Patents Assigned to Sumitomo Electric Sintered Alloy, Ltd.
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Publication number: 20140191839Abstract: A compact 10 is obtained by compression-molding coated soft magnetic particles covered with insulating coatings, and is a modified frustum body having, as a main body, a frustum portion 113 sandwiched between plate-shaped portions 111 and 112 arranged in opposing relation. A vertical cross-section of the compact 10 is made up of a trapezoidal surface 113s, a long-side rectangular surface 111s joining to a long side of the trapezoidal surface 113s, and a short-side rectangular surface 112s joining to a short side of the trapezoidal surface 113s.Type: ApplicationFiled: November 28, 2011Publication date: July 10, 2014Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Atsushi Sato, Masato Uozumi, Koji Yamaguchi, Kazushi Kusawake
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Patent number: 8632323Abstract: A gear pump rotor is provided including a combination of an inner rotor and an outer rotor whose numbers of teeth are different by one, and the discharge amount of the pump is increased by an increase of the tooth depth. At least one of an addendum curve and a dedendum curve of an inner rotor is formed by a locus of one point on formation circles that satisfy moving conditions that the formation circles move from moving start points to moving end points while changing the distances from an inner rotor center to the centers of the formation circles. The centers of the formation circles move by a distance in the radial direction of a base circle, and the formation circles rotate by an angle at a constant angular velocity in the same directions of the moving directions of the formation circles.Type: GrantFiled: August 4, 2009Date of Patent: January 21, 2014Assignee: Sumitomo Electric Sintered Alloy, Ltd.Inventors: Masato Uozumi, Harumitsu Sasaki, Kentaro Yoshida, Yuichirou Egami
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Publication number: 20130322135Abstract: A low-loss compact and a method for producing the compact are provided. A method for producing a compact by using coated soft magnetic powder that includes coated soft magnetic particles constituted by soft magnetic particles and insulating coatings coating outer peripheries of the soft magnetic particles includes a raw material preparation step and an irradiation step. In the raw material preparation step, a raw compact is prepared by press-forming coated soft magnetic powder. In the irradiation step, part of a surface of the raw compact is irradiated with a laser. Irradiating a part of a surface of a raw compact with laser increases the number of disrupted portions of conductive portions where constituent materials of the soft magnetic particles at the surface of the raw compact have become conductive to each other, and the loss of the compact can be decreased.Type: ApplicationFiled: December 28, 2011Publication date: December 5, 2013Applicants: Sumitomo Electric Sintered Alloy, Ltd., Sumitomo Electric Industries, Ltd.Inventors: Kazushi Kusawake, Masato Uozumi, Atsushi Sato, Koji Yamaguchi, Mamoru Ono, Hiroyuki Murase, Kazuo Nakamae
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Publication number: 20130271256Abstract: A method includes a step of compacting an insulation-coated pure iron powder or an iron-based alloy powder mainly containing iron using a die to obtain a dust core, a step of heat-treating the obtained dust core, and a step of post-machining at least one portion of the heat-treated dust core using a grinding wheel. In the post-machining step, grinding is performed in such a manner that the dust core and the grinding wheel are rotated, whereby isotropic machining marks are formed on a machined surface of the dust core.Type: ApplicationFiled: July 6, 2012Publication date: October 17, 2013Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Tomoyuki Ueno, Yoshiyuki Shimada
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Publication number: 20130127574Abstract: When an outer core that is to be mounted on a reactor is seen in plan, the outer core is a compact that has a plan-view shape in which a side of the outer core that is opposite to a facing side of the outer core, which faces the inner cores, has a smaller dimension in a width direction, which is parallel to a facing surface, than the facing side of the outer core. A method of manufacturing such an outer core includes a preparing step and a compacting step. In the preparing step, coated soft magnetic powder including multiple coated soft magnetic particles formed by coating soft magnetic particles with insulating coated films is prepared as raw-material powder of the outer core.Type: ApplicationFiled: February 9, 2012Publication date: May 23, 2013Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Masato Uozumi, Atsushi Sato, Kazushi Kusawake
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Publication number: 20130038420Abstract: Provided are a green compact from which a low-loss core can be formed, a method of manufacturing the green compact, and a core for a reactor using the green compact. Parts of outer circumferential surfaces of green compacts 41 and 42 are molded with an inner peripheral surface of a through hole 10hA of a die 10A, and the other parts are molded with an outer circumferential surface of a core rod 13A that is inserted and disposed in the through hole 10hA. A raw-material powder P, which is a coated soft magnetic powder, is fed into compacting spaces 31 and 32 and pressurized by using a lower punch 12 (first punch) and an upper punch 11 (second punch). Then, the green compacts 41 and 42 are removed from the compacting spaces 31 and 32 by moving the die 10A with respect to the green compacts 41 and 42 without moving the core rod 13A with respect to the green compacts 41 and 42.Type: ApplicationFiled: February 16, 2012Publication date: February 14, 2013Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Masato Uozumi, Atsushi Sato, Kazushi Kusawake
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Patent number: 8241518Abstract: A soft magnetic material includes a plurality of composite magnetic particles including a metal magnetic particle and an insulating film surrounding a surface of the metal magnetic particle. The insulating film also contains a phosphate. The soft magnetic material further includes an aromatic polyetherketone resin and a metallic soap and/or an inorganic lubricant having a hexagonal crystal structure. The metallic soap and the inorganic lubricant are particles with an average particle size of not more than 2.0 ?m.Type: GrantFiled: May 15, 2007Date of Patent: August 14, 2012Assignees: Sumitomo Electric Industries, Ltd., Denso Corporation, Sumitomo Electric Sintered Alloy, Ltd.Inventors: Naoto Igarashi, Takao Nishioka, Yoshiyuki Shimada, Tsuyoshi Akao
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Publication number: 20120177525Abstract: An object is to meet the demands for increasing the number of teeth of a rotor in an internal gear pump while maintaining a theoretical discharge amount by using an equivalent body configuration so as to enhance the pump performance relating to discharge pulsation due to the increased number of teeth. In a pump rotor 1 formed by combining of an inner rotor (2) having N teeth and an outer rotor (3) having (N+1) teeth and disposing the rotors eccentrically relative to each other, the relational expression ?Dma <1.7e·sin(?/180)/sin {?/(180·N)} is satisfied, ?Dmax being a maximum value of a working pitch diameter of the inner rotor (2) and the outer rotor (3), and a working position (G) of the inner rotor (2) and the outer rotor (3) is always located rearward of an eccentric axis (CL) in a rotating direction of the rotor.Type: ApplicationFiled: November 2, 2010Publication date: July 12, 2012Applicant: SUMITOMO ELECTRIC SINTERED ALLOY, LTD.Inventors: Masato Uozumi, Harumitsu Sasaki, Kentaro Yoshida
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Patent number: 8051566Abstract: A method for manufacturing a rigid internal gear of a wave gear device in which an internally toothed portion formed with internal teeth and a gear main body portion are joined integrally, the method including preforming an internal teeth-forming ring or disc for forming the internally toothed portion by using a first aluminum alloy powder; manufacturing a forging in which the internal teeth-forming ring or disc is placed in a forging die and is integrally formed on its outer side with the gear main body portion using a second aluminum alloy powder, the first aluminum alloy powder being harder and having higher abrasion resistance than the second aluminum alloy powder; and applying post-processing including cutting teeth to the forging.Type: GrantFiled: May 27, 2010Date of Patent: November 8, 2011Assignees: Harmonic Drive Systems, Inc., Sumitomo Electric Sintered Alloy, Ltd.Inventors: Masaru Kobayashi, Toshihiko Kaji
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Publication number: 20100229395Abstract: A method for manufacturing a rigid internal gear of a wave gear device in which an internally toothed portion formed with internal teeth and a gear main body portion are joined integrally, the method including preforming an internal teeth-forming ring or disc for forming the internally toothed portion by using a first aluminum alloy powder; manufacturing a forging in which the internal teeth-forming ring or disc is placed in a forging die and is integrally formed on its outer side with the gear main body portion using a second aluminum alloy powder, the first aluminum alloy powder being harder and having higher abrasion resistance than the second aluminum alloy powder; and applying post-processing including cutting teeth to the forging.Type: ApplicationFiled: May 27, 2010Publication date: September 16, 2010Applicants: HARMONIC DRIVE SYSTEMS, INC., SUMITOMO ELECTRIC SINTERED ALLOY, LTD.Inventors: Masaru KOBAYASHI, Toshihiko Kaji
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Publication number: 20100209276Abstract: Flexibility is given in setting the tooth depth and the number of teeth of a pump rotor including a combination of an inner rotor and an outer rotor whose numbers of teeth are different by one, and the discharge amount of the pump is increased by the increase of the tooth depth. At least one of an addendum curve and a dedendum curve of an inner rotor (2) is formed by a locus of one point (j) on formation circles (B, C) that satisfy moving conditions that the formation circles (B, C) move from moving start points (Spa, Spb) to moving end points (Lpa, Lpb) while changing the distances from an inner rotor center (OI) to the centers of the formation circles, the centers of the formation circles move by a distance (R) in the radial direction of a base circle (A) during this, and the formation circles (B, C) rotate by an angle ? at a constant angular velocity in the same directions of the moving directions of the formation circles.Type: ApplicationFiled: August 4, 2009Publication date: August 19, 2010Applicant: SUMITOMO ELECTRIC SINTERED ALLOY, LTD.Inventors: Masato Uozumi, Harumitsu Sasaki, Kentaro Yoshida, Yuichirou Egami
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Patent number: 7748118Abstract: The present invention provides a method for manufacturing a rigid internal gear for a wave gear device comprising an internally toothed portion and a gear main body portion comprised of different materials. In this method, a gear main body ring for forming a gear main body portion is preformed using a first aluminum alloy powder; an internal teeth-forming ring is preformed using a second aluminum alloy powder that has lower processability, is less durable, has higher abrasion resistance, and is harder than the first aluminum alloy powder; the internal teeth-forming ring is fitted inside the gear main body ring and the assembly is integrated by powder forging; and the resulting ring-shaped forging is subjected to post-processing, including cutting teeth. The gear main body portion and internally toothed portion are securely integrated by powder forging, and a lightweight rigid internal gear with high durability can therefore be obtained.Type: GrantFiled: June 29, 2005Date of Patent: July 6, 2010Assignees: Harmonic Drive Systems Inc., Sumitomo Electric Sintered Alloy, Ltd.Inventors: Masaru Kobayashi, Toshihiko Kaji
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Patent number: 7716838Abstract: An outer ring of a cross roller bearing is a composite component having an outer ring main body portion constructed of a lightweight metal alloy and a raceway surface formation portion linked to an inner side thereof and constructed of a ferrous material. A ring for forming the raceway surface formation portion is preformed, and is inserted into a forging die, powder forging is performed using a metal powder for manufacturing the outer ring main body portion, a composite component is manufactured in which a ringshaped portion for forming the outer ring main body portion is integrally formed with the raceway surface formation ring, and an after-treatment is performed on the product.Type: GrantFiled: June 28, 2005Date of Patent: May 18, 2010Assignees: Harmonic Drive Systems, Inc., Sumitomo Electric Sintered Alloy, Ltd.Inventors: Masaru Kobayashi, Toshihiko Kaji
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Publication number: 20090197782Abstract: A soft magnetic material includes a plurality of composite magnetic particles including a metal magnetic particle and an insulating film surrounding a surface of the metal magnetic particle. The insulating film also contains a phosphate. The soft magnetic material further includes an aromatic polyetherketone resin and a metallic soap and/or an inorganic lubricant having a hexagonal crystal structure. The metallic soap and the inorganic lubricant are particles with an average particle size of not more than 2.0 ?m.Type: ApplicationFiled: May 15, 2007Publication date: August 6, 2009Applicants: SUMITOMO ELECTRIC INDUSTRIES, LTD., DENSO CORPORATION, SUMITOMO ELECTRIC SINTERED ALLOY, LTD.Inventors: Naoto Igarashi, Takao Nishioka, Yoshiyuki Shimada, Tsuyoshi Akao
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Patent number: 7407373Abstract: An inner motor is structured to increase the discharge rate of an internal gear pump by making it possible to freely adjust the eccentricity e between the inner and outer rotors. Each tooth of the inner rotor includes a tooth bottom defined by hypocycloidal curves, an engaging portion to be brought into engagement with the outer rotor and defined by involute curves, and a tooth top defined by a predetermined curve such as a part of a circle or an oval or an epicycloidal curve.Type: GrantFiled: July 7, 2004Date of Patent: August 5, 2008Assignee: Sumitomo Electric Sintered Alloy, Ltd.Inventors: Daisuke Ogata, Naoki Inui, Shinya Arinaga
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Patent number: 7258812Abstract: A compound magnetic material having high heat resistance is provided. A fabrication method of a compound magnetic material includes the step of preparing mixed powder including an organic resin and compound magnetic particles. The long-period heat resistance temperature of the organic resin is at least 200° C. The containing ratio of the organic resin to the compound magnetic particles exceeds 0 mass % and not more than 0.2 mass %. The compound magnetic particle includes a metal magnetic particles, and a coat layer containing metal oxide, directly bound to the surface of the metal magnetic particle. The fabrication method of a compound magnetic material includes the steps of forming a compact by introducing mixed powder into a die having a lubricant applied to its surface and conducting warm-compacting, and applying heat treatment to the compact.Type: GrantFiled: October 28, 2002Date of Patent: August 21, 2007Assignees: Sumitomo Electric Sintered Alloy, Ltd., DENSO CORPORATIONInventors: Yoshiyuki Shimada, Hitoshi Oyama, Takao Nishioka
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Publication number: 20070158003Abstract: This invention provides a heat-resistant, high-toughness aluminum alloy which has a good balance between strength and ductility at a temperature from room temperature to around 300 degrees C. and has a high fracture toughness, a method of manufacturing the same, and engine parts. The heat-resistant, high-toughness aluminum alloy of this invention contains 10 to 16 mass. % of silicon, 1 to 3 mass % of iron, 1 to 2 mass % of nickel, 0.5 to 2 mass % in total of one or more selected from the group consisting of titanium, zirconium, chromium and vanadium, 0.6 to 3 mass % of copper, and 0.2 to 2 mass % of magnesium, the balance being essentially aluminum, and is obtained by densifying aluminum alloy powder prepared by gas atomizing. The silicon has an average grain diameter of 4 ?m or less.Type: ApplicationFiled: December 2, 2004Publication date: July 12, 2007Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., KABUSHIKI KAISHA HONDA GIJUTSU KENKYUSHOInventors: Terukazu Tokuoka, Toshihiko Kaji, Hiroyuki Horimura, Tomoo Oka
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Publication number: 20060000093Abstract: The present invention provides a method for manufacturing a rigid internal gear for a wave gear device comprising an internally toothed portion and a gear main body portion comprised of different materials. In this method, a gear main body ring for forming a gear main body portion is preformed using a first aluminum alloy powder; an internal teeth-forming ring is preformed using a second aluminum alloy powder that has lower processability, is less durable, has higher abrasion resistance, and is harder than the first aluminum alloy powder; the internal teeth-forming ring is fitted inside the gear main body ring and the assembly is integrated by powder forging; and the resulting ring-shaped forging is subjected to post-processing, including cutting teeth. The gear main body portion and internally toothed portion are securely integrated by powder forging, and a lightweight rigid internal gear with high durability can therefore be obtained.Type: ApplicationFiled: June 29, 2005Publication date: January 5, 2006Applicants: Harmonic Drive Systems Inc., Sumitomo Electric Sintered Alloy, Ltd.Inventors: Masaru Kobayashi, Toshihiko Kaji
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Patent number: 6962673Abstract: A heat-resistant, creep-resistant aluminum alloy according to the present invention contains at least 10 mass % and not more than 30 mass % of silicon, at least 3 mass % and not more than 10 mass % of at least either iron or nickel in total, at least 1 mass % and not more than 6 mass % of at least one rare earth element in total and at least 1 mass % and not more than 3 mass % of zirconium with the rest substantially consisting of aluminum, while the mean crystal grain size of silicon is not more than 2 ?m, the mean grain size of compounds other than silicon is not more than 1 ?m, and the mean crystal grain size of an aluminum matrix is at least 0.2 ?m and not more than 2 ?m. Thus, an aluminum alloy excellent in heat resistance and creep resistance is obtained.Type: GrantFiled: March 20, 2002Date of Patent: November 8, 2005Assignee: Sumitomo Electric Sintered Alloy, Ltd.Inventors: Hisao Hattori, Terukazu Tokuoka, Takatoshi Takikawa
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Publication number: 20040191101Abstract: A noise-reduced internal gear pump incorporating an inner rotor having an addendum formed by a smooth curve and a dedendum formed by a hypocycloid. The tooth profile of the outer rotor is determined by the following steps. The center Oi of an inner rotor 1 is revolved around the center Oo of the outer rotor so as to form a circle S having a diameter of 2e+t, where “e” is the amount of eccentricity between the inner and outer rotors and “t” is the maximum value of the interrotor clearance between the outer rotor and the inner rotor pressed against it. The inner rotor 1 is rotated on its axis 1/n times while its center Oi makes one revolution in the circular orbit S, where “n” is the number of teeth of the inner rotor. The envelope of the group of the tooth profile-curves of the inner rotor formed by its revolution is used as the tooth profile of the outer rotor.Type: ApplicationFiled: March 10, 2004Publication date: September 30, 2004Applicant: SUMITOMO ELECTRIC SINTERED ALLOY, LTD.Inventors: Daisuke Ogata, Naoki Inui, Shinya Arinaga, Harumitsu Sasaki