How to Make Better Ferrite Powder for Industrial Use
A specific recipe for creating highly spherical magnetic ferrite particles that mix easily into plastics without ruining the curing process.
Original patent title: “Ferrite powder and method for producing same”
A specific recipe for creating highly spherical magnetic ferrite particles that mix easily into plastics without ruining the curing process. Granted to Powdertech Co Ltd in 2024 with 9 claims.
Key facts
Coverage
What does this patent actually cover?
This patent describes a specific chemical composition and manufacturing process for ferrite powder, which is a magnetic material often used as a filler in resins or plastics. By controlling the iron and manganese content, as well as keeping the carbon levels very low, the inventors ensure the powder remains highly magnetic while allowing the resin to harden properly. The process involves thermally spraying a mixture that includes a specific lubricant, resulting in particles that are nearly perfect spheres, measured by a shape factor (SF-1) of 100 to 110. This spherical shape is critical because it allows for a higher 'filling ratio,' meaning you can pack more magnetic material into a plastic component without making it too thick or difficult to work with.
The gap
What does this patent NOT cover?
- Does not cover ferrite powders with a carbon content higher than 0.100 mass percent.
- Does not cover non-spherical or irregularly shaped ferrite particles outside the SF-1 range of 100-110.
- Does not cover manufacturing processes that skip the thermal spray step.
- Does not cover ferrite compositions containing manganese levels outside the 3.5 to 10 mass percent range.
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
What made this novel
The innovation lies in the specific inclusion of a carbon-hydrogen-oxygen lubricant during the thermal spray process, which balances the need for spherical particle formation with the requirement for extremely low residual carbon in the final product.
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
Magnetic resin composites for electronic shielding
High-density magnetic filler for industrial plastics
Specialized components for electromagnetic interference (EMI) suppression
Why it matters
The bigger picture
Ferrite powders are essential for creating magnetic plastics used in electronics, such as electromagnetic interference shielding or specialized sensors. If the powder inhibits the resin from curing, the final product will be brittle or structurally weak. This patent provides a precise technical standard for manufacturers to achieve high magnetic performance without compromising the physical integrity of the host material.
Filed
January 22, 2021
Granted
November 5, 2024
Market context
Who's building on this
Companies in this space
Powdertech Co. Ltd. is a major player in the specialized ferrite powder market. Their work is primarily utilized by manufacturers of high-performance electronic components and resin-based magnetic materials who need precise control over particle geometry and chemical purity.
Market impact
This patent establishes a technical benchmark for high-purity, spherical ferrite powders. By defining the precise mass percentages for iron and manganese, it helps manufacturers avoid common production defects like poor resin curing, which is a significant bottleneck in the production of high-density magnetic composites.
Claim 1 — Plain English
What this patent covers
This patent describes a specific chemical composition and manufacturing process for ferrite powder, which is a magnetic material often used as a filler in resins or plastics. By controlling the iron and manganese content, as well as keeping the carbon levels very low, the inventors ensure the powder remains highly magnetic while allowing the resin to harden properly. The process involves thermally spraying a mixture that includes a specific lubricant, resulting in particles that are nearly perfect spheres, measured by a shape factor (SF-1) of 100 to 110. This spherical shape is critical because it allows for a higher 'filling ratio,' meaning you can pack more magnetic material into a plastic component without making it too thick or difficult to work with.
The clever bit
The innovation lies in the specific inclusion of a carbon-hydrogen-oxygen lubricant during the thermal spray process, which balances the need for spherical particle formation with the requirement for extremely low residual carbon in the final product.
What it does not cover
- Does not cover ferrite powders with a carbon content higher than 0.100 mass percent.
- Does not cover non-spherical or irregularly shaped ferrite particles outside the SF-1 range of 100-110.
- Does not cover manufacturing processes that skip the thermal spray step.
- Does not cover ferrite compositions containing manganese levels outside the 3.5 to 10 mass percent range.
Patent timeline
Application submitted to the patent office
Application published, typically 18 months after filing
Patent officially issued
PatentBrief Score
Impact Score
Early stage
Citation count
0/40
No citations yet
Claim breadth
6/20
Moderate scope
Recency
20/20
Granted within 5 years
Assignee scale
0/20
Independent or smaller assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$25K – $81K
Midpoint $50K · 14.6 yr remaining · industry ×1.4
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
The original legal language
Original claims
9 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Kojima, T., & Aga, K. (2024). How to Make Better Ferrite Powder for Industrial Use (U.S. Patent No. 12,134,567). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/12134567/falcon-9-block-5
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
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Common Questions
Frequently Asked Questions
What does How to Make Better Ferrite Powder for Industrial Use cover?
A specific recipe for creating highly spherical magnetic ferrite particles that mix easily into plastics without ruining the curing process.
Who owns patent US 12134567?
Powdertech Co Ltd owns this patent, granted in 2024.
When does this patent expire?
This patent is expected to expire on November 5, 2044, when the invention enters the public domain.
What problem does this patent solve?
Ferrite powders are essential for creating magnetic plastics used in electronics, such as electromagnetic interference shielding or specialized sensors. If the powder inhibits the resin from curing, the final product will be brittle or structurally weak. This patent provides a precise technical standard for manufacturers to achieve high magnetic performance without compromising the physical integrity of the host material.
What does this patent NOT cover?
Does not cover ferrite powders with a carbon content higher than 0.100 mass percent.
Patent monitoring