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- Nachgewiesen in: USPTO Patent Applications
- Sprachen: English
- Document Number: 20210123126
- Publication Date: April 29, 2021
- Appl. No: 16/949038
- Application Filed: October 09, 2020
- Claim: 1. A method comprising: forming a soft magnetic material by a technique comprising melt spinning, wherein the soft magnetic material comprises 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: 2. The method of claim 1, wherein forming the soft magnetic material by the technique comprising melt spinning comprises: forming a molten mixture comprising iron and carbon; melt spinning the molten mixture comprising iron and carbon to form iron-carbon ribbons; and nitriding the iron-carbon ribbons to form an iron-carbon-nitrogen material.
- Claim: 3. The method of claim 2, wherein nitriding the iron-carbon ribbons comprises exposing the iron-carbon ribbons to a nitrogen source at a temperature of between about 650° C. and about 900° C.
- Claim: 4. The method of claim 3, wherein the nitrogen source comprises at least one of ammonia, ammonium nitrate, urea, an amide, or hydrazine.
- Claim: 5. The method of claim 2, further comprising cryo-treating the iron-carbon-nitrogen material in liquid nitrogen.
- Claim: 6. The method of claim 2, further comprising annealing the iron-carbon-nitrogen material in a nitrogen-containing atmosphere at a temperature between about 100° C. and about 210° C. for between about 5 hours and about 100 hours.
- Claim: 7. The method of claim 2, further comprising, prior to nitriding the iron-carbon ribbons, exposing the iron-carbon ribbons to a reducing atmosphere to reduce a concentration of oxides in the iron-carbon ribbon.
- Claim: 8. The method of claim 7, further comprising, prior to exposing the iron-carbon ribbons to the reducing atmosphere, exposing the iron-carbon ribbons to an oxidizing atmosphere to form oxides in the iron-carbon ribbons, wherein exposing the iron-carbon ribbons to the reducing atmosphere removes at least some of the oxides and forms pores in the iron-carbon ribbons.
- Claim: 9. The method of claim 2, further comprising, prior to nitriding the iron-carbon ribbons, leaching some carbon from at least a surface of the iron-carbon ribbons to create porosity in the iron-carbon ribbons.
- Claim: 10. The method of claim 1, wherein forming the soft magnetic material by the technique comprising melt spinning comprises: forming a molten mixture comprising iron and carbon; melt spinning the molten mixture comprising iron and carbon to form iron-carbon ribbons; ball milling the iron-carbon ribbons to form iron-carbon powder; and nitriding the iron-carbon powder.
- Claim: 11. The method of claim 10, wherein nitriding the iron-carbon powder comprises exposing the iron-carbon powder to a nitrogen source at a temperature between about 100° C. and about 210° C. for between about 5 hours and about 100 hours.
- Claim: 12. The method of claim 11, wherein the nitrogen source comprises at least one of ammonia, ammonium nitrate, urea, an amide, or hydrazine.
- Claim: 13. The method of claim 10, further comprising, prior to nitriding the iron-carbon powder, exposing the iron-carbon powder to a reducing atmosphere to reduce a concentration of oxides in the iron-carbon powder.
- Claim: 14. The method of claim 13, further comprising, prior to exposing the iron-carbon powder to the reducing atmosphere, exposing the iron-carbon powder to an oxidizing atmosphere to form oxides in the iron-carbon powder, wherein exposing the iron-carbon powder to the reducing atmosphere removes at least some of the oxides and forms pores in the iron-carbon powder.
- Claim: 15. The method of claim 10, further comprising, prior to nitriding the iron-carbon powder, leaching some carbon from at least a surface of the iron-carbon powder to create porosity in the iron-carbon powder.
- Claim: 16. The method of claim 2, wherein forming the molten mixture comprising iron and carbon comprises melting cast iron.
- Claim: 17. The method of claim 16, wherein the cast iron is encapsulated in elemental iron.
- Claim: 18. The method of claim 10, wherein forming the molten mixture comprising iron and carbon comprises melting cast iron.
- Claim: 19. The method of claim 1, wherein the soft magnetic material comprises at least one dopant, and wherein the at least one dopant comprises at least one of Cu, Co, Ti, Mn, Al, V, Cr, Zn, Ga, Ge, Zr, Nb, Mo, P, Si, or Mg.
- Claim: 20. The method of claim 1, further comprising: assembling a plurality of the soft magnetic materials to form a bulk soft magnetic material.
- Claim: 21. The method of claim 1, wherein forming the soft magnetic material by the technique comprising melt spinning comprises: forming a molten mixture comprising iron; melt spinning the molten mixture comprising iron and carbon to form iron ribbons; and carburizing and nitriding the iron ribbons to form an iron-carbon-nitrogen material.
- Claim: 22. The method of claim 1, wherein forming the soft magnetic material by the technique comprising melt spinning comprises: forming a molten mixture comprising iron and nitrogen; melt spinning the molten mixture comprising iron and nitrogen to form iron-nitrogen ribbons; and carburizing the iron-nitrogen ribbons to form an iron-carbon-nitrogen material.
- Current International Class: 23; 22; 23; 22; 01
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