US4946746A
Expired / Lapsed
US
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Novel metal fiber and process for producing the same
Assignee: Toyobo Co Ltd
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Filing: 1988-12-06
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Granted: 1990-08-07
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Expires: 2008-12-06
Abstract
Abstract A metal fiber having unidirectional dendritic texture which is an assembly of a group of dendrites wherein primary arms have grown at angle of within 20° relative to the metal fiber axis, diameter of said fiber being not greater than 100 μm. There is also disclosed a single crystalline metal fiber which is a single crystalline material throughout the entire length, diameter of said fiber being not greater than 100 μm, length of said fiber being not less than 40 mm. These fibers can be produced by melt-spinning of metal.
Inventors
- 👤 Takaharu Ichiryu
- 👤 Yoshiki Ono
- 👤 Hideaki Ishihara
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 05:56
CPC Classifications
H; H01; H01F; H01F1/00; H01F1/01; H01F1/03; H01F1/12; H01F1/14; H01F1/20; B; B22; B22D; B22D11/00; B22D11/005; C; C30; C30B; C30B15/00; C30B15/007; C30B29/00; C30B29/10; C30B29/52; C30B29/60; H01F1/147; H01F1/153; H01F1/15325; H01F1/15391; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12431
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
50 words
A soft magnetic metal fiber having a unidirectional dendritic texture which is an assembly texture of a group of dendrites wherein primary arms have grown at an angle of, at largest, 20° relative to the metal fiber axis, a diameter of said metal fiber being not larger than 100 μm.
Claim 2
Dependent Claim
50 words
A soft magnetic metal fiber having a unidirectional dendritic texture which is an assembly texture of a group of dendrites wherein primary arms have grown at an angle of, at largest, 20° relative to the metal fiber axis, a diameter of said metal fiber being not larger than 100 μm.
Claim 3
Dependent Claim
26 words
A soft magnetic metal fiber according to claim 1, wherein the metal is selected from the group consisting of Fe-Si alloy, Fe-Al- alloy and Fe-Si-Al alloy.
Claim 4
Dependent Claim
16 words
A soft magnetic metal fiber according to claim 1, wherein the fiber has a round section.
Claim 5
Dependent Claim
32 words
A soft magnetic metal fiber according to claim 1, wherein the metal is selected from the group consisting of Fe-Si-rare earth metal alloy, Fe-Al-rare earth metal alloy and Fe-Si-Al-rare earth metal alloy.
Claim 6
Dependent Claim
35 words
A soft magnetic metal fiber according to claim 4, wherein the rare earth metal is one or more metal selected from the group consisting of lanthanum series having the atomic number of 57 to 71.
Claim 7
Dependent Claim
16 words
A soft magnetic metal fiber according to claim 4, wherein the rare earth metal is Ce.
Claim 8
Dependent Claim
72 words
A single crystalline soft magnetic metal fiber having defects which include dislocations and sub-boundaries and wherein said sub-boundaries are where the orientations of the crystals differ from each other in a angle range of not larger than a few degrees, and which is a single crystalline material throughout the entire length thereof, diameter of said fiber being not larger than 100 μm, length of said fiber being not less than 40 mm.
Claim 9
Dependent Claim
72 words
A single crystalline soft magnetic metal fiber having defects which include dislocations and sub-boundaries and wherein said sub-boundaries are where the orientations of the crystals differ from each other in a angle range of not larger than a few degrees, and which is a single crystalline material throughout the entire length thereof, diameter of said fiber being not larger than 100 μm, length of said fiber being not less than 40 mm.
Claim 10
Dependent Claim
26 words
A soft magnetic metal fiber according to claim 7, wherein the metal is selected from the group consisting of Fe-Si alloy, Fe-Al alloy and Fe-Si-Al alloy.
Claim 11
Dependent Claim
16 words
A soft magnetic metal fiber according to claim 7, wherein the fiber has a round section.
Claim 12
Dependent Claim
32 words
A soft magnetic metal fiber according to claim 7, wherein the metal is selected from the group consisting of Fe-Si-rare earth metal alloy, Fe-Al-rare earth metal alloy and Fe-Si-Al-rare earth metal alloy.
Claim 13
Dependent Claim
30 words
A soft magnetic metal fiber according to claim 10, wherein the rare earth metal is one or more metals selected from lanthanum series having 57 to 71 of atomic number.
Claim 14
Dependent Claim
16 words
A soft magnetic metal fiber according to claim 10, wherein the rare earth metal is Ce.
Claim 15
Dependent Claim
24 words
A single crystalline soft magnetic metal fiber according to claim 7, wherein the specific permeability under direct current magnetization is not less than 90,000.
Claim 16
Dependent Claim
51 words
A single crystalline soft magnetic metal fiber according to claim 7, wherein the squareness ratio (Br/Bs) is not less than 0.9 and the coercive force is not larger than 0.3 oersted under direct current magnetization, in which Br is a remaining magnetic flux density and Bs is saturated magnetic flux density.
Claim 17
Dependent Claim
44 words
A single crystalline soft magnetic metal fiber according to claim 7, wherein the saturation magnetic flux density under direct current magnetization is not less than 18 kGauss and the magnetic flux density under 10 oersted of magnetic field is not less than 17 kGauss.
Claim 18
Dependent Claim
71 words
A process for producing a soft magnetic metal fiber having unidirectional dendritic texture which comprises melt-spinning a molten metal from a spinning nozzle of not larger than 100 μm in diameter and quenching the resulting wire material to solidify to obtain the metal fiber having an assembly texture of a group of dendrites wherein primary arms have grown at an angle of, at largest, 20° relative to the metal fiber axis.
Claim 19
Dependent Claim
71 words
A process for producing a soft magnetic metal fiber having unidirectional dendritic texture which comprises melt-spinning a molten metal from a spinning nozzle of not larger than 100 μm in diameter and quenching the resulting wire material to solidify to obtain the metal fiber having an assembly texture of a group of dendrites wherein primary arms have grown at an angle of, at largest, 20° relative to the metal fiber axis.
Claim 20
Dependent Claim
23 words
A process according to claim 16, wherein the metal is selected from the group consisting of Fe-Si alloy, Fe-Al alloy and Fe-Si-Al alloy.
Claim 21
Dependent Claim
26 words
A process according to claim 16, wherein the metal is selected from the group consisting of Fe-Si-rare earth metal, Fe-Al-rare earth metal and Fe-Si-Al-rare earth metal.
Claim 22
Dependent Claim
28 words
A process according to claim 18, wherein the rare earth metal is one or more metal selected from lanthanum series having the atomic number of 57 to 71.
Claim 23
Dependent Claim
13 words
A process according to claim 18, wherein the rare earth metal is Ce.
Claim 24
Dependent Claim
38 words
A process according to claim 16, wherein the melt spinning is carried out by injecting the molten metal into a cooling liquid layer formed along an inner circumferential surface of a rotating cylindrical drum through the spinning nozzle.
Claim 25
Dependent Claim
21 words
A process according to claim 16, wherein the melt spinning is carried out by spinning the molten metal in quenching gas.
Claim 26
Dependent Claim
109 words
A process for producing a single crystalline soft magnetic metal fiber having defects which include dislocations and sub-boundaries and wherein said sub-boundaries are where the orientations of the crystals differ from each other in a angle range of not larger than a few degrees, and which process comprises melt-spinning a molten metal from a spinning nozzle of not larger than 100 μm in diameter, quenching the resulting wire material to solidify, heat-treating the resulting wire to homogenize to obtain a metal fiber which is a single crystalline material throughout the entire length and is not less than 100 μm in diameter and not less than 40 mm in length.
Claim 27
Dependent Claim
109 words
A process for producing a single crystalline soft magnetic metal fiber having defects which include dislocations and sub-boundaries and wherein said sub-boundaries are where the orientations of the crystals differ from each other in a angle range of not larger than a few degrees, and which process comprises melt-spinning a molten metal from a spinning nozzle of not larger than 100 μm in diameter, quenching the resulting wire material to solidify, heat-treating the resulting wire to homogenize to obtain a metal fiber which is a single crystalline material throughout the entire length and is not less than 100 μm in diameter and not less than 40 mm in length.
Claim 28
Dependent Claim
23 words
A process according to claim 23, wherein the metal is selected from the group consisting of Fe-Si alloy, Fe-Al alloy and Fe-Si-Al alloy.
Claim 29
Dependent Claim
29 words
A process according to claim 23, wherein the metal is selected from the group consisting of Fe-Si-rare earth metal alloy, Fe-Al-rare earth metal alloy and Fe-Si-Al-rare earth metal alloy.
Claim 30
Dependent Claim
28 words
A process according to claim 25, wherein the rare earth metal is one or more metals selected from lanthanum series having the atomic number of 57 to 71.
Claim 31
Dependent Claim
13 words
A process according to claim 25, wherein the rare earth metal is Ce.
Claim 32
Dependent Claim
40 words
A process according to claim 23, wherein the heat treatment temperature is lower than a temperature a solidus melting curve of the metal by 10° C. but not lower than 1/3 of the melting point of the alloy in °C.
Claim 33
Dependent Claim
37 words
A process according to claim 23, wherein the melt-spinning is carried out by injecting a molten metal into a cooling liquid layer formed along an inner circumferential surface of a rotating cylindrical drum through the spinning nozzle.
Claim 34
Dependent Claim
20 words
A process according to claim 23, wherein the melt-spinning is carried out by spinning the molten metal in quenching gas.
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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) | 1993-08-06 | 1994-02-05 | 1994-08-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-08-06 | 1998-02-05 | 1998-08-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-08-06 | 2002-02-05 | 2002-08-07 | $7700.00 | Window Closed / Lapsed |