Patents by Inventor Kimiharu Kayukawa
Kimiharu Kayukawa 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: 9009948Abstract: A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.Type: GrantFiled: July 13, 2012Date of Patent: April 21, 2015Assignee: Denso CorporationInventors: Kimiharu Kayukawa, Masaomi Dobashi, Hideji Shimaoka, Youichi Kamakura
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Publication number: 20130014381Abstract: A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.Type: ApplicationFiled: July 13, 2012Publication date: January 17, 2013Applicant: DENSO CORPORATIONInventors: Kimiharu KAYUKAWA, Masaomi DOBASHI, Hideji SHIMAOKA, Youichi KAMAKURA
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Patent number: 8156804Abstract: A capacitive semiconductor sensor includes a sensor chip, a circuit chip, a plurality of bumps, and a plurality of dummy bumps. The sensor chip includes a dynamic quantity detector, which has a detection axis in one direction. The circuit chip includes a signal processing circuit. The sensor chip and the circuit chip are coupled by flip-chip bonding through the plurality of bumps. Furthermore, the sensor chip and the circuit chip are mechanically coupled through the plurality of dummy bumps.Type: GrantFiled: July 31, 2007Date of Patent: April 17, 2012Assignee: Denso CorporationInventors: Minekazu Sakai, Michihiro Masuda, Kimiharu Kayukawa
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Patent number: 7971349Abstract: In a method of bonding a first bump on a surface of a first member and a second bump on a surface of a second member, a tip portion of the first bump is provided with a projection having a hardness greater than a hardness of each of the first and second bumps. The first and second members are positioned with respect to each other such that the first and second bumps face each other. The tip portion of the first bump is brought into contact with a tip portion of the second bump by sticking the projection into the tip portion of the second bump.Type: GrantFiled: March 26, 2009Date of Patent: July 5, 2011Assignee: DENSO CORPORATIONInventors: Masaaki Tanaka, Kimiharu Kayukawa
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Publication number: 20110042812Abstract: An electronic device includes a power element on a first substrate and an electronic component on a second substrate. The first and second substrates are stacked so that the power element and the electronic component can be located between the first and second substrates. A first end of a first wire is connected to the power element. A second end of the first wire is connected to the first substrate. A middle portion of the first wire projects toward the second substrate. A first end of a second wire is connected to the power element. A second end of the wire extends above a top of the middle portion of the first conductive member and is connected to the second substrate.Type: ApplicationFiled: July 29, 2010Publication date: February 24, 2011Applicant: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Rikiya Kamimura, Masaya Mizutani
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Patent number: 7659127Abstract: A manufacturing device of a semiconductor package includes: a holding element for holding a substrate; a bonding element for holding the package and bonding a first metal bump of the package to a second metal bump of the substrate; a monitoring element for irradiating an infrared light toward the substrate and monitoring an electrode pad under the second metal bump based on a reflected light reflected on the pad; and a determination element for determining a state of a bonding surface between the first and second metal bumps based on monitoring information of the pad. The monitoring element faces the bonding element through the holding element, the substrate and the package.Type: GrantFiled: July 31, 2007Date of Patent: February 9, 2010Assignee: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Michihiro Masuda, Takashige Saitoh
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Publication number: 20090241337Abstract: In a method of bonding a first bump on a surface of a first member and a second bump on a surface of a second member, a tip portion of the first bump is provided with a projection having a hardness greater than a hardness of each of the first and second bumps. The first and second members are positioned with respect to each other such that the first and second bumps face each other. The tip portion of the first bump is brought into contact with a tip portion of the second bump by sticking the projection into the tip portion of the second bump.Type: ApplicationFiled: March 26, 2009Publication date: October 1, 2009Applicant: DENSO CORPORATIONInventors: Masaaki Tanaka, Kimiharu Kayukawa
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Patent number: 7579212Abstract: A semiconductor device includes: a semiconductor substrate; a base member; a tin-based solder layer; a first metal layer; and a first alloy layer. The semiconductor substrate is bonded to the base member through the first metal layer, the first alloy layer and the tin-based solder layer in this order. The first alloy layer is made of a first metal in the first metal layer and tin in the tin-based solder layer. The first metal layer is made of at least one of material selected from the group consisting of titanium, aluminum, iron, molybdenum, chromium, vanadium and iron-nickel-chromium alloy.Type: GrantFiled: February 20, 2007Date of Patent: August 25, 2009Assignee: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Akira Tanahashi, Chikage Noritake, Shoji Miura
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Patent number: 7470996Abstract: A packaging method includes ultrasonically bonding a semiconductor device and a substrate together via bumps that include gold as a main component thereof. A contact surface of a primary bump on a surface of an aluminum pad on one side of the substrate contacts and is ultrasonically bonded to a distal end surface of each opposed secondary bump on one side of the semiconductor device. An area of the contact surface is larger than that of the opposed distal end surface. By this method, damage to the substrate from the ultrasonic can be reduced without using a reinforcing layer.Type: GrantFiled: July 12, 2006Date of Patent: December 30, 2008Assignee: DENSO CORPORATIONInventors: Takao Yoneyama, Kimiharu Kayukawa, Nobuya Makino, Ryuichiro Abe
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Patent number: 7420246Abstract: A vertical type semiconductor device includes: a silicon substrate having a first surface and a second surface; a first electrode disposed on the first surface of the silicon substrate; and a second electrode disposed on the second surface of the silicon substrate. Current is capable of flowing between the first electrode and the second electrode in a vertical direction of the silicon substrate. The second surface of the silicon substrate includes a re-crystallized silicon layer. The second electrode includes an aluminum film so that the aluminum film contacts the re-crystallized silicon layer with ohmic contact.Type: GrantFiled: May 30, 2006Date of Patent: September 2, 2008Assignee: DENSO CORPORATIONInventors: Shoji Ozoe, Tomofusa Shiga, Yoshifumi Okabe, Takaaki Aoki, Takeshi Fukazawa, Kimiharu Kayukawa
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Publication number: 20080093740Abstract: A capacitive semiconductor sensor includes a sensor chip, a circuit chip, a plurality of bumps, and a plurality of dummy bumps. The sensor chip includes a dynamic quantity detector, which has a detection axis in one direction. The circuit chip includes a signal processing circuit. The sensor chip and the circuit chip are coupled by flip-chip bonding through the plurality of bumps. Furthermore, the sensor chip and the circuit chip are mechanically coupled through the plurality of dummy bumps.Type: ApplicationFiled: July 31, 2007Publication date: April 24, 2008Applicant: DENSO CORPORATIONInventors: Minekazu Sakai, Michihiro Masuda, Kimiharu Kayukawa
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Patent number: 7361996Abstract: A semiconductor device includes: a semiconductor substrate; a base member; a tin-based solder layer; a first metal layer; and a first alloy layer. The semiconductor substrate is bonded to the base member through the first metal layer, the first alloy layer and the tin-based solder layer in this order. The first alloy layer is made of a first metal in the first metal layer and tin in the tin-based solder layer. The first metal layer is made of at least one of material selected from the group consisting of titanium, aluminum, iron, molybdenum, chromium, vanadium and iron-nickel-chromium alloy.Type: GrantFiled: September 8, 2005Date of Patent: April 22, 2008Assignee: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Akira Tanahashi, Chikage Noritake, Shoji Miura
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Publication number: 20080090313Abstract: A manufacturing device of a semiconductor package includes: a holding element for holding a substrate; a bonding element for holding the package and bonding a first metal bump of the package to a second metal bump of the substrate; a monitoring element for irradiating an infrared light toward the substrate and monitoring an electrode pad under the second metal bump based on a reflected light reflected on the pad; and a determination element for determining a state of a bonding surface between the first and second metal bumps based on monitoring information of the pad. The monitoring element faces the bonding element through the holding element, the substrate and the package.Type: ApplicationFiled: July 31, 2007Publication date: April 17, 2008Inventors: Kimiharu Kayukawa, Michihiro Masuda, Takashige Saitoh
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Publication number: 20070176293Abstract: A semiconductor device includes: a semiconductor substrate; a base member; a tin-based solder layer; a first metal layer; and a first alloy layer. The semiconductor substrate is bonded to the base member through the first metal layer, the first alloy layer and the tin-based solder layer in this order. The first alloy layer is made of a first metal in the first metal layer and tin in the tin-based solder layer. The first metal layer is made of at least one of material selected from the group consisting of titanium, aluminum, iron, molybdenum, chromium, vanadium and iron-nickel-chromium alloy.Type: ApplicationFiled: February 20, 2007Publication date: August 2, 2007Applicant: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Akira Tanahashi, Chikage Noritake, Shoji Miura
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Publication number: 20070023483Abstract: A packaging method includes ultrasonically bonding a semiconductor device and a substrate together via bumps that include gold as a main component thereof. A contact surface of a primary bump on a surface of an aluminum pad on one side of the substrate contacts and is ultrasonically bonded to a distal end surface of each opposed secondary bump on one side of the semiconductor device. An area of the contact surface is larger than that of the opposed distal end surface. By this method, damage to the substrate from the ultrasonic can be reduced without using a reinforcing layer.Type: ApplicationFiled: July 12, 2006Publication date: February 1, 2007Applicant: DENSO CORPORATIONInventors: Takao Yoneyama, Kimiharu Kayukawa, Nobuya Makino, Ryuichiro Abe
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Publication number: 20060273351Abstract: A vertical type semiconductor device includes: a silicon substrate having a first surface and a second surface; a first electrode disposed on the first surface of the silicon substrate; and a second electrode disposed on the second surface of the silicon substrate. Current is capable of flowing between the first electrode and the second electrode in a vertical direction of the silicon substrate. The second surface of the silicon substrate includes a re-crystallized silicon layer. The second electrode includes an aluminum film so that the aluminum film contacts the re-crystallized silicon layer with ohmic contact.Type: ApplicationFiled: May 30, 2006Publication date: December 7, 2006Applicant: DENSO CORPORATIONInventors: Shoji Ozoe, Tomofusa Shiga, Yoshifumi Okabe, Takaaki Aoki, Takeshi Fukazawa, Kimiharu Kayukawa
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Publication number: 20060081996Abstract: A semiconductor device includes: a semiconductor substrate; an aluminum electrode disposed on the surface of the substrate; a protection film disposed on the aluminum electrode and having an opening; and a metallic electrode disposed on a surface of the aluminum electrode through the opening of the protection film. The surface of the aluminum electrode includes a concavity. The concavity has an opening side and a bottom side, which is wider than the opening side. In the device, a concavity and a convexity of the metallic electrode become small.Type: ApplicationFiled: October 13, 2005Publication date: April 20, 2006Applicant: DENSO CORPORATIONInventors: Keiji Shinyama, Ichiharu Kondo, Kimiharu Kayukawa, Shoji Miura
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Publication number: 20060049521Abstract: A semiconductor device includes: a semiconductor substrate; a base member; a tin-based solder layer; a first metal layer; and a first alloy layer. The semiconductor substrate is bonded to the base member through the first metal layer, the first alloy layer and the tin-based solder layer in this order. The first alloy layer is made of a first metal in the first metal layer and tin in the tin-based solder layer. The first metal layer is made of at least one of material selected from the group consisting of titanium, aluminum, iron, molybdenum, chromium, vanadium and iron-nickel-chromium alloy.Type: ApplicationFiled: September 8, 2005Publication date: March 9, 2006Applicant: DENSO CORPORATIONInventors: Kimiharu Kayukawa, Akira Tanahashi, Chikage Noritake, Shoji Miura