Patents by Inventor Kazuaki HAGA
Kazuaki HAGA 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: 11804741Abstract: A motor includes a rotor fixed to a rotary shaft, a stator arranged so as to surround the rotor with a gap from the rotor in a radial direction orthogonal to an axis direction of the rotary shaft, and a case accommodating the rotor and the stator. The rotor includes a plurality of rotor cores made from a soft magnetic material, and a rotor fixing member that fixes the rotor cores. The stator includes a plurality of stator cores made from a soft magnetic material, a stator fixing member that fixes the stator cores, and coils wound around the stator cores, respectively. The motor includes at least two sets of the rotor and the stator, and the sets are stacked in an axis direction of the rotary shaft.Type: GrantFiled: May 3, 2022Date of Patent: October 31, 2023Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Mayumi Takazawa, Kazuaki Haga, Toshimitsu Takahashi, Takuya Nomura, Shinya Sano, Yasuhide Yagyu, Takeshi Tomonaga, Hisanori Koma, Keiu Kanada
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Publication number: 20230318423Abstract: In an axial gap motor, a rotor includes a plurality of rotor cores fixed in a circumferential direction of a rotor base, and a stator includes a plurality of stator cores fixed in a circumferential direction of a stator base, and coils wound around the stator cores. End faces of each of the rotor cores and end faces of the corresponding stator core are opposed to each other while being exposed to each other.Type: ApplicationFiled: June 8, 2023Publication date: October 5, 2023Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Keiu Kanada, Kazuaki Haga, Toshimitsu Takahashi, Mayumi Takazawa, Takuya Nomura, Shinya Sano, Takeshi Tomonaga, Hisanori Koma, Yasuhide Yagyu, Kensuke Komori, Tatsuhiko Hirano, Masaaki Ito, Hiroaki Wakimoto
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Patent number: 11711004Abstract: In an axial gap motor, a rotor includes a plurality of rotor cores fixed in a circumferential direction of a rotor base, and a stator includes a plurality of stator cores fixed in a circumferential direction of a stator base, and coils wound around the stator cores. End faces of each of the rotor cores and end faces of the corresponding stator core are opposed to each other while being exposed to each other.Type: GrantFiled: April 12, 2021Date of Patent: July 25, 2023Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Keiu Kanada, Kazuaki Haga, Toshimitsu Takahashi, Mayumi Takazawa, Takuya Nomura, Shinya Sano, Takeshi Tomonaga, Hisanori Koma, Yasuhide Yagyu, Kensuke Komori, Tatsuhiko Hirano, Masaaki Ito, Hiroaki Wakimoto
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Patent number: 11594946Abstract: An axial gap motor is configured such that: a rotor includes a plurality of rotor cores fixed along the circumferential direction of a rotor pedestal, and a plurality of magnets; and a stator includes a plurality of stator cores fixed along the circumferential direction of a stator pedestal, and coils wound around the stator cores. A first divided surface of each rotor core faces an N-pole of a corresponding magnet, and a second divided surface of the each rotor core faces an S-pole of a corresponding magnet. Respective divided surfaces of the rotor cores are placed to face respective divided surfaces of the stator cores across the magnets.Type: GrantFiled: March 17, 2021Date of Patent: February 28, 2023Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki Haga, Keiu Kanada, Kensuke Komori, Masaaki Ito
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Publication number: 20220376567Abstract: A motor includes a rotor fixed to a rotary shaft, a stator arranged so as to surround the rotor with a gap from the rotor in a radial direction orthogonal to an axis direction of the rotary shaft, and a case accommodating the rotor and the stator. The rotor includes a plurality of rotor cores made from a soft magnetic material, and a rotor fixing member that fixes the rotor cores. The stator includes a plurality of stator cores made from a soft magnetic material, a stator fixing member that fixes the stator cores, and coils wound around the stator cores, respectively. The motor includes at least two sets of the rotor and the stator, and the sets are stacked in an axis direction of the rotary shaft.Type: ApplicationFiled: May 3, 2022Publication date: November 24, 2022Inventors: Mayumi TAKAZAWA, Kazuaki HAGA, Toshimitsu TAKAHASHI, Takuya NOMURA, Shinya SANO, Yasuhide YAGYU, Takeshi TOMONAGA, Hisanori KOMA, Keiu KANADA
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Patent number: 11476020Abstract: To provide a rare earth magnet having excellent coercive force and a production method thereof. A rare earth magnet, wherein the rare earth magnet comprises a magnetic phase containing Sm, Fe, and N, a Zn phase present around the magnetic phase, and an intermediate phase present between the magnetic phase and the Zn phase, wherein the intermediate phase contains Zn and the oxygen content of the intermediate phase is higher than the oxygen content of the Zn phase; and a method for producing a rare earth magnet, including mixing a magnetic raw material powder having an oxygen content of 1.0 mass % or less and an improving agent powder containing metallic Zn and/or a Zn alloy, and heat-treating the mixed powder.Type: GrantFiled: June 20, 2018Date of Patent: October 18, 2022Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITYInventors: Noritsugu Sakuma, Tetsuya Shoji, Kazuaki Haga, Satoshi Sugimoto, Masashi Matsuura
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Publication number: 20220203440Abstract: Provided is a rare earth magnet that allows suppressing deterioration of magnetic properties and a method for manufacturing the same. The rare earth magnet of the present disclosure includes a magnet body containing a rare earth element R1, a transition metal element T, and boron B and includes a main phase. A region in the vicinity of a corner portion of the magnet body of a constituent surface constituting a surface of the magnet body is a processed surface on which a removal process has been performed, and a region closer to a center than the region in the vicinity of the corner portion of the constituent surface is a non-processed surface on which the removal process is not performed.Type: ApplicationFiled: December 8, 2021Publication date: June 30, 2022Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Mayumi TAKAZAWA, Kazuaki HAGA, Daisuke ICHIGOZAKI, Masaaki ITO, Hisanori KOMA, Shinya SANO, Kensuke KOMORI, Keiu KANADA
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Patent number: 11313022Abstract: There is provided a method for manufacturing a soft magnetic member where a coating formed of an ?-Fe2O3 single phase having a high electrical resistivity is formed on a soft magnetic alloy substrate. A soft magnetic alloy substrate is heated in an atmosphere containing water vapor and inert gas to form a coating on the soft magnetic alloy substrate. The atmosphere has an oxygen partial pressure in a range of 0 to 1.5 kPa. A soft magnetic member including the soft magnetic alloy substrate and the coating formed on its surface can be obtained.Type: GrantFiled: November 20, 2019Date of Patent: April 26, 2022Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Fumitaka Yoshinaga, Kazuaki Haga, Seishi Utsuno
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Patent number: 11309777Abstract: A rotating electrical machine capable of obtaining a higher torque while limiting the amount of permanent magnets used. A magnetic pole of a rotor includes an auxiliary magnet embedded in a rotor core and at least one main magnet arranged on an outer circumferential side than the auxiliary magnet of the rotor. In each magnetic pole, the distance from an end of the main magnet, the end facing the auxiliary magnet, to the auxiliary magnet facing the main magnet is shorter than the length of the main magnet in the radial direction. In a cross-section orthogonal to the rotation axis of the rotating electrical machine, the main magnets of each magnetic pole are arranged so as to be asymmetrical about a virtual line passing the rotation axis and axisymmetrically dividing the auxiliary magnet.Type: GrantFiled: March 4, 2021Date of Patent: April 19, 2022Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Keiu Kanada, Daisuke Ichigozaki, Kazuaki Haga, Motoki Hiraoka, Daichi Maruyama, Hisamitsu Toshida, Kyoko Nakamura, Akira Yamashita
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Patent number: 11177725Abstract: Provided is an IPM motor that is strong and has high output. An IPM motor has a rotor that includes a rotor core as a laminate of a plurality of metal foil pieces made of a soft magnetic material that are stacked in a direction of a rotation axis of the rotor. The rotor core has a plurality of through-holes that penetrates through the rotor core in the direction of the rotation axis, the plurality of through-holes including through-holes embedding magnets. The rotor core includes inner bridges and outer bridges. At least one of the inner bridges and the outer bridges of the rotor core is made of an amorphous soft magnetic material, and other parts are made of a nanocrystal soft magnetic material.Type: GrantFiled: June 5, 2019Date of Patent: November 16, 2021Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Fumitaka Yoshinaga, Akira Yamashita, Airi Kamimura, Kazuaki Haga, Kensuke Komori
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Publication number: 20210328490Abstract: In an axial gap motor, a rotor includes a plurality of rotor cores fixed in a circumferential direction of a rotor base, and a stator includes a plurality of stator cores fixed in a circumferential direction of a stator base, and coils wound around the stator cores. End faces of each of the rotor cores and end faces of the corresponding stator core are opposed to each other while being exposed to each other.Type: ApplicationFiled: April 12, 2021Publication date: October 21, 2021Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Keiu KANADA, Kazuaki HAGA, Toshimitsu TAKAHASHI, Mayumi TAKAZAWA, Takuya NOMURA, Shinya SANO, Takeshi TOMONAGA, Hisanori KOMA, Yasuhide YAGYU, Kensuke KOMORI, Tatsuhiko HIRANO, Masaaki ITO, Hiroaki WAKIMOTO
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Publication number: 20210328489Abstract: An axial gap motor is configured such that: a rotor includes a plurality of rotor cores fixed along the circumferential direction of a rotor pedestal, and a plurality of magnets; and a stator includes a plurality of stator cores fixed along the circumferential direction of a stator pedestal, and coils wound around the stator cores. A first divided surface of each rotor core faces an N-pole of a corresponding magnet, and a second divided surface of the each rotor core faces an S-pole of a corresponding magnet. Respective divided surfaces of the rotor cores are placed to face respective divided surfaces of the stator cores across the magnets.Type: ApplicationFiled: March 17, 2021Publication date: October 21, 2021Inventors: Kazuaki HAGA, Keiu KANADA, Kensuke Komori, Masaaki ITO
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Publication number: 20210281153Abstract: A rotating electrical machine capable of obtaining a higher torque while limiting the amount of permanent magnets used. A magnetic pole of a rotor includes an auxiliary magnet embedded in a rotor core and at least one main magnet arranged on an outer circumferential side than the auxiliary magnet of the rotor. In each magnetic pole, the distance from an end of the main magnet, the end facing the auxiliary magnet, to the auxiliary magnet facing the main magnet is shorter than the length of the main magnet in the radial direction.Type: ApplicationFiled: March 4, 2021Publication date: September 9, 2021Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Keiu KANADA, Daisuke ICHIGOZAKI, Kazuaki HAGA, Motoki HIRAOKA, Daichi MARUYAMA, Hisamitsu TOSHIDA, Kyoko NAKAMURA, Akira YAMASHITA
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Patent number: 10958112Abstract: Provided is a laminate of soft magnetic ribbons having a simple structure and capable of avoiding a damage of the soft magnetic ribbons and improving the occupancy of the soft magnetic ribbons. The laminate of soft magnetic ribbons includes: a laminated part of first soft magnetic ribbons stacked; and a reinforcing part disposed at both ends of the laminated part in the stacking direction of the first soft magnetic ribbons. The reinforcing part includes second soft magnetic ribbons stacked in the stacking direction of the first soft magnetic ribbons and hardening resin that covers the second soft magnetic ribbons as a whole and is impregnated into areas between the neighboring second soft magnetic ribbons.Type: GrantFiled: January 24, 2019Date of Patent: March 23, 2021Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Fumitaka Yoshinaga, Kazuaki Haga
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Patent number: 10892089Abstract: The present disclosure provides a method for producing a magnetic component that enables efficient processing of an amorphous soft magnetic material or a nanocrystalline soft magnetic material. The method for producing a magnetic component comprising an amorphous soft magnetic material or nanocrystalline soft magnetic material comprises: a step of preparing a stacked body comprising a plurality of plate-shaped amorphous soft magnetic materials or nanocrystalline soft magnetic materials; a step of heating at least a portion of shearing in the stacked body to a temperature equal to or higher than the crystallization temperature of the soft magnetic materials; and a step of shearing the stacked body at the portion of shearing after the step of heating.Type: GrantFiled: October 1, 2018Date of Patent: January 12, 2021Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Airi Kamimura, Kazuaki Haga, Kensuke Komori, Katsuhiko Tatebe, Shingo Fubuki
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Patent number: 10855122Abstract: Provided is a stator for rotating electrical machine that can avoid the sagging of teeth stacked at the distal ends under the self-weight. A stator core is a laminate of metal foil members stacked in a direction of a rotation axis of the rotating electrical machine. Each tooth has a pair of side walls facing the neighboring teeth in the circumferential direction. The stator includes a pair of insulating reinforcing members so as to become a bridge between the corresponding tooth and a part of the yoke and sandwich the corresponding tooth from both sides in the direction of the rotation axis while exposing the pair of side walls; insulating fixing members, each fixing member fixing the corresponding pair of reinforcing members to the corresponding tooth while wrapping around the pair of reinforcing members and tooth; and coils formed as distributed windings at the teeth fixed with the fixing members.Type: GrantFiled: February 19, 2019Date of Patent: December 1, 2020Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kensuke Komori, Hisamitsu Toshida, Kazuaki Haga
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Publication number: 20200224302Abstract: There is provided a method for manufacturing a soft magnetic member where a coating formed of an ?-Fe2O3 single phase having a high electrical resistivity is formed on a soft magnetic alloy substrate. A soft magnetic alloy substrate is heated in an atmosphere containing water vapor and inert gas to form a coating on the soft magnetic alloy substrate. The atmosphere has an oxygen partial pressure in a range of 0 to 1.5 kPa. A soft magnetic member including the soft magnetic alloy substrate and the coating formed on its surface can be obtained.Type: ApplicationFiled: November 20, 2019Publication date: July 16, 2020Inventors: Fumitaka YOSHINAGA, Kazuaki HAGA, Seishi UTSUNO
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Patent number: 10658107Abstract: In a method of manufacturing a permanent magnet having a curved surface, a permeating material including metal particles and a flux is applied to the curved surface of a magnet. The magnet to which the permeating material is applied is then positioned within a furnace and the furnace is placed in a vacuum or filled with inert gas to volatilize a solvent and the like of the flux contained in the permeating material. The furnace is set to be a temperature within a range of 300 through 500 degrees C. to heat the permeating material. This enables the flux to be carbonized to form reticulated carbon. The furnace is then set to be a temperature within a range of 500 through 800 degrees C. to melt the metal particles in the permeating material, thereby permeating the melted metal particles into the magnet through the reticulated carbon uniformly.Type: GrantFiled: October 11, 2017Date of Patent: May 19, 2020Assignee: Senju Metal Industry Co., Ltd.Inventors: Daisuke Sakuma, Kazuaki Haga, Takaaki Takahashi, Minoru Ueshima, Takashi Akagawa, Yoshie Tachibana
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Publication number: 20200098497Abstract: To provide a rare earth magnet in which particles of SmFeN powder are bound using a Zn powder, wherein generation of a knick at a magnetic field of around 0 is prevented and high residual magnetic flux density Br is thereby achieved, and a production method thereof. A rare earth magnet including a main phase containing Sm, Fe, and N, at least a part of the main phase having a Th2Zn17-type or Th2Ni17-type crystal structure, a sub-phase containing Zn and Fe and being present around the main phase, and an intermediate phase containing Sm, Fe and N as well as Zn and being present between the main phase and the sub-phase, wherein the average Fe content in the sub-phase is 33 at % or less relative to the whole sub-phase.Type: ApplicationFiled: September 19, 2019Publication date: March 26, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITYInventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Kazuaki HAGA, Daisuke ICHIGOZAKI, Yukio TAKADA, Satoshi SUGIMOTO, Masashi MATSUURA
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Publication number: 20200098496Abstract: To provide a rare earth magnet in which particles of SmFeN powder are bound using a Zn alloy powder, wherein generation of a knick at a magnetic field of around 0 is prevented, and a production method thereof. A rare earth magnet including a main phase containing Sm, Fe, and N, at least a part of the main phase having a Th2Zn17-type or Th2Ni17-type crystal structure, a sub-phase containing at least either Si or Sm, and Zn and Fe and being present around the main phase, and an intermediate phase containing Sm, Fe and N as well as Zn and being present between the main phase and the sub-phase, wherein the average Fe content in the sub-phase is 33 at % or less relative to the whole sub-phase, and the average total content of Si and Sm in the sub-phase is from 1.4 to 4.5 at % relative to the whole subs-phase.Type: ApplicationFiled: September 19, 2019Publication date: March 26, 2020Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITYInventors: Akihito KINOSHITA, Noritsugu SAKUMA, Tetsuya SHOJI, Daisuke ICHIGOZAKI, Tatsuhiko HIRANO, Kazuaki HAGA, Yukio TAKADA, Satoshi SUGIMOTO, Masashi MATSUURA