Patents by Inventor Shuichi Tada

Shuichi Tada 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).

  • Publication number: 20240013961
    Abstract: The present invention relates to a method of producing a composite component, the method including: preparing a second composite by fitting a first molded body onto a first composite including a rare earth magnet and a component contacting the rare earth magnet, such that the first molded body covers at least the entire surface of the first composite corresponding to the rare earth magnet; and forming a second molded body by inserting the second composite into a mold and injection-molding a thermoplastic resin such that the thermoplastic resin covers at least the entire surface of the first composite not covered by the first molded body and also contacts the first molded body.
    Type: Application
    Filed: September 28, 2021
    Publication date: January 11, 2024
    Applicant: NICHIA CORPORATION
    Inventors: Masahiro ABE, Rie YOSHIDA, Shuichi TADA, Michiya KUME, Kohei IHARA, Naotake FUJITA
  • Publication number: 20240006101
    Abstract: A method for producing a phosphate-coated SmFeN-based anisotropic magnetic powder, the method includes a phosphate treatment of adding an inorganic acid to a slurry containing an SmFeN-based anisotropic magnetic powder, water, and a phosphate compound to adjust a pH of the slurry to a range of 1 to 4.5 to form a phosphate-coated SmFeN-based anisotropic magnetic powder having a surface coated with a phosphate.
    Type: Application
    Filed: September 30, 2021
    Publication date: January 4, 2024
    Applicant: NICHIA CORPORATION
    Inventors: Masahiro ABE, Satoshi YAMANAKA, Shuichi TADA, Kenta IWAI, Takayuki YANO
  • Patent number: 11862372
    Abstract: The present invention relates to a composition for bonded magnets having good hot water resistance and a method of manufacturing the composition. The method of manufacturing a composition for bonded magnets includes: obtaining a first kneaded mixture by kneading a rare earth-iron-nitrogen-based magnetic powder and an acid-modified polypropylene resin; and obtaining a second kneaded mixture by kneading the first kneaded mixture with a polypropylene resin and an amorphous resin having a glass transition temperature of 120° C. or higher and 250° C. or lower, wherein, with respect to 100 parts by weight of the rare earth-iron-nitrogen-based magnetic powder, the amount of the acid-modified polypropylene resin is 3.5 parts by weight or greater and less than 10.4 parts by weight, and the total amount of the polypropylene resin and the amorphous resin is 0.35 part by weight or greater and less than 3.88 parts by weight.
    Type: Grant
    Filed: January 28, 2022
    Date of Patent: January 2, 2024
    Assignee: NICHIA CORPORATION
    Inventors: Shuichi Tada, Satoshi Yamanaka
  • Publication number: 20230415227
    Abstract: A method for producing a phosphate-coated SmFeN-based anisotropic magnetic powder, the method includes: a phosphate treatment of adding an inorganic acid to a slurry containing an SmFeN-based anisotropic magnetic powder, water, and a phosphate compound to adjust a pH of the slurry to a range from 1 to 4.5 to form an SmFeN-based anisotropic magnetic powder having a surface on which a phosphate coating is formed; and oxidizing by heat treating the SmFeN-based anisotropic magnetic powder having the surface on which the phosphate coating is formed, in an oxygen-containing atmosphere at a temperature in a range of 200° C. to 330° C., to form the phosphate-coated SmFeN-based anisotropic magnetic powder.
    Type: Application
    Filed: September 30, 2021
    Publication date: December 28, 2023
    Applicant: NICHIA CORPORATION
    Inventors: Masahiro ABE, Satoshi YAMANAKA, Shuichi TADA, Kenta IWAI
  • Publication number: 20230374257
    Abstract: A method, including: preparing at least one magnetic powder having an average particle size that is at least 1 ?m but not more than 10 ?m, at least one thermosetting resin, and at least one curing agent, wherein at least one of the thermosetting resin and the curing agent includes at least one monomer having a melting point that is higher than 70° C. but not higher than 140° C., and wherein an amount of the monomer having the melting point that is higher than 70° C. but not higher than 140° C. is at least 33% by volume but not more than 100% by volume of a combined amount of the thermosetting resin and the curing agent; and obtaining a magnetic powder-containing resin composition by kneading the magnetic powder, the thermosetting resin, and the curing agent at a temperature of higher than 70° C. but not higher than 140° C. and then lowering the temperature.
    Type: Application
    Filed: May 17, 2023
    Publication date: November 23, 2023
    Applicant: NICHIA CORPORATION
    Inventors: Shuichi TADA, Takashi ASADA, Masahiro ABE
  • Publication number: 20230360827
    Abstract: The present disclosure aims to provide a bonded magnet having good magnetic properties and a method of preparing the bonded magnet. The present disclosure provides a method of preparing a bonded magnet, including: a first compression step of compressing a magnetic powder having an average particle size of 10 µm or less while magnetically orienting it to obtain a first molded article; a second compression step of bringing the first molded article into contact with a thermosetting resin having a viscosity of 200 mPa·s or less, followed by compression to obtain a second molded article; and a heat treatment step of heat treating the second molded article.
    Type: Application
    Filed: May 16, 2023
    Publication date: November 9, 2023
    Applicant: NICHIA CORPORATION
    Inventors: Takashi ASADA, Shuichi TADA
  • Patent number: 11710586
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Grant
    Filed: July 14, 2022
    Date of Patent: July 25, 2023
    Assignee: NICHIA CORPORATION
    Inventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
  • Patent number: 11694826
    Abstract: The present disclosure aims to provide a bonded magnet having good magnetic properties and a method of preparing the bonded magnet. The present disclosure provides a method of preparing a bonded magnet, including: a first compression step of compressing a magnetic powder having an average particle size of 10 ?m or less while magnetically orienting it to obtain a first molded article; a second compression step of bringing the first molded article into contact with a thermosetting resin having a viscosity of 200 mPa·s or less, followed by compression to obtain a second molded article; and a heat treatment step of heat treating the second molded article.
    Type: Grant
    Filed: December 27, 2019
    Date of Patent: July 4, 2023
    Assignee: NICHIA CORPORATION
    Inventors: Takashi Asada, Shuichi Tada
  • Publication number: 20230207166
    Abstract: A method of producing a phosphate-coated SmFeN-based anisotropic magnetic powder, the method including performing a phosphate treatment including adding an inorganic acid to a slurry containing a raw material SmFeN-based anisotropic magnetic powder, water, a phosphate compound, and a rare earth compound so that the slurry is adjusted to have a pH of at least 1 and not higher than 4.5 to obtain a phosphate-coated SmFeN-based anisotropic magnetic powder having a surface coated with a phosphate.
    Type: Application
    Filed: December 27, 2022
    Publication date: June 29, 2023
    Applicant: NICHIA CORPORATION
    Inventors: Masahiro Abe, Satoshi Yamanaka, Shuichi Tada, Kenta Iwai
  • Patent number: 11646154
    Abstract: The present invention relates to a composite component including a metal component having a substantially cylindrical shape or a substantially annular shape, and a ring-shaped bonded magnet disposed on the outer periphery of the metal component, the ring-shaped bonded magnet containing a thermoplastic resin, magnetic particles, and rubber particles.
    Type: Grant
    Filed: June 2, 2021
    Date of Patent: May 9, 2023
    Assignee: NICHIA CORPORATION
    Inventors: Rie Yoshida, Masahiro Abe, Michiya Kume, Kohei Ihara, Shuichi Tada
  • Publication number: 20220351882
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Application
    Filed: July 14, 2022
    Publication date: November 3, 2022
    Applicant: NICHIA CORPORATION
    Inventors: Rieko YOSHIMOTO, Satoshi YAMANAKA, Shuichi TADA, Hideaki YOSHIWARA
  • Patent number: 11424055
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Grant
    Filed: September 25, 2019
    Date of Patent: August 23, 2022
    Assignee: NICHIA CORPORATION
    Inventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
  • Publication number: 20220157500
    Abstract: The present invention relates to a composition for bonded magnets having good hot water resistance and a method of manufacturing the composition. The method of manufacturing a composition for bonded magnets includes: obtaining a first kneaded mixture by kneading a rare earth-iron-nitrogen-based magnetic powder and an acid-modified polypropylene resin; and obtaining a second kneaded mixture by kneading the first kneaded mixture with a polypropylene resin and an amorphous resin having a glass transition temperature of 120° C. or higher and 250° C. or lower, wherein, with respect to 100 parts by weight of the rare earth-iron-nitrogen-based magnetic powder, the amount of the acid-modified polypropylene resin is 3.5 parts by weight or greater and less than 10.4 parts by weight, and the total amount of the polypropylene resin and the amorphous resin is 0.35 part by weight or greater and less than 3.88 parts by weight.
    Type: Application
    Filed: January 28, 2022
    Publication date: May 19, 2022
    Applicant: NICHIA CORPORATION
    Inventors: Shuichi TADA, Satoshi YAMANAKA
  • Publication number: 20220157520
    Abstract: A method of producing a compound for bonded magnets, the method including: heat-curing a thermosetting resin and a curing agent having a ratio of the number of reactive groups of the curing agent to the number of reactive groups of the thermosetting resin of at least 2 but not higher than 11 to obtain an additive for bonded magnets; and kneading the additive for bonded magnets, magnetic powder, and a thermoplastic resin to obtain a compound for bonded magnets in which a filling ratio of the magnetic powder is at least 91.5% by mass.
    Type: Application
    Filed: November 16, 2021
    Publication date: May 19, 2022
    Applicant: NICHIA CORPORATION
    Inventors: Satoshi YAMANAKA, Takayuki YANO, Shuichi TADA, Masahiro ABE, Kenta IWAI
  • Patent number: 11270820
    Abstract: The present invention relates to a composition for bonded magnets having good hot water resistance and a method of manufacturing the composition. The method of manufacturing a composition for bonded magnets includes: obtaining a first kneaded mixture by kneading a rare earth-iron-nitrogen-based magnetic powder and an acid-modified polypropylene resin; and obtaining a second kneaded mixture by kneading the first kneaded mixture with a polypropylene resin and an amorphous resin having a glass transition temperature of 120° C. or higher and 250° C. or lower, wherein, with respect to 100 parts by weight of the rare earth-iron-nitrogen-based magnetic powder, the amount of the acid-modified polypropylene resin is 3.5 parts by weight or greater and less than 10.4 parts by weight, and the total amount of the polypropylene resin and the amorphous resin is 0.35 part by weight or greater and less than 3.88 parts by weight.
    Type: Grant
    Filed: July 19, 2018
    Date of Patent: March 8, 2022
    Assignee: NICHIA CORPORATION
    Inventors: Shuichi Tada, Satoshi Yamanaka
  • Publication number: 20210287832
    Abstract: The present invention relates to a composite component including a metal component having a substantially cylindrical shape or a substantially annular shape, and a ring-shaped bonded magnet disposed on the outer periphery of the metal component, the ring-shaped bonded magnet containing a thermoplastic resin, magnetic particles, and rubber particles.
    Type: Application
    Filed: June 2, 2021
    Publication date: September 16, 2021
    Applicant: NICHIA CORPORATION
    Inventors: Rie YOSHIDA, Masahiro ABE, Michiya KUME, Kohei IHARA, Shuichi TADA
  • Patent number: 11056255
    Abstract: The present invention relates to a composite component including a metal component having a substantially cylindrical shape or a substantially annular shape, and a ring-shaped bonded magnet disposed on the outer periphery of the metal component, the ring-shaped bonded magnet containing a thermoplastic resin, magnetic particles, and rubber particles.
    Type: Grant
    Filed: April 27, 2018
    Date of Patent: July 6, 2021
    Assignee: NICHIA CORPORATION
    Inventors: Rie Yoshida, Masahiro Abe, Michiya Kume, Kohei Ihara, Shuichi Tada
  • Publication number: 20200211742
    Abstract: The present disclosure aims to provide a bonded magnet having good magnetic properties and a method of preparing the bonded magnet. The present disclosure provides a method of preparing a bonded magnet, including: a first compression step of compressing a magnetic powder having an average particle size of 10 ?m or less while magnetically orienting it to obtain a first molded article; a second compression step of bringing the first molded article into contact with a thermosetting resin having a viscosity of 200 mPa·s or less, followed by compression to obtain a second molded article; and a heat treatment step of heat treating the second molded article.
    Type: Application
    Filed: December 27, 2019
    Publication date: July 2, 2020
    Applicant: NICHIA CORPORATION
    Inventors: Takashi ASADA, Shuichi TADA
  • Publication number: 20200105445
    Abstract: The present invention provides a bonded magnet having good heat resistance. The present invention relates to a bonded magnet containing a SmFeN magnetic powder, nylon 12, and a hexafluoroisopropanol-unextractable component. The present invention also relates to a method of preparing a bonded magnet, including: bringing a raw material bonded magnet containing a SmFeN magnetic powder and nylon 12 into contact with an amorphizing agent; and heat-treating the raw material bonded magnet in contact with the amorphizing agent.
    Type: Application
    Filed: September 27, 2019
    Publication date: April 2, 2020
    Applicant: NICHIA CORPORATION
    Inventor: Shuichi TADA
  • Publication number: 20200098495
    Abstract: Provided are a SmFeN magnetic powder which is superior not only in water resistance and corrosion resistance but also in hot water resistance, and a method of preparing the powder. The present invention relates to a method of preparing a magnetic powder, comprising: plasma-treating a gas; surface-treating a SmFeN magnetic powder with the plasma-treated gas; and forming a coat layer on the surface of the surface-treated SmFeN magnetic powder.
    Type: Application
    Filed: September 25, 2019
    Publication date: March 26, 2020
    Applicant: NICHIA CORPORATION
    Inventors: Rieko YOSHIMOTO, Satoshi YAMANAKA, Shuichi TADA, Hideaki YOSHIWARA