Patents by Inventor Hisashi MAEHARA
Hisashi MAEHARA has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11990260Abstract: The present invention is a method for producing a rare earth magnet, including preparing a magnetic powder and a modifier powder, mixing them to obtain a mixed powder, compression-molding the mixed powder in a magnetic field to obtain a magnetic-field molded body, and pressure-sintering the magnetic-field molded body to obtain a sintered body, wherein the magnetic powder includes a first particle group and a second particle group, the D50 values of the first particle group and the second particle group are denoted by d1 ?m and d2 ?m, respectively, d1 and d2 satisfy the relationship of 0.350?d2/d1?0.500, and the ratio between the total volume of the first particle group and the total volume of the second particle group is from 9:1 to 4:1; and a rare earth magnet obtained by the production method.Type: GrantFiled: November 1, 2022Date of Patent: May 21, 2024Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, NICHIA CORPORATIONInventors: Masaaki Ito, Motoki Hiraoka, Reimi Tabuchi, Hisashi Maehara, Masanori Okanan
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Publication number: 20240161975Abstract: A method of producing a SmFeN-based rare earth magnet, the method including: heat-treating a SmFeN-based anisotropic magnetic powder having a surface coated with a phosphate at a temperature of at least 80° C. but lower than 150° C.; mixing the heat-treated SmFeN-based anisotropic magnetic powder and a Zn-containing modifier powder by dispersion using resin-coated metal media or resin-coated ceramic media to obtain a powder mixture containing the SmFeN-based anisotropic magnetic powder and the modifier powder; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; and pressure-sintering the magnetic field compact to obtain a sintered compact.Type: ApplicationFiled: November 10, 2023Publication date: May 16, 2024Applicants: NICHIA CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Hisashi MAEHARA, Tomonori INUZUKA, Masaaki ITO, Motoki HIRAOKA
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Publication number: 20240116046Abstract: A sensor package 10 includes a plurality of sensors 19 and a container 18. Each of the sensors 19 detects a detection target component in the fluid. The container 18 includes an inner channel 21 and a first surface os1. The plurality of sensors 19 are provided in the inner channel 21. The inner channel 21 enables the fluid to flow. An inflow opening 25 to the inner channel 21 and an outflow opening 25 from the inner channel 21 are formed on the first surface os1. An electrode group electrically connected to the plurality of sensors 19 is provided on a surface different from the first surface os1 of the container 18.Type: ApplicationFiled: February 9, 2022Publication date: April 11, 2024Inventors: Hisashi SAKAI, Masahiko TAJIMA, Tadatomo MAEHARA, Masami YOSHIKAWA
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Publication number: 20240062936Abstract: A method of producing a rare earth magnetic powder, the method including: heat-treating a mixture containing a SmFeN-based magnetic powder containing Sm, Fe, and N and a modifier powder containing Zn; and dispersing the heat-treated SmFeN-based magnetic powder using a resin-coated metal media or a resin-coated ceramic media.Type: ApplicationFiled: August 11, 2023Publication date: February 22, 2024Applicants: NICHIA CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Hisashi MAEHARA, Masaaki ITO, Tomonori INUZUKA, Motoki HIRAOKA
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Publication number: 20230268105Abstract: A method of producing anisotropic magnetic powders comprising obtaining a precipitate containing an element R, iron and lanthanum from a solution including R, iron and lanthanum, wherein R is at least one selected from the group consisting of Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm and Lu; obtaining an oxide containing R, iron and lanthanum from the precipitate; treating the oxide with a reducing gas to obtain a partial oxide; obtaining alloy particles by reduction diffusion of the partial oxide at a temperature in the range of 920° C. to 1200° C.; and nitriding the alloy particles to produce an anisotropic magnetic powder represented by the following general formula: Rv-xFe(100-v-w-z)NwLaxWz, where 3?v?x?30, 5?w?15, 0.08?x?0.3, and 0?z?2.5.Type: ApplicationFiled: May 1, 2023Publication date: August 24, 2023Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA
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Publication number: 20230238161Abstract: Provided is an anisotropic magnetic powder having a low oxygen concentration, a small average particle size, a narrow particle size distribution, and a high remanence, and a method for producing the anisotropic magnetic powder. The present disclosure relates to a method for producing an anisotropic magnetic powder, including: pretreating an oxide containing Sm and Fe by heat-treating the oxide in a reducing gas atmosphere to obtain a partial oxide; heat-treating the partial oxide in the presence of a reducing agent to obtain alloy particles; nitriding the alloy particles to obtain a nitride; and treating the nitride with an alkali to obtain a magnetic powder.Type: ApplicationFiled: June 16, 2021Publication date: July 27, 2023Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA
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Patent number: 11685654Abstract: Provided are a method of producing a titanium-containing rare earth-iron-nitrogen anisotropic magnetic powder having good magnetic properties, and secondary particles for a titanium-containing anisotropic magnetic powder. The method includes: obtaining a first precipitate containing R, iron, and titanium by mixing a first precipitating agent with a solution containing R, iron, and titanium, wherein R is at least one selected from Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, and Lu; obtaining a second precipitate containing R and iron by mixing, in the presence of the first precipitate, a second precipitating agent with a solution containing R and iron; obtaining an oxide containing R, iron, and titanium by calcining the second precipitate; obtaining a partial oxide by heat treating the oxide in a reducing gas atmosphere; obtaining alloy particles by reducing the partial oxide; and obtaining an anisotropic magnetic powder by nitriding the alloy particles.Type: GrantFiled: October 8, 2021Date of Patent: June 27, 2023Assignee: NICHIA CORPORATIONInventor: Hisashi Maehara
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Patent number: 11676748Abstract: A method of producing anisotropic magnetic powders comprising obtaining a precipitate containing an element R, iron and lanthanum from a solution including R, iron and lanthanum, wherein R is at least one selected from the group consisting of Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm and Lu; obtaining an oxide containing R, iron and lanthanum from the precipitate; treating the oxide with a reducing gas to obtain a partial oxide; obtaining alloy particles by reduction diffusion of the partial oxide at a temperature in the range of 920° C. to 1200° C.; and nitriding the alloy particles to produce an anisotropic magnetic powder represented by the following general formula: Rv-xFe(100-v-w-z)NwLaxWz, where 3?v?x?30, 5?w?15, 0.08?x?0.3, and 0?z?2.5.Type: GrantFiled: December 22, 2016Date of Patent: June 13, 2023Assignee: NICHIA CORPORATIONInventor: Hisashi Maehara
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Publication number: 20230139716Abstract: The present invention is a method for producing a rare earth magnet, including preparing a magnetic powder and a modifier powder, mixing them to obtain a mixed powder, compression-molding the mixed powder in a magnetic field to obtain a magnetic-field molded body, and pressure-sintering the magnetic-field molded body to obtain a sintered body, wherein the magnetic powder includes a first particle group and a second particle group, the D50 values of the first particle group and the second particle group are denoted by d1 ?m and d2 ?m, respectively, d1 and d2 satisfy the relationship of 0.350?d2/d1?0.500, and the ratio between the total volume of the first particle group and the total volume of the second particle group is from 9:1 to 4:1; and a rare earth magnet obtained by the production method.Type: ApplicationFiled: November 1, 2022Publication date: May 4, 2023Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, NICHIA CORPORATIONInventors: Masaaki ITO, Motoki HIRAOKA, Reimi TABUCHI, Hisashi MAEHARA, Masanori OKANAN
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Publication number: 20230105234Abstract: A method of producing a SmFeN-based rare earth magnet, the method including: dispersing a SmFeN-based anisotropic magnetic powder including Sm, Fe, La, W, R, and N, wherein R is at least one selected from the group consisting of Ti, Ba, and Sr, using a resin-coated metal media or a resin-coated ceramic media to obtain a dispersed SmFeN-based anisotropic magnetic powder; mixing the dispersed SmFeN-based anisotropic magnetic powder with a modifier powder to obtain a powder mixture; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; pressure-sintering the magnetic field compact to obtain a sintered compact; and heat-treating the sintered compact.Type: ApplicationFiled: September 27, 2022Publication date: April 6, 2023Applicants: NICHIA CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Hisashi MAEHARA, Masaaki ITO
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Publication number: 20230099171Abstract: An L10 type iron-nickel (FeNi) ordered alloy has an L10 type ordered structure and contains sulfur. The L10 type FeNi ordered alloy may have a sulfur content in a range from 0.01% by mass to 10% by mass. A manufacturing method of an L10 type FeNi ordered alloy includes performing a nitriding treatment to an FeNi alloy containing sulfur to obtain a nitride containing Fe and Ni.Type: ApplicationFiled: September 22, 2022Publication date: March 30, 2023Inventors: Hiroaki KURA, Takahiro NISHIO, Eiji WATANABE, Yoshiaki HAYASHI, Takayuki YAMAMOTO, Hisashi MAEHARA, Takanori MATSUNO
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Patent number: 11594352Abstract: The present disclosure provides a method of producing a magnetic powder capable of providing a bonded magnet having a high remanence. The present disclosure relates to a method of producing a magnetic powder, including: 1) mixing an alkyl silicate with an acidic solution; 2) mixing the resultant alkyl silicate mixture with a SmFeLaN anisotropic magnetic powder; and 3) mixing the resultant magnetic powder mixture with an alkali solution.Type: GrantFiled: September 26, 2020Date of Patent: February 28, 2023Assignee: NICHIA CORPORATIONInventor: Hisashi Maehara
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Publication number: 20220406496Abstract: A method of producing a SmFeN-based anisotropic magnetic powder is provided, the method including preparing a SmFeN-based anisotropic magnetic powder before dispersing comprising Sm, Fe, W, and N, and dispersing the SmFeN-based anisotropic magnetic powder before dispersing using a resin-coated metal media or a resin-coated ceramic media to obtain a SmFeN-based anisotropic magnetic powder. Also provided is a SmFeN-based anisotropic magnetic powder comprising Sm, Fe, W, and N and having an average particle size of less than 2.5 ?m, a residual magnetization ?r of not less than 130 emu/g, and an oxygen content of not higher than 0.75% by mass.Type: ApplicationFiled: June 10, 2022Publication date: December 22, 2022Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA
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Publication number: 20220399163Abstract: A method of producing a SmFeN-based rare earth magnet, the method including: dispersing a SmFeN-based anisotropic magnetic powder comprising Sm, Fe, and N using a resin-coated metal media or a resin-coated ceramic media to obtain a dispersed SmFeN-based anisotropic magnetic powder; mixing the dispersed SmFeN-based anisotropic magnetic powder with a modifier powder to obtain a powder mixture; compacting the powder mixture in a magnetic field to obtain a magnetic field compact; pressure-sintering the magnetic field compact to obtain a sintered compact; and heat treating the sintered compact.Type: ApplicationFiled: June 10, 2022Publication date: December 15, 2022Applicants: NICHIA CORPORATION, TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Hisashi MAEHARA, Michiya KUME, Masaaki ITO
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Publication number: 20220199321Abstract: A rare-earth magnet and a method of manufacturing the same are provided. The method includes: preparing Sm-Fe-N magnetic powder; preparing reforming material powder containing metallic zinc; mixing the magnetic powder and the reforming material powder to obtain mixed powder; subjecting the mixed powder to compression molding in a magnetic field to obtain a magnetic-field molded body; subjecting the magnetic-field molded body to pressure sintering to obtain a sintered body; and subjecting the sintered body to heat treatment. A content proportion of the metallic zinc in the reforming material powder is 10 to 30% by mass with respect to the mixed powder. When a temperature and time in conditions for the heat treatment are defined as x° C. and y hours, respectively, the formulas y??0.32x+136 and 350?x?410 are met.Type: ApplicationFiled: December 1, 2021Publication date: June 23, 2022Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, NICHIA CORPORATIONInventors: Masaaki ITO, Daisuke ICHIGOZAKI, Noritsugu SAKUMA, Akihito KINOSHITA, Michiya KUME, Hisashi MAEHARA
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Publication number: 20220041447Abstract: Provided are a method of producing a titanium-containing rare earth-iron-nitrogen anisotropic magnetic powder having good magnetic properties, and secondary particles for a titanium-containing anisotropic magnetic powder. The method includes: obtaining a first precipitate containing R, iron, and titanium by mixing a first precipitating agent with a solution containing R, iron, and titanium, wherein R is at least one selected from Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, and Lu; obtaining a second precipitate containing R and iron by mixing, in the presence of the first precipitate, a second precipitating agent with a solution containing R and iron; obtaining an oxide containing R, iron, and titanium by calcining the second precipitate; obtaining a partial oxide by heat treating the oxide in a reducing gas atmosphere; obtaining alloy particles by reducing the partial oxide; and obtaining an anisotropic magnetic powder by nitriding the alloy particles.Type: ApplicationFiled: October 8, 2021Publication date: February 10, 2022Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA
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Patent number: 11167987Abstract: Provided are a method of producing a titanium-containing rare earth-iron-nitrogen anisotropic magnetic powder having good magnetic properties, and secondary particles for a titanium-containing anisotropic magnetic powder. The method includes: obtaining a first precipitate containing R, iron, and titanium by mixing a first precipitating agent with a solution containing R, iron, and titanium, wherein R is at least one selected from Sc, Y, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, and Lu; obtaining a second precipitate containing R and iron by mixing, in the presence of the first precipitate, a second precipitating agent with a solution containing R and iron; obtaining an oxide containing R, iron, and titanium by calcining the second precipitate; obtaining a partial oxide by heat treating the oxide in a reducing gas atmosphere; obtaining alloy particles by reducing the partial oxide; and obtaining an anisotropic magnetic powder by nitriding the alloy particles.Type: GrantFiled: May 15, 2018Date of Patent: November 9, 2021Assignee: NICHIA CORPORATIONInventor: Hisashi Maehara
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Publication number: 20210098161Abstract: The present disclosure provides a method of producing a magnetic powder capable of providing a bonded magnet having a high remanence. The present disclosure relates to a method of producing a magnetic powder, including: 1) mixing an alkyl silicate with an acidic solution; 2) mixing the resultant alkyl silicate mixture with a SmFeLaN anisotropic magnetic powder; and 3) mixing the resultant magnetic powder mixture with an alkali solution.Type: ApplicationFiled: September 26, 2020Publication date: April 1, 2021Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA
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Patent number: 10867728Abstract: The present invention relates to a method of producing an anisotropic magnetic powder having good magnetic properties. The method of producing an anisotropic magnetic powder includes: pretreating an oxide containing Sm and Fe by heat treatment in a reducing gas atmosphere to obtain a partial oxide; heat treating the partial oxide in the presence of a reductant at a first temperature of 1000° C. or higher and 1090° C. or lower and then at a second temperature lower than the first temperature and in the range of 980° C. or higher and 1070° C. or lower to obtain alloy particles; and nitriding the alloy particles to obtain an anisotropic magnetic powder.Type: GrantFiled: December 20, 2018Date of Patent: December 15, 2020Assignee: NICHIA CORPORATIONInventor: Hisashi Maehara
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Publication number: 20190198207Abstract: The present invention relates to a method of producing an anisotropic magnetic powder having good magnetic properties. The method of producing an anisotropic magnetic powder includes: pretreating an oxide containing Sm and Fe by heat treatment in a reducing gas atmosphere to obtain a partial oxide; heat treating the partial oxide in the presence of a reductant at a first temperature of 1000° C. or higher and 1090° C. or lower and then at a second temperature lower than the first temperature and in the range of 980° C. or higher and 1070° C. or lower to obtain alloy particles; and nitriding the alloy particles to obtain an anisotropic magnetic powder.Type: ApplicationFiled: December 20, 2018Publication date: June 27, 2019Applicant: NICHIA CORPORATIONInventor: Hisashi MAEHARA