# US 2009/0010784 A1 · Powdered metals and structural metals having improved resistance to heat and corrosive fluids and b-stage powders for making such powdered metals > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2009/0010784 A1 - Document ID: US20090010784A1 - Status: Published application - Kind: A1 - Application number: 12/152,383 - Filed: 2008-05-13 - Published: 2009-01-08 - Earliest claimed: 2007-07-06 - Assignees: MBS Engineering, LLC - Inventors: Edward E. Welker; Mitchell L. Spencer; Viswanathan Panchanathan - Web page: https://patentgrep.com/patent/US20090010784A1 ## CPC - H01F 1/0578: {bonded together} - B22F 1/102: Metallic powder coated with organic material - C08L 61/06: of aldehydes with phenols - C22C 33/0257: {characterised by the range of the alloying elements} - C22C 2202/02: Magnetic - Y10T 428/25: Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles - Y10T 428/258: Alkali metal or alkaline earth metal or compound thereof - Y10T 428/31504: Composite [nonstructural laminate] - Y10T 428/31678: Of metal - Y10T 428/31942: Of aldehyde or ketone condensation product - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - C22C: ALLOYS (treatment of alloys C21D, C22F) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Improved resin-bonded powdered metal components are protected against corrosion and reduction of crush strength during contact with corrosive fluids such as alcohols, ethanol-containing fuels, glycols and peroxide-containing fuels by a resin system coating that, when cured, provides a relatively high crosslink density and relatively few hydrolysable radicals. Magnetic properties of resin-bonded powdered metal magnets are protected from heat degradation by the cured resin coating. The coating can be a heat-cured resin system comprising a phenol novolac resin and a compatible hardener. In one embodiment magnetizable powdered materials have an uncured resin system coating to provide a B-stage material that can be cured after compression shaping. ## Claims ### Claim 1 A resin-bonded powdered-material component of predetermined shape having improved crush strength upon contact with corrosive liquids, the component comprising: a. powdered material; and b. a cured resin system bonding the powdered material, the resin system having high crosslink density and low hydrolysable content. ### Claim 2 (depends on 1) The component of claim 1 wherein the cured resin system comprises a novolac resin. ### Claim 3 (depends on 2) The component of claim 2 wherein the cured resin system is from about 0.5 wt. % to about 5.0 wt. % of the component. ### Claim 4 (depends on 2) The component of claim 2 wherein the powdered material has an average particle size of from about 20 microns to about 400 microns. ### Claim 5 (depends on 1) The component of claim 1 wherein the powdered material comprises magnetic material and wherein the component demonstrates magnetic properties that resist degradation upon exposure to elevated temperatures. ### Claim 6 (depends on 5) The component of claim 5 wherein the magnetic material comprises rare earths, transition metals, boron and mixtures thereof. ### Claim 7 (depends on 6) The component of claim 6 wherein the magnetic material comprises elements selected from the group consisting of Nd, Pr, Fe, B and Co. ### Claim 8 (depends on 1) The component of claim 1 adapted for use in contact with a fluid containing high concentrations of corrosive materials. ### Claim 9 A flowable B-stage material curable to a component of predetermined shape having improved stability upon contact with corrosive liquids, the flowable B-stage material comprising: a. a particulate material; and b. a curable resin system at least partially coating the particulate material, the resin system being curable to a resin having a high crosslink density and a low concentration of hydrolysable moieties. ### Claim 10 (depends on 9) The B-stage material of claim 9 wherein the particulate material comprises magnetic material and wherein the B-stage material is curable to a component of predetermined shape with magnetic properties that have improved resistance to heat exposure. ### Claim 11 (depends on 10) The B-stage material of claim 10 wherein the particulate material comprises rare earths, transition metals, boron and mixtures thereof. ### Claim 12 (depends on 11) The B-stage material of claim 11 wherein the magnetic material comprises elements selected from the group consisting of Nd, Pr, Fe, B and Co. ### Claim 13 (depends on 9) The B-stage material of claim 9 wherein the cured resin system is from about 0.5 wt. % to about 5.0 wt. % of the component. ### Claim 14 (depends on 9) The B-stage material of claim 9 wherein the particulate material has an average particle size of from about 20 microns to about 400 microns. ### Claim 15 (depends on 9) The B-stage material of claim 9 comprising about 97.7% by weight of an Nd—Fe—B particulate material consisting essentially of Nd2Fe14B having an average particle size of about 150 microns coated with a heat curable resin system comprising about four parts phenyl novolac resin and about one part diamine crosslinker, the heat curable resin system comprising about 2.3% by wt. of the material. ### Claim 16 A electric fuel pump adapted for operation submerged in a corrosive fuel containing a high concentration of ethanol, the electric fuel pump comprising a shaped, magnetic powdered metal component comprising about 97.7% by weight of an Nd—Fe—B particulate material consisting essentially of Nd2Fe14B having an average particle size of about 150 microns bound in about 2.3% by weight of a heat cured resin binder system comprising about four parts phenyl novolac resin crosslinked with about one part diamine hardener. ### Claim 17 A method for protecting a material from a corrosive fluid comprising: a. coating at least a portion of the material with an effective amount of a curable resin system that when cured has a relatively high crosslink density and a relatively low hydrolysable content; and b. curing the resin system. ### Claim 18 (depends on 17) The method of claim 17 wherein the curable resin is a phenol Novolac resin. ### Claim 19 (depends on 17) The method of claim 17 wherein the material is a particulate having magnetic properties that are protected by the method from degradation by exposure to heat. ### Claim 20 (depends on 17) The method of claim 17 wherein the material is a structural component that is coated by spraying, immersion or painting.