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).

  • Patent number: 11804741
    Abstract: 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: Grant
    Filed: May 3, 2022
    Date of Patent: October 31, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Mayumi Takazawa, Kazuaki Haga, Toshimitsu Takahashi, Takuya Nomura, Shinya Sano, Yasuhide Yagyu, Takeshi Tomonaga, Hisanori Koma, Keiu Kanada
  • Publication number: 20230318423
    Abstract: 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: Application
    Filed: June 8, 2023
    Publication date: October 5, 2023
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: 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
  • Patent number: 11711004
    Abstract: 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: Grant
    Filed: April 12, 2021
    Date of Patent: July 25, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: 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
  • Patent number: 11594946
    Abstract: 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: Grant
    Filed: March 17, 2021
    Date of Patent: February 28, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuaki Haga, Keiu Kanada, Kensuke Komori, Masaaki Ito
  • Publication number: 20220376567
    Abstract: 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: Application
    Filed: May 3, 2022
    Publication date: November 24, 2022
    Inventors: Mayumi TAKAZAWA, Kazuaki HAGA, Toshimitsu TAKAHASHI, Takuya NOMURA, Shinya SANO, Yasuhide YAGYU, Takeshi TOMONAGA, Hisanori KOMA, Keiu KANADA
  • Patent number: 11476020
    Abstract: 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: Grant
    Filed: June 20, 2018
    Date of Patent: October 18, 2022
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITY
    Inventors: Noritsugu Sakuma, Tetsuya Shoji, Kazuaki Haga, Satoshi Sugimoto, Masashi Matsuura
  • Publication number: 20220203440
    Abstract: 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: Application
    Filed: December 8, 2021
    Publication date: June 30, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Mayumi TAKAZAWA, Kazuaki HAGA, Daisuke ICHIGOZAKI, Masaaki ITO, Hisanori KOMA, Shinya SANO, Kensuke KOMORI, Keiu KANADA
  • Patent number: 11313022
    Abstract: 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: Grant
    Filed: November 20, 2019
    Date of Patent: April 26, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Fumitaka Yoshinaga, Kazuaki Haga, Seishi Utsuno
  • Patent number: 11309777
    Abstract: 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: Grant
    Filed: March 4, 2021
    Date of Patent: April 19, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Keiu Kanada, Daisuke Ichigozaki, Kazuaki Haga, Motoki Hiraoka, Daichi Maruyama, Hisamitsu Toshida, Kyoko Nakamura, Akira Yamashita
  • Patent number: 11177725
    Abstract: 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: Grant
    Filed: June 5, 2019
    Date of Patent: November 16, 2021
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Fumitaka Yoshinaga, Akira Yamashita, Airi Kamimura, Kazuaki Haga, Kensuke Komori
  • Publication number: 20210328490
    Abstract: 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: Application
    Filed: April 12, 2021
    Publication date: October 21, 2021
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: 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
  • Publication number: 20210328489
    Abstract: 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: Application
    Filed: March 17, 2021
    Publication date: October 21, 2021
    Inventors: Kazuaki HAGA, Keiu KANADA, Kensuke Komori, Masaaki ITO
  • Publication number: 20210281153
    Abstract: 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: Application
    Filed: March 4, 2021
    Publication date: September 9, 2021
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Keiu KANADA, Daisuke ICHIGOZAKI, Kazuaki HAGA, Motoki HIRAOKA, Daichi MARUYAMA, Hisamitsu TOSHIDA, Kyoko NAKAMURA, Akira YAMASHITA
  • Patent number: 10958112
    Abstract: 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: Grant
    Filed: January 24, 2019
    Date of Patent: March 23, 2021
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Fumitaka Yoshinaga, Kazuaki Haga
  • Patent number: 10892089
    Abstract: 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: Grant
    Filed: October 1, 2018
    Date of Patent: January 12, 2021
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Airi Kamimura, Kazuaki Haga, Kensuke Komori, Katsuhiko Tatebe, Shingo Fubuki
  • Patent number: 10855122
    Abstract: 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: Grant
    Filed: February 19, 2019
    Date of Patent: December 1, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kensuke Komori, Hisamitsu Toshida, Kazuaki Haga
  • Publication number: 20200224302
    Abstract: 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: Application
    Filed: November 20, 2019
    Publication date: July 16, 2020
    Inventors: Fumitaka YOSHINAGA, Kazuaki HAGA, Seishi UTSUNO
  • Patent number: 10658107
    Abstract: 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: Grant
    Filed: October 11, 2017
    Date of Patent: May 19, 2020
    Assignee: Senju Metal Industry Co., Ltd.
    Inventors: Daisuke Sakuma, Kazuaki Haga, Takaaki Takahashi, Minoru Ueshima, Takashi Akagawa, Yoshie Tachibana
  • Publication number: 20200098497
    Abstract: 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: Application
    Filed: September 19, 2019
    Publication date: March 26, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITY
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Kazuaki HAGA, Daisuke ICHIGOZAKI, Yukio TAKADA, Satoshi SUGIMOTO, Masashi MATSUURA
  • Publication number: 20200098496
    Abstract: 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: Application
    Filed: September 19, 2019
    Publication date: March 26, 2020
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, TOHOKU UNIVERSITY
    Inventors: Akihito KINOSHITA, Noritsugu SAKUMA, Tetsuya SHOJI, Daisuke ICHIGOZAKI, Tatsuhiko HIRANO, Kazuaki HAGA, Yukio TAKADA, Satoshi SUGIMOTO, Masashi MATSUURA