Patents by Inventor Hirokazu Kugai
Hirokazu Kugai 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: 8323725Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.Type: GrantFiled: June 16, 2010Date of Patent: December 4, 2012Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
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Publication number: 20100255188Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.Type: ApplicationFiled: June 16, 2010Publication date: October 7, 2010Applicants: SUMITOMO ELECTRIC INDUSTRIES, LTD., TODA KOGYO CORP.Inventors: Toru MAEDA, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
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Patent number: 7767034Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.Type: GrantFiled: September 29, 2005Date of Patent: August 3, 2010Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
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Patent number: 7682695Abstract: The object of the present invention is to provide a powder core and method for making the same that is equipped with insulative coating having superior heat resistance, with the coating making it possible to adequately restrict the flow of eddy currents between particles. The powder core is equipped with a plurality of compound magnetic particles bonded to each other. Each of said plurality of composite magnetic particles includes: a metal magnetic particle 10; an insulative lower layer coating 20 surrounding a surface 10a of said metal magnetic particle 10; an upper layer coating 30 surrounding said lower layer coating 20 and containing silicon; and dispersed particles 50 containing a metal oxide compound and disposed in said lower layer coating 20 and/or said upper layer coating 30. A mean particle diameter R of the dispersed particles 50 meets the condition 10 nm<R?2 T, where the average thickness of the coating combining the lower layer coating 20 and the upper layer coating 30 is T.Type: GrantFiled: January 28, 2005Date of Patent: March 23, 2010Assignee: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
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Patent number: 7601229Abstract: A method for making soft magnetic material includes: a first heat treatment step applying a temperature of at least 400 deg C. and less than 900 deg C. to metal magnetic particles; a step for forming a plurality of compound magnetic particles in which said metal magnetic particles are surrounded by insulation film; and a step for forming a shaped body by compacting a plurality of compound magnetic particles. This provides a method for making soft magnetic material that provides desired magnetic properties.Type: GrantFiled: October 1, 2004Date of Patent: October 13, 2009Assignee: Sumitomo Electric Industries Ltd.Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
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Patent number: 7588648Abstract: The present invention provides a soft magnetic material and a powder magnetic core having desired magnetic characteristics. A soft magnetic material contains a metal magnetic powder 10. The metal magnetic powder 10 is formed from crystals 1 with an average size, as determined from X-ray diffraction, of at least 30 nm. It would be preferable, in the metal magnetic particles 10, for crystal grains 2 to have an average size of at least 10 microns.Type: GrantFiled: October 7, 2004Date of Patent: September 15, 2009Assignee: Sumitomo Electric Industries, Inc.Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
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Patent number: 7517616Abstract: A sulfide-based inorganic solid electrolyte that suppresses the reaction between silicon sulfide and metallic lithium even when the electrolyte is in contact with metallic lithium, a method of forming the electrolyte, and a lithium battery's member and lithium secondary battery both incorporating the electrolyte. The electrolyte comprises Li, P, and S without containing Si. It is desirable that the oxygen content vary gradually from the electrolyte to the lithium-containing material at the boundary zone between the two members when analyzed by using an XPS having an analyzing chamber capable of maintaining a super-high vacuum less than 1.33×10?9 hPa and that the oxygen-containing layer on the surface of the lithium-containing material be removed nearly completely. The electrolyte can be formed such that at least part of the forming step is performed concurrently with the step for etching the surface of the substrate by irradiating the surface with inert-gas ions.Type: GrantFiled: March 8, 2006Date of Patent: April 14, 2009Assignee: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Nobuhiro Ota
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Publication number: 20080231409Abstract: The object of the present invention is to provide a powder core and method for making the same that is equipped with insulative coating having superior heat resistance, with the coating making it possible to adequately restrict the flow of eddy currents between particles. The powder core is equipped with a plurality of compound magnetic particles bonded to each other. Each of said plurality of composite magnetic particles includes: a metal magnetic particle 10; an insulative lower layer coating 20 surrounding a surface 10a of said metal magnetic particle 10; an upper layer coating 30 surrounding said lower layer coating 20 and containing silicon; and dispersed particles 50 containing a metal oxide compound and disposed in said lower layer coating 20 and/or said upper layer coating 30. A mean particle diameter R of the dispersed particles 50 meets the condition 10 nm<R?2 T, where the average thickness of the coating combining the lower layer coating 20 and the upper layer coating 30 is T.Type: ApplicationFiled: January 28, 2005Publication date: September 25, 2008Applicant: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
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Publication number: 20070235109Abstract: A soft magnetic material is a soft magnetic material including a composite magnetic particle (30) having a metal magnetic particle (10) mainly composed of Fe and an insulating coating (20) covering metal magnetic particle (10), and insulating coating (20) contains an iron phosphate compound and an aluminum phosphate compound. The atomic ratio of Fe contained in a contact surface of insulating coating (20) in contact with metal magnetic particle (10) is larger than the atomic ratio of Fe contained in the surface of insulating coating (20). The atomic ratio of Al contained in the contact surface of insulating coating (20) in contact with metal magnetic particle (10) is smaller than the atomic ratio of Al contained in the surface of insulating coating (20). Thus, iron loss can be reduced.Type: ApplicationFiled: September 29, 2005Publication date: October 11, 2007Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
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Publication number: 20070169851Abstract: An object of the present invention is to provide a soft magnetic material exhibiting excellent magnetic characteristics regardless of the frequency to be applied and a dust core produced from the soft magnetic material. The means for solving the invention is a soft magnetic material that comprises metal magnetic particles 10 containing iron and oxygen. The ratio of oxygen contained in metal magnetic particles 10 is more than 0 and less than 0.05% by mass. A dust core produced using such a soft magnetic material has a coercive force of 2.0×102 A/m or less.Type: ApplicationFiled: January 26, 2005Publication date: July 26, 2007Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
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Publication number: 20070102066Abstract: A method for making soft magnetic material includes: a first heat treatment step applying a temperature of at least 400 deg C. and less than 900 deg C. to metal magnetic particles (10); a step for forming a plurality of compound magnetic particles (30) in which said metal magnetic particles (10) are surrounded by insulation film (20); and a step for forming a shaped body by compacting a plurality of compound magnetic particles (30). This provides a method for making soft magnetic material that provides desired magnetic properties.Type: ApplicationFiled: October 1, 2004Publication date: May 10, 2007Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
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Patent number: 7150943Abstract: A sulfide-based inorganic solid electrolyte that suppresses the reaction between silicon sulfide and metallic lithium even when the electrolyte is in contact with metallic lithium, a method of forming the electrolyte, and a lithium battery's member and lithium secondary battery both incorporating the electrolyte. The electrolyte comprises Li, P, and S without containing Si. It is desirable that the oxygen content vary gradually from the electrolyte to the lithium-containing material at the boundary zone between the two members when analyzed by using an XPS having an analyzing chamber capable of maintaining a super-high vacuum less than 1.33×10?9 h Pa and that the oxygen-containing layer on the surface of the lithium-containing material be removed nearly completely. The electrolyte can be formed such that at least part of the forming step is performed concurrently with the step for etching the surface of the substrate by irradiating the surface with inert-gas ions.Type: GrantFiled: February 22, 2002Date of Patent: December 19, 2006Assignee: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Nobuhiro Ota
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Publication number: 20060237096Abstract: A soft magnetic material includes a plurality of composite magnetic particles each having a metal magnetic particle and an insulating film surrounding a surface of the metal magnetic particle, and an organic substance joining the plurality of composite magnetic particles together. The organic substance has a deflection temperature under load of not more than 100° C. With this structure, the soft magnetic material can obtain a desired magnetic property.Type: ApplicationFiled: July 30, 2004Publication date: October 26, 2006Inventors: Haruhisa Toyoda, Ryuji Shiga, Hirokazu Kugai, Yoshiyuki Shimada, Shohzoh Tanaka, Kazuhiko Ueda
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Publication number: 20060216507Abstract: The present invention provides a soft magnetic material and a powder magnetic core having desired magnetic characteristics. A soft magnetic material contains a metal magnetic powder 10. The metal magnetic powder 10 is formed from crystals 1 with an average size, as determined from X-ray diffraction, of at least 30 nm. It would be preferable, in the metal magnetic particles 10, for crystal grains 2 to have an average size of at least 10 microns.Type: ApplicationFiled: October 7, 2004Publication date: September 28, 2006Applicant: Sumitomo Electric Industries, Ltd.Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
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Publication number: 20060147806Abstract: A sulfide-based inorganic solid electrolyte that suppresses the reaction between silicon sulfide and metallic lithium even when the electrolyte is in contact with metallic lithium, a method of forming the electrolyte, and a lithium battery's member and lithium secondary battery both incorporating the electrolyte. The electrolyte comprises Li, P, and S without containing Si. It is desirable that the oxygen content vary gradually from the electrolyte to the lithium-containing material at the boundary zone between the two members when analyzed by using an XPS having an analyzing chamber capable of maintaining a super-high vacuum less than 1.33×10?9 hPa and that the oxygen-containing layer on the surface of the lithium-containing material be removed nearly completely. The electrolyte can be formed such that at least part of the forming step is performed concurrently with the step for etching the surface of the substrate by irradiating the surface with inert-gas ions.Type: ApplicationFiled: March 8, 2006Publication date: July 6, 2006Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Hirokazu Kugai, Nobuhiro Ota
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Publication number: 20050016633Abstract: The method of manufacturing soft magnetic articles comprises a step of preparing a melt solution containing soft magnetic materials and a step of forming soft magnetic particles from the melt solution in a magnetic field by an atomization rapid solidification method.Type: ApplicationFiled: July 20, 2004Publication date: January 27, 2005Inventors: Hirokazu Kugai, Haruhisa Toyoda, Naoto Igarashi, Kazuhiro Hirose, Takao Nishioka, Akihiko Ikegaya, Ryosuke Hata, Hitoshi Oyama, Kenichi Sato, Kazuhiko Hayashi, Masayuki Hirose, koji Muranaka
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Publication number: 20040109940Abstract: A method of independently producing a negative electrode for a lithium secondary cell having thin films of lithium and a sulfide-based inorganic solid electrolyte begins with a negative electrode base material and an inorganic solid electrolyte source material being removed from closed containers in a chamber space, which is substantially inactive to lithium and insulated from air. The materials are transferred into an adjacent thin film deposition system without being exposed to the air. In the system, the source material is used to form a thin film of an inorganic solid electrolyte on the base material, to make the electrode. The electrode is transferred, without being exposed to the air, into a chamber space, which is substantially inactive to lithium, where the electrode is placed into a closed container. Thus, a negative electrode can be produced without being degraded by air.Type: ApplicationFiled: December 1, 2003Publication date: June 10, 2004Applicant: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
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Patent number: 6713216Abstract: A member having a lithium metal thin film is provided, which is extremely thin, uniform, and not degraded by air. The member includes a substrate and a thin lithium metal film formed on the substrate by a vapor deposition method. The thin film typically has a thickness of 0.1 &mgr;m to 20 &mgr;m. The substrate is typically made of a metal, an alloy, a metal oxide, or carbon. The substrate typically has a thickness of 1 &mgr;m to 100 &mgr;m. The member is used as an electrode member for a lithium cell.Type: GrantFiled: June 18, 2001Date of Patent: March 30, 2004Assignee: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
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Patent number: 6699619Abstract: A lithium-secondary-battery negative electrode having a protective layer to prevent the surface deterioration of the inorganic solid electrolytic layer. The negative electrode comprises metallic lithium or a lithium-containing metal, a first inorganic solid electrolytic layer (thickness: a) formed on the metal, and a second inorganic solid electrolytic layer (thickness: b) formed on the first inorganic solid electrolytic layer. The thickness ratio b/a is specified to be more than 0.5.Type: GrantFiled: April 20, 2001Date of Patent: March 2, 2004Assignee: Sumitomo Electric Industries, Ltd.Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
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Publication number: 20040005504Abstract: A sulfide-based inorganic solid electrolyte that suppresses the reaction between silicon sulfide and metallic lithium even when the electrolyte is in contact with metallic lithium, a method of forming the electrolyte, and a lithium battery's member and lithium secondary battery both incorporating the electrolyte. The electrolyte comprises Li, P, and S without containing Si. It is desirable that the oxygen content vary gradually from the electrolyte to the lithium-containing material at the boundary zone between the two members when analyzed by using an XPS having an analyzing chamber capable of maintaining a super-high vacuum less than 1.33×10−9 h Pa and that the oxygen-containing layer on the surface of the lithium-containing material be removed nearly completely. The electrolyte can be formed such that at least part of the forming step is performed concurrently with the step for etching the surface of the substrate by irradiating the surface with inert-gas ions.Type: ApplicationFiled: March 19, 2003Publication date: January 8, 2004Inventors: Hirokazu Kugai, Nobuhiro Ota