an evaporable solvent, a polmer binder and a high purity, annealed electrolytically prepared iron powder; (b) substantially drying the product of step (a); (c) forming an insert from said substantially dried composition at a pressure of about 30 to about 50 Tsi; and (d) curing the formed insert at an elevated temperature of about 150 to about 500 degrees F.
Claim 24
Independent Claim
76 words
A method of preparing a block or insert for conductors comprising: (a) preparing a premix comprising an evaporable solvent, a polmer binder and a high purity, annealed electrolytically prepared iron powder; (b) substantially drying the product of step (a); (c) forming an insert from said substantially dried composition at a pressure of about 30 to about 50 Tsi; and (d) curing the formed insert at an elevated temperature of about 150 to about 500 degrees F.
Claim 25
Dependent Claim
13 words
A fabricated block or insert prepared by a process according to claim 11.
Claim 26
Dependent Claim
24 words
A method according to claim 16 wherein the binder is selected from the group consisting of epoxies, flourocarbons, hot melt adhesives, and mixtures thereof.
Claim 27
Dependent Claim
12 words
A method according to claim 18 wherein the binder is an epoxy.
Claim 28
Dependent Claim
14 words
A method according to claim 18 wherein the binder is a hot melt adhesive.
Claim 29
Dependent Claim
14 words
A method according to claim 18 wherein the binder is a fluorinated ethylene propylene.
Claim 30
Dependent Claim
15 words
The method according to claim 18 wherein the binder is a fluorinated ethylene propylene material.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-10-11 | 1992-04-11 | 1992-10-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-10-11 | 1996-04-11 | 1996-10-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-10-11 | 2000-04-11 | 2000-10-11 | $7700.00 | Window Closed / Lapsed |