公开(公告)号：US20190156999A1

公开(公告)日：2019-05-23

申请号：US16148198

申请日：2018-10-01

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Airi KAMIMURA ,  Kazuaki HAGA ,  Kensuke KOMORI ,  Katsuhiko TATEBE ,  Shingo FUBUKI

IPC: H01F41/00 ,  H01F1/153 ,  H01F1/16 ,  C21D1/26 ,  B21D28/34

Abstract: The present disclosure provides a method for producing a magnetic component that enables efficient processing of an amorphous soft magnetic material or a nanocrystalline soft magnetic material. The method for producing a magnetic component comprising an amorphous soft magnetic material or nanocrystalline soft magnetic material comprises: a step of preparing a stacked body comprising a plurality of plate-shaped amorphous soft magnetic materials or nanocrystalline soft magnetic materials; a step of heating at least a portion of shearing in the stacked body to a temperature equal to or higher than the crystallization temperature of the soft magnetic materials; and a step of shearing the stacked body at the portion of shearing after the step of heating.

公开(公告)号：US20190267854A1

公开(公告)日：2019-08-29

申请号：US16279294

申请日：2019-02-19

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kensuke KOMORI ,  Hisamitsu TOSHIDA ,  Kazuaki HAGA

IPC: H02K1/14 ,  H02K3/18 ,  H02K3/52

Abstract: Provided is a stator for rotating electrical machine that can avoid the sagging of teeth stacked at the distal ends under the self-weight. A stator core is a laminate of metal foil members stacked in a direction of a rotation axis of the rotating electrical machine. Each tooth has a pair of side walls facing the neighboring teeth in the circumferential direction. The stator includes a pair of insulating reinforcing members so as to become a bridge between the corresponding tooth and a part of the yoke and sandwich the corresponding tooth from both sides in the direction of the rotation axis while exposing the pair of side walls; insulating fixing members, each fixing member fixing the corresponding pair of reinforcing members to the corresponding tooth while wrapping around the pair of reinforcing members and tooth; and coils formed as distributed windings at the teeth fixed with the fixing members.

公开(公告)号：US20220203440A1

公开(公告)日：2022-06-30

申请号：US17545245

申请日：2021-12-08

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Mayumi TAKAZAWA ,  Kazuaki HAGA ,  Daisuke ICHIGOZAKI ,  Masaaki ITO ,  Hisanori KOMA ,  Shinya SANO ,  Kensuke KOMORI ,  Keiu KANADA

IPC: B22F3/24 ,  B22F3/16 ,  H01F41/02

Abstract: Provided is a rare earth magnet that allows suppressing deterioration of magnetic properties and a method for manufacturing the same. The rare earth magnet of the present disclosure includes a magnet body containing a rare earth element R1, a transition metal element T, and boron B and includes a main phase. A region in the vicinity of a corner portion of the magnet body of a constituent surface constituting a surface of the magnet body is a processed surface on which a removal process has been performed, and a region closer to a center than the region in the vicinity of the corner portion of the constituent surface is a non-processed surface on which the removal process is not performed.

公开(公告)号：US20220085702A1

公开(公告)日：2022-03-17

申请号：US17444476

申请日：2021-08-04

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Shinya SANO ,  Kensuke KOMORI

IPC: H02K15/03

Abstract: A rotor manufacturing method is a method that allows magnetized magnets inserted in second magnet holes of a second rotor core to be inserted, while retaining magnetism, into first magnet holes of a first rotor core. This method includes a placing step of placing the second rotor core on a first end surface, in a stack thickness direction, of the first rotor core such that the second magnet holes overlap the first magnet holes, and an extruding step of extruding the magnetized magnets from the second magnet holes toward the first magnet holes using a non-magnetic jig.

公开(公告)号：US20190181731A1

公开(公告)日：2019-06-13

申请号：US16197018

申请日：2018-11-20

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Fumitaka YOSHINAGA ,  Kazuaki HAGA ,  Kensuke KOMORI ,  Kiyotaka ONODERA

IPC: H02K15/02 ,  H02K3/34 ,  H02K3/32 ,  H02K1/02

Abstract: An object of the present disclosure is to provide a production method for a stator in which a breakage of the stator core can be prevented when coils are mounted thereon. The present embodiment is a production method for a stator that includes a stator core having a tooth and includes a coil wound around the tooth. The method includes: a step of preparing a stacked body which has the tooth and in which a plurality of plate-like soft magnetic materials each including an amorphous structure are stacked; a step of mounting the coil on the tooth; and a step of, after the coil is mounted, heating the stacked body to a temperature equal to or higher than a crystallization temperature of the soft magnetic materials.

公开(公告)号：US20250118470A1

公开(公告)日：2025-04-10

申请号：US18891038

申请日：2024-09-20

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Masaaki ITO ,  Motoki HIRAOKA ,  Kensuke KOMORI ,  Yusuke ONITSUKA ,  Takuya NOMURA

IPC: H01F1/153 ,  C22C38/00 ,  C22C38/02 ,  H01F1/147

Abstract: A soft magnetic material and a method for producing the same. The soft magnetic material is: Fe100-x-y-z-wBxNiySizMw (In the formula, M is one or more inevitable elements selected from Nb, Mo, Ta, W, Co, and Sn, and x, y, z, and w are in atomic percent satisfying 12≤x≤17, 1≤y≤3, 0

公开(公告)号：US20240204632A1

公开(公告)日：2024-06-20

申请号：US18498683

申请日：2023-10-31

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kensuke KOMORI ,  Minoru NAKAMURA ,  Junichi DEGUCHI

IPC: H02K15/02 ,  H02K15/12

CPC classification number: H02K15/02 ,  H02K15/12 ,  H02K2201/09

Abstract: Provided is a method for manufacturing a laminated core capable of reducing the likelihood that the iron loss increases while increasing the space factor of the laminated core. A method for manufacturing a laminated core includes a laminating step of laminating a plurality of thin plates made of a soft magnetic material, an impregnating step of filling a resin into spaces between the plurality of thin plates laminated, and a fixing step of curing the filled resin to fix the plurality of thin plates laminated. In the fixing step, the resin is cured while applying a pressure larger than 0 MPa and equal to or smaller than 1.5 MPa to the plurality of thin plates laminated in a laminating direction of the plurality of thin plates.

公开(公告)号：US20210328490A1

公开(公告)日：2021-10-21

申请号：US17227653

申请日：2021-04-12

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Keiu KANADA ,  Kazuaki HAGA ,  Toshimitsu TAKAHASHI ,  Mayumi TAKAZAWA ,  Takuya NOMURA ,  Shinya SANO ,  Takeshi TOMONAGA ,  Hisanori KOMA ,  Yasuhide YAGYU ,  Kensuke KOMORI ,  Tatsuhiko HIRANO ,  Masaaki ITO ,  Hiroaki WAKIMOTO

IPC: H02K21/24 ,  H02K1/27 ,  H02K1/18 ,  H02K1/28

Abstract: In an axial gap motor, a rotor includes a plurality of rotor cores fixed in a circumferential direction of a rotor base, and a stator includes a plurality of stator cores fixed in a circumferential direction of a stator base, and coils wound around the stator cores. End faces of each of the rotor cores and end faces of the corresponding stator core are opposed to each other while being exposed to each other.

公开(公告)号：US20200224286A1

公开(公告)日：2020-07-16

申请号：US16725028

申请日：2019-12-23

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Yu TAKANEZAWA ,  Tomohiro TAKAO ,  Hideki MANABE ,  Shinichi HIRAMATSU ,  Kensuke KOMORI

IPC: C21D8/02 ,  C22C45/02 ,  C21D9/46 ,  C22C1/00

Abstract: After an first heat treatment step, an ambient temperature of a stack is held so that the stack is kept in a temperature range that allows the stack to be crystallized by heating the end of the stack to a second temperature range in the second heat treatment step; and a following expression (1) is satisfied, where Q1 represents an amount of heat required to heat the stack to the first temperature range in the first heat treatment step, Q2 represents an amount of heat that is applied to the stack when heating the end of the stack to the second temperature range in the second heat treatment step, Q3 represents an amount of heat that is released during crystallization of the stack, and Q4 represents an amount of heat required to heat the entire stack to the crystallization start temperature Q1+Q2+Q3≥Q4  (1).

公开(公告)号：US20190386548A1

公开(公告)日：2019-12-19

申请号：US16431982

申请日：2019-06-05

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Fumitaka YOSHINAGA ,  Akira YAMASHITA ,  Airi KAMIMURA ,  Kazuaki HAGA ,  Kensuke KOMORI

IPC: H02K15/03 ,  H02K1/27

Abstract: Provided is an IPM motor that is strong and has high output. An IPM motor has a rotor that includes a rotor core as a laminate of a plurality of metal foil pieces made of a soft magnetic material that are stacked in a direction of a rotation axis of the rotor. The rotor core has a plurality of through-holes that penetrates through the rotor core in the direction of the rotation axis, the plurality of through-holes including through-holes embedding magnets. The rotor core includes inner bridges and outer bridges. At least one of the inner bridges and the outer bridges of the rotor core is made of an amorphous soft magnetic material, and other parts are made of a nanocrystal soft magnetic material.