Patents by Inventor Noritaka Miyamoto

Noritaka Miyamoto 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: 10301713
    Abstract: There is provided a thermal spray powder for forming an abradable thermal spray coating. The thermal spray powder includes NiCr alloy particles and synthetic mica particles. The synthetic mica particles are contained at 40 volume % or less with respect to a total volume of the thermal spray powder.
    Type: Grant
    Filed: March 28, 2017
    Date of Patent: May 28, 2019
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Masahiro Kurase, Toshio Hotta, Mototsugu Koyama, Eisuke Yamamoto
  • Patent number: 10227685
    Abstract: A method for forming an iron sprayed coating on a substrate with droplets of a wire molten by an electric arc includes: a step of forming a first iron sprayed coating on the substrate, the wire for arc spraying being a first wire containing iron and 0.03 to 0.10% by mass of carbon and the compressed gas being inert gas; and a step of forming a second iron sprayed coating on the first iron sprayed coating, the wire for arc spraying being a second wire containing iron and 0.03 to 0.10% by mass of carbon and the compressed gas containing 10 to 21% by volume of oxygen gas.
    Type: Grant
    Filed: September 18, 2014
    Date of Patent: March 12, 2019
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Masaki Hirano, Tomoko Kozaki
  • Patent number: 10199145
    Abstract: Provided is a rare-earth magnet containing no heavy rare-earth metals such as Dy or Tb in a grain boundary phase, has a modifying alloy for increasing coercivity (in particular, coercivity under a high-temperature atmosphere) infiltrated thereinto at lower temperature than in the conventional rare-earth magnets, has high coercivity, and has relatively high magnetizability, and a production method therefor. The rare-earth magnet RM includes a RE-Fe—B-based main phase MP with a nanocrystalline structure (where RE is at least one of Nd or Pr) and a grain boundary phase BP around the main phase, the grain boundary phase containing a RE-X alloy (where X is a metallic element other than heavy rare-earth elements). Crystal grains of the main phase MP are oriented along the anisotropy axis, and each crystal grain of the main phase, when viewed from a direction perpendicular to the anisotropy axis, has a plane that is quadrilateral in shape or has a close shape thereto.
    Type: Grant
    Filed: November 12, 2012
    Date of Patent: February 5, 2019
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Tetsuya Shoji, Akira Manabe, Noritaka Miyamoto, Motoki Hiraoka, Shinya Omura, Daisuke Ichigozaki, Shinya Nagashima
  • Publication number: 20180298480
    Abstract: Provided are spraying powder that can suppress a decrease in the machinability of the resulting sprayed coating even under a high-temperature environment, and a method for depositing a sprayed coating using the same. The spraying powder is spraying powder for depositing a sprayed coating with an abradable property. The spraying powder includes NiCr-based alloy particles and h-BN particles. A NiCr-based alloy of the NiCr-based alloy particles contains 2 to 10 mass % of Si, and the content of the h-BN particles in the spraying powder is 4 to 8 mass %.
    Type: Application
    Filed: April 11, 2018
    Publication date: October 18, 2018
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Noritaka MIYAMOTO
  • Patent number: 9905362
    Abstract: A method for manufacturing a rare-earth magnet, through hot deformation processing, having a high degree of orientation at the entire area thereof and high remanence, without increasing processing cost including a step of press-forming powder as a rare-earth magnetic material to form a compact S; and a step of performing hot deformation processing to the compact S, thus manufacturing the rare-earth magnet C. The hot deformation processing includes two steps of extruding and upsetting. The extruding is to place a compact S in a die Da, and apply pressure to the compact S? in a heated state with an extrusion punch PD so as to reduce the thickness for extrusion to prepare the rare-earth magnet intermediary body S? having a sheet form, and the upsetting is to apply pressure to the rare-earth magnet intermediary body S? in the thickness direction to reduce the thickness, thus manufacturing the rare-earth magnet C.
    Type: Grant
    Filed: October 17, 2013
    Date of Patent: February 27, 2018
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Noritaka Miyamoto, Tetsuya Shoji, Yuya Ikeda, Akira Manabe
  • Patent number: 9859055
    Abstract: Provided is a method for manufacturing a rare-earth magnet capable of manufacturing a rare-earth magnet with high degree of orientation by sufficient plastic deformation while suppressing cracks at the side faces of a compact that is plastic-deformed during the hot deformation processing. The method includes a step of preparing a compact S, preparing a plastic processing mold including a die D in which a cavity Ca is provided, and punches P that are slidable in the cavity Ca, the cavity Ca having a cross section that is larger in cross-sectional dimensions than a cross section of the compact S that is orthogonal to a pressing direction by the punches P; and a step of placing the compact S in the cavity Ca and performing hot deformation processing, thus manufacturing an orientational magnet C.
    Type: Grant
    Filed: October 4, 2013
    Date of Patent: January 2, 2018
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Daisuke Ichigozaki, Tetsuya Shoji, Eisuke Hoshina, Akira Kano, Osamu Yamashita
  • Patent number: 9847169
    Abstract: A production method includes producing a rare-earth magnet precursor (S?) by performing first hot working in which, in two side surfaces of a sintered body, which are parallel to a pressing direction and are opposite to each other, one side surface is brought to a constrained state to suppress deformation, and the other side surface is brought to an unconstrained state to permit deformation; and producing a rare-earth magnet by performing second hot working in which, in two side surfaces (S?1, S?2) of the rare-earth magnet precursor (S?), which are parallel to the pressing direction, a side surface (S?2), which is in the unconstrained state in the first hot working, is brought to the constrained state to suppress deformation, and a side surface (S?1), which is in the constrained state in the first hot working, is brought to the unconstrained state to permit deformation.
    Type: Grant
    Filed: March 31, 2014
    Date of Patent: December 19, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akira Kano, Dai Kobuchi, Eisuke Hoshina, Osamu Yamashita, Noritaka Miyamoto
  • Publication number: 20170283932
    Abstract: There is provided a thermal spray powder for forming an abradable thermal spray coating. The thermal spray powder includes NiCr alloy particles and synthetic mica particles. The synthetic mica particles are contained at 40 volume % or less with respect to a total volume of the thermal spray powder.
    Type: Application
    Filed: March 28, 2017
    Publication date: October 5, 2017
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka MIYAMOTO, Masahiro KURASE, Toshio HOTTA, Mototsugu KOYAMA, Eisuke YAMAMOTO
  • Publication number: 20160237543
    Abstract: A method for forming an iron sprayed coating on a substrate with droplets of a wire molten by an electric arc includes: a step of forming a first iron sprayed coating on the substrate, the wire for arc spraying being a first wire containing iron and 0.03 to 0.10% by mass of carbon and the compressed gas being inert gas; and a step of forming a second iron sprayed coating on the first iron sprayed coating, the wire for arc spraying being a second wire containing iron and 0.03 to 0.10% by mass of carbon and the compressed gas containing 10 to 21% by volume of oxygen gas.
    Type: Application
    Filed: September 18, 2014
    Publication date: August 18, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka MIYAMOTO, Masaki HIRANO, Tomoko KOZAKI
  • Patent number: 9281105
    Abstract: A permanent magnet has a grain structure that includes a main phase and a grain boundary phase that is primarily composed of a first metal. A second metal that enhances the coercivity of the permanent magnet and a third metal that has a lower standard free energy of oxide formation than the first metal and the second metal are diffused in the permanent magnet, and the third metal is present in the form of an oxide in the grain boundary phase.
    Type: Grant
    Filed: July 13, 2011
    Date of Patent: March 8, 2016
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Noritaka Miyamoto, Shinya Omura
  • Publication number: 20160055968
    Abstract: A production method includes producing a rare-earth magnet precursor (S?) by performing first hot working in which, in two side surfaces of a sintered body, which are parallel to a pressing direction and are opposite to each other, one side surface is brought to a constrained state to suppress deformation, and the other side surface is brought to an unconstrained state to permit deformation; and producing a rare-earth magnet by performing second hot working in which, in two side surfaces (S?1, S?2) of the rare-earth magnet precursor (S?), which are parallel to the pressing direction, a side surface (S?2), which is in the unconstrained state in the first hot working, is brought to the constrained state to suppress deformation, and a side surface (S?1), which is in the constrained state in the first hot working, is brought to the unconstrained state to permit deformation.
    Type: Application
    Filed: March 31, 2014
    Publication date: February 25, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akira KANO, Dai KOBUCHI, Eisuke HOSHINA, Osamu YAMASHITA, Noritaka MIYAMOTO
  • Patent number: 9257227
    Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.
    Type: Grant
    Filed: January 25, 2013
    Date of Patent: February 9, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Shinya Omura, Motoki Hiraoka
  • Patent number: 9230733
    Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.
    Type: Grant
    Filed: January 25, 2013
    Date of Patent: January 5, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Shinya Omura, Motoki Hiraoka
  • Publication number: 20150302986
    Abstract: A permanent magnet has a grain structure that includes a main phase and a grain boundary phase that is primarily composed of a first metal. A second metal that enhances the coercivity of the permanent magnet and a third metal that has a lower standard free energy of oxide formation than the first metal and the second metal are diffused in the permanent magnet, and the third metal is present in the form of an oxide in the grain boundary phase.
    Type: Application
    Filed: June 30, 2015
    Publication date: October 22, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Shinya Omura
  • Publication number: 20150287528
    Abstract: Provided is a method for manufacturing a rare-earth magnet enabling effective penetrant-diffusion of a melt of modifier alloy powder without generating oxidation reaction or hydroxylation reaction when the modifier alloy powder is used for a better coercive force as well.
    Type: Application
    Filed: November 13, 2013
    Publication date: October 8, 2015
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Daisuke Sakuma
  • Publication number: 20150287530
    Abstract: A method for manufacturing a rare-earth magnet, through hot deformation processing, having a high degree of orientation at the entire area thereof and high remanence, without increasing processing cost including a step of press-forming powder as a rare-earth magnetic material to form a compact S; and a step of performing hot deformation processing to the compact S, thus manufacturing the rare-earth magnet C. The hot deformation processing includes two steps of extruding and upsetting. The extruding is to place a compact S in a die Da, and apply pressure to the compact S? in a heated state with an extrusion punch PD so as to reduce the thickness for extrusion to prepare the rare-earth magnet intermediary body S? having a sheet form, and the upsetting is to apply pressure to the rare-earth magnet intermediary body S? in the thickness direction to reduce the thickness, thus manufacturing the rare-earth magnet C.
    Type: Application
    Filed: October 17, 2013
    Publication date: October 8, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke ICHIGOZAKI, Noritaka MIYAMOTO, Tetsuya SHOJI, Yuya IKEDA, Akira MANABE
  • Publication number: 20150279559
    Abstract: Provided is a method for manufacturing a rare-earth magnet capable of manufacturing a rare-earth magnet with high degree of orientation by sufficient plastic deformation while suppressing cracks at the side faces of a compact that is plastic-deformed during the hot deformation processing. The method includes a step of preparing a compact S, preparing a plastic processing mold including a die D in which a cavity Ca is provided, and punches P that are slidable in the cavity Ca, the cavity Ca having a cross section that is larger in cross-sectional dimensions than a cross section of the compact S that is orthogonal to a pressing direction by the punches P; and a step of placing the compact S in the cavity Ca and performing hot deformation processing, thus manufacturing an orientational magnet C.
    Type: Application
    Filed: October 4, 2013
    Publication date: October 1, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Daisuke Ichigozaki, Tetsuya Shoji, Eisuke Hoshina, Akira Kano, Osamu Yamashita
  • Publication number: 20150279529
    Abstract: A method for manufacturing a rare-earth magnet having excellent workability and coercive-force performance in a high-temperature atmosphere and magnetization performance by controlling the content of Pr as the alloy composition to an optimum range, including: press-forming magnetic powder B to form a compact, the magnetic powder B including a RE-Fe-B main phase MP (RE: Nd and Pr) and an RE-X alloy (X: metal element) grain boundary phase BP around the main phase MP having an average grain size of 10 nm to 200 nm; and performing hot deformation processing to the compact to give magnetic anisotropy thereto, thus manufacturing the rare-earth magnet C that is a nano-crystalline magnet. The content of Nd, B, Co and Pr included in the magnetic powder B is Nd: 25 to 35, B: 0.5 to 1.5 and Co: 2 to 7 in terms of at %, and Pr: 0.2 to 5 at % and Fe.
    Type: Application
    Filed: October 8, 2013
    Publication date: October 1, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Yuya Ikeda
  • Publication number: 20150235747
    Abstract: A rare-earth sintered magnet including a relatively large main phase, and method for manufacturing same. The rare-earth sintered magnet having excellent coercive-force performance that can be manufactured without using heavy rare-earth elements such as Dy, and including: a RE-T-B main phase C (RE: Nd or Pr, T: Fe or Fe and a part thereof substituted with Co), and a grain boundary phase B surrounding the main phase C, the grain boundary phase including the RE element and the T element. The T element at the grain boundary phase B has density of 60 at % or less, and the grain boundary B has a thickness decreasing from a surface S of the rare-earth sintered magnet M to an inside thereof, and the grain boundary phase B at an area SA of a surface layer of the rare-earth sintered magnet M has an average thickness of 10 nm or more.
    Type: Application
    Filed: October 2, 2013
    Publication date: August 20, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Tetsuya Shoji, Kazuaki Haga
  • Patent number: 9111679
    Abstract: A method of producing an R-T-B rare earth magnet that include forming an R-T-B (R: rare-earth element, T: Fe, or Fe and partially Co that substitutes for part of Fe) rare earth alloy powder into a compact and performing hot working on the compact, wherein the hot working is performed in a direction that is different from the direction in which the forming was performed.
    Type: Grant
    Filed: February 22, 2012
    Date of Patent: August 18, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki