Patents by Inventor Tomonori Inuzuka
Tomonori Inuzuka 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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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: 20230317327Abstract: A production method of a Sm—Fe—N-based rare earth magnet, enabling to stably impart sufficient anisotropy, is provided. The present disclosure provides a production method of a rare earth magnet, including preparing a raw material powder containing a magnetic powder (SmFeN powder 10) having a magnetic phase which contains Sm, Fe and N and at least partially has a crystal structure of at least either Th2Zn17 type or Th2Ni17 type, and pressure-sintering the raw material powder. In this production method, magnetic orientation is imparted to the raw material powder by applying a magnetic field before the pressure sintering, and the application of magnetic field is continued to maintain the magnetic orientation at least until the middle of the pressure sintering.Type: ApplicationFiled: March 21, 2023Publication date: October 5, 2023Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Masaaki ITO, Noritsugu SAKUMA, Akihito KINOSHITA, Reimi TABUCHI, Tomonori INUZUKA, Kunihiro MATSUYAMA, Masashi HARADA
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Patent number: 10629370Abstract: The method including: applying a graphite-based lubricant to a cavity surface of a die; forming a first graphite-based powder layer by disposing graphite-based powder that does not contain a binder on a cavity surface of a lower punch, forming a magnet powder body by putting magnet powder on the first graphite-based powder layer, and forming a second graphite-based powder layer by disposing graphite-based powder that does not contain a binder on the magnet powder body; and producing a compact by performing press forming using the lower punch and a upper punch while heating the magnet powder body surrounded by the graphite-based lubricant applied to the cavity surface of the die, the first graphite-based powder layer, and the second graphite-based powder layer, and releasing the compact from a forming die.Type: GrantFiled: July 5, 2016Date of Patent: April 21, 2020Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tomonori Inuzuka, Akira Kano
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Patent number: 10062504Abstract: A manufacturing method of a rare-earth magnet includes: manufacturing a first sealing body by filling a graphite container with a magnetic powder to be a rare-earth magnet material and by sealing the graphite container; manufacturing a sintered body by sintering the first sealing body to manufacture a second sealing body in which the sintered body is accommodated; and manufacturing a rare-earth magnet by performing hot plastic working on the second sealing body to give magnetic anisotropy to the sintered body.Type: GrantFiled: August 24, 2015Date of Patent: August 28, 2018Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki Haga, Noriyuki Ueno, Akira Kano, Tomonori Inuzuka, Noritsugu Sakuma
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Patent number: 10058919Abstract: A manufacturing method for a sintered compact includes a first step in which magnetic powder is fabricated by rapid solidification, a second step in which a mass of the magnetic powder is housed in a forming mold, and preliminary heating is performed by placing the mass of the magnetic powder in a preliminary heating part of the forming mold at first temperature that is lower than coarse crystal particle generation temperature, and a third step in which main heating is performed by placing the preliminarily heated mass of the magnetic powder at second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and press forming is performed while keeping temperature of the magnetic powder at densification temperature or higher.Type: GrantFiled: July 7, 2015Date of Patent: August 28, 2018Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tomonori Inuzuka, Akira Kano
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Patent number: 10002695Abstract: Provided is a method for manufacturing a rare-earth magnet having good workability and capable of manufacturing a rare-earth magnet having low oxygen density. A method for manufacturing a rare-earth magnet includes: a first step of applying or spraying graphite-based lubricant GF on an inner face of a forming die M, and charging magnetic powder MF as a rare-earth magnet material in the forming die M, followed by cold forming, to form a cold-forming compact 10 having a surface on which a graphite-based lubricant coat 12 is formed; a second step of performing hot forming to the cold-forming compact 10 to form a sintered body 20 having a surface on which a graphite-based lubricant coat 22 is formed; and a third step of, in order to give the sintered body 20 anisotropy, performing hot deformation processing to the sintered body 20 to form the rare-earth magnet 30.Type: GrantFiled: August 19, 2015Date of Patent: June 19, 2018Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki Haga, Tomonori Inuzuka, Yuya Ikeda
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Publication number: 20170011848Abstract: The method including: applying a graphite-based lubricant to a cavity surface of a die; forming a first graphite-based powder layer by disposing graphite-based powder that does not contain a binder on a cavity surface of a lower punch, forming a magnet powder body by putting magnet powder on the first graphite-based powder layer, and forming a second graphite-based powder layer by disposing graphite-based powder that does not contain a binder on the magnet powder body; and producing a compact by performing press forming using the lower punch and a upper punch while heating the magnet powder body surrounded by the graphite-based lubricant applied to the cavity surface of the die, the first graphite-based powder layer, and the second graphite-based powder layer, and releasing the compact from a forming die.Type: ApplicationFiled: July 5, 2016Publication date: January 12, 2017Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tomonori INUZUKA, Akira KANO
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Publication number: 20160099104Abstract: Provided is a method for manufacturing a rare-earth magnet having good workability and capable of manufacturing a rare-earth magnet having low oxygen density. A method for manufacturing a rare-earth magnet includes: a first step of applying or spraying graphite-based lubricant GF on an inner face of a forming die M, and charging magnetic powder MF as a rare-earth magnet material in the forming die M, followed by cold forming, to form a cold-forming compact 10 having a surface on which a graphite-based lubricant coat 12 is formed; a second step of performing hot forming to the cold-forming compact 10 to form a sintered body 20 having a surface on which a graphite-based lubricant coat 22 is formed; and a third step of, in order to give the sintered body 20 anisotropy, performing hot deformation processing to the sintered body 20 to form the rare-earth magnet 30.Type: ApplicationFiled: August 19, 2015Publication date: April 7, 2016Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki HAGA, Tomonori INUZUKA, Yuya IKEDA
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Publication number: 20160055969Abstract: A manufacturing method of a rare-earth magnet includes: manufacturing a first sealing body by filling a graphite container with a magnetic powder to be a rare-earth magnet material and by sealing the graphite container; manufacturing a sintered body by sintering the first sealing body to manufacture a second sealing body in which the sintered body is accommodated; and manufacturing a rare-earth magnet by performing hot plastic working on the second sealing body to give magnetic anisotropy to the sintered body.Type: ApplicationFiled: August 24, 2015Publication date: February 25, 2016Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Kazuaki HAGA, Noriyuki UENO, Akira KANO, Tomonori INUZUKA, Noritsugu SAKUMA
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Publication number: 20160008885Abstract: A manufacturing method for a sintered compact includes a first step in which magnetic powder is fabricated by rapid solidification, a second step in which a mass of the magnetic powder is housed in a forming mold, and preliminary heating is performed by placing the mass of the magnetic powder in a preliminary heating part of the forming mold at first temperature that is lower than coarse crystal particle generation temperature, and a third step in which main heating is performed by placing the preliminarily heated mass of the magnetic powder at second temperature that is lower than the coarse crystal particle generation temperature and higher than the first temperature, and press forming is performed while keeping temperature of the magnetic powder at densification temperature or higher.Type: ApplicationFiled: July 7, 2015Publication date: January 14, 2016Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tomonori INUZUKA, Akira KANO
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Publication number: 20130336832Abstract: A reactor core, which has a pair of press surfaces (a-b planar surfaces) formed by compression molding with an edge part of each of the press surfaces being plastically formed by pressure treatment, is disposed in a direction in which a magnetic flux generated upon energization of a coil does not penetrate each of the press surfaces.Type: ApplicationFiled: July 24, 2013Publication date: December 19, 2013Applicant: Toyota Jidosha Kabushiki KaishaInventors: Masaki SUGIYAMA, Toshiya Yamaguchi, Tomonori Inuzuka
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Publication number: 20110025444Abstract: A reactor core, which has a pair of press surfaces (a-b planar surfaces) formed by compression molding with an edge part of each of the press surfaces being plastically formed by pressure treatment, is disposed in a direction in which a magnetic flux generated upon energization of a coil does not penetrate each of the press surfaces.Type: ApplicationFiled: March 16, 2009Publication date: February 3, 2011Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Masaki Sugiyama, Toshiya Yamaguchi, Tomonori Inuzuka