Patents by Inventor Osamu Itatani
Osamu Itatani 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: 9884368Abstract: An applicator for grain boundary diffusion process that uniformly applies an RH powder without excess or deficiency onto a predetermined surface of a sintered compact with a given thickness and in a given pattern, the applicator being automated and performed on many sintered compacts during the production of a NdFeB system sintered magnet. The applicator includes a work loader and a print head, located above the work loader. The work loader includes: a laterally movable base; a lift being vertically movable with respect to the base; a frame that is attachable to and detachable from the lift; a tray that is attachable to and detachable from the frame; a supporter provided on the upper surface of the tray; and a vertically movable magnetic clamp. The print head includes: a screen having a passage section; and a movable squeegee and a backward scraper that maintains contact with the upper screen surface.Type: GrantFiled: April 26, 2011Date of Patent: February 6, 2018Assignee: INTERMETALLICS CO., LTD.Inventors: Osamu Itatani, Masato Sagawa
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Publication number: 20160293329Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.Type: ApplicationFiled: May 31, 2016Publication date: October 6, 2016Applicants: INTERMETALLICS CO., LTD., DAIDO STEEL CO., LTD.Inventors: Masato SAGAWA, Osamu ITATANI, Norio YOSHIKAWA
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Patent number: 9449758Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.Type: GrantFiled: May 31, 2016Date of Patent: September 20, 2016Assignees: INTERMETALLICS CO., LTD., DAIDO STEEL CO., LTD.Inventors: Masato Sagawa, Osamu Itatani, Norio Yoshikawa
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Patent number: 9384890Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.Type: GrantFiled: February 3, 2014Date of Patent: July 5, 2016Assignees: INTERMETALLICS CO., LTD., DAIDO STEEL CO., LTD.Inventors: Masato Sagawa, Osamu Itatani, Norio Yoshikawa
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Publication number: 20150364252Abstract: A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.Type: ApplicationFiled: February 3, 2014Publication date: December 17, 2015Applicants: INTERMETALLICS CO., LTD., DAIDO STEEL CO., LTD.Inventors: Masato SAGAWA, Osamu ITATANI, Norio YOSHIKAWA
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Publication number: 20130343946Abstract: A method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. A fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace. A multi-cavity mold for manufacturing a sintered rare-earth magnet having an industrially important shape, such as a plate magnet or an arched plate magnet, may be used.Type: ApplicationFiled: August 26, 2013Publication date: December 26, 2013Applicant: INTERMETALLICS CO., LTD.Inventors: Masato SAGAWA, Hiroshi NAGATA, Osamu ITATANI
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Patent number: 8545641Abstract: A method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. A fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace. A multi-cavity mold for manufacturing a sintered rare-earth magnet having an industrially important shape, such as a plate magnet or an arched plate magnet, may be used.Type: GrantFiled: June 30, 2005Date of Patent: October 1, 2013Assignee: Intermetallics Co., Ltd.Inventors: Masato Sagawa, Hiroshi Nagata, Osamu Itatani
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Publication number: 20130040050Abstract: An applicator for grain boundary diffusion process that uniformly applies an RH powder without excess or deficiency onto a predetermined surface of a sintered compact with a given thickness and in a given pattern, the applicator being automated and performed on many sintered compacts during the production of a NdFeB system sintered magnet. The applicator includes a work loader and a print head, located above the work loader. The work loader includes: a laterally movable base; a lift being vertically movable with respect to the base; a frame that is attachable to and detachable from the lift; a tray that is attachable to and detachable from the frame; a supporter provided on the upper surface of the tray; and a vertically movable magnetic clamp. The print head includes: a screen having a passage section; and a movable squeegee and a backward scraper that maintains contact with the upper screen surface.Type: ApplicationFiled: April 26, 2011Publication date: February 14, 2013Applicant: INTERMETALLICS CO., LTD.Inventors: Osamu Itatani, Masato Sagawa
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Patent number: 7354621Abstract: In a method for forming an adhesive layer on the surface of a workpiece before the formation of a coating film containing a powder on the workpiece, the present invention provides a method for forming the adhesive layer having a desired thickness. This object is achieved by the following method: An adhesive layer formation medium m1 coated with an adhesive material is made to collide with a workpiece W so that the adhesive material is transferred from the adhesive layer formation medium m1 to the workpiece W and forms an adhesive layer on the workpiece. An adhesive layer having a desired thickness can be formed on the workpiece by regulating the thickness of the adhesive material applied to the surface of the adhesive layer formation medium (i.e. the amount of the adhesive material held by a single adhesive layer formation medium). This enables the thickness of the powder coating as the final product to be controlled as desired.Type: GrantFiled: June 2, 2004Date of Patent: April 8, 2008Assignee: Intermetallics Co., Ltd.Inventors: Osamu Itatani, Masato Sagawa
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Publication number: 20070245851Abstract: To improve the performance of a rare-earth magnet, it is effective to use a low-oxidized powder having a small grain size. One objective of the present invention is to provide a method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. Another objective is to provide a method capable of efficiently manufacturing products having various shapes. In a weighing and loading section 41 and a high-density loading section 42, a fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section 43, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace 44.Type: ApplicationFiled: June 30, 2005Publication date: October 25, 2007Applicant: INTERMETALLICS CO., LTD.Inventors: Masato Sagawa, Hiroshi Nagata, Osamu Itatani
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Publication number: 20060134319Abstract: In a method for forming an adhesive layer on the surface of a workpiece before the formation of a coating film containing a powder on the workpiece, the present invention provides a method for forming the adhesive layer having a desired thickness. This object is achieved by the following method: An adhesive layer formation medium m1 coated with an adhesive material is made to collide with a workpiece W so that the adhesive material is transferred from the adhesive layer formation medium m1 to the workpiece W and forms an adhesive layer on the workpiece. An adhesive layer having a desired thickness can be formed on the workpiece by regulating the thickness of the adhesive material applied to the surface of the adhesive layer formation medium (i.e. the amount of the adhesive material held by a single adhesive layer formation medium). This enables the thickness of the powder coating as the final product to be controlled as desired.Type: ApplicationFiled: June 2, 2004Publication date: June 22, 2006Applicant: INTERMETALLICS CO., LTDInventors: Osamu Itatani, Masato Sagawa
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Publication number: 20010006733Abstract: Constitution: Impact media m to which a powder is attached impinge an article 19 with an adhesive layer formed thereon so that the powder adheres to the surface of the article, in which the impact media comprises a magnetic material and are subject to a magnetic field.Type: ApplicationFiled: November 30, 2000Publication date: July 5, 2001Inventors: Masato Sagawa, Osamu Itatani
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Patent number: 6113979Abstract: The powder coating of the present invention was used for a method for forming coatings comprising the steps of making the powder coating adhere to an adhesive layer previously formed on the surface of a material to be coated, and then heating it, thereby forming a coating, comprising a resin particle containing a thermosetting resin, and a particle containing a curing agent.Type: GrantFiled: August 28, 1998Date of Patent: September 5, 2000Assignees: Intermetallics Co., Ltd., Tomoegawa Paper Co., Ltd.Inventors: Masato Sagawa, Osamu Itatani, Akira Fujiwara
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Patent number: 5449481Abstract: Methods and apparatuses for producing a powder compacts are disclosed. A powder compaction apparatus includes a recess formed by die and a lower punch inserted into the die. The recess is loaded with rubber mold provided with a cavity shaped according to the desired configuration of the compact. Subsequently, the powder is packed in the cavity of the rubber mold, and an upper punch is placed on die to press the rubber mold with powder in the space formed by the die, the lower punch and the upper punch, thereby producing a powder compact.Type: GrantFiled: November 22, 1993Date of Patent: September 12, 1995Assignee: Intermetallics Co., Ltd.Inventors: Masato Sagawa, Hiroshi Nagata, Osamu Itatani