Tape casting method and tape cast materials
AssigneeInframat Corporation
InventorsShiqiang Hui, Yide Zhang, Danny Xiao, Mingzhong Wu
Life of this patent
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Abstract
A precursor tape casting method is one in which chemical precursors are converted into a final chemical phase from green tapes to products. Because chemical precursors are employed rather than the final powder materials, sintering is not required to form the material. Lower annealing temperatures instead of high temperature sintering allow the formation of grains of about 1 to about 100 nanometers in the final material. In addition, when the final material is a magnetic/insulator composite, improved magnetic properties may be obtained.
Claims20
A method of tape casting a material, comprising:
- drying a first mixture comprising one or more chemical precursors and a liquid medium at a temperature effective to form agglomerates;
- grinding the agglomerates to form a precomposite powder comprising the one or more chemical precursors;
- combining the precomposite powder with a binder to form a second mixture;
- casting the second mixture to form a green tape;
- and
- heating the green tape for a time and at a temperature sufficient to convert the chemical precursors to their final chemical phase, and to anneal and form the material wherein the material comprises a composite selected from the group consisting of Fe—Ni/Silica, Co/Silica, Fe/Silica, Ni-Ferrite, Fe—Co/Silica, Fe—Co and (FeCo)1-x(Al2O3)x where x is greater than zero and less than or equal to about 0.50.
A method of forming a magnetic composite tape, comprising:
- tape casting a magnetic component chemical precursor and an insulating material chemical precursor using a scraping blade to form a green tape;
- and
- heating the green tape for a time and at a temperature sufficient to simultaneously convert the magnetic component chemical precursor and the insulating material chemical precursor to their final chemical phase and to anneal the green tape, thereby forming a magnetic composite tape comprising magnetic particles embedded in an insulating material such that each magnetic particle is surrounded by the insulating material, wherein each magnetic particle has a grain size of about 1 nanometer to about 100 nanometers.
A method of tape casting a material, comprising:
- drying a first mixture comprising one or more chemical precursors and a liquid medium at a temperature effective to form agglomerates;
- the chemical precursors being selected from the group consisting of carboxylate salts, acetate salts, nitrate salts, chloride salts, alkoxide salts, butoxide salts, alkali elements, alkaline earth metals, transition metals, rare earth metals, combinations comprising one or more of the foregoing elements and metals, and combinations of the foregoing salts, elements and metals;
- the liquid medium being selected from the group consisting of water, alcohols, acetone, methyl ethyl ketones and a combination of one or more of the foregoing liquid medium;
- grinding the agglomerates to form a precomposite powder comprising the one or more chemical precursors;
- combining the precomposite powder with a binder to form a second mixture;
- casting the second mixture to form a green tape;
- and
- heating the green tape for a time and at a temperature sufficient to convert the chemical precursors to their final chemical phase, and to anneal and form the material wherein the material comprises a composite selected from the group consisting of Fe—Ni/Silica, Co/Silica, Fe/Silica, Ni-Ferrite, Fe—Co/Silica, Fe—Co and (FeCo)1-x(Al2O3) where x is greater than zero and less than or equal to about 0.50.
Dependencies are inferred from the claim text.