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- Nachgewiesen in: USPTO Patent Applications
- Sprachen: English
- Document Number: 20160042849
- Publication Date: February 11, 2016
- Appl. No: 14/820284
- Application Filed: August 06, 2015
- Claim: 1. A magnetic material comprising: at least one of an α″-Fe16(NxZ1-x)2 phase domain or an α′-Fe8(NxZ1-x) phase domain, wherein Z includes at least one of C, B, or O, and wherein x is a number greater than zero and less than one.
- Claim: 2. The magnetic material of claim 1, wherein x is equal to about 0.5.
- Claim: 3. The magnetic material of claim 1, wherein x is equal to about 0.4667
- Claim: 4. The magnetic material of claim 1, wherein Z consists of C.
- Claim: 5. The magnetic material of claim 1, further comprising at least one of an α″-Fe16N2 phase domain, an α″-Fe16Z2 phase domain, a α′-Fe8(N) phase domain, or an α′-Fe8(Z) phase domain.
- Claim: 6. The magnetic material of claim 1, comprising a saturation magnetization of at least about 219 emu/gram.
- Claim: 7. The magnetic material of claim 1, comprising a magnetic coercivity of less than or equal to about 10 Oerstads.
- Claim: 8. The magnetic material of claim 1, wherein at least about 35 volume percent of the magnetic material is the at least one of the α″-Fe16(NxZ1-x)2 phase domain or the α′-Fe8(NxZ1-x) phase domain.
- Claim: 9. The magnetic material of claim 1, wherein at least about 60 volume percent of the magnetic material is the at least one of the α″-Fe16(NxZ1-x)2 phase domain or the α′-Fe8(NxZ1-x) phase domain.
- Claim: 10. The magnetic material of claim 1, wherein the at least one of the α″-Fe16(NxZ1-x)2 phase domain or the α′-Fe8(NxZ1-x) phase domain comprises a plurality of at least one of α″-Fe16(NxZ1-x)2 crystals or α′-Fe8(NxZ1-x) crystals, and wherein respective [001] axes of the plurality of crystals are randomly distributed within the magnetic material.
- Claim: 11. A magnetic material comprising: at least one of an α″-Fe16N2 phase domain or an α′-Fe8N phase domain; and at least one of an α″-Fe16Z2 phase domain or an α′-Fe8Z phase domain, wherein Z includes at least one of C, B, or O.
- Claim: 12. The magnetic material of claim 11, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain comprises a first layer comprising the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain, wherein the α″-Fe16Z2 phase domain comprises a second layer comprising the at least one of the α″-Fe16Z2 phase domain or the α′-Fe8Z phase domain, and wherein the first layer and the second layer are adjacent to each other.
- Claim: 13. The magnetic material of claim 11, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain comprises a first set of layers, each layer of the first set of layers comprising the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain comprises a second set of layers, each layer of the second set of layers comprising the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain, and wherein one or more respective layers of the first set of layers alternate with one or more respective layers of the second set of layers.
- Claim: 14. The magnetic material of claim 11, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain comprises a plurality of at least one of α″-Fe16N2 crystals or α′-Fe8N crystals, wherein the at least one α″-Fe16Z2 phase domain comprises a plurality of at least one of α″-Fe16Z2 crystals or α′-Fe8Z crystals and wherein respective [001] axes of the plurality of at least one of α″-Fe16N2 crystals or α′-Fe8N crystals and respective [001] axes of the plurality of at least one of α″-Fe16Z2 crystals or α′-Fe8Z crystals are randomly distributed within the magnetic material.
- Claim: 15. The magnetic material of claim 11, wherein Z consists of C.
- Claim: 16. The magnetic material of claim 11, comprising a saturation magnetization of at least about 219 emu/gram.
- Claim: 17. The magnetic material of claim 11, comprising a magnetic coercivity of less than or equal to about 10 Oerstads.
- Claim: 18. The magnetic material of claim 11, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domains and the at least one of the α″-Fe16Z2 phase domain or the α′-Fe8Z phase domain together form at least about 35 volume percent of the magnetic material.
- Claim: 19. The magnetic material of claim 11, wherein the at least one of the α″-Fe16N2 phase domain or the α′-Fe8N phase domain and the at least one of the α″-Fe16Z2 phase domain or the α′-Fe8Z phase domain together form at least about 60 volume percent of the magnetic material.
- Claim: 20. A method comprising: forming a magnetic material comprising at least one of: at least one of an α″-Fe16(NxZ1-x)2 phase domain or an α′-Fe8(NxZ1-x), wherein Z includes at least one of C, B, or O, and wherein x is a number greater than zero and less than one; or at least one of an α″-Fe16N2 phase domain or an α′-Fe8N phase domain, and at least one of an α″-Fe16Z2 phase domain or an α′-Fe8Z phase domain.
- Claim: 21. The method of claim 20, wherein forming the magnetic material comprises sputtering from a carbon-doped iron target to form a layer comprising iron, carbon, and nitrogen over a substrate.
- Claim: 22. The method of claim 21, wherein the carbon-doped iron target comprises between about 1 at. % and about 10 at. % carbon.
- Claim: 23. The method of claim 21, wherein sputtering comprises forming a nitrogen plasma to provide a source of nitrogen atoms.
- Claim: 24. The method of claim 21, further comprising annealing the layer at a temperature between about 100° C. and about 210° C. for between about 5 hours and about 100 hours.
- Claim: 25. The method of claim 20, wherein forming the magnetic material comprises depositing the magnetic material over a substrate using at least one of chemical vapor deposition, molecular beam epitaxy, low temperature epitaxy, liquid phase epitaxy, or ion implantation.
- Claim: 26. The method of claim 20, wherein forming the magnetic material comprises: straining an iron workpiece comprising at least one iron crystal in a direction substantially parallel to a <001> crystal axis of the iron crystal; nitridizing and carbonizing the iron workpiece to form a nitridized and carbonized iron wire or sheet; and annealing the nitridized and carbonized iron workpiece to form the magnetic material.
- Claim: 27. The method of claim 20, wherein forming the magnetic material comprises: implanting nitrogen and carbon atoms in an iron workpiece using ion implantation; pre-annealing the iron workpiece to attach the iron workpiece to a substrate; and annealing the nitridized and carbonized iron workpiece to form the magnetic material.
- Claim: 28. The method of claim 20, wherein forming the magnetic material comprises: heating an iron source to form a vapor comprising an iron-containing compound; depositing iron from the vapor comprising the iron-containing compound, nitrogen from a vapor comprising a nitrogen-containing compound, and at least one of carbon, boron, or oxygen from a vapor comprising the compound containing the at least one of carbon, boron, or oxygen over a substrate to form a layer comprising iron, nitrogen, and the at least one of carbon, boron, or oxygen; and annealing the layer comprising iron, nitrogen, and the at least one of carbon, boron, or oxygen to form the magnetic material.
- Claim: 29. The method of claim 20, wherein forming the magnetic material comprises: heating an iron source to form a vapor comprising an iron-containing compound; depositing iron from the vapor comprising the iron-containing compound and nitrogen from a vapor comprising a nitrogen-containing compound over a substrate to form a first layer comprising iron and nitrogen; heating an iron source to form a vapor comprising an iron-containing compound; depositing iron from the vapor comprising the iron-containing compound and at least one of carbon, boron, or oxygen from a vapor comprising the at least one of carbon, boron, or oxygen over the substrate to form a second layer comprising iron and the at least one of carbon, boron, or oxygen; and annealing the first layer and the second layer to form the magnetic material.
- Claim: 30. The method of claim 20, wherein forming the magnetic material comprises: submerging a substrate in a coating solution comprising a nitrogen-containing solvent, an iron source, and a carbon source, wherein the coating solution is saturated with the iron source at a first temperature above a liquidus temperature of an iron-carbon-nitrogen mixture to be deposited from the coating solution; cooling the coating solution to a second temperature to form a supersaturated coating solution, wherein the second temperature is below the liquidus temperature of the iron-carbon-nitrogen mixture; maintaining the substrate in the supersaturated coating solution to allow a coating comprising iron, carbon, and nitrogen to form over the substrate; and annealing the coating comprising iron, carbon, and nitrogen to form the magnetic material.
- Claim: 31. The method of claim 20, wherein forming the magnetic material comprises: submerging a substrate in a first coating solution comprising a nitrogen-containing solvent and an iron source, wherein the first coating solution is saturated with the iron source at a first temperature above a liquidus temperature of an iron-nitrogen mixture to be deposited from the first coating solution; cooling the first coating solution to a second temperature to form a supersaturated first coating solution, wherein the second temperature is below the liquidus temperature of the iron-nitrogen mixture; maintaining the substrate in the supersaturated first coating solution to allow a first coating comprising iron and nitrogen to form over the substrate; submerging the substrate in a second coating solution comprising a solvent, an iron source, and a compound containing at least one of carbon, boron, or oxygen, wherein the second coating solution is saturated with the iron source at a third temperature above a liquidus temperature of a mixture to be deposited from the second coating solution; cooling the second coating solution to a fourth temperature to form a supersaturated second coating solution, wherein the fourth temperature is below the liquidus temperature of the mixture; maintaining the substrate in the supersaturated second coating solution to allow a second coating comprising iron, nitrogen, and the at least one of carbon, boron, or oxygen to form over the substrate; annealing the first coating and the second coating to form the magnetic material.
- Claim: 32. The method of claim 20, wherein forming the magnetic material comprises: milling, in a bin of a milling apparatus, an iron-containing raw material in the presence of a nitrogen source and a source of at least one of carbon, boron, or oxygen to generate a powder including iron, nitrogen, and the at least one of carbon, boron, or oxygen; annealing the powder to form the magnetic material.
- Claim: 33. The method of claim 20, wherein forming the magnetic material comprises: milling, in a bin of a milling apparatus, an iron-containing raw material in the presence of a nitrogen source to generate a first powder including iron and nitrogen; annealing the first powder to form at least one phase domain including α-Fe16N2 or at least one phase domain including α′-Fe8N; milling, in a bin of a milling apparatus, an iron-containing raw material in the presence of a source including at least one of carbon, boron, or oxygen to generate a second powder including iron and the at least one of carbon, boron, or oxygen; annealing the second powder to form at least one phase domain including α-Fe16Z2 or at least one phase domain including α′-Fe8Z, where Z includes the at least one of carbon, boron, or oxygen; and consolidating the first powder and the second powder to form the magnetic material.
- Current International Class: 01; 23; 23; 21; 01; 22; 30; 30; 30; 01; 22; 21
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