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).
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Publication number: 20150287528Abstract: 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: ApplicationFiled: November 13, 2013Publication date: October 8, 2015Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Daisuke Sakuma
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Publication number: 20150279559Abstract: 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: ApplicationFiled: October 4, 2013Publication date: October 1, 2015Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Noritaka Miyamoto, Daisuke Ichigozaki, Tetsuya Shoji, Eisuke Hoshina, Akira Kano, Osamu Yamashita
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Publication number: 20150279529Abstract: 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: ApplicationFiled: October 8, 2013Publication date: October 1, 2015Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Daisuke Ichigozaki, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Yuya Ikeda
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Publication number: 20150235747Abstract: 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: ApplicationFiled: October 2, 2013Publication date: August 20, 2015Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Noritaka Miyamoto, Tetsuya Shoji, Kazuaki Haga
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Patent number: 9111679Abstract: 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: GrantFiled: February 22, 2012Date of Patent: August 18, 2015Assignee: Toyota Jidosha Kabushiki KaishaInventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki
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Patent number: 9070508Abstract: 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: GrantFiled: February 22, 2012Date of Patent: June 30, 2015Assignee: Toyota Jidosha Kabushiki KaishaInventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki
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Patent number: 8957346Abstract: A thermal spraying apparatus prevents adhesion of spray fumes to unsprayed regions of a bore surface during arc spraying. The apparatus includes a spray gun movable within a cylinder bore. The spray gun has at one end thereof a first discharge opening facing a direction orthogonal to the movement direction, has a second discharge opening facing direction orthogonal to the nozzle, and has, at a predetermined region located further to the side in the movement direction of the spray gun than the nozzle, third discharge openings for discharging a fluid and facing the same direction as the nozzle. A droplet, formed as arc spray wire material melts at the tip of the spray gun, is stretched with auxiliary air. By blowing atomizing air onto the droplet, spray particles are formed and sprayed onto the bore surface. Simultaneously, fume adhesion prevention air is blown toward the cylinder bore surface.Type: GrantFiled: September 15, 2011Date of Patent: February 17, 2015Assignee: Toyota Jidosha Kabushiki KaishaInventors: Kota Kodama, Noritaka Miyamoto
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Patent number: 8846136Abstract: PROBLEM: To provide a production method of an anisotropic rare earth magnet capable of being enhanced in coercivity without adding a large amount of a rare metal such as Dy and Tb. MEANS FOR RESOLUTION: A production method of a rare earth magnet, comprising a step of bringing a compact obtained by applying hot working to impart anisotropy to a sintered body having a rare earth magnet composition into contact with a low-melting-point alloy melt containing a rare earth element.Type: GrantFiled: September 13, 2011Date of Patent: September 30, 2014Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tetsuya Shoji, Noritaka Miyamoto, Shinya Omura, Daisuke Ichigozaki, Takeshi Yamamoto
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Publication number: 20140260800Abstract: A method for producing magnetic powder for forming a sintered body that is a precursor of a rare-earth magnet. Provided is a method for producing magnetic powder for forming a sintered body that is a precursor of a rare-earth magnet, which can produce magnetic powder with a structure containing optimal nanosized crystal grains by accurately and efficiently sorting out magnetic powder containing no coarse grains in the structure thereof.Type: ApplicationFiled: October 9, 2012Publication date: September 18, 2014Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Noritsugu Sakuma, Hidefumi Kishimoto, Noritaka Miyamoto, Akira Kato, Akira Manabe, Daisuke Ichigozaki, Tetsuya Shoji, Shoichi Harakawa
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Publication number: 20140242267Abstract: 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: ApplicationFiled: November 12, 2012Publication date: August 28, 2014Inventors: Tetsuya Shoji, Akira Manabe, Noritaka Miyamoto, Motoki Hiraoka, Shinya Omura, Daisuke Ichigozaki, Shinya Nagashima
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Patent number: 8642132Abstract: A method of depositing a carbon particle-containing film that contains carbon particles includes: manufacturing film deposition slurry by mixing liquid into film deposition powder that contains carbon powder formed of the carbon particles; and depositing the carbon particle-containing film by spraying the film deposition slurry to a surface of a base material so that the liquid is vaporized.Type: GrantFiled: May 12, 2010Date of Patent: February 4, 2014Assignee: Toyota Jidosha Kabushiki KaishaInventors: Noritaka Miyamoto, Yoshihiko Tsuzuki, Tomoko Kozaki
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Publication number: 20130321112Abstract: 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: ApplicationFiled: February 22, 2012Publication date: December 5, 2013Inventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki
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Publication number: 20130323111Abstract: The present invention provides a method of production of a rare earth magnet which achieves high magnetization by hot working and at the same time secures high coercivity. A method of production of the present invention is a method for producing an R-T-B-based rare earth magnet comprising: molding a powder of an R-T-B-based rare earth alloy (R: rare earth element, T: Fe or Fe part of which is substituted by Co) to form a bulk; then hot working the bulk; and before the molding, mixing with the powder of an R-T-B-based rare earth alloy either a metal which forms a liquid phase in copresence with R at a temperature lower than the hot working temperature, or an alloy which forms a liquid phase at a temperature lower than the hot working temperature.Type: ApplicationFiled: February 21, 2011Publication date: December 5, 2013Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Noritaka Miyamoto, Tetsuya Shoji, Shinya Omura, Daisuke Ichigozaki, Akira Manabe
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Patent number: 8499825Abstract: The present invention provides a method for manufacturing a heat transfer member which method allows peel-off and cracking possibly caused by thermal expansion to be inhibited. That is, the present invention provides a method for manufacturing a heat transfer member 10, the method at least including a step of forming metal powder into a coating film 12 on a surface of a base material 11 by spraying the metal powder in a solid state onto the surface of the base material 11 together with compressed gas. In the film forming step, a spraying pressure at which the metal powder is sprayed onto the surface of the base material 11 is set so that the coating film 12 has a porous structure.Type: GrantFiled: July 17, 2008Date of Patent: August 6, 2013Assignee: Toyota Jidosha Kabushiki KaishaInventors: Yoshihiko Tsuzuki, Noritaka Miyamoto
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Publication number: 20130195710Abstract: Provided is a manufacturing method of a rare-earth magnet capable of penetrant-diffusing a modifier alloy to increase a coercive force (especially a coercive force under a high-temperature atmosphere) at a temperature lower than the conventional method for manufacturing a rare-earth magnet without using heavy rare-earth metals such as Dy and Tb, and accordingly capable of manufacturing a high coercivity rare-earth magnet at the lowest cost possible.Type: ApplicationFiled: January 25, 2013Publication date: August 1, 2013Inventors: Kazuaki HAGA, Noritaka MIYAMOTO, Tetsuya SHOJI, Noritsugu SAKUMA, Shinya OMURA, Motoki HIRAOKA
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Publication number: 20130135069Abstract: 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: ApplicationFiled: July 13, 2011Publication date: May 30, 2013Inventors: Noritaka Miyamoto, Shinya Omura
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Publication number: 20130078369Abstract: PROBLEM: To provide a production method of an anisotropic rare earth magnet capable of being enhanced in coercivity without adding a large amount of a rare metal such as Dy and Tb. MEANS FOR RESOLUTION: A production method of a rare earth magnet, comprising a step of bringing a compact obtained by applying hot working to impart anisotropy to a sintered body having a rare earth magnet composition into contact with a low-melting-point alloy melt containing a rare earth element.Type: ApplicationFiled: September 13, 2011Publication date: March 28, 2013Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tetsuya Shoji, Noritaka Miyamoto, Shinya Omura, Daisuke Ichigozaki, Takeshi Yamamoto
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Publication number: 20120121451Abstract: An arc spray coating that is superior in both wear resistance and machinability, method of forming same, an arc spray wire used to form such a coating, and a cylinder block on whose bore inner surface is formed such an arc spray coating are provided. To this end, the arc spray coating contains Fe as a main component, 0.01% to 0.15% by weight of C, and at least 0.12% by weight of N, and the arc spray wire (wire) contains Fe as a main component, 0.01% to 0.2% by weight of C, and 0.25% to 1.7% by weight of Si, and may further contain at least 11% by weight of Cr as another embodiment.Type: ApplicationFiled: January 25, 2012Publication date: May 17, 2012Inventors: Kota Kodama, Noritaka Miyamoto
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Publication number: 20120067285Abstract: A thermal spraying apparatus prevents adhesion of spray fumes to unsprayed regions of a bore surface during arc spraying. The apparatus includes a spray gun movable within a cylinder bore. The spray gun has at one end thereof a first discharge opening facing a direction orthogonal to the movement direction, has a second discharge opening facing direction orthogonal to the nozzle, and has, at a predetermined region located further to the side in the movement direction of the spray gun than the nozzle, third discharge openings for discharging a fluid and facing the same direction as the nozzle. A droplet, formed as arc spray wire material melts at the tip of the spray gun, is stretched with auxiliary air. By blowing atomizing air onto the droplet, spray particles are formed and sprayed onto the bore surface. Simultaneously, fume adhesion prevention air is blown toward the cylinder bore surface.Type: ApplicationFiled: September 15, 2011Publication date: March 22, 2012Inventors: Kota KODAMA, Noritaka MIYAMOTO
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Patent number: 8037860Abstract: A cylinder liner has an upper portion and a lower portion with respect to an axial direction of the cylinder liner. A high thermal conductive film is provided on an outer circumferential surface of the upper portion. A low thermal conductive film is provided on an outer circumferential surface of the lower portion. The cylinder liner reduces temperature difference of a cylinder along its axial direction.Type: GrantFiled: July 6, 2006Date of Patent: October 18, 2011Assignees: Toyota Jidosha Kabushiki Kaisha, Teikoku Piston Ring Co., Ltd., Teipi Industry Co., Ltd.Inventors: Toshihiro Takami, Kouhei Hori, Takeshi Tsukahara, Noritaka Miyamoto, Masaki Hirano, Yukinori Ohta, Satoshi Yamada, Kouhei Shibata, Nobuyuki Yamashita, Toshihiro Mihara, Giichiro Saito, Masami Horigome, Takashi Sato