公开(公告)号：US20170263359A1

公开(公告)日：2017-09-14

申请号：US15500957

申请日：2015-09-04

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Masashi OHTSUBO ,  Masaaki TANI ,  Takeshi HATTORI ,  Jung hwan HWANG ,  Masashi HARA ,  Shin TAJIMA ,  Naoki IWATA ,  Shinjiro SAIGUSA ,  Kohei ISHII ,  Daisuke OKAMOTO ,  Toshimitsu TAKAHASHI

IPC: H01F3/08 ,  H01F41/02 ,  B22F1/02 ,  C03C8/02 ,  C22C38/06 ,  C03C8/04 ,  C03C8/08 ,  H01F1/147 ,  C22C38/02

CPC classification number: H01F3/08 ,  B22F1/02 ,  C03C8/02 ,  C03C8/04 ,  C03C8/08 ,  C03C2209/00 ,  C22C38/02 ,  C22C38/06 ,  H01F1/147 ,  H01F1/14791 ,  H01F1/24 ,  H01F41/0246

Abstract: A powder magnetic core having excellent specific resistance or strength. The powder magnetic core has soft magnetic particles, first coating layers that coat the surfaces of the soft magnetic particles and include aluminum nitride, and second coating layers that coat at least a part of the surfaces of the first coating layers and include a low-melting-point glass having a softening point lower than an annealing temperature for the soft magnetic particles. The first coating layers including aluminum nitride are excellent in the wettability to the low-melting-point glass which constitutes the second coating layers and suppress diffusion of constitutional elements between the soft magnetic particles and the low-melting-point glass of the second coating layers. The powder magnetic core can stably exhibit a higher specific resistance and higher strength than the prior art owing to such a synergistic action of the first coating layers and second coating layers.

公开(公告)号：US20230065875A1

公开(公告)日：2023-03-02

申请号：US17809420

申请日：2022-06-28

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kohei ISHII

IPC: H01F41/02 ,  B22F3/03

Abstract: An apparatus for forming E-shaped or U-shaped dust cores includes: a die; an upper punch arranged to be insertable and removable into and from the die; a lower punch arranged so as to face the upper punch and to be insertable and removable into and from the die; and a core rod arranged to be insertable and removable into and from the upper punch and the lower punch. The upper punch and the lower punch each has a horizontal cross-sectional shape corresponding to the horizontal cross-sectional shape of two dust cores that are arranged distant from each other with their respective magnetic pole surfaces facing each other. The core rod has a horizontal cross-sectional shape corresponding to the horizontal cross-sectional shape of a hollow part formed between the two dust cores that are arranged distant from each other with their respective magnetic pole surfaces facing each other.

公开(公告)号：US20150364235A1

公开(公告)日：2015-12-17

申请号：US14737876

申请日：2015-06-12

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Daisuke OKAMOTO ,  Kiyotaka ONODERA ,  Shinjiro SAIGUSA ,  Kohei ISHII ,  Masashi OHTSUBO ,  Junghwan HWANG ,  Masaaki TANI ,  Takeshi HATTORI

IPC: H01F1/24 ,  B22F3/12 ,  H01F27/255 ,  H01F1/147 ,  H01F41/02 ,  H01F3/08

CPC classification number: H01F1/24 ,  B22F1/02 ,  B22F2998/10 ,  C22C33/0257 ,  C22C33/0264 ,  H01F1/14791 ,  H01F1/33 ,  H01F3/08 ,  H01F27/255 ,  H01F41/0246 ,  B22F2009/0828 ,  B22F9/08 ,  B22F9/04 ,  B22F3/02 ,  B22F3/10

Abstract: A soft magnetic member is formed such that, when a differential relative permeability in an applied magnetic field of 100 A/m is represented by a first differential relative permeability μ′L, and when a differential relative permeability in an applied magnetic field of 40 kA/m is represented by a second differential relative permeability μ′H, a ratio of the first differential relative permeability μ′L to the second differential relative permeability μ′H satisfies a relationship of μ′L/μ′H≦10, and a magnetic flux density in an applied magnetic field of 60 kA/m is 1.15 T or higher.

Abstract translation: 形成软磁性构件，使得当施加的100A / m的磁场中的微分相对磁导率由第一差分相对磁导率μ'L表示时，并且当施加的磁场中的差分相对磁导率为40kA时 / m由第二微分相对磁导率μ'H表示，第一微分相对磁导率μ'L与第二微分相对磁导率μ'H的比率满足μ'L/μ'H＆nlE; 10的关系，a 60kA / m的施加磁场中的磁通密度为1.15T以上。

公开(公告)号：US20220020531A1

公开(公告)日：2022-01-20

申请号：US17343941

申请日：2021-06-10

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Hiroto NAGAKI ,  Kazumichi NAKATANI ,  Kohei ISHII

IPC: H01F41/02 ,  B22F3/03 ,  B22F7/02 ,  B22F7/00

Abstract: A method for manufacturing a powder magnetic core, the method including: forming a soft magnetic powder (SMP) layer by putting an SMP having a surface on which an insulating coating film is formed into a space surrounded by a lower punch and a die; forming a pressed powder by compressing the SMP layer in the die by the lower punch and an upper punch; and causing the pressed powder and the die to slide relative to each other and then removing the pressed powder from the die is provided. In forming the SMP layer, a different powder different from the SMP is put into the space before and after the SMP is put into the space and a different powder layer having a spring back rate higher than that of the SMP layer by 0.6-1.1% is formed on upper and lower sides of the SMP layer.

公开(公告)号：US20200294702A1

公开(公告)日：2020-09-17

申请号：US16785069

申请日：2020-02-07

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Kohei ISHII ,  Masaki SUGIYAMA ,  Hiroaki HATSUYAMA

IPC: H01F27/255 ,  H01F1/26

Abstract: A method for manufacturing a powder magnetic core according to an aspect includes filling a case with a soft magnetic powder obtained by pulverizing a soft magnetic foil having an amorphous structure or a nanocrystal structure, applying at least one of a vibration and a magnetic field to the soft magnetic powder contained in the case and thereby aligning the soft magnetic powder, and injecting a curable resin into the case, impregnating the aligned soft magnetic powder with the curable resin, and then curing the curable resin while deaerating the curable resin under a reduced pressure.

公开(公告)号：US20190214172A1

公开(公告)日：2019-07-11

申请号：US16356696

申请日：2019-03-18

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Masashi OHTSUBO ,  Masaaki TANI ,  Takeshi HATTORI ,  Junghwan HWANG ,  Masashi HARA ,  Shin TAJIMA ,  Shinjiro SAIGUSA ,  Kohei ISHII ,  Daisuke OKAMOTO ,  Toshimitsu TAKAHASHI

IPC: H01F1/33 ,  H01F41/02 ,  H01F1/26 ,  B22F3/02 ,  C21D1/26 ,  B22F1/00 ,  B22F1/02 ,  H01F1/20 ,  B22F3/24 ,  C21D6/00 ,  C22C38/02 ,  C22C38/06

CPC classification number: H01F1/33 ,  B22F1/0003 ,  B22F1/02 ,  B22F3/02 ,  B22F3/24 ,  C21D1/26 ,  C21D6/008 ,  C22C38/02 ,  C22C38/06 ,  H01F1/20 ,  H01F1/24 ,  H01F1/26 ,  H01F41/02 ,  H01F41/0246

Abstract: A dust core includes soft magnetic particles, a first coating layer, a second coating layer, and a third coating layer. The first coating layer is made of aluminum oxide with which at least a part of surfaces of the soft magnetic particles are coated. The second coating layer is made of aluminum nitride with which at least a part of a surface of the first coating layer is coated. The third coating layer is made of low-melting-point glass with which at least a part of a surface of the second coating layer is coated. The low-melting-point glass has a softening point lower than an annealing temperature of the soft magnetic particles.

公开(公告)号：US20170110227A1

公开(公告)日：2017-04-20

申请号：US15291350

申请日：2016-10-12

Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA

Inventor： Daisuke OKAMOTO ,  Toshimitsu TAKAHASHI ,  Sinjiro SAIGUSA ,  Kohei ISHII ,  Naoki IWATA ,  Jung Hwan HWANG ,  Masashi OHTSUBO ,  Takeshi HATTORI ,  Masashi HARA

IPC: H01F1/147 ,  H01F41/02 ,  H01F3/08

CPC classification number: H01F1/14791 ,  H01F1/24 ,  H01F1/28 ,  H01F3/08 ,  H01F41/0246

Abstract: Provided is a compressed powder core that can suppress a decrease in the inductance even when a high magnetic field (of greater than or equal to 40 kA/m) is applied to the compressed powder core while suppressing an iron loss and a decrease in the strength of the compressed powder core. The compressed powder core 1A has soft magnetic particles 11A and aluminum nitride layers 12A formed on the surface layers of the respective soft magnetic particles 11A. The compressed powder core 1A has a ratio of the first differential relative permeability μ′L to the second differential relative permeability μ′H satisfying a relationship of μ′L/μ′H≦6, and has a magnetic flux density of greater than or equal to 1.4 T when a magnetic field of 60 kA/m is applied. The soft magnetic particles of the compressed powder core 1A contain Si in the range of 1.0 to 3.0 mass % and have, when analyzed using XRD, a peak area ratio Sal/Sfe of greater than or equal to 4%, the peak area ratio Sal/Sfe being the ratio of the area Sal of a peak waveform derived from AlN to the area Sfe of a peak waveform derived from Fe.