Patents by Inventor Tetsuya Shoji

Tetsuya Shoji 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: 20160336112
    Abstract: A method of manufacturing a rare earth magnet includes: preparing a powder by preparing a rapidly-solidified ribbon by liquid solidification, and by crushing the rapidly-solidified ribbon; manufacturing a sintered compact by press-forming the powder; and manufacturing a rare earth magnet by performing hot deformation processing on the sintered compact to impart anisotropy to the sintered compact. In this method, the rapidly-solidified ribbon is a plurality of fine crystal grains. The powder includes a RE-Fe—B main phase and a grain boundary phase of a RE-X alloy present around the main phase. RE represents at least one of Nd and Pr. X represents a metal element. A nitrogen content in the powder is adjusted to be at least 1,000 ppm and less than 3,000 ppm by performing at least one of the preparation of the powder and the manufacturing of the sintered compact in a nitrogen atmosphere.
    Type: Application
    Filed: December 19, 2014
    Publication date: November 17, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Akira KANO, Tetsuya SHOJI, Osamu YAMASHITA, Daisuke ICHIGOZAKI
  • Publication number: 20160322159
    Abstract: A manufacturing method includes: manufacturing a sintered compact having a composition of (Rl)x(Rh)yTzBsMt; manufacturing a precursor by performing hot deformation processing on the sintered compact; and manufacturing a rare earth magnet by performing an aging treatment on the precursor in a temperature range of 450° C. to 700° C. In this method, a main phase thereof is formed of a (RlRh)2T14B phase. A content of a (RlRh)1.1T4B4 phase in a grain boundary phase thereof is more than 0 mass % and 50 mass % or less. Rl represents a light rare earth element. Rh represents a heavy rare earth element. T represents a transition metal. M represents at least one of Ga, Al, Cu, and Co. x, y, z, s, and t are percentages by mass of Rl, Rh, T, B, and M. x, y, z, s, and t are expressed by the following expressions: 27?x?44, 0?y?10, z=100?x?y?s?t, 0.75?s?3.4, 0?t?3.
    Type: Application
    Filed: December 19, 2014
    Publication date: November 3, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Daisuke SAKUMA, Kazuaki HAGA
  • Publication number: 20160314899
    Abstract: A method includes: manufacturing a sintered compact represented by (Rl)x(Rh)yTzBsMt and has a grain boundary phase; manufacturing a rare earth magnet precursor from the sintered compact; and performing a heat treatment on the rare earth magnet precursor at 450° C. to 700° C. to diffuse and to infiltrate a melt of a modified alloy containing a light rare earth element and either a transition metal element, Al, In, Zn, or Ga into the grain boundary phase. Rl represents a light rare earth element. Rh represents Dy or Tb. T represents a transition metal containing at least one of Fe, Ni, and Co. B represents boron. M represents at Ga, Al, or Cu. x, y, z, s, and t represent mass % of Rl, Rh, T, B, and M. Following expressions are established: 27?x?44, 0?y?10, z=100?x?y?s?t, 0.75?s?3.4, 0?t?3. An infiltration amount of the modified alloy is 0 mass % to 5 mass %.
    Type: Application
    Filed: December 17, 2014
    Publication date: October 27, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Daisuke SAKUMA, Kazuaki HAGA
  • Publication number: 20160141083
    Abstract: To provide a rare earth magnet ensuring excellent magnetic anisotropy while reducing the amount of Nd, etc., and a manufacturing method thereof. A rare earth magnet comprising a crystal grain having an overall composition of (R2(1-x)R1x)yFe100-y-w-z-vCowBzTMv (wherein R2 is at least one of Nd, Pr, Dy and Tb, R1 is an alloy of at least one or two or more of Ce, La, Gd, Y and Sc, TM is at least one of Ga, Al, Cu, Au, Ag, Zn, In and Mn, 0<x<1, y=12 to 20, z=5.6 to 6.5, w=0 to 8, and v=0 to 2), wherein the average grain size of the crystal grain is 1,000 nm or less, the crystal grain consists of a core and an outer shell, the core has a composition of R1 that is richer than R2, and the outer shell has a composition of R2 that is richer than R1.
    Type: Application
    Filed: June 5, 2014
    Publication date: May 19, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Masaaki ITO, Masao YANO, Hidefumi KISHIMOTO, Noritsugu SAKUMA, Tetsuya SHOJI, Akira MANABE
  • Publication number: 20160074936
    Abstract: A method for producing a raw material powder of a permanent magnet, includes: preparing a material powder of a permanent magnet, measuring magnetic characteristics of the material powder, and judging the quality of the material powder as the raw material powder based on a preliminarily determined relation between magnetic characteristics and the structure of the material powder. A method for producing a permanent magnet includes integrating material powders judged as good in the step of judging the quality as raw material powders by the method for producing a raw material powder of a permanent magnet. A method for inspecting a permanent magnet material powder includes transmitting a magnetic field to a material powder of a permanent magnet, receiving the magnetic field from the material powder, and measuring a magnetic field difference between the transmitted magnetic field and the received magnetic field as magnetic characteristics of the material powder.
    Type: Application
    Filed: May 24, 2013
    Publication date: March 17, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Hidefumi KISHIMOTO, Mikiya NOZAKI, Masao YANO, Tetsuya SHOJI, Akira MANABE
  • Patent number: 9257227
    Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.
    Type: Grant
    Filed: January 25, 2013
    Date of Patent: February 9, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Shinya Omura, Motoki Hiraoka
  • Patent number: 9230733
    Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.
    Type: Grant
    Filed: January 25, 2013
    Date of Patent: January 5, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Shinya Omura, Motoki Hiraoka
  • Publication number: 20150357100
    Abstract: A nanocomposite magnet includes grains including a shell of a Re-TM-B phase and a core of a TM or TM-B phase. Re is a rare earth element, and TM is a transition metal.
    Type: Application
    Filed: June 4, 2015
    Publication date: December 10, 2015
    Inventors: Masao YANO, Tetsuya SHOJI, Akira MANABE, Noritsugu SAKUMA, Masaaki ITO
  • Patent number: 9190196
    Abstract: A rare earth magnet of the invention has a composition represented by the compositional formula RaHbFecCodBeMf, where: R is at least one rare earth element including Y; H is at least one heavy rare earth element from among Dy and Tb; M is at least one element from among Ga, Zn, Si, Al, Nb, Zr, Ni, Cu, Cr, Hf, Mo, P, C, Mg, and V; 13?a?20; 0?b?4; c=100?a?b?d?e?f; 0?d?30; 4?e?20; 0?f?3, and has a structure constituted by a main phase: a (RH)2(FeCo)14B phase, and a grain boundary phase: a (RH)(FeCo)4B4 phase and a RH phase, with a crystal grain size of the main phase of 10 nm to 200 nm.
    Type: Grant
    Filed: December 16, 2010
    Date of Patent: November 17, 2015
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu Sakuma, Tetsuya Shoji, Masao Yano
  • Publication number: 20150287528
    Abstract: 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: Application
    Filed: November 13, 2013
    Publication date: October 8, 2015
    Inventors: Kazuaki Haga, Noritaka Miyamoto, Tetsuya Shoji, Daisuke Sakuma
  • Publication number: 20150287530
    Abstract: A method for manufacturing a rare-earth magnet, through hot deformation processing, having a high degree of orientation at the entire area thereof and high remanence, without increasing processing cost including a step of press-forming powder as a rare-earth magnetic material to form a compact S; and a step of performing hot deformation processing to the compact S, thus manufacturing the rare-earth magnet C. The hot deformation processing includes two steps of extruding and upsetting. The extruding is to place a compact S in a die Da, and apply pressure to the compact S? in a heated state with an extrusion punch PD so as to reduce the thickness for extrusion to prepare the rare-earth magnet intermediary body S? having a sheet form, and the upsetting is to apply pressure to the rare-earth magnet intermediary body S? in the thickness direction to reduce the thickness, thus manufacturing the rare-earth magnet C.
    Type: Application
    Filed: October 17, 2013
    Publication date: October 8, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke ICHIGOZAKI, Noritaka MIYAMOTO, Tetsuya SHOJI, Yuya IKEDA, Akira MANABE
  • Publication number: 20150279559
    Abstract: 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: Application
    Filed: October 4, 2013
    Publication date: October 1, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Daisuke Ichigozaki, Tetsuya Shoji, Eisuke Hoshina, Akira Kano, Osamu Yamashita
  • Publication number: 20150279529
    Abstract: 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: Application
    Filed: October 8, 2013
    Publication date: October 1, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Noritaka Miyamoto, Tetsuya Shoji, Noritsugu Sakuma, Yuya Ikeda
  • Publication number: 20150235747
    Abstract: 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: Application
    Filed: October 2, 2013
    Publication date: August 20, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritaka Miyamoto, Tetsuya Shoji, Kazuaki Haga
  • Patent number: 9111679
    Abstract: 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: Grant
    Filed: February 22, 2012
    Date of Patent: August 18, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki
  • Publication number: 20150228386
    Abstract: The present invention is a method capable of producing a rare-earth magnet with excellent magnetization and coercivity. The method includes producing a sintered body including a main phase and grain boundary phase and represented by (R11-xR2x)aTMbBcMd (where R1 represents one or more rare-earth elements including Y, R2 represents a rare-earth element different than R1, TM represents transition metal including at least one of Fe, Ni, or Co, B represents boron, M represents at least one of Ti, Ga, Zn, Si, Al, etc., 0.01?x?1, 12?a?20, b=100?a?c?d, 5?c?20, and 0?d?3 (all at %)); applying hot deformation processing to the sintered body to produce a precursor of the magnet; and diffusing/infiltrating melt of a R3-M modifying alloy (rare-earth element where R3 includes R1 and R2) into the grain boundary phase of the precursor.
    Type: Application
    Filed: January 30, 2015
    Publication date: August 13, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu SAKUMA, Tetsuya SHOJI, Kazuaki HAGA
  • Patent number: 9070508
    Abstract: 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: Grant
    Filed: February 22, 2012
    Date of Patent: June 30, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Noritaka Miyamoto, Akira Manabe, Tetsuya Shoji, Daisuke Ichigozaki
  • Publication number: 20140308441
    Abstract: A method of manufacturing rare-earth magnets includes, a first step of producing a compact C by subjecting a sintered body S, which is formed of a RE—Fe—B main phase MP having a nanocrystalline structure (where RE is at least one of neodymium and praseodymium) and a grain boundary phase BP of an RE—X alloy (where X is a metal element) located around the main phase, to hot plastic processing that imparts anisotropy; and a second step of producing a rare-earth magnet RM by melting a RE—Y—Z alloy which increases the coercive force of the compact C (where Y is a transition metal element, and Z is a heavy rare-earth element), together with the grain boundary phase BP, and liquid-phase infiltrating the RE—Y—Z alloy melt from a surface of the compact C.
    Type: Application
    Filed: November 7, 2012
    Publication date: October 16, 2014
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Tetsuya Shoji, Shinya Omura, Motoki Hiraoka
  • Patent number: 8846136
    Abstract: 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: Grant
    Filed: September 13, 2011
    Date of Patent: September 30, 2014
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Tetsuya Shoji, Noritaka Miyamoto, Shinya Omura, Daisuke Ichigozaki, Takeshi Yamamoto
  • Publication number: 20140260800
    Abstract: 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: Application
    Filed: October 9, 2012
    Publication date: September 18, 2014
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Noritsugu Sakuma, Hidefumi Kishimoto, Noritaka Miyamoto, Akira Kato, Akira Manabe, Daisuke Ichigozaki, Tetsuya Shoji, Shoichi Harakawa