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).

  • Patent number: 8323725
    Abstract: 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: Grant
    Filed: June 16, 2010
    Date of Patent: December 4, 2012
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Publication number: 20100255188
    Abstract: 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: Application
    Filed: June 16, 2010
    Publication date: October 7, 2010
    Applicants: SUMITOMO ELECTRIC INDUSTRIES, LTD., TODA KOGYO CORP.
    Inventors: Toru MAEDA, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Patent number: 7767034
    Abstract: 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: Grant
    Filed: September 29, 2005
    Date of Patent: August 3, 2010
    Assignees: Sumitomo Electric Industries, Ltd., Toda Kogyo Corp.
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Patent number: 7682695
    Abstract: 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: Grant
    Filed: January 28, 2005
    Date of Patent: March 23, 2010
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
  • Patent number: 7601229
    Abstract: 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: Grant
    Filed: October 1, 2004
    Date of Patent: October 13, 2009
    Assignee: Sumitomo Electric Industries Ltd.
    Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
  • Patent number: 7588648
    Abstract: 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: Grant
    Filed: October 7, 2004
    Date of Patent: September 15, 2009
    Assignee: Sumitomo Electric Industries, Inc.
    Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
  • Patent number: 7517616
    Abstract: 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: Grant
    Filed: March 8, 2006
    Date of Patent: April 14, 2009
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Nobuhiro Ota
  • Publication number: 20080231409
    Abstract: 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: Application
    Filed: January 28, 2005
    Publication date: September 25, 2008
    Applicant: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
  • Publication number: 20070235109
    Abstract: 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: Application
    Filed: September 29, 2005
    Publication date: October 11, 2007
    Inventors: Toru Maeda, Naoto Igarashi, Haruhisa Toyoda, Hirokazu Kugai, Kazuyuki Hayashi, Hiroko Morii, Seiji Ishitani
  • Publication number: 20070169851
    Abstract: 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: Application
    Filed: January 26, 2005
    Publication date: July 26, 2007
    Inventors: Hirokazu Kugai, Naoto Igarashi, Toru Maeda, Kazuhiro Hirose, Haruhisa Toyoda, Koji Mimura, Takao Nishioka
  • Publication number: 20070102066
    Abstract: 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: Application
    Filed: October 1, 2004
    Publication date: May 10, 2007
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
  • Patent number: 7150943
    Abstract: 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: Grant
    Filed: February 22, 2002
    Date of Patent: December 19, 2006
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Nobuhiro Ota
  • Publication number: 20060237096
    Abstract: 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: Application
    Filed: July 30, 2004
    Publication date: October 26, 2006
    Inventors: Haruhisa Toyoda, Ryuji Shiga, Hirokazu Kugai, Yoshiyuki Shimada, Shohzoh Tanaka, Kazuhiko Ueda
  • Publication number: 20060216507
    Abstract: 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: Application
    Filed: October 7, 2004
    Publication date: September 28, 2006
    Applicant: Sumitomo Electric Industries, Ltd.
    Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
  • Publication number: 20060147806
    Abstract: 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: Application
    Filed: March 8, 2006
    Publication date: July 6, 2006
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Hirokazu Kugai, Nobuhiro Ota
  • Publication number: 20050016633
    Abstract: 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: Application
    Filed: July 20, 2004
    Publication date: January 27, 2005
    Inventors: Hirokazu Kugai, Haruhisa Toyoda, Naoto Igarashi, Kazuhiro Hirose, Takao Nishioka, Akihiko Ikegaya, Ryosuke Hata, Hitoshi Oyama, Kenichi Sato, Kazuhiko Hayashi, Masayuki Hirose, koji Muranaka
  • Publication number: 20040109940
    Abstract: 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: Application
    Filed: December 1, 2003
    Publication date: June 10, 2004
    Applicant: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
  • Patent number: 6713216
    Abstract: 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: Grant
    Filed: June 18, 2001
    Date of Patent: March 30, 2004
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
  • Patent number: 6699619
    Abstract: 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: Grant
    Filed: April 20, 2001
    Date of Patent: March 2, 2004
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Hirokazu Kugai, Nobuhiro Ota, Shosaku Yamanaka
  • Publication number: 20040005504
    Abstract: 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: Application
    Filed: March 19, 2003
    Publication date: January 8, 2004
    Inventors: Hirokazu Kugai, Nobuhiro Ota