Patent Date
September 20, 2023
Court Intellectual Property High
Right
Court, First Division
Case number 2021 (Gyo-Ke) 10152- Each of the Inventions includes not only the invention including the conveyancetray on which the laminated rotor core is mounted, but also the invention that does
not include the conveyance tray, and on the premise that the description of the
Scope of Claims which does not include the conveyance tray, it cannot be
considered that the Invention falls within a range that a person ordinarily skilled in
the art could solve the problems of the Invention that the work of inserting thelaminated core into the bottomed hole portion of the lower die, heating thelaminated core, and then taking out the laminated core from the bottomed holeportion of the lower die requires time either by a human hand or a machine, and theworkability is extremely poor, and could provide a method of resin sealing
permanent magnets, which is excellent in productivity and workability and enables
work to be performed inexpensively, on the basis of the Detailed Description of theInvention. Also, it cannot be considered that it falls within a range that a person
ordinarily skilled in the art could solve the problem relating to the processes offixing the laminated rotor core on the lower die and removing it from the lower die,by means of referring to the common general technical knowledge upon filing theapplication even in the absence of the specific statements in the Detailed
Description of the Invention. The Invention includes the invention that is notdescribed in the Detailed Description of the Invention of the Description, and thus
does not satisfy the requirements stipulated in Article 36, paragraph (6), item (i) of
the Patent Act.
Case type: Rescission of Trial Decision
Result: Granted
References: Article 36, paragraph (6), item (i) of the Patent Act
Related rights, etc.: Invalidation Trial No. 2020-800097, Patent No. 6180569
Summary of the Judgment
1

Y filed applications (the second generation application to the fifth generation

application) which are sequentially divided from a patent application dated November
24, 2005 (the first generation application), which is a divisional application from apatent application filed on January 24, 2005 (Patent Application No. 2005 -15860 (thefirst parent application)), and further filed a divisional application (Patent Application
No. 2016-40066, the Application) on March 2, 2016 on the invention titled "Methodof resin sealing permanent magnets," from a patent application dated January 16, 2015
(the original application).

The establishment of patent right was registered on July28, 2017 (Patent No. 6180569, Number of claims: 3, the Patent).
Although X made a request for a trial for invalidation of the Patent (Invalidation
Trial No. 2020-800097) for the invention pertaining to Claims 1 to 3 in the Patent on
October 8, 2020, the Japan Patent Office made a decision that "The request for thetrial is not established." ("the JPO decision") on October 22, 2021, and the certifiedicopy thereof was delivered to X on November 5 of the same year.
2

In the case, as reasons for rescission, there were presented Reason for Rescission

1 (Determination error on novelty based on Exhibit Ko 1 on the premise of violationsof requirements of division), Reason for Rescission 2 (Determination error on
inventive step based on Exhibit Ko 1 on the premise of violations of requirements ofdivision), Reason for Rescission 3 (Determination error on inventive step mainly
citing Exhibit Ko 5), Reason for Rescission 4 (Determination error on correction
requirements),

ReasonforRescission

5(Determination

error

on

enabling

requirements), Reason for Rescission 6 (Determination error on requirements forsupport), Reason for Rescission 7 (Determination error on requirements for clarity)
were alleged, however, the judgment of this case, regarding Reason for Rescission 6(Determination error on requirements for support), summarized and determined asfollows, and rescinded the JPO decision.
(1)

It should be determined whether or not the invention for which a patent issought is stated in the Detailed Description of the Invention by comparing thedescription of the Scope of Claims and the Detailed Description of the Invention, andexamining whether or not the invention described in the Scope of Claims is stated in
the Detailed Description of the Invention and a person ordinarily skilled in the art
could solve the problems of the invention on the basis of the Detailed Description of
the Invention or suggestion thereof, and whether or not a person ordinarily skilled in
the art could solve the problems of the invention by means of referring to the common
general technical knowledge upon filing the application even in the absence of thedescriptions or the suggestions.
The Scope of Claims of the Invention does not specify the shape and structure of
the upper die and the lower die, and the layout, state, or the like of the laminated rotor
core in a case other than "pressing the laminated rotor core with the lower die and theupper die," and, for example, does not have the conveyance tray on which thelaminated rotor core placed on the lower die as a structure, so that it is recognized that
the Scope of Claims of Invention includes not only the invention including theconveyance tray on which the laminated rotor core of Invention 1 is mounted, but also
the invention that does not include the conveyance tray.
Regarding the problem to be solved by the invention described in the Detailed
Description of the Invention and Means for Solving the Problem, on the assumptionthat there are the problem in the prior art 1 (it is difficult to uniformly fill eachmagnet insertion hole with the resin member, and reliability is deteriorated, and in
addition, a pump for supplying the resin member requires a large supply pressure,iiwhich makes the device expensive) and the problem in the prior art 2 (the work ofinserting the laminated core into the bottomed hole portion of the lower die, heating
the laminated core, and then taking out the laminated core from the bottomed holeportion of the lower die requires time either by a human hand or a machine, and theworkability is extremely poor), the problem to be solved by the invention (theproblem of the Invention) is recognized to "provide a method of resin sealing
permanent magnets, which is excellent in productivity and workability and enables
work to be performed inexpensively".

Further, it can be recognized that the JPO

decision made determination on requirements for support based on the matter that the
problem of the Invention is to solve the problem in the prior art 2, so that it cannot be
considered that there is an error in the recognition of the problem of this point.
(2)

As means for solving the problem in the prior art 2, Invention 1 isacknowledged to specify the layout of the laminated rotor core with reference to theupper die and the lower die when pressing the laminated rotor core, and to specify apositional relationship or a state of the upper die and the lower die, whereas theinvention described in the Detailed Description of the Invention of the Description isto "convey the laminated rotor core 12 set in the conveyance tray 16 including a
rectangular plate-shaped tray portion 26 with which a lower surface 25 of thelaminated rotor core 12 comes into contact, and a diameter-fixed and rod-shaped
guide member 27 provided to stand at the central portion of the tray portion 26 andfitted into the shaft hole 11 of the laminated rotor core 12 onto the lower die 17, " andis to "remove the conveyance tray 16 from the lower die 17 together with thelaminated rotor core 12, the laminated rotor core 12 is removed from the conveyancetray 16," so that, according to the Detailed Description of the Invention of the
Description, it is understood that the conveyance tray is an essential configuration.
Then, Invention 1 includes not only the invention including the conveyance tray on
which the laminated rotor core is mounted, but also the invention that does notinclude the conveyance tray, and if assuming the description of the Scope of Claims
which does not include the conveyance tray, it cannot be considered that Invention 1
falls within a range that a person ordinarily skilled in the art could solve the problemsof Invention 1 that the work of inserting the laminated core into the bottomed holeportion of the lower die, heating the laminated core, and then taking out the lamina tedcore from the bottomed hole portion of the lower die requires time either by a human
hand or a machine, and the workability is extremely poor (the problem in the prior art2), and could provide a method of resin sealing permanent magnets, which is excellent
in productivity and workability and enables work to be performed inexpensively, oniii

the basis of the Detailed Description of the Invention.
Further, according to the statement of the Detailed Description of the Invention of
the Description, the conveyance tray is made to be an essential structure so as to solve
the problem in the prior art 2, so that it is understood that an alternative structure to
the conveyance tray is required to solve the problem of the Invention without using a
conveyance tray.

However, even in the statement of the Description, although there

are descriptions ([0047] and [0048]) relating to the specific structure of theconveyance tray, there is no description that specifically suggests the alternative
structure to the conveyance tray, and there is no evidence sufficient to find that thealternative structure would be obvious to a person ordinarily skilled in the art.
Therefore, it cannot be considered that it falls within a range that a person ordinarily
skilled in the art could solve the problem relating to the processes of fixing thelaminated rotor core on the lower die and removing it from the lower die, by means ofreferring to the common general technical knowledge upon filing the application evenin the absence of the specific statements in the Detailed Description of the Invention.
In view of the above, the Invention includes the invention that is not described in
the Detailed Description of the Invention of the Description, and thus does not satisfy
the requirements stipulated in Article 36, paragraph (6), item (i) of the Patent Act.
(3)

The JPO decision merely means that it can be recognized that a person

ordinarily skilled in the art could solve the problem regarding the embodiments of theInvention described in the Detailed Description of the Invention of the Description,and it cannot be considered that the JPO decision was determined, through comparing
the description in the Scope of Claims with the description in the Detailed Descriptionof the Invention, by examining whether or not the invention described in the Scope ofClaims is the invention described in the Detailed Description of the Invention, andwhether or not it can be acknowledged that a person ordinarily skilled in the art could
solve the problems of the invention on the basis of the description, and whether or nota person ordinarily skilled in the art could solve the problems of the invention bymeans of referring to the common general technical knowledge upon filing theapplication even in the absence of the descriptions or the suggestions.
Accordingly, it cannot be considered that the JPO decision determined that "theinvention for which a patent is sought is stated in the Detailed Description of theInvention" prescribed in Article 36, paragraph (6), item (i) of the Patent Act.

iv

Judgment Rendered on September 20, 2023
2021 (Gyo-Ke) 10152, Case of Seeking Rescission of the JPO Decision
Date of Conclusion of Oral Argument: July 20, 2023
Judgment

Plaintiff: TOYOTA BOSHOKU CORPOTATION
Defendant: Mitsui High-tec, Inc.
Main Text
1 The JPO decision on the case of Invalidation Trial No. 2020-800097 rendered by theJapan Patent Office on October 22, 2021 shall be rescinded.
2 The Defendant shall bear the court costs.
Facts and ReasonsNo. 1 Claim
The same gist as the Main Text
No. 2 Background
1. Outline of Procedures and the like at the JPO(1) The Defendant filed a divisional application (Patent Application No.
2016-40066, hereinafter, referred to as "the Application," Exhibit Ko 33) on March 2,
2016 on the invention titled "Method of resin sealing permanent magnets," from apatent application dated September 14, 2009 (Patent Application No. 2009-212139,
hereinafter, referred to as "the second generation application," Exhibit Ko 40), a
patent application dated October 13, 2011 (Patent Application No. 2011 -226055,
hereinafter, referred to as "the third generation application," Exhibit Ko 19), a patentapplication dated April 2, 2013 (Patent Application No. 2013-76991, hereinafter,
referred to as "the fourth generation application," Exhibit Ko 41), a patent application
dated February 3, 2014 (Patent Application No. 2014-18680, hereinafter, referred toas "the fifth generation application," Exhibit Ko 42), and a patent application dated
January 16, 2015 (Patent Application No. 2015-6922, hereinafter referred to as "theoriginal application," Exhibit Ko 14), which are sequentially divided from a patentapplication dated November 24, 2005 (Patent Application No. 2005-339116,
hereinafter referred to as "the first generation application," Exhibit Ko 39), which is a1divisional application from a patent application filed on January 24, 2005 (Patent
Application No. 2005-15860, hereinafter, referred to as "the first parent application,"
Exhibit Ko 13).
The Defendant submitted a written amendment on the Scope of Claims and the
Description dated February 9, 2017 (hereinafter, referred to as "the Amendment,"
Exhibit Ko 9), and the establishment of patent right was registered on July 28, 2017
(Patent No. 6180569, Number of claims: 3, hereinafter, this patent is referred to as"the Patent," and the description and the drawings of the Patent after the Amendment
are collectively referred to as "the Description") (Exhibit Ko 50).
(2) The Plaintiff made a request for a trial for invalidation of the Patent(Invalidation Trial No. 2020-800097) for the inventions pertaining to Claims 1 to 3 in
the Patent on October 8, 2020 (Exhibit Ko 51).
The Japan Patent Office made a decision that "The request for the trial is notestablished." (hereinafter, referred to as "the JPO decision") on October 22, 2021, anda certified copy thereof was delivered to the Plaintiff on November 5 of the same year.
2 The description of the Scope of Claims(1) At the time of filing of the first parent application
The Scope of Claims originally attached to the application of the first parent
application is composed of Claims 1 to 6, and the description of Claim 1 is as follows.
(Exhibit Ko 13).
[Claim 1]
A resin sealing device of a permanent magnet for injecting a resin member into
magnet insertion holes to fix the permanent magnets inserted into a plurality ofmagnet insertion holes formed in a laminated rotor core in which a plurality of corepieces are laminated and which includes a shaft hole at a center, the resin sealing
device comprising:a conveyance tray on which the laminated rotor core is mounted;
a lower die on which the laminated rotor core mounted on the conveyance tray
is placed, the lower die being provided with a first heating means that heats thelaminated rotor core from below and moves up and down;
an upper die that is mounted on the laminated rotor core, has a second heatingmeans for heating the laminated rotor core from above and a plurality of pots forcontaining a raw material of the resin member, is provided with a flow path for
guiding the resin member from the pot to the magnet insertion hole in a bottom
portion thereof, and moves upward in accordance with upward movement of the lowerdie;2

a fixed frame fixedly disposed above the upper die with a gap serving as awork space between the fixed frame and the upper die at a lower limit position;a plurality of plungers that pass through the fixed frame and press the resin
member put in the pot of the raised upper die; anda stopper that holds the upper die at an upper limit position.
(2) At the time of filing of the original application
The Scope of Claims originally attached to the application of the original
application is composed of Claims 1 and 2, and the description of Claim 1 is asfollows.

(Exhibit Ko 14).

[Claim 1]
A method of respectively inserting permanent magnets into a plurality ofmagnet insertion holes of a laminated rotor core in which a plurality of core pieces arelaminated, arranging the laminated rotor core between a lower die and an upper die,and resin sealing the permanent magnets in the respective magnet insertion holes, themethod comprising:disposing the laminated rotor core between the upper die and the lower die; andpressing the laminated rotor core with the lower die and the upper die to resin seal thepermanent magnets in the magnet insertion holes of the laminated rotor core, whereina shaft hole is provided at a center of the laminated rotor core and the magnet
insertion holes are formed around the shaft hole.
(3) At the time of filing of the Patent (before the Amendment)
The descriptions of Claims 1 to 3 of the Scope of Claims at the time of filing of
the Patent are as follows (Hereinafter, according to claim number, the invention
relating to Claim 1 is referred to as "Invention 1 before the Amendment" and the like.
Exhibit Ko 33).
[Claim 1]
A method of respectively inserting permanent magnets into each of a pluralityof magnet insertion holes of a laminated rotor core in which a plurality of core pieces
are laminated and resin sealing the permanent magnets in the respective magnet
insertion holes, the method comprising:disposing the laminated rotor core between an upper die and a lower die;pressing the laminated rotor core with the lower die and the upper die; and resin
sealing the permanent magnets in the magnet insertion holes of the laminated rotor
core.
[Claim 2]
The method of resin sealing permanent magnets to a laminated rotor core3

according to Claim 1, wherein the laminated rotor core is pressed with the upper die
and the lower die by raising the lower die.
[Claim 3]
The method of resin sealing permanent magnets in a laminated rotor coreaccording to Claim 1 or 2, wherein the upper die is provided with a pot for pushing aresin member into the magnet insertion hole.
(4) The descriptions of claims of the Scope of Claims after the Amendment are
as follows (hereinafter, the inventions relating to Claims 1 to 3 of the Scope of Claims
after the Amendment are respectively referred to as "Invention 1," "Invention 2," and"Invention 3," and these are collectively referred to as "the Invention"; further, thefollowing underlined part is the amended part of Claims of the Amendment.
Exhibits Ko 9 and 50).
[Claim 1]
A method of respectively inserting permanent magnets into a plurality ofmagnet insertion holes of a laminated rotor core in which a plurality of core pieces arelaminated and resin sealing the permanent magnets in the respective magnet insertion
holes, the method comprising:disposing the laminated rotor core between an upper die and a lower die;pressing the laminated rotor core with the lower die and the upper die without
bringing the upper die and the lower die into contact with each other; and resin
sealing the permanent magnets in the magnet insertion holes of the laminated rotor
core.
[Claim 2]
The method of resin sealing permanent magnets to a laminated rotor coreaccording to Claim 1, wherein the laminated rotor core is pressed with the upper die
and the lower die by raising the lower die.
[Claim 3]
The method of resin sealing permanent magnets in a laminated rotor coreaccording to Claim 1 or 2, wherein the upper die is provided with a pot for pushing aresin member into the magnet insertion hole.
3 Abstract of reasons of the JPO decision
The reason for the JPO decision is as described in the attached written trial
decision (copy).

In summary, (1) regarding the reasons for invalidation due to lackof novelty and inventive step on the premise of violations of requirements of divisionof the Application (Reasons for Invalidation 1 and 2), it can be considered that theInvention was described in the first parent application, the divisional applications
4

from the first generation to the fifth generation, and the description of the original
application initially filed, so that the Application does not violate the requirements ofdivision, and the application of the Patent is regarded to be filed on the filing date of
the first parent application; that is, January 24, 2005, so that it cannot be consideredthat the invention described in Exhibit Ko 1 (Patent No. 3786946, date of issue is June21, 2006) (hereinafter, referred to as "Exhibit Ko 1 Invention") is the invention
described in the publication distributed before the application for the Patent, and it
cannot be considered that it could have been easily invented by a person ordinarily
skilled in the art based on the invention, (2) regarding the reasons for invalidation due
to lack of inventive step (Reason for Invalidation 3), it cannot be considered that theInvention could have been easily invented by a person ordinarily skilled in the art by
applying technical matters described in Exhibit Ko 2 (Unexamined Patent Application
Publication No. 1993-278079) and well-known arts to the invention described in
Exhibit Ko 5 (Unexamined Patent Application Publication No. 2001-157394)(hereinafter, referred to as "Exhibit Ko 5 Invention"), (3) regarding the reasons forinvalidation due to violation of correction requirements (Reason for Invalidation 4), it
cannot be considered that the matter "without bringing the upper die and the lower die
into contact with each other" added in the Amendment is a new technical matter thatis not described in the description of the original application initially filed, (4)regarding the reason for invalidation due to violation of enabling requirements(Reason for invalidation 5), the Detailed Description of the Invention in the
Description discloses to the extent that a person ordinarily skilled in the art can
implement the invention without requiring excessive trial and error, (5) regarding thereasons for invalidation due to violation of requirements for support (Reason forInvalidation 6), it can be recognized that the problem of the Invention, that is "thework of inserting the laminated core into the bottomed hole portion of the lower die,heating the laminated core, and then taking out the laminated core from the bottomed
hole portion of the lower die requires time either by a human hand or a machine, andthe workability is extremely poor" can be solved by "disposing the laminat ed rotor
core between an upper die and a lower die; pressing the laminated rotor core with thelower die and the upper die without bringing the upper die and the lower die into
contact with each other; and resin sealing the permanent magnets in the magnet
insertion holes of the laminated rotor core," so that the Invention is as described in the
Detailed Description of the Invention, and (6) regarding the reasons for invalidation
due to violation of requirements for clarity (Reason for Invalidation 7), it cannot be
considered that the description of the Scope of Claims of the Patent is unclear to the5extent that the interests of a third party are unduly harmed.
(omitted)
No. 4 Judgment of this court
1 Regarding described matters of the Description(1) The Description (Exhibit Ko 50) includes the following description (Figurescited in the following description are as attached.).
A [Detailed Description of the Invention][Technical field][0001]The present invention relates to a method of resin sealing permanent magnets,
which fixes the permanent magnets inserted in a plurality of magnet insertion holes
formed in a laminated rotor core in which a plurality of core pieces are laminated, by
injecting a resin member into the magnet insertion holes.
[Background of the Invention][0002]
Conventionally, as a method of fixing permanent magnets to a laminated coreby resin sealing, for example, a method described in Patent Document 1 is known.
In the method of resin sealing permanent magnets described in Pat ent
Document 1, a laminated core in which a plurality of core pieces are laminated bybeing fixed and integrated by punching and caulking or the like, a plurality of magnet
insertion holes for inserting permanent magnets are formed in an outer peripheral
portion, and a plurality of injection hole portions for injecting a sealing resin areformed is inserted in a bottomed hole portion of a lower die.

After the permanent

magnets are inserted into the magnet insertion holes, an upper die having an injection
hole portion formed at a position corresponding to an injecting hole portion is placedon an upper end of the lower die so that the injection hole portion is aligned with theinjecting hole portion, and while the lower die and the upper die are fixed to eac hother by a fastening means, the resin member is supplied at a predetermined pressure
from a resin-supply hole portion communicating with the injection hole portion of theupper die to fill the magnet insertion hole with the resin member, and then thelaminated core is heated by a heating means to cure the resin member, thereby fixing
the permanent magnets to the laminated core.
[Prior art reference][Patent document]
6

[0003][Patent Document 1] Unexamined Patent Application Publication No. 2002 34187 (Fig. 1 to Fig. 6)[Summary of the invention]
B [Problem to be solved by the invention][0004]
However, the conventional method of resin sealing permanent magnets has thefollowing problems to be solved.
In addition, when the magnet insertion holes are filled with the resin member,the resin member is injected into the magnet insertion holes through the resin-supply
hole portion formed in the upper die, the plurality of injection hole portions branchedfrom the resin-supply hole portion, and the injecting hole portion of the laminated
core.

Therefore, it is difficult to uniformly fill each magnet insertion hole with theresin member, and reliability is deteriorated.

In addition, a pump for supplying theresin member requires a large supply pressure, which makes the apparatus expensive.
Further, the work of inserting the laminated core into the bottomed hole portionof the lower die, heating the laminated core, and then taking out the laminated corefrom the bottomed hole portion of the lower die is time-consuming either by a human
hand or a machine, and the workability is extremely poor.
[0005]The present invention has been made in view of the above circumstances, andan object of the present invention is to provide a method of resin sealing perma nent
magnets, which is excellent in productivity and workability and enables work to be
performed inexpensively.
[Means for solving the problem][0009]The method of resin sealing of permanent magnets according to the present
invention in accordance with the aforementioned object, which is a method ofrespectively inserting permanent magnets in a plurality of magnet insertion holes of alaminated rotor in which a plurality of core pieces are laminated, and resin sealing thepermanent magnets in the magnet insertion holes, respectively, the method
comprising:disposing the laminated rotor core between an upper die and a lower die;pressing the laminated rotor core with the lower die and the upper die without
bringing the upper die and the lower die into contact with each other; and resin
sealing the permanent magnets in the magnet insertion holes of the laminated rotor
7core.
[0010]In the method of resin sealing permanent magnets according to the present
invention, the laminated rotor core may have a shaft hole at a center thereof, and thelaminated rotor core may be placed on a conveyance tray including a guide member tomake the laminated rotor core fit into the shaft hole and may be disposed between theupper die and the lower die.
[Effect of the invention][0011]In the method of resin sealing permanent magnets according to Claims 1 to 3,
when the permanent magnets inserted into the plurality of magnet insertion holes
formed in the laminated rotor core in which the plurality of core pieces are lamin ated
are fixed by injecting a resin member into the magnet insertion holes, the laminatedrotor core is pressed by the upper die and the lower die, and the magnet insertion holeis filled with the resin member, so that the resin sealing is surely performed , resin
sealing can be performed in a short time by a simple process, productivity andworkability are excellent, and work can be performed inexpensively.
C [Mode for carrying out the invention][0015]
Subsequently, an embodiment of the present invention will be described withreference to the accompanying drawings for understanding of the present invention.
As schematically shown in FIGS. 1 and 2, a resin sealing device 10 for
permanent magnets according to an embodiment of the present invention is a device
which fixes permanent magnets 14 inserted into a plurality of (eight in thisembodiment) magnet insertion holes 13 formed in a laminated rotor core 12 in whicha plurality of core pieces are laminated and which is provided with a shaft hole 11 at
the center, by injecting a thermosetting resin 15 as an example of a resin member into
the magnet insertion holes 13.
[0016]The resin sealing device 10 for permanent magnets includes a conveyance tray
16 on which a laminated rotor core 12 is mounted, a lower die 17 on which thelaminated rotor core 12 mounted on the conveyance tray 16 is placed and which isprovided with a first heating means (not shown) that heats the laminated rotor core 12
from below and moves up and down, and an upper die 21 which has a second heatingmeans (not shown) that is mounted on the laminated rotor core 12 and heats thelaminated rotor core 12 from above and a plurality of (eight in the present
8embodiment) pots 19 in which a raw material (referred to as a tablet) 18 of thethermosetting resin 15 is put, is further provided with a flow path 20 for guiding thethermosetting resin 15 from the pots 19 to the magnet insertion holes 13 in the bottom
part, and is raised with the rise of the lower die 17.
[0017]The resin sealing device 10 for permanent magnets further includes a fixed
frame 22 that is disposed above the upper die 21 and is fixed to the upper die 21 at thelower limit position with a gap G (see FIG. 5) serving as a work space S for inserting
the raw material 18, a plurality of (eight in the present embodiment) plungers 23
which pass through the fixed frame 22 and press the thermosetting resin 15 input into
the pots 19 of the upper die 21 which has been raised, and a stopper 24 which holds
the upper die 21 at the upper limit position when the upper die 21 is raised.

The

conveyance tray 16 includes a rectangular plate-shaped tray portion 26 with which alower surface 25 of the laminated rotor core 12 comes into contact, and a diameterfixed type rod-shaped guide member 27 provided to stand at the central portion of the
tray portion 26 and fitted into the shaft hole 11 of the laminated rotor core 12.
will be described in detail below.

These

The components are basically fastened by screws

in consideration of assembly and replacement.
[0018]As shown in FIGS. 1, 3, and 4, the rectangular plate-shaped fixed frame 22 isattached to an upper fixed plate 29 provided on an upper portion of a mounting frame
28.

The lower die 17 is placed on an elevating plate 32 which moves up and downalong four guide posts 31 connecting a lower fixed plate 30 provided at a lower
portion of the mounting frame 28 and the upper fixed plate 29.

The heating means isprovided inside the fixed frame 22, so that the plunger 23 is heated in advance tofacilitate the extrusion of the thermosetting resin 15, and a difference in thermal
expansion between the fixed frame 22 and the lower die 17 is eliminated to eliminate
a gap between the plungers 23 and the pots 19.
[0019]The elevating plate 32 is moved up and down by a lower-die elevating means
33 provided on the lower fixed plate 30.

The plurality of plungers 23 aresimultaneously moved up and down by a plunger driving means 34 provided on theupper fixed plate 29.
[0020]
With reference to FIGS. 3 and 4, the resin sealing device 10 for permanent
magnets will be described in further detail.
9The rectangular upper fixed plate 29 and the rectangular lower fixed plate 30
are horizontally disposed at a vertical interval on an upper portion and a lower portion,
respectively, of a mounting frame 28 made of shape steel or the like.

Four corners ofeach of the upper fixed plate 29 and the lower fixed plate 30 are connected by four
guide posts 31.
[0021]A rectangular elevating plate 32 which vertically slides up and down along theguide posts 31 and on which the lower die 17 is mounted is horizontally disposed at
an intermediate position in the vertical direction of the four guide posts 31.

A lower-

die elevating means 33 for driving the elevating plate 32 includes a servo motor 34a
mounted on the lower fixed plate 30 and a worm jack 35 with a reduction gear which
is driven by the servo motor 34a and mounted on the lower fixed plate 30, a discspring 35b provided through a joint on an output shaft 35a projecting out to an upperside of the worm jack 35 with a reduction gear, and a load cell 36 provided at an
upper end of the disc spring 35b and disposed in contact with a lower surface of theelevating plate 32.

The pressing force of the lower die 17 against the upper die 21

can be measured by the load cell 36.
[0022]The plunger driving means 34 for driving the plurality of plungers 23 includes
a servo motor 38 provided on a mounting bracket 37 fixed on the upper fixed plate 29,
a worm jack 39 with a reduction gear driven by the servo motor 38, a load cell 39a
provided through a joint on the output shaft projecting out to the lower side of theworm jack 39 with a reduction gear, and a push rod 40 moving up and down incontact with the lower surface of the load cell 39a through a disc spring 39b.

The

pushing pressure of the plungers 23 is measured by the load cell 39a.
[0023]As shown in FIGS. 5 to 7, the push rod 40 of the worm jack 39 is provided so
as to penetrate the central portion of the upper fixed plate 29, and sliding metals 41
and 41a are attached to the penetrating portion.

The push rod 40 at the upper limit

position is disposed so as to penetrate a rectangular heat insulating plate 42 screwed
to the lower surface of the upper fixed plate 29 and also penetrate a rectangularmounting plate 43 screwed to the lower surface of the heat insulating plate 42.
[0024]On the lower surface of the upper fixed plate 29, on both sides in the left -andright direction of the heat insulating plate 42, suspension metal fittings 46 and 47 aresuspended by screw fastening via heat insulating plates 44 and 45 having an elo ngated10

rectangular shape.

Concave hooking grooves 48 and 49 facing each other are

horizontally formed inside the suspension metal fittings 46 and 47 arranged facing
each other, and both end portions of the fixed frame 22 are fitted into the hooking
grooves 48 and 49, respectively.

Heat insulating boards 46a, 47a are attached to theoutside of the suspension metal fittings 46, 47.
[0025]On the lower surface of the mounting plate 43, there are provided a pair ofshutter plates 50 and 51 which are slidable in the left-and-right direction and used at
the time of setup of the die.

A shank-backing plate 53 is attached to a hooking

portion 40a at the distal end of the push rod 40 via a horseshoe-shaped (U-shaped)
shank-holder 52 that can be hooked by the hooking portion 40a.

Further, a plunger

holder 54 is provided on the lower surface of the shank-backing plate 53.
[0026]
Between the lower surfaces of the shutter plates 50 and 51 and the uppersurface of the fixed frame 22, a plunger guide 55 for guiding the upward anddownward movement of the plunger holder 54 is fixed to the fixed frame 22.

Eachof the shank-backing plate 53 and the plunger holder 54 is provided with a spring 54b
for urging the eight plungers 23 downward through a connection fitting 54a.
[0027]As shown in FIG. 8 (A), the plunger guide 55 having a substantially squareouter cross section has a substantially circular inner shape, and projections 58 eachhaving a U-shaped cross section and arranged radially are formed at equal pitches on
the inner periphery of the plunger guide 55 at equal pitches in the circumferential
direction.

On the other hand, as shown in FIG. 8 (B), on the outer periphery of theplunger holder 54 having a substantially circular outer cross section, eight notches 57
each having a U-shaped cross section and radially arranged, through which the
projections 58 are vertically inserted, are formed at equal pitches in thecircumferential direction, and eight circular holes 56 in which the plungers 23 slide
are formed at equal pitches in the circumferential direction between the adjacent
notches 57.

With such a configuration, thermal expansion of the plunger holder 54

and the plunger guide 55 is absorbed, and defects in the quality of the product and the
movement of the dies (the upper die 21 and the lower die 17) are prevented fromoccurring.

Further, since the projections 58 of the plunger guide 55 and the notches

57 of the plunger holder 54 are radially formed, it is possible to suppress thedeflection of the plunger guide 55 at the time of die clamping.
[0028]
11

As shown in FIGS. 5 and 6, four sets of the fixed frame 22 and the upper die 21
are provided, and are connected by a pipe-shaped spacer 60 provided with a ringshaped hooking portion 59 at an upper end portion and a bolt 62 which is disposed in
the spacer 60 and formed with a male screw portion 61 at a lower end portion.
Spring receiving blocks 63 are screwed to both sides in the left-and-right
direction of the plunger guide 55 on the upper surface of the fixed frame 22, and coilsprings 65 are disposed between two receiving seats 64 formed inside each spring
receiving block 63 and the upper surface of the upper die 21.
[0029]As shown in FIG. 8 (C), eight circular holes 67 in which the eight plungers 23
slide are formed at equal pitches in the circumferential direction in the central portionof the fixed frame 22 having a substantially square outer cross section.

Four circularthrough-holes 68 through which the spacer 60 passes are formed near four corners,
and two circular insertion holes 69 through which the coil spring 65 passes are formedat an interval between the two through-holes 68 arranged in the fore-and-aft direction.
Guide portions 71, each of which is an example of a sliding guide member and inwhich a concave notch 70 is formed, are provided at the four corners of the fixed
frame 22.
[0030]As shown in FIG. 9 (A), at four corners of the upper surface of the upper die 21,
guide posts 72 each having a substantially rectangular outer cross section and inserted
into the notches 70 of the guide portions 71 of the fixed frame 22 are provided tostand by screw fastening.

In the central portion of the upper die 21, the eight pots 19

into which the eight plungers 23 are fitted are provided at equal pitch es in thecircumferential direction.

The pot 19 is formed in a pipe shape having a ring -shaped

hooking portion 73 at a lower end portion thereof, and is detachably attached to theupper die 21 from below.
[0031]As shown in FIGS. 5 to 7 and FIG. 9 (B), a rectangular plate-shaped cavity
block 74 is screwed to the lower surface of the upper die 21, and circular holes 75 inwhich eight lower pots 19a (see FIGS. 5 and 6) on which the eight plungers 23 slide
can be mounted are formed at the center of the cavity block 74 at equal pitches in thecircumferential direction.

A shallow circular groove 76 is formed on the lower

surface of the cavity block 74 and on the radially inner side of the circular hole 75,
thereby forming a space into which the distal end portion of the guide member 27 of
the conveyance tray 16 is inserted.
12

[0032]A vent groove (not shown) for releasing air from the magnet insertion holes 13
to the outside is provided on a pressing surface 12a of the laminated rotor core 12 of
the cavity block 74.

On the other hand, a vent groove (not shown) for releasing air

from the magnet insertion holes 13 to the outside is provided on a mounting surface
12b of the laminated rotor core 12 of the tray portion 26 of the conveyance tray 16.
The depth of the vent groove is, for example, 30 to 50 μm.

The pots 19 are provided

at positions different from the positions corresponding to the magnet insertion holes
13, and the flow paths 20 communicating with the magnet insertion holes 13 areprovided in the bottom portions of the pots 19 (see FIG. 2).
[0033]As shown in FIG. 7, between the mounting plate 43 and the fixed frame 22,heat insulating plates 77 and 78 are removably provided on both sides in the fore -andaft direction with the plunger guide 55 between them so as to face each other via
brackets which are not shown.
[0034]As shown in FIGS. 5 and 6, on the outer side in the left-and-right direction of
the heat insulating board 46a and the suspension metal fitting 46 and the heatinsulating board 47a and the suspension metal fitting 47, air cylinders 79 and 80 for
mounting the stopper 24 are provided via a bracket 81, and the stopper 24 ishorizontally advanced and retracted in the left-and-right direction by the air cylinders
79 and 80.

Therefore, as can be seen from a comparison between FIGS. 5 and 6, thefour stoppers 24 abut on the lower surfaces of both end portions in the left -and-right
direction of the upper die 21 at the upper limit position, and the downward movementof the upper die 21 is restricted.
[0035]As shown in FIGS. 5 and 6, a pair of rectangular guide blocks 82 and 83 arescrewed to a lower central portion of the fixed frame 22 and an upper central portionof the upper die 21, respectively, so that the lower surface of the fixed fram e 22 andthe upper surface of the upper die 21 are in contact with each other, and the plunger
23 and the pot 19 are aligned with each other.

A truncated conical groove portion 84

which is reduced in diameter along the upper side is formed in the central portion of
the lower surface of the guide block 82, while a projection portion 85, which is
reduced in diameter along the upper side and is fitted into the groove portion 84, isformed in the central portion of the upper surface of the guide block 83.
positioning is performed by corresponding tapered surfaces.
13The[0036]
As shown in FIGS. 5 and 6, the upper portion is held by the lower surface ofthe shank-backing plate 53 and the plunger holder 54, and a total of 16 ejector pins 86
capable of penetrating the fixed frame 22 and the upper die 21 are provided outside
the plunger 23.
[0037]As shown in FIG. 7, the lower die 17 is placed on the elevating plate 32 via a
rectangular heat insulating plate 87, and three rollers 88, which are in contact with thelower surface of the tray portion 26 of the conveyance tray 16, are disposed in thelower die 17 at intervals in the fore-and-aft direction, and moreover, two pairs ofrollers 88 are disposed in the left-and-right direction.

Each roller 88 is urged upward

via a spring 89 disposed immediately below the roller 88.

The lower die 17 can bealigned with the upper die 21 by L-shaped clamping members 90 provided at the front
and rear, and is fixed to the elevating plate 32 by a fastening bolt (not shown).
[0038]As shown in FIGS. 3, 5, and 6, four reciprocating rods 91 that move up anddown are disposed through the elevating plate 32, the heat insulating plate 87, and thelower die 17, and each reciprocating rod 91 is provided with an air cylinder 92 fordriving via a guide mechanism.

Four corners of the elevating plate 32 are slidably

attached to the guide post 31 by a bearing portion 95 including bearing metals 93 and94.

Reference numerals 99 and 100 in FIG. 3 denote area sensors, reference numeral

101 in FIG. 4 denotes an area sensor, reference numeral 102 denotes an operation box,
and reference numeral 103 denotes a control panel.
[0039]
Subsequently, a method of resin sealing permanent magnets according to anembodiment of the present invention using the permanent magnet resin sealing device
10 will be described mainly with reference to FIG. 10.
(a) The permanent magnet 14 sent from the previous process is inserted into themagnet insertion hole 13, and the laminated rotor core 12 set in the conveyance tray
16 is conveyed onto the lower die 17 by using a separate conveying means or the like,and is positioned and fixed with respect to the upper die 21 (hereinafter, also
including the cavity block 74) (laminated rotor core supply work).
[0040](b) The lower die 17 is slightly raised by the lower-die elevating means 33 via
the elevating plate 32, and the laminated rotor core 12 and the cavity block 74 arebrought into close contact with each other.
14

Then, the material 18 of thethermosetting resin 15 is supplied to the pot 19 of the upper die 21 through the gap G(80 mm in the embodiment) between the fixed frame 22 and the upper die 21, and thematerial 18 is heated to about 170°C by the second heating means (tablet supply
work).
[0041](c) When the viscosity of the raw material 18 is decreased by heating, the lower
die 17 is further raised by the lower-die elevating means 33 via the elevating plate 32,
and the laminated rotor core 12 set on the conveyance tray 16 is pressed against theupper die 21 (at this time, centering is performed by the pair of guide blocks 82 and83, and the gap G becomes 0).

By lowering the eight plungers 23 through theplunger holder 54 by the plunger driving means 34, the fluidized raw material 18; thatis, the thermosetting resin 15, is pushed out from the pot 19, and the thermosetting
resin 15 is filled in the magnet insertion hole 13 through the flow path 20 connecting
the pot 19 and the magnet insertion hole 13.
[0042]The second heating means of the upper die 21 and the first heating means of
the lower die 17 keep heating the thermosetting resin 15 at about 170°C for about
three minutes, so that the thermosetting resin 15 can be cured and the permanent
magnet 14 can be fixed to the magnet insertion hole 13.

At this time, since thepermanent magnets 14 are stacked with the reference of the lower surface, a slightstep is formed between the upper end surface of the laminated rotor core 12 and theupper end surface of the permanent magnet 14.

Further, air in the magnet inse rtion

hole 13 can be released to the outside through the vent grooves formed on the pressing
surface 12a of the cavity block 74 and the mounting surface 12b of the tray portion 26of the conveyance tray 16.

(Mold clamping and resin injection work)[0043]In this way, since the raw material 18 of the thermosetting resin 15 is heated (atabout 170°C), melted, and filled into the magnet insertion hole 13 from the uppersurface of the laminated rotor core 12, the thermosetting resin 15 easily enters themagnet insertion hole 13.
[0044](d) As shown in FIG. 6, the four stoppers 24 are protruded, and the stoppers 24
are brought into contact with the lower surfaces of both end portions in the left -andright direction of the upper die 21 at the upper limit position, thereby restraining thedownward movement of the upper die 21.

Then, the ejector pin 86 is lowered by aslight stroke (about 5 mm) by the plunger driving means 34 via the plunger holder 54,
15and the lower die 17 is lowered by the lower-die elevating means 33 via the elevatingplate 32 (die opening work).

Thereafter, the conveyance tray 16 is removed from thelower die 17 together with the laminated rotor core 12, the laminated rotor core 12 isremoved from the conveyance tray 16, and the conveyance tray 16 is sent to a
subsequent process by the separate carrying means.
[0045](e) The plunger 23 and the pot 19 are cleaned by a cleaner 96 (plunger cleaningwork).
(f) The lower die 17 is raised by the lower-die elevating means 33 via theelevating plate 32, and the air cylinder 92 is driven to raise the reciprocating rods 91,
so that the upper die 21 is supported by the upper ends of the reciprocating rods 91(upper die opening preparation work).
[0046](g) After the four stoppers 24 are retracted, the lower die 17 is lowered by thelower-die elevating means 33 via the elevating plate 32, the upper die 21 is lowered tothe original position, and the lower die 17 is further lowered (upper die opening work).
(h) The four reciprocating rods 91 are retracted, and the insertion portion of the
raw material 18 in the gap G between the fixed frame 22 and the upper die 21 iscleaned by a cleaner 97 (tablet inputting portion cleaning work).
(i) The upper die 21 and the lower die 17 are cleaned by a cleaner 98 (diecleaning work).
[0047]The present invention is not limited to the above-described embodiments, andmodifications may be made without departing from the scope of the present invention.
For example, a case where the method of resin sealing permanent magnets according
to the present invention is configured by combining some or all of the abovedescribed embodiments and modifications is also included in the scope of the present
invention.
Although the cavity block 74 is detachably provided on the lower surface of theupper die 21, the present invention is not limited to this, and the upper die and thecavity block may be integrally formed if necessary.
The conveyance tray 16 is provided with the diameter-fixed type guide member
27 to be fitted into the shaft hole 11 of the laminated rotor core 12, but the present
invention is not limited to this, and a diameter expandable/contractible-type guide
member whose diameter can be expanded/contracted according to the size of shaft
holes of various laminated rotor cores may also be used if necessary.
16[0048]
Although the vent grooves are formed in the mounting surface 12b of the tray
portion 26 of the conveyance tray 16 and the pressing surface 12a of the cavity block74, the present invention is not limited thereto, and the vent grooves may be omitted if
necessary.
The sliding guide member of the upper die 21 is provided around the fixed
frame 22, and the plunger holder 54 is configured to be guided by the plunger guide55.

However, the present invention is not limited thereto, and the plunger holder 54

may be guided by another method if necessary.
Although the spring 54b is provided at the upper end of each of the plungers 23,
the present invention is not limited thereto, and the spring may be omitted if n ecessary.
The thermosetting resin 15 is used as the resin member, but the resin member is
not limited thereto, and for example, when a heat generation temperature of a motor
product is low, a thermoplastic resin may be used.
Although the flow path 20 for guiding the thermosetting resin 15 from the pot
19 to the magnet insertion hole 13 is provided in the bottom portion of the upper die
21, the present invention is not limited to this, and the pot may be provided at a
position corresponding to the magnet insertion hole if necessary.

In this case, a flow

path for guiding the thermosetting resin 15 to the magnet insertion hole 13 is not
required, and the amount of the thermosetting resin 15 used can be reduced.
(2) According to the described matters of the aforementioned (1), it can berecognized that the Detailed Description of the Invention of the Description discloses
the following.
The Invention relates to a method of resin sealing permanent magnets, which
fixes the permanent magnets inserted in a plurality of magnet insertion holes formed
in a laminated rotor core in which a plurality of core pieces are laminated, by
injecting a resin member into the magnet insertion holes ([0001]), and conventionallyas a method of fixing permanent magnets to a laminated core by resin sealing, amethod described in the following is known.

In the method, a laminated core inwhich a plurality of core pieces are laminated by being fixed and integrated bypunching and caulking or the like, a plurality of magnet insertion holes for inserting
permanent magnets are formed in an outer peripheral portion, and a plurality of
injection hole portions for injecting a sealing resin are formed is inserted in abottomed hole portion of a lower die.

After the permanent magnets are inse rted into

the magnet insertion holes, an upper die having an injection hole portion formed at a
position corresponding to an injecting hole portion is placed on an upper end of the17lower die so that the injection hole portion is aligned with the injecting hole portion,
and while the lower die and the upper die are fixed to each other by a fastening means,the resin member is supplied at a predetermined pressure from a resin-supply holeportion communicating with the injection hole portion of the upper die to fill themagnet insertion hole with the resin member, and then the laminated core is heated bya heating means to cure the resin member, thereby fixing the permanent magnets tothe laminated core ([0002]).

However, the method has the following two probl ems.

One problem is that when the magnet insertion holes are filled with the resin member,the resin member is injected into the magnet insertion holes through the resin-supply
hole portion formed in the upper die, the plurality of injection hole portions branchedfrom the resin-supply hole portion, and the injecting hole portion of the laminatedcore, and therefore, it is difficult to uniformly fill each magnet insertion hole with theresin member, and reliability is deteriorated, and in addition, a pump for supplying theresin member requires a large supply pressure, which makes the device expensive(hereinafter, referred to as "the problem in the prior art 1").

The other is that thework of inserting the laminated core into the bottomed hole portion of the lower die,heating the laminated core, and then taking out the laminated core from the bottomed
hole portion of the lower die requires time either by a human hand or a machine, andthe workability is extremely poor (hereinafter, referred to as "the pro blem in the priorart 2") ([0004] and [0005]).

The object of the Invention is acknowledged to provide

a method of resin sealing permanent magnets, which is excellent in productivity andworkability and enables work to be performed inexpensively.
2 Regarding Reason for Rescission 6 (Determination error on requirements forsupport)In consideration of the case, Reason for Invalidation 6 (Determination error of
requirements for support) will be determined first.
(1) It should be determined whether or not the invention for which a patent issought is stated in the Detailed Description of the Invention by comparing thedescription of the Scope of Claims and the description of the Detailed Description of
the Invention, and examining whether or not the invention described in the Scope ofClaims is the invention described in the Detailed Description of the Invention and aperson ordinarily skilled in the art could solve the problems of the invention on thebasis of the invention described in the Detailed Description of the Invention orsuggestion thereof, and whether or not a person ordinarily skilled in the art could
solve the problems of the invention in light of the common general technicalknowledge at the time of filing of the application even in the absence of the18

descriptions or the suggestions.
(2) Regarding the Scope of Claims of the Invention
A The Scope of Claims of Invention 1 is as described in 2 (4) of No. 2 above,and usually, "between" means "a part sandwiched between two objects.

A space/partsandwiched between articles" (KOJIEN, 6th edition), and "die" means "something that
becomes the basis for creating a shape.

Molds, paper patterns, etc." (KOJIEN, 6thedition), so that the matters specifying the invention that "disposing the laminatedrotor core between an upper die and a lower die; pressing the laminated rotor corewith the lower die and the upper die without bringing the upper die and the lower die
into contact with each other," of Invention 1 is acknowledged to specify the layout of
the laminated rotor core with reference to the upper die and the lower die whenpressing the laminated rotor core by "disposing between an upper die and a lower
die," and is acknowledged to specify a positional relationship or a state of the upper
die and the lower die when pressing the laminated rotor core by "without bringing theupper die and the lower die into contact with each other".

On the other hand, theScope of Claims of Invention 1 does not specify the shape and structure of the upper
die and the lower die, and the layout, state, or the like of the laminated rotor core in acase other than "pressing the laminated rotor core with the lower die and the upper
die," and, for example, does not have the conveyance tray on which the laminatedrotor core placed on the lower die as a structure, so that it is recognized that the Scopeof Claims of Invention 1 includes not only the invention including the conveyancetray on which the laminated rotor core of Invention 1 is mounted, but also theinvention that does not include the conveyance tray.
B In addition, although the matter specifying the invention that "the laminatedrotor core is pressed with the upper die and the lower die by raising the lower die" of
Invention 2 is added, it is acknowledged to specify the movement of the lower die
when pressing the laminated rotor core, and it is recognized that other structures of
the Scope of Claims of Inventions 2 are as described in the aforementioned A.
C Further, the matter specifying the invention that "the upper die is provided
with a pot for pushing a resin member into the magnet insertion hole" of Invention 3
is acknowledged to specify the structure relating to resin sealing about the upper die,and it is recognized that other structures of the Scope of Claims of Inventions 3 are as
described in the aforementioned A.
(3) Regarding the problem to be solved by the invention described in the
Detailed Description of the Invention and means for solving the problem
A As described in 1(2) above, on the premise that there are the problems in the19prior art 1 and 2, the problem to be solved by the Invention (the problem of theInvention) is recognized to "provide a method of resin sealing permanent magnets,
which is excellent in productivity and workability and enables work to be performed
inexpensively".
B Here, the "productivity" means "a degree that labor and other production
factors input into a production process contribute to productivity output" (KOJIEN ,6th edition), and it can be understood that "enables work to be performed
inexpensively" indicates a degree of compensation for work.

As the causes ofcompensation for this work, various factors can be thought from items such as "anexpensive pump" in the problem in the prior art 1 and "a machine" in the problem inthe prior art 2 to "a human hand" in the problem in the prior art 2, so that it is also
understood that the problem of the Invention is to solve the problem of the Invention
not only by solving both of the problems in the prior art 1 and 2, but also by solving
either one of the problem in the prior art 1 or 2, so that it can be understood that it isalso enough to solve either one of the problem in the prior art 1 or 2 for solving the
problem of the Invention.
Accordingly, it can be recognized that the JPO decision made determination onrequirements for support on the basis of the matter that the problem of the Invention is
to solve the problem in the prior art 2, so that it cannot be considered that there is anerror in the recognition of the problem of this point.
Therefore, the allegation of the Plaintiff relating to the problem of theInvention against that (the allegation of an error that the JPO decision does notrecognize the point that "it is difficult to uniformly fill each magnet insertion holewith the resin member, and reliability is deteriorated" as the problem) and theallegation of violation of requirements for support based on this point cannot be
accepted.
C Subsequently, according to 1 above, in the Detailed Description of theInvention of the Description, regarding processes of fixing the laminated rotor core on
the lower die and removing it from the lower die again in the method of resin sealing
permanent magnets according to the Invention, it is described that "(a) The permanent
magnet 14 sent from the previous process is inserted into the magnet insertion hole 13,
and the laminated rotor core 12 set in the conveyance tray 16 is conveyed onto thelower die 17 by using a separate conveying means or the like, and is positioned andfixed with respect to the upper die 21 (hereinafter, also including the cavity block 74)(supply work of a laminated rotor core)" ([0039], hereinafter, referred to as "theprocess (a)") and that "... Thereafter, the conveyance tray 16 is removed from the20

lower die 17 together with the laminated rotor core 12, the laminated rotor core 12 isremoved from the conveyance tray 16, and the conveyance tray 16 is sent to a
subsequent process by the separate conveying means" ([0044], hereinafter, referred toas "the process (d)"), and regarding the conveyance tray that is essential in theprocesses (a) and (d), it is described that "the conveyance tray 16 includes arectangular plate-shaped tray portion 26 with which a lower surface 25 of thelaminated rotor core 12 comes into contact, and a diameter-fixed type rod-shaped
guide member 27 provided to stand at the central portion of the tray portion 26 andfitted into the shaft hole 11 of the laminated rotor core 12" ([0017]).
According to the descriptions above, regarding the process of fixing thelaminated rotor core on the lower die or the process of removing it from the lower die,
it is recognized that the invention described in the Detailed Description of theInvention of the Description is to "convey the laminated rotor core 12 set in theconveyance tray 16 including a rectangular plate-shaped tray portion 26 with which alower surface 25 of the laminated rotor core 12 comes into contact, and a diameterfixed type rod-shaped guide member 27 provided to stand at the central portion of the
tray portion 26 and fitted into the shaft hole 11 of the laminated rotor core 12 onto thelower die 17," and is to "remove the conveyance tray 16 from the lower die 17
together with the laminated rotor core 12, the laminated rotor core 12 is removed fromthe conveyance tray 16".
(4) Examination on requirements for support regarding the Invention
A As mans for solving the problem in the prior art 2, Invention 1, as describedin 2 (2) A above, is acknowledged to specify the layout of the laminated rotor corewith reference to the upper die and the lower die when pressing the laminated rotor
core, and to specify a positional relationship or a state of the upper die and the lower
die, whereas the invention described in the Detailed Description of the Invention of
the Description, as described in 2 (3) C above, is to "convey the laminated rotor core
12 set in the conveyance tray 16 including a rectangular plate-shaped tray portion 26
with which a lower surface 25 of the laminated rotor core 12 comes into contact, and adiameter-fixed type rod-shaped guide member 27 provided to stand at the central
portion of the tray portion 26 and fitted into the shaft hole 11 of the laminated rotor
core 12 onto the lower die 17," and is to "remove the conveyance tray 16 from thelower die 17 together with the laminated rotor core 12, the laminated rotor core 12 isremoved from the conveyance tray 16," so that, according to the Detailed Descriptionof the Invention of the Description, it is understood that the conveyance tray is an
essential configuration.

Then, Invention 1 includes not only the invention including
21

the conveyance tray on which the laminated rotor core is mounted, but also theinvention that does not include the conveyance tray, and if assuming the descriptionof the Scope of Claims which does not include the conveyance tray, it cannot be
considered that Invention 1 falls within a range that a person ordinarily skilled in theart could solve the problems of Invention 1 that the work of inserting the laminatedcore into the bottomed hole portion of the lower die, heating the laminated core, andthen taking out the laminated core from the bottomed hole portion of the lower die
requires time either by a human hand or a machine, and the workability is extremely
poor (the problem in the prior art 2), and could provide a method of resin sealing
permanent magnets, which is excellent in productivity and workability and enables
work to be performed inexpensively, on the basis of the Detailed Description of theInvention.

Then, in this respect, Invention 2 and Invention 3 include the invention

that does not include the conveyance tray, so that the same applies to them.
B Further, in Paragraph [0010], it is described that "in the method of resin
sealing permanent magnets according to the present invention, the laminated rotor
core may have a shaft hole at a center thereof, and the laminated rotor core may beplaced on a conveyance tray including a guide member to make the laminated rotor
core fit into the shaft hole and may be disposed between the upper die and the lower
die," so that there is the statement of the Detailed Description of the Invention basedon the assumption that the conveyance tray is not an essential structure.

However, as

described in 2 (4) A above, according to the statement of the Detailed Description of
the Invention of the Description, the conveyance tray is made to be an essential
structure so as to solve the problem in the prior art 2, so that it is understood that analternative structure to the conveyance tray is required.

However, even in thestatement of the Description, although there are descriptions ([0047] and [0048])
relating to the specific structure of the conveyance tray, there is no description thatspecifically suggests the alternative structure to the conveyance tray, and there is noevidence sufficient to find that the alternative structure would be obvious to a person
ordinarily skilled in the art.

Therefore, it cannot be considered that it falls within arange that a person ordinarily skilled in the art could solve the problem relating to t heprocesses of fixing the laminated rotor core on the lower die and removing it from thelower die, in light of the common general technical knowledge at the time of filing of
the application even in the absence of the specific statements in the Detailed
Description of the Invention.

In this respect, Invention 2 and Invention 3 are also thesame.
C In view of the above, the Invention includes the invention that is not22described in the Detailed Description of the Invention of the Description, and thus
does not satisfy with the requirements stipulated in Article 36, paragraph (6), item (i)of the Patent Act.
D In this respect, in the JPO decision, it is determined that the Invention is as
described in the Detailed Description of the Invention of the Description, since it canbe recognized that the problems of the Invention could be solved by "disposing thelaminated rotor core between an upper die and a lower die; pressing the laminatedrotor core with the lower die and the upper die without bringing the upper die and thelower die into contact with each other; and resin sealing the permanent magnets ...".
Also, the Defendant alleges that there is no error in the recognition of the JPO
decision that determines the Invention satisfies the requirements for support even if it
is not provided with the conveyance tray.
However, for a premise for the above determination, in the Description, it canbe considered that "as the embodiments of the invention solving such problems, it isdescribed that '(a) The permanent magnet 14 sent from the previous process isinserted into the magnet insertion hole 13, and the laminated rotor core 12 set in theconveyance tray 16 is conveyed onto the lower die 17 by using a separate conveying
means or the like, and is positioned and fixed with respect to the upper die 21(hereinafter, also including the cavity block 74)' ([0039]), '(b) The lower die 17 isslightly raised by the lower-die elevating means 33 via the elevating plate 32, and thelaminated rotor core 12 and the cavity block 74 are brought into close contact witheach other...' ([0040]), '(c) When the viscosity of the raw material 18 is decreased byheating, the lower die 17 is further raised by the lower-die elevating means 33 via theelevating plate 32, and the laminated rotor core 12 set on the conveyance tray 16 ispressed against the upper die 21' ([0041]), the permanent magnets are fixed to themagnet insertion holes by the thermosetting resin, and then 'the lower die 17 islowered by the lower-die elevating means 33 via the elevating plate 32' ([0044]), and'Thereafter, the conveyance tray 16 is removed from the lower die 17 together withthe laminated rotor core 12, the laminated rotor core 12 is removed from theconveyance tray 16, and the conveyance tray 16 is sent to a subsequent process by theseparate conveying means' ([0044]).

Therefore, there is described the invention

providing the effect that 'when the permanent magnets inserted into the plurality ofmagnet insertion holes formed in the laminated rotor core in which the plurality ofcore pieces are laminated are fixed by injecting a resin member into the magnet
insertion holes, the laminated rotor core is pressed by the upper die and the lower die,and the magnet insertion hole is filled with the resin member, so that ... can be23performed in a short time by a simple process, productivity and workability areexcellent, and work can be performed inexpensively' ([0011])," so that it is recognizedthat the JPO decision determines that the embodiments of the Invention composed of
the above-mentioned processes described in the Detailed Description of the Inventionof the Description could solve the problems.
Therefore, the JPO decision merely means that it can be recognized that aperson ordinarily skilled in the art could solve the problem regarding theembodiments of the Invention described in the Detailed Description of the Inventionof the Description, and it cannot be considered that the JPO decision determined,
through comparing the description in the Scope of Claims with the description in the
Detailed Description of the Invention, by examining whether or not the invention
described in the Scope of Claims is the invention described in the Detailed
Description of the Invention, and whether or not it can be acknowledged that a person
ordinarily skilled in the art could solve the problems of the invention on the basis of
the description, and whether or not a person ordinarily skilled in the art could solve
the problems of the invention in light of the common general technical knowledge at
the time of filing of the application even in the absence of the descriptions or thesuggestions.
Accordingly, it cannot be considered that the JPO decision determined that "theinvention for which a patent is sought is stated in the Detailed Description of theInvention" prescribed in Article 36, paragraph (6), item (i) of the Patent Act.
(5) Summary
Therefore, none of the Invention complies with requirements for support, sothat the determination of the JPO decision that the Invention complies withrequirements for support is erroneous.
3 Conclusion
As described above, there are grounds for Reason for Invalidation 6 alleged by
the Plaintiff, and the JPO decision should be rescinded without even determining theother reasons for rescission, and thus the Court rules as in the main text.
Intellectual Property High Court, First Division

24

Presiding Judge:

HONDA Tomonari

Judge:TOYAMA Atsushi

Judge:AMANO KenjiAttachment
FIG. 125

FIG. 226

FIG. 327

FIG. 428

FIG. 5
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FIG. 6
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FIG. 7

FRONT

BACK

31

FIG. 8
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LEFT

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FIG. 9

RIGHT

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FIG. 1034