Patents by Inventor Masanobu Shimao

Masanobu Shimao 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: 10179955
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid comprising a slurry obtained by dispersing a powder containing an R2 fluoride (R2 represents one or more elements selected from among rare earth elements, including Y and Sc) in water; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Grant
    Filed: August 30, 2013
    Date of Patent: January 15, 2019
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Patent number: 10181377
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxyfluoride and/or an R3 hydride (R2 and R3 represent one or more elements selected from among rare earth elements, including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Grant
    Filed: August 30, 2013
    Date of Patent: January 15, 2019
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Patent number: 10138564
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from rare earth elements including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxide (R2 represents one or more elements selected from rare earth elements including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder to the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Grant
    Filed: August 30, 2013
    Date of Patent: November 27, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Publication number: 20150211138
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from rare earth elements including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxide (R2 represents one or more elements selected from rare earth elements including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder to the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Application
    Filed: August 30, 2013
    Publication date: July 30, 2015
    Applicant: Shin-Etsu Chemical Co., Ltd.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Publication number: 20150211139
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid comprising a slurry obtained by dispersing a powder containing an R2 fluoride (R2 represents one or more elements selected from among rare earth elements, including Y and Sc) in water; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Application
    Filed: August 30, 2013
    Publication date: July 30, 2015
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Publication number: 20150206653
    Abstract: A production method for a rare earth permanent magnet, wherein: a sintered magnet body comprising an R1—Fe—B composition (R1 represents one or more elements selected from among rare earth elements, including Y and Sc) is immersed in an electrodeposition liquid obtained by dispersing a powder containing an R2 oxyfluoride and/or an R3 hydride (R2 and R3 represent one or more elements selected from among rare earth elements, including Y and Sc) in a solvent; an electrodeposition process is used to coat the powder onto the surface of the sintered magnet body; and, in the state in which the powder is present on the surface of the magnet body, the magnet body and the powder are subjected to a heat treatment in a vacuum or an inert gas at a temperature equal to or less than the sintering temperature of the magnet.
    Type: Application
    Filed: August 30, 2013
    Publication date: July 23, 2015
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Yoshifumi Nagasaki, Masanobu Shimao
  • Publication number: 20090224613
    Abstract: Provided are a magnetic circuit capable of being manufactured inexpensively due to omission of formation of a corrosion-resistant metallic surface film as well as a voice coil motor or an actuator by utilizing the same. The magnetic circuit comprises yoke members prepared from a plate material of 0.1 mm to 5 mm thickness of a martensite-type, ferrite-type or precipitation-hardening stainless steel material or a Cr-based heat-resistant steel material containing 0.0001-1% (% by mass, the same hereinbelow) of C, 0.0001-5% of Si, 0.001-2% of Mn, 0.0001-0.1% of P, 0.0001-0.2% of S, 0.0001-5% of Al, 0.0001-0.1% of O, 0.0001-0.1% of N, 0.0001-1% of Ni and 10.5-30% of Cr together with at least one alloying element selected from Ti, Co, Cu, Zr, Nb, V, Mo, W, Ta and B as the additive elements in a total amount of 0.0001-5%, the balance being Fe.
    Type: Application
    Filed: April 26, 2005
    Publication date: September 10, 2009
    Inventors: Masanobu Shimao, Takehisa Minowa, Takayuki Hasegawa
  • Patent number: 7520941
    Abstract: A functionally graded rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, R2 is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, and the magnet body includes a surface layer having a higher coercive force than in the interior. The invention provides permanent magnets having improved heat resistance.
    Type: Grant
    Filed: January 27, 2006
    Date of Patent: April 21, 2009
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Patent number: 7488394
    Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, and grain boundaries having a concentration of R2/(R1+R2) which is on the average higher than the concentration of R2/(R1+R2) contained in primary phase grains of (R1,R2)2T14A tetragonal system form a three-dimensional network structure which is continuous from the magnet body surface to a depth of at least 10 ?m. The invention provides R—Fe—B sintered magnets which exhibit a high coercive force.
    Type: Grant
    Filed: January 27, 2006
    Date of Patent: February 10, 2009
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Patent number: 7488393
    Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, and the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m. The invention provides R—Fe—B sintered magnets which exhibit high magnet performance despite minimal amounts of Tb and Dy used.
    Type: Grant
    Filed: January 27, 2006
    Date of Patent: February 10, 2009
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Patent number: 7488395
    Abstract: A functionally graded rare earth permanent magnet having a reduced eddy current loss in the form of a sintered magnet body having a composition RaEbTcAdFeOfMg is obtained by causing E and fluorine atoms to be absorbed in a R—Fe—B sintered magnet body from its surface. F is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the concentration of E/(R+E) contained in grain boundaries surrounding primary phase grains of (R,E)2T14A tetragonal system is on the average higher than the concentration of E/(R+E) contained in the primary phase grains, the oxyfluoride of (R,E) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, particles of the oxyfluoride having an equivalent circle diameter of at least 1 ?m are distributed in the grain boundary region at a population of at least 2,000 particles/mm2, the oxyfluoride is present in an area fraction of at least 1%.
    Type: Grant
    Filed: January 27, 2006
    Date of Patent: February 10, 2009
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Publication number: 20060213583
    Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, and the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m. The invention provides R—Fe—B sintered magnets which exhibit high magnet performance despite minimal amounts of Tb and Dy used.
    Type: Application
    Filed: January 27, 2006
    Publication date: September 28, 2006
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Publication number: 20060213585
    Abstract: A functionally graded rare earth permanent magnet having a reduced eddy current loss in the form of a sintered magnet body having a composition RaEbTcAdFeOfMg is obtained by causing E and fluorine atoms to be absorbed in a R—Fe—B sintered magnet body from its surface. F is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the concentration of E/(R+E) contained in grain boundaries surrounding primary phase grains of (R,E)2T14A tetragonal system is on the average higher than the concentration of E/(R+E) contained in the primary phase grains, the oxyfluoride of (R,E) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, particles of the oxyfluoride having an equivalent circle diameter of at least 1 ?m are distributed in the grain boundary region at a population of at least 2,000 particles/mm2, the oxyfluoride is present in an area fraction of at least 1%.
    Type: Application
    Filed: January 27, 2006
    Publication date: September 28, 2006
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Publication number: 20060213582
    Abstract: A functionally graded rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, R2 is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, and the magnet body includes a surface layer having a higher coercive force than in the interior. The invention provides permanent magnets having improved heat resistance.
    Type: Application
    Filed: January 27, 2006
    Publication date: September 28, 2006
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Publication number: 20060213584
    Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, and grain boundaries having a concentration of R2/(R1+R2) which is on the average higher than the concentration of R2/(R1+R2) contained in primary phase grains of (R1,R2)2T14A tetragonal system form a three-dimensional network structure which is continuous from the magnet body surface to a depth of at least 10 ?m. The invention provides R—Fe—B sintered magnets which exhibit a high coercive force.
    Type: Application
    Filed: January 27, 2006
    Publication date: September 28, 2006
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
  • Patent number: 6942741
    Abstract: An iron alloy strip having a gage of 0.1 to 5 mm and a magnetic field strength variation within the strip of 0 to 10 Hz, made of an iron alloy consisting essentially of, in % by weight, 0.0001-0.02% of C, 0.0001-5% of Si, 0.001-0.2% of Mn, 0.0001-0.05% of P, 0.0001-0.05% of S, 0.0001-5% of Al, 0.001-0.1% of O, 0.0001-0.03% of N, 0-10% of Co, 0-10% of Cr, 0.01-5% in total of Ti, Zr, Nb, Mo, V, Ni, W, Ta and/or B, and the balance of Fe, and having a saturation magnetic flux density of 1.7-2.3 Tesla, a maximum relative permeability of 1,200-22,000 and a coercive force of 20-380 A/m is suited for use as yokes in voice coil motor magnetic circuits. The iron alloy strip is highly resistant to corrosion and eliminates a need for a corrosion resistant coating.
    Type: Grant
    Filed: August 7, 2002
    Date of Patent: September 13, 2005
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Masanobu Shimao, Masaaki Nishino, Takehisa Minowa
  • Patent number: 6746545
    Abstract: An R—Fe—B permanent magnet wherein R is Nd or a combination of Nd with a rare earth element is prepared by casting an R—Fe—B alloy, crushing the alloy in an oxygen-free atmosphere of argon, nitrogen or vacuum, effecting comminution, compaction, sintering, aging, and cutting and/or polishing the magnet to give a finished surface. The magnet is then heat treated in an argon, nitrogen or low-pressure vacuum atmosphere having a limited oxygen partial pressure, obtaining a highly oil resistant sintered permanent magnet having corrosion resistance and hydrogen barrier property even in a high pressure hot environment of refrigerant and/or lubricant as encountered in compressors.
    Type: Grant
    Filed: May 30, 2001
    Date of Patent: June 8, 2004
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuo Tamura, Masanobu Shimao, Ryuji Hamada, Takehisa Minowa
  • Patent number: 6623541
    Abstract: A sintered rare earth magnet consisting essentially of 20-30% by weight of R (wherein R is Sm or a mixture of Sm and another rare earth element), 10-45% by weight of Fe, 1-10% by weight of Cu, 0.5-5% by weight of Zr, and the balance of Co has on its surface a composite layer containing Sm2O3 and/or CoFe2O4 in Co or Co and Fe. The magnet is resistant to hydrogen embrittlement.
    Type: Grant
    Filed: July 30, 2001
    Date of Patent: September 23, 2003
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuaki Sakaki, Masanobu Shimao, Hajime Nakamura, Takehisa Minowa
  • Patent number: 6547889
    Abstract: The invention discloses an iron-based alloy sheet as a material for preparing a magnetic yoke member to build up a magnetic circuit in a hard-disk voice-coil motor as well as a magnetic yoke member made from such a sheet material. With an object to improve the magnetic circuit in respect of compactness and flatness, the iron-based alloy forming the sheet material contains inherent side elements including C, Si, Mn, P, S, Al, O and N each in a specified amount and is characterized by specified values of saturated magnetic flux density, maximum magnetic permeability and coercive force. The iron-based alloy may further contain up to 10% by weight of cobalt and/or one or a combination of adjuvant elements selected from Ti, Zr, Nb, Mo, Cr, V, Ni, W, Ta and B.
    Type: Grant
    Filed: September 5, 2001
    Date of Patent: April 15, 2003
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Masanobu Shimao, Takehisa Minowa, Masaaki Nishino
  • Publication number: 20030034091
    Abstract: An iron alloy strip having a gage of 0.1 to 5 mm and a magnetic field strength variation within the strip of 0 to 10 Hz, made of an iron alloy consisting essentially of, in % by weight, 0.0001-0.02% of C, 0.0001-5% of Si, 0.001-0.2% of Mn, 0.0001-0.05% of P, 0.0001-0.05% of S, 0.0001-5% of Al, 0.001-0.1% of O, 0.0001-0.03% of N, 0-10% of Co, 0-10% of Cr, 0.01-5% in total of Ti, Zr, Nb, Mo, V, Ni, W, Ta and/or B, and the balance of Fe, and having a saturation magnetic flux density of 1.7-2.3 Tesla, a maximum relative permeability of 1,200-22,000 and a coercive force of 20-380 A/m is suited for use as yokes in voice coil motor magnetic circuits. The iron alloy strip is highly resistant to corrosion and eliminates a need for a corrosion resistant coating.
    Type: Application
    Filed: August 7, 2002
    Publication date: February 20, 2003
    Inventors: Masanobu Shimao, Masaaki Nishino, Takehisa Minowa