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).
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Publication number: 20240112857Abstract: A method of preparing an anisotropic magnetic powder compression molded product, the method including: compressing a magnetic powder in a mold using a compression punch while magnetically orienting the magnetic powder to obtain a compressed magnetic powder, wherein the compression punch has a contact surface with the magnetic powder that is not perpendicular to a compression direction; and compression molding the compressed magnetic powder using a molding punch having a different shape from the compression punch.Type: ApplicationFiled: September 29, 2023Publication date: April 4, 2024Applicant: NICHIA CORPORATIONInventors: Takashi ASADA, Shuichi TADA
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Publication number: 20240112838Abstract: A method of producing a phosphate-coated SmFeN-based anisotropic magnetic powder, the method including stirring a slurry containing a raw material SmFeN-based anisotropic magnetic powder, water, a phosphate source, and an aluminum source to obtain a SmFeN-based anisotropic magnetic powder having a surface coated with a phosphate.Type: ApplicationFiled: September 29, 2023Publication date: April 4, 2024Applicant: NICHIA CORPORATIONInventors: Masahiro ABE, Shuichi TADA, Satoshi YAMANAKA, Kenta IWAI
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Publication number: 20240013961Abstract: 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: ApplicationFiled: September 28, 2021Publication date: January 11, 2024Applicant: NICHIA CORPORATIONInventors: Masahiro ABE, Rie YOSHIDA, Shuichi TADA, Michiya KUME, Kohei IHARA, Naotake FUJITA
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Publication number: 20240006101Abstract: 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: ApplicationFiled: September 30, 2021Publication date: January 4, 2024Applicant: NICHIA CORPORATIONInventors: Masahiro ABE, Satoshi YAMANAKA, Shuichi TADA, Kenta IWAI, Takayuki YANO
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Patent number: 11862372Abstract: 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: GrantFiled: January 28, 2022Date of Patent: January 2, 2024Assignee: NICHIA CORPORATIONInventors: Shuichi Tada, Satoshi Yamanaka
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Publication number: 20230415227Abstract: 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: ApplicationFiled: September 30, 2021Publication date: December 28, 2023Applicant: NICHIA CORPORATIONInventors: Masahiro ABE, Satoshi YAMANAKA, Shuichi TADA, Kenta IWAI
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Publication number: 20230374257Abstract: 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: ApplicationFiled: May 17, 2023Publication date: November 23, 2023Applicant: NICHIA CORPORATIONInventors: Shuichi TADA, Takashi ASADA, Masahiro ABE
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Publication number: 20230360827Abstract: 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: ApplicationFiled: May 16, 2023Publication date: November 9, 2023Applicant: NICHIA CORPORATIONInventors: Takashi ASADA, Shuichi TADA
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Patent number: 11710586Abstract: 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: GrantFiled: July 14, 2022Date of Patent: July 25, 2023Assignee: NICHIA CORPORATIONInventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
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Patent number: 11694826Abstract: 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: GrantFiled: December 27, 2019Date of Patent: July 4, 2023Assignee: NICHIA CORPORATIONInventors: Takashi Asada, Shuichi Tada
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Publication number: 20230207166Abstract: 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: ApplicationFiled: December 27, 2022Publication date: June 29, 2023Applicant: NICHIA CORPORATIONInventors: Masahiro Abe, Satoshi Yamanaka, Shuichi Tada, Kenta Iwai
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Patent number: 11646154Abstract: 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: GrantFiled: June 2, 2021Date of Patent: May 9, 2023Assignee: NICHIA CORPORATIONInventors: Rie Yoshida, Masahiro Abe, Michiya Kume, Kohei Ihara, Shuichi Tada
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Publication number: 20220351882Abstract: 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: ApplicationFiled: July 14, 2022Publication date: November 3, 2022Applicant: NICHIA CORPORATIONInventors: Rieko YOSHIMOTO, Satoshi YAMANAKA, Shuichi TADA, Hideaki YOSHIWARA
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Patent number: 11424055Abstract: 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: GrantFiled: September 25, 2019Date of Patent: August 23, 2022Assignee: NICHIA CORPORATIONInventors: Rieko Yoshimoto, Satoshi Yamanaka, Shuichi Tada, Hideaki Yoshiwara
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Publication number: 20220157520Abstract: 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: ApplicationFiled: November 16, 2021Publication date: May 19, 2022Applicant: NICHIA CORPORATIONInventors: Satoshi YAMANAKA, Takayuki YANO, Shuichi TADA, Masahiro ABE, Kenta IWAI
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Publication number: 20220157500Abstract: 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: ApplicationFiled: January 28, 2022Publication date: May 19, 2022Applicant: NICHIA CORPORATIONInventors: Shuichi TADA, Satoshi YAMANAKA
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Patent number: 11270820Abstract: 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: GrantFiled: July 19, 2018Date of Patent: March 8, 2022Assignee: NICHIA CORPORATIONInventors: Shuichi Tada, Satoshi Yamanaka
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Publication number: 20210287832Abstract: 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: ApplicationFiled: June 2, 2021Publication date: September 16, 2021Applicant: NICHIA CORPORATIONInventors: Rie YOSHIDA, Masahiro ABE, Michiya KUME, Kohei IHARA, Shuichi TADA
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Patent number: 11056255Abstract: 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: GrantFiled: April 27, 2018Date of Patent: July 6, 2021Assignee: NICHIA CORPORATIONInventors: Rie Yoshida, Masahiro Abe, Michiya Kume, Kohei Ihara, Shuichi Tada
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Publication number: 20200211742Abstract: 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: ApplicationFiled: December 27, 2019Publication date: July 2, 2020Applicant: NICHIA CORPORATIONInventors: Takashi ASADA, Shuichi TADA