Patents by Inventor Shin Noguchi

Shin Noguchi 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: 11545286
    Abstract: A crystalline Fe-based alloy powder composed of Fe-based alloy particles containing, within a structure thereof, nanocrystal grains having an average grain size of 30 nm or less, and in which d50, which is a particle diameter corresponding to a cumulative frequency of 50% by volume, is from 3.5 ?m to 35.0 ?m in a cumulative distribution curve that is obtained by laser diffractometry and that shows the relationship between the particle diameter and the cumulative frequency from the small particle diameter side, and a ratio of Fe-based alloy particles having a particle diameter of 2 ?m or less to the total of the Fe-based alloy particles, which is determined by laser diffractometry, is from 0% by volume to 8% by volume.
    Type: Grant
    Filed: August 6, 2018
    Date of Patent: January 3, 2023
    Assignee: HITACHI METALS, LTD.
    Inventors: Tetsuro Kato, Nobuhiko Chiwata, Motoki Ohta, Shin Noguchi, Shuji Yamanaka
  • Patent number: 11508512
    Abstract: The invention provides a method for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. The invention is directed to a method for manufacturing a powder magnetic core with a metallic soft magnetic material powder, the method including: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.
    Type: Grant
    Filed: June 4, 2019
    Date of Patent: November 22, 2022
    Assignee: HITACHI METALS, LTD.
    Inventors: Kazunori Nishimura, Shin Noguchi, Toshio Mihara
  • Publication number: 20220294279
    Abstract: A magnetic wedge has high electrical resistance and bending strength, a rotary electric machine employs the magnetic wedge, and a method is for manufacturing the magnetic wedge. The magnetic wedge includes Fe-based soft magnetic particles, which contain an element M that is more readily oxidized than Fe and are bound by an oxide phase including the element M.
    Type: Application
    Filed: August 6, 2020
    Publication date: September 15, 2022
    Applicant: HITACHI METALS, LTD.
    Inventors: Shin NOGUCHI, Keiko KIKUCHI, Mamoru KIMURA, Kazunori NISHIMURA
  • Publication number: 20220176448
    Abstract: A manufacturing system according to an aspect of the present disclosure includes: a molding apparatus configured to uniaxially press raw material powder containing metal powder to fabricate a powder compact whose whole or part has a relative density of 93% or more; a robot processing apparatus including an articulated robot configured to machine the powder compact to fabricate a processed molded article; and an induction heating sintering furnace configured to sinter the processed molded article by high frequency induction heating to fabricate a sintered product.
    Type: Application
    Filed: April 24, 2019
    Publication date: June 9, 2022
    Applicant: Sumitomo Electric Sintered Alloy, Ltd.
    Inventors: Shin NOGUCHI, Tatsushi YAMAMOTO, Tetsuya HAYASHI
  • Patent number: 11192183
    Abstract: A powder magnetic core manufacturing method includes: a first step of mixing a binder with a soft magnetic material powder containing Fe-M (M: Al or Cr)-based alloy particles on which an insulating layer is formed; a second step of filling a pressing die with a mixture obtained through the first step, subjecting the mixture to pressing to obtain a green compact, and slidingly demolding the green compact from the pressing die; a third step of processing the green compact after the second step and removing expansion deformed matter of the alloy particles present in a region of pressing flaws formed on a surface of the green compact during the slidingly demolding; and a fourth step of subjecting the green compact after the third step to heat treatment to oxidize surfaces of the Fe-M (M: Al or Cr)-based alloy particles at high temperature, so that the oxide phase is formed.
    Type: Grant
    Filed: September 16, 2016
    Date of Patent: December 7, 2021
    Assignee: HITACHI METALS, LTD.
    Inventors: Tetsuroh Katoh, Kazunori Nishimura, Shin Noguchi
  • Patent number: 11097347
    Abstract: A method of producing an atomized powder includes: an atomizing step of forming magnetic alloy particles from a molten metal by an atomizing method, to obtain a slurry in which the magnetic alloy particles are dispersed in an aqueous dispersion medium; a slurry concentration step of causing magnetic separation means to separate the magnetic alloy particles from the slurry to form a concentrated slurry having the magnetic alloy particles of more than 80% by mass, the magnetic separation means using a rotary drum including a magnetic circuit part fixedly disposed at a position where at least a part of the magnetic circuit part is immersed in the slurry and an outer sleeve capable of rotating outside the magnetic circuit part; and a drying step of causing drying means using an air flow dryer to dry the concentrated slurry to form a magnetic alloy powder.
    Type: Grant
    Filed: March 23, 2018
    Date of Patent: August 24, 2021
    Assignee: HITACHI METALS, LTD.
    Inventors: Kazunori Nishimura, Shin Noguchi, Nobuaki Yoshioka
  • Patent number: 11011305
    Abstract: A method for manufacturing a powder magnetic core using a soft magnetic material powder, wherein the method has: a first step of mixing the soft magnetic material powder with a binder, a second step of subjecting a mixture obtained through the first step to pressure forming, and a third step of subjecting a formed body obtained through the second step to heat treatment. The soft magnetic material powder is an Fe—Cr—Al based alloy powder comprising Fe, Cr and Al. An oxide layer is formed on a surface of the soft magnetic material powder by the heat treatment. The oxide layer has a higher ratio by mass of Al to the sum of Fe, Cr and Al than an alloy phase inside the powder.
    Type: Grant
    Filed: May 24, 2018
    Date of Patent: May 18, 2021
    Assignee: HITACHI METALS, LTD.
    Inventors: Yoshimasa Nishio, Shin Noguchi, Kazunori Nishimura, Tetsuroh Katoh, Toshio Mihara
  • Publication number: 20200243238
    Abstract: A crystalline Fe-based alloy powder composed of Fe-based alloy particles containing, within a structure thereof, nanocrystal grains having an average grain size of 30 nm or less, and in which d50, which is a particle diameter corresponding to a cumulative frequency of 50% by volume, is from 3.5 ?m to 35.0 ?m in a cumulative distribution curve that is obtained by laser diffractometry and that shows the relationship between the particle diameter and the cumulative frequency from the small particle diameter side, and a ratio of Fe-based alloy particles having a particle diameter of 2 ?m or less to the total of the Fe-based alloy particles, which is determined by laser diffractometry, is from 0% by volume to 8% by volume.
    Type: Application
    Filed: August 6, 2018
    Publication date: July 30, 2020
    Applicant: HITACHI METALS, LTD.
    Inventors: Tetsuro KATO, Nobuhiko CHIWATA, Motoki OHTA, Shin NOGUCHI, Shuji YAMANAKA
  • Publication number: 20200222986
    Abstract: A powder magnetic core manufacturing method includes: a first step of mixing a binder with a soft magnetic material powder containing Fe-M (M: Al or Cr)-based alloy particles on which an insulating layer is formed; a second step of filling a pressing die with a mixture obtained through the first step, subjecting the mixture to pressing to obtain a green compact, and slidingly demolding the green compact from the pressing die; a third step of processing the green compact after the second step and removing expansion deformed matter of the alloy particles present in a region of pressing flaws formed on a surface of the green compact during the slidingly demolding; and a fourth step of subjecting the green compact after the third step to heat treatment to oxidize surfaces of the Fe-M (M: Al or Cr)-based alloy particles at high temperature, so that the oxide phase is formed.
    Type: Application
    Filed: September 16, 2016
    Publication date: July 16, 2020
    Applicant: HITACHI METALS, LTD.
    Inventors: Tetsuroh KATOH, Kazunori NISHIMURA, Shin NOGUCHI
  • Patent number: 10586646
    Abstract: A magnetic core has a high initial permeability and a small core loss, reducing a core loss at high frequencies; and a coil component including the same. This magnetic core is formed by binding a plurality of Fe-based alloy particles containing Al via an oxide layer containing an Fe oxide. In an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, a peak intensity ratio (P1/P2) of peak intensity P1 of a diffraction peak derived from the Fe oxide having a corundum structure appearing in the vicinity of 2?=33.2° to peak intensity P2 of a diffraction peak derived from the Fe-based alloy having a bcc structure appearing in the vicinity of 2?=44.7° is 0.010 or less (excluding 0). A superlattice peak intensity of an Fe3Al ordered structure is at most a noise level within a range of 2?=20° to 40°.
    Type: Grant
    Filed: September 15, 2017
    Date of Patent: March 10, 2020
    Assignee: HITACHI METALS, LTD.
    Inventors: Toshio Mihara, Tetsuroh Katoh, Kazunori Nishimura, Shin Noguchi
  • Patent number: 10573441
    Abstract: There is provided a magnetic core having both high strength and high resistivity, a coil component produced with such a magnetic core, and a magnetic core manufacturing method capable of easily manufacturing a magnetic core with high strength and high resistivity. A method for manufacturing a magnetic core having a structure including dispersed Fe-based soft magnetic alloy particles includes: a first step including mixing a first Fe-based soft magnetic alloy powder containing Al and Cr, a second Fe-based soft magnetic alloy powder containing Cr and Si, and a binder; a second step including pressing the mixture obtained after the first step; and a third step including heat-treating the compact obtained after the second step, wherein the heat treatment forms an oxide layer on the surface of Fe-based soft magnetic alloy particles and bonds the Fe-based soft magnetic alloy particles together through the oxide layer.
    Type: Grant
    Filed: July 16, 2015
    Date of Patent: February 25, 2020
    Assignee: HITACHI METALS, LTD.
    Inventors: Shin Noguchi, Kazunori Nishimura, Toshio Mihara
  • Publication number: 20200047255
    Abstract: A method of producing an atomized powder includes: an atomizing step of forming magnetic alloy particles from a molten metal by an atomizing method, to obtain a slurry in which the magnetic alloy particles are dispersed in an aqueous dispersion medium; a slurry concentration step of causing magnetic separation means to separate the magnetic alloy particles from the slurry to form a concentrated slurry having the magnetic alloy particles of more than 80% by mass, the magnetic separation means using a rotary drum including a magnetic circuit part fixedly disposed at a position where at least a part of the magnetic circuit part is immersed in the slurry and an outer sleeve capable of rotating outside the magnetic circuit part; and a drying step of causing drying means using an air flow dryer to dry the concentrated slurry to form a magnetic alloy powder.
    Type: Application
    Filed: March 23, 2018
    Publication date: February 13, 2020
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazunori NISHIMURA, Shin NOGUCHI, Nobuaki YOSHIOKA
  • Publication number: 20190355504
    Abstract: The invention provides a method for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. The invention is directed to a method for manufacturing a powder magnetic core with a metallic soft magnetic material powder, the method including: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.
    Type: Application
    Filed: June 4, 2019
    Publication date: November 21, 2019
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazunori NISHIMURA, Shin NOGUCHI, Toshio MIHARA
  • Publication number: 20190355503
    Abstract: The invention provides a powder magnetic core and a method for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. A method for manufacturing a powder magnetic core with a metallic soft magnetic material powder includes: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.
    Type: Application
    Filed: June 4, 2019
    Publication date: November 21, 2019
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazunori NISHIMURA, Shin Noguchi, Toshio Mihara
  • Patent number: 10468174
    Abstract: Provided are a magnetic core having a high initial permeability and a coil component including the same. The magnetic core has an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, wherein a peak intensity ratio (P1/P2) of a peak intensity P1 of a diffraction peak of an Fe oxide having a corundum structure appearing in a vicinity of 2?=33.2° to a peak intensity P2 of a diffraction peak of the Fe-based alloy having a bcc structure appearing in a vicinity of 2?=44.7° is 0.015 or less; and in the X-ray diffraction spectrum, a peak intensity ratio (P3/P2) of a peak intensity P3 of a superlattice peak of an Fe3Al ordered structure appearing in a vicinity of 2?=26.6° to the peak intensity P2 is 0.015 or more and 0.050 or less.
    Type: Grant
    Filed: September 15, 2017
    Date of Patent: November 5, 2019
    Assignee: HITACHI METALS, LTD.
    Inventors: Toshio Mihara, Tetsuroh Katoh, Kazunori Nishimura, Shin Noguchi
  • Patent number: 10453599
    Abstract: There is provided a magnetic core having high manufacturability and high magnetic permeability, to provide a method for manufacturing such a magnetic core, and to provide a coil component having such a magnetic core. The invention is directed to a magnetic core including: Fe-based soft magnetic alloy particles; and an oxide phase existing between the Fe-based soft magnetic alloy particles, wherein the Fe-based soft magnetic alloy particles include Fe—Al—Cr alloy particles and Fe—Si—Al alloy particles.
    Type: Grant
    Filed: July 16, 2015
    Date of Patent: October 22, 2019
    Assignee: HITACHI METALS, LTD.
    Inventors: Shin Noguchi, Kazunori Nishimura, Toshio Mihara
  • Patent number: 10418160
    Abstract: Provided are: a metal powder core having a configuration suitable for core loss reduction and strength improvement; a coil component employing this; and a fabrication method for metal powder core. The metal powder core is obtained by dispersing Cu powder among soft magnetic material powder comprising pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy and then by performing compaction. The fabrication method for metal powder core includes: a mixing step of mixing together soft magnetic material powder containing thin-leaf shaped pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy, Cu powder, and a binder and thereby obtaining a mixture; a forming step of performing pressure forming on the mixture obtained at the mixing step; and a heat treatment step of annealing a formed article obtained at the forming step.
    Type: Grant
    Filed: November 28, 2018
    Date of Patent: September 17, 2019
    Assignee: Hitachi Metals, Ltd.
    Inventors: Tetsuro Kato, Shin Noguchi, Kazunori Nishimura
  • Publication number: 20190272937
    Abstract: A magnetic core has a high initial permeability and a small core loss, reducing a core loss at high frequencies; and a coil component including the same. This magnetic core is formed by binding a plurality of Fe-based alloy particles containing Al via an oxide layer containing an Fe oxide. In an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, a peak intensity ratio (P1/P2) of peak intensity P1 of a diffraction peak derived from the Fe oxide having a corundum structure appearing in the vicinity of 2?=33.2° to peak intensity P2 of a diffraction peak derived from the Fe-based alloy having a bcc structure appearing in the vicinity of 2?=44.7° is 0.010 or less (excluding 0). A superlattice peak intensity of an Fe3Al ordered structure is at most a noise level within a range of 2?=20° to 40°.
    Type: Application
    Filed: September 15, 2017
    Publication date: September 5, 2019
    Applicant: HITACHI METALS, LTD.
    Inventors: Toshio MIHARA, Tetsuroh KATOH, Kazunori NISHIMURA, Shin NOGUCHI
  • Publication number: 20190228897
    Abstract: Provided are a magnetic core having a high initial permeability and a coil component including the same. The magnetic core has an X-ray diffraction spectrum of the magnetic core measured using Cu-K? characteristic X-rays, wherein a peak intensity ratio (P1/P2) of a peak intensity P1 of a diffraction peak of an Fe oxide having a corundum structure appearing in a vicinity of 2?=33.2° to a peak intensity P2 of a diffraction peak of the Fe-based alloy having a bcc structure appearing in a vicinity of 2?=44.7° is 0.015 or less; and in the X-ray diffraction spectrum, a peak intensity ratio (P3/P2) of a peak intensity P3 of a superlattice peak of an Fe3Al ordered structure appearing in a vicinity of 2?=26.6° to the peak intensity P2 is 0.015 or more and 0.050 or less.
    Type: Application
    Filed: September 15, 2017
    Publication date: July 25, 2019
    Applicant: HITACHI METALS, LTD.
    Inventors: Toshio MIHARA, Tetsuroh KATOH, Kazunori NISHIMURA, Shin NOGUCHI
  • Patent number: 10354790
    Abstract: An object of the invention is to provide a method that is for manufacturing a powder magnetic core through simple compression molding and capable of manufacturing a complicatedly shaped powder magnetic core with reliable high strength and insulating properties. The invention is directed to a method for manufacturing a powder magnetic core with a metallic soft magnetic material powder, the method including: a first step including mixing a soft magnetic material powder and a binder; a second step including compression molding the mixture obtained after the first step; a third step including performing at least one of grinding and cutting on the compact obtained after the second step; and a fourth step including heat-treating the compact after the third step, wherein in the fourth step, the compact is heat-treated so that an oxide layer containing an element constituting the soft magnetic material powder is formed on the surface of the soft magnetic material powder.
    Type: Grant
    Filed: March 12, 2015
    Date of Patent: July 16, 2019
    Assignee: HITACHI METALS, LTD.
    Inventors: Kazunori Nishimura, Shin Noguchi, Toshio Mihara