Patents by Inventor Akihito Kinoshita

Akihito Kinoshita 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: 11935676
    Abstract: An Sm—Fe—N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by a molar ratio formula (Sm(1-x-y-z)LaxCeyR1z)2(Fe(1-p-q-s)CopNiqMs)17Nh (where, R1 is a predetermined rare earth element, M is a predetermined element, and 0?x+y<0.04, 0?z?0.10, 0<p+q?0.10, 0?s?0.10, and 2.9?h?3.1 are satisfied). A lattice volume of the main phase is 0.830 nm3 to 0.840 nm3, and a density of the main phase is 7.70 g/cm3 to 8.00 g/cm3.
    Type: Grant
    Filed: September 21, 2021
    Date of Patent: March 19, 2024
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Tetsuya Shoji, Noritsugu Sakuma, Akihito Kinoshita, Masaaki Ito
  • Patent number: 11869690
    Abstract: A rare earth magnet in which the amount used of a heavy rare earth element is more reduced while maintaining enhancement of the coercive force, and a producing method thereof are provided. The rare earth magnet of the present disclosure has a main phase 10 and a grain boundary phase 20. The main phase 10 has a composition represented by R12T14B. The main phase 10 has a core part 12 and a shell part 14. Denoting the abundances of R2 and Ce (R2 is heavy rare earth element) occupying 4f site of the shell part 14 as R24f and Ce4f, respectively, and denoting the abundances of R2 and Ce occupying 4g site of the shell part 14 as R24g and Ce4g, respectively, the rare earth magnet satisfies 0.44?R24g/(R24f+R24g)?0.70 and 0.04?(Ce4f+Ce4g)/(R24f+R24g). The rare earth magnet-producing method of the present disclosure uses a modifier containing at least R2 and Ce.
    Type: Grant
    Filed: January 19, 2022
    Date of Patent: January 9, 2024
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu Sakuma, Tetsuya Shoji, Akihito Kinoshita, Akira Kato
  • Publication number: 20230317327
    Abstract: 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: Application
    Filed: March 21, 2023
    Publication date: October 5, 2023
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Masaaki ITO, Noritsugu SAKUMA, Akihito KINOSHITA, Reimi TABUCHI, Tomonori INUZUKA, Kunihiro MATSUYAMA, Masashi HARADA
  • Patent number: 11664140
    Abstract: A rare earth magnet includes a main phase and a particle boundary phase and in which an overall composition is represented by a formula, (R2(1-x)R1x)yFe(100-y-w-z-v)CowBzM1v.(R3(1-p)M2p)q.(R4(1-s)M3s)t, where R1 is a light rare earth element, R2 and R3 are a medium rare earth element, R4 is a heavy rare earth element, M1, M2, M3 are a predetermined metal element. The main phase includes a core portion, a first shell portion, and a second shell portion. The content proportion of medium rare earth element is higher in the first shell portion than in the core portion, the content proportion of medium rare earth element is lower in the second shell portion than in the first shell portion. The second shell portion contains heavy rare earth elements.
    Type: Grant
    Filed: February 23, 2021
    Date of Patent: May 30, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu Sakuma, Tetsuya Shoji, Akihito Kinoshita
  • Patent number: 11522420
    Abstract: A method of producing a motor core includes preparing a soft magnetic plate containing a transition metal element, preparing a modifying member containing an alloy having a melting point lower than a melting point of the soft magnetic plate, bringing the modifying member into contact with a part of a plate surface of the soft magnetic plate, causing the modifying member to diffuse and penetrate into the soft magnetic plate from a contact surface between the soft magnetic plate and the modifying member and forming a hard magnetic phase-containing part in a part of the soft magnetic plate, and laminating a plurality of soft magnetic plates on each other after the modifying member is brought into contact with the part of the plate surface of the soft magnetic plate.
    Type: Grant
    Filed: March 6, 2020
    Date of Patent: December 6, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akihito Kinoshita, Noritsugu Sakuma, Tetsuya Shoji, Kosuke Yonekawa
  • Publication number: 20220301753
    Abstract: A rare earth magnet in which the amount used of a heavy rare earth element is more reduced while maintaining enhancement of the coercive force, and a producing method thereof are provided. The rare earth magnet of the present disclosure has a main phase 10 and a grain boundary phase 20. The main phase 10 has a composition represented by R12T14B. The main phase 10 has a core part 12 and a shell part 14. Denoting the abundances of R2 and Ce (R2 is heavy rare earth element) occupying 4f site of the shell part 14 as R24f and Ce4f, respectively, and denoting the abundances of R2 and Ce occupying 4g site of the shell part 14 as R24g and Ce4g, respectively, the rare earth magnet satisfies 0.44?R24g/(R24f+R24g)?0.70 and 0.04?(Ce4f+Ce4g)/(R24f+R24g). The rare earth magnet-producing method of the present disclosure uses a modifier containing at least R2 and Ce.
    Type: Application
    Filed: January 19, 2022
    Publication date: September 22, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Akira KATO
  • Publication number: 20220246336
    Abstract: There is provided a manufacturing method for a rare earth magnet, including forming a zinc-containing coating film on a surface of a particle of a samarium-iron-nitrogen-based magnetic powder to obtain a coated powder, subjecting the coated powder to compression molding to obtain a compacted powder body, and subjecting the compacted powder body to pressure sintering, in which a coating rate of the coating film with respect to an entire surface of the particle of the coated powder is 96% or more, and the formation of the coating film and the pressure sintering of the compacted powder body is carried out in a vacuum or an inert gas atmosphere, and the compression molding of the coated powder is carried out in the atmospheric air.
    Type: Application
    Filed: December 28, 2021
    Publication date: August 4, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke ICHIGOZAKI, Noritsugu SAKUMA, Akihito KINOSHITA, Masaaki ITO
  • Publication number: 20220199321
    Abstract: 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: Application
    Filed: December 1, 2021
    Publication date: June 23, 2022
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, NICHIA CORPORATION
    Inventors: Masaaki ITO, Daisuke ICHIGOZAKI, Noritsugu SAKUMA, Akihito KINOSHITA, Michiya KUME, Hisashi MAEHARA
  • Publication number: 20220139601
    Abstract: The present disclosure provides a rare earth magnet having a main phase and a grain boundary phase and a manufacturing method therefor. In the rare earth magnet of the present disclosure, the overall composition is represented by a formula (R1(1-x-y)LaxCey)u(Fe(1-z)Coz)(100-u-w-v)BwM1v. (R1 is a predetermined rare earth element, M1 is a predetermined element, and the followings are satisfied, 0.05?x?0.25, 0.5?y/(x+y)?0.50, 13.5?u?20.0, 0?z?0.100, 5.0?w?10.0, and 0?v?2.00). The main phase has an R2Fe14B-type crystal structure, and the average grain size and the volume fraction of the main phase are respectively 1.0 ?m to 20.0 ?m and 80.0% to 90.0%. The main phase and the grain boundary phase satisfy, (the existence proportion of La in the grain boundary phase)/(the existence proportion of La in the main phase)>1.30.
    Type: Application
    Filed: October 25, 2021
    Publication date: May 5, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Katsunori DANNO, Daisuke ICHIGOZAKI, Masaaki ITO, Reimi SAKAGUCHI
  • Publication number: 20220130580
    Abstract: To provide an R—Fe—B-based rare earth magnet excellent in the squareness and magnetic properties at high temperatures, and method for producing thereof. The present disclosure relates to a rare earth magnet including a main phase 10 and a grain boundary phase 20 present around the main phase 10, and a method for producing thereof. In the rare earth magnet of the present disclosure, the overall composition is represented, in terms of molar ratio, by the formula: (R1(1-x)Lax)y(Fe(1-z)Coz)(100-y-w-v)BwM1v, wherein R1 is a predetermined rare earth element, M1 is a predetermined element, 0?x?0.1, 12.0?y?20.0, 0.1?z?0.3, 5.0?w?20.0, and 0?v?2.0. The main phase 10 has an R2Fe14B-type crystal structure, the average particle diameter of the main phase 10 is less than 1 ?m, and the volume ratio of a phase having an RFe2-type crystal structure in the grain boundary phase 20 is 0.40 or less relative to the grain boundary phase 20.
    Type: Application
    Filed: September 3, 2021
    Publication date: April 28, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Akira KATO
  • Publication number: 20220102033
    Abstract: A magnetic material according to the present disclosure includes a main phase having an R2T14B type crystal structure (R is a rare earth element and T is a transition metal element). The main phase has a composition represented by ((Nd, Pr)(1-x-y)LaxR1y))2((Fe(1-z-w)(Co, Ni)zMw))14B (where, R1 is a rare earth element other than Nd, Pr, and La, M is an element other than Fe, Co, Ni, and a rare earth element, and the like, and 0.25?x?1.00, 0?y?0.10, 0.15?z?0.40, and 0?w?0.1 are satisfied). A manufacturing method of the magnetic material according to the present disclosure includes melting a raw material containing the elements constituting the main phase and solidifying the melted raw material.
    Type: Application
    Filed: September 17, 2021
    Publication date: March 31, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: NORITSUGU SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA, Akira KATO
  • Publication number: 20220093298
    Abstract: An Sm—Fe—N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by a molar ratio formula (Sm(1-x-y-z)LaxCeyR1z)2(Fe(1-p-q-s)CopNiqMs)17Nh (where, R1 is a predetermined rare earth element, M is a predetermined element, and 0?x+y<0.04, 0?z?0.10, 0<p+q?0.10, 0?s?0.10, and 2.9?h?3.1 are satisfied). A lattice volume of the main phase is 0.830 nm3 to 0.840 nm3, and a density of the main phase is 7.70 g/cm3 to 8.00 g/cm3.
    Type: Application
    Filed: September 21, 2021
    Publication date: March 24, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Tetsuya Shoji, Noritsugu Sakuma, Akihito Kinoshita, Masaaki Ito
  • Publication number: 20220093297
    Abstract: An Sm-Fe-N-based magnetic material according to the present disclosure includes a main phase having a predetermined crystal structure. The main phase has a composition represented by (Sm(1-x-y-z)LaxCeyR1z)2(Fe(1-p-q-s)CopNiqMs)17Nh (where, R1 is predetermined rare earth elements and the like, M is predetermined elements and the like, and 0.04?x+y?0.50, 0?z?0.10, 0?p+q?0.10, 0?s?0.10, and 2.9?h?3.1 are satisfied). A crystal volume of the main phase is 0.833 nm3 to 0.840 nm3. A manufacturing method of the Sm-Fe-N-based magnetic material according to the present disclosure includes nitriding a magnetic material precursor including a crystal phase having a composition represented by (Sm(1-x-y-z)LaxCeyR1z)2(Fe(1-p-q-s)CopNiqMs)17.
    Type: Application
    Filed: September 15, 2021
    Publication date: March 24, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke ICHIGOZAKI, Tetsuya SHOJI, Noritsugu SAKUMA, Akihito KINOSHITA, Masaaki ITO
  • Publication number: 20210327620
    Abstract: A rare earth magnet includes a main phase and a particle boundary phase and in which an overall composition is represented by a formula, (R2(1-x)R1x)yFe(100-y-w-z-v)CowBzM1v.(R3(1-p)M2p)q.(R4(1-s)M3s)t, where R1 is a light rare earth element, R2 and R3 are a medium rare earth element, R4 is a heavy rare earth element, M1, M2, M3 are a predetermined metal element. The main phase includes a core portion, a first shell portion, and a second shell portion. The content proportion of medium rare earth element is higher in the first shell portion than in the core portion, the content proportion of medium rare earth element is lower in the second shell portion than in the first shell portion. The second shell portion contains heavy rare earth elements.
    Type: Application
    Filed: February 23, 2021
    Publication date: October 21, 2021
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Akihito KINOSHITA
  • Publication number: 20210272751
    Abstract: The production method of a rare earth magnet of the present disclosure includes a coated magnetic powder preparation step, a mixed powder preparation step, and a pressure sintering step. In the coated magnetic preparation step, a zinc-containing coating 12 is formed on the particle surface of a samarium-iron-nitrogen-based magnetic powder to obtain a coated magnetic powder 14. In the mixed powder preparation step, a binder powder 20 having a melting point not higher than the melting point of the coating 12 and the coated magnetic powder 14 are mixed to obtain a mixed powder. In the pressure sintering step, denoting as T1° C. the temperature at which the peak disappears in an X-ray diffraction pattern of the binder powder 20 and as T2° C. the temperature at which the magnetic phase in the samarium-iron-nitrogen-based magnetic powder 10 decomposes, the mixed powder is pressure-sintered at T1° C. or more and (T2?50)° C. or less.
    Type: Application
    Filed: December 29, 2020
    Publication date: September 2, 2021
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke ICHIGOZAKI, Tatsuhiko HIRANO, Noritsugu SAKUMA, Akihito KINOSHITA, Masaaki ITO
  • Publication number: 20200303998
    Abstract: A method of producing a motor core includes preparing a soft magnetic plate containing a transition metal element, preparing a modifying member containing an alloy having a melting point lower than a melting point of the soft magnetic plate, bringing the modifying member into contact with a part of a plate surface of the soft magnetic plate, causing the modifying member to diffuse and penetrate into the soft magnetic plate from a contact surface between the soft magnetic plate and the modifying member and forming a hard magnetic phase-containing part in a part of the soft magnetic plate, and laminating a plurality of soft magnetic plates on each other after the modifying member is brought into contact with the part of the plate surface of the soft magnetic plate.
    Type: Application
    Filed: March 6, 2020
    Publication date: September 24, 2020
    Inventors: Akihito KINOSHITA, Noritsugu SAKUMA, Tetsuya SHOJI, Kosuke YONEKAWA
  • 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
  • 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
  • Patent number: 9396857
    Abstract: There is provided a magnetic circuit including a first magnetic body configured to include a magnet and a yoke plate, and a second magnetic body. The yoke plate forms an opening space at a position facing the second magnetic body. The magnet is disposed in the opening space or at a position sandwiched between the yoke plates.
    Type: Grant
    Filed: October 24, 2013
    Date of Patent: July 19, 2016
    Assignee: Sony Corporation
    Inventors: Akihito Kinoshita, Hitoshi Kubota, Yasushi Tsuji, Shuichi Chihara, Masahiro Kobori, Junichiro Misawa
  • Patent number: 9324514
    Abstract: There is provided a key input device including a supporting member including groove portions inclined with respect to a horizontal direction, a plurality of keytops each including a sliding portion which is fitted in a corresponding groove portion of the groove portions and slides along the groove portion, and a control member configured to cause two or more keytops of the plurality of keytops to slide obliquely downward along the groove portions.
    Type: Grant
    Filed: December 20, 2013
    Date of Patent: April 26, 2016
    Assignee: Sony Corporation
    Inventors: Junichiro Misawa, Masahiro Kobori, Shuichi Chihara, Hitoshi Kubota, Akihito Kinoshita, Yasushi Tsuji