Patents by Inventor Isao Fuwa
Isao Fuwa has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10898953Abstract: There is provided a manufacturing method of a three-dimensional shaped object, the method being capable of reducing a warp deformation of the three-dimensional shaped object. The manufacturing method according to an embodiment of the present invention produces a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming on a base plate, wherein the forming of at least one prior solidified layer is performed under a higher temperature condition than that for the forming of a subsequent solidified layer, the at least one prior solidified layer being formed prior to the subsequent solidified layer.Type: GrantFiled: March 8, 2017Date of Patent: January 26, 2021Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Isao Fuwa, Mikio Mori
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Patent number: 10821663Abstract: There is provided a manufacturing method of a three-dimensional shaped object, the method being capable of reducing a warp deformation of the three-dimensional shaped object. The manufacturing method according to an embodiment of the present invention produces a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming by light beam irradiation, wherein as a platform for the three-dimensional shaped object, a plate laminate body comprising a dummy solidified layer and a base plate for the shaped object is used, and the dummy solidified layer is formed on one of principal surfaces of the base plate, whereas the three-dimensional shaped object is manufactured on the other of the principal surfaces of the base plate.Type: GrantFiled: March 8, 2017Date of Patent: November 3, 2020Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Isao Fuwa, Mikio Mori
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Publication number: 20190091923Abstract: There is provided a manufacturing method of a three-dimensional shaped object, the method being capable of reducing a warp deformation of the three-dimensional shaped object. The manufacturing method according to an embodiment of the present invention produces a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming by light beam irradiation, wherein as a platform for the three-dimensional shaped object, a plate laminate body comprising a dummy solidified layer and a base plate for the shaped object is used, and the dummy solidified layer is formed on one of principal surfaces of the base plate, whereas the three-dimensional shaped object is manufactured on the other of the principal surfaces of the base plate.Type: ApplicationFiled: March 8, 2017Publication date: March 28, 2019Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi ABE, Isao FUWA, Mikio MORI
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Publication number: 20190076923Abstract: There is provided a manufacturing method of a three-dimensional shaped object, the method being capable of reducing a warp deformation of the three-dimensional shaped object. The manufacturing method according to an embodiment of the present invention produces a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming on a base plate, wherein the forming of at least one prior solidified layer is performed under a higher temperature condition than that for the forming of a subsequent solidified layer, the at least one prior solidified layer being formed prior to the subsequent solidified layer.Type: ApplicationFiled: March 8, 2017Publication date: March 14, 2019Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi ABE, Isao FUWA, Mikio MORI
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Publication number: 20180214948Abstract: In order to provide a manufacturing method of the three-dimensional shaped object having a more proper heat property to be used as a metal mold, there is provided a method for manufacturing a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming, the repetition comprising: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification of the powder; and (ii) forming another solidified layer by forming a new powder layer on the formed solidified layer, followed by irradiation of a predetermined portion of the newly formed powder layer with the light beam, wherein the three-dimensional shaped object is manufactured such that it has a heat source element in the three-dimensional shaped object, and also has a surface in a form of a concavity-convexity, and wherein a main surface of the heat source eType: ApplicationFiled: February 8, 2016Publication date: August 2, 2018Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Masanori MORIMOTO, Satoshi ABE, Isao FUWA, Akifumi NAKAMURA
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Publication number: 20180200795Abstract: In order to to provide a manufacturing method of a three-dimensional shaped object having a more proper heat removal property to be used as a metal mold, there is provided that a method for manufacturing a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming, the repetition comprising: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification of the powder; and (ii) forming another solidified layer by forming a new powder layer on the formed solidified layer, followed by irradiation of a predetermined portion of the newly formed powder layer with the light beam, wherein the manufacturing method of the present invention, the three-dimensional shaped object is manufactured such that it has a flow path for cooling media in the three-dimensional shaped object, and also has a surface in a formType: ApplicationFiled: February 8, 2016Publication date: July 19, 2018Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Masanori MORIMOTO, Satoshi ABE, Akifumi NAKAMURA, Isao FUWA
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Patent number: 10022797Abstract: A method for manufacturing a three-dimensional shaped object wherein the warping of the base plate is suitably addressed. The method of the present invention comprises: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer on a base plate with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed; wherein, prior to or upon the manufacturing of the three-dimensional shaped object, the base plate is subjected to a heat treatment, thereby causing the base plate to be warped, and at least a lower surface of the warped base plate is subjected to a flattening process.Type: GrantFiled: February 16, 2011Date of Patent: July 17, 2018Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Norio Yoshida, Isao Fuwa, Yoshikazu Higashi, Masataka Takenami, Isamu Matumoto
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Patent number: 10000021Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam; wherein only the surface portion of the solidified layer, to which a force is applied when the three-dimensional shaped object is used, is subjected to a machining process.Type: GrantFiled: June 23, 2010Date of Patent: June 19, 2018Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Yoshikazu Higashi, Isao Fuwa, Masataka Takenami
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Publication number: 20170341143Abstract: There is provided a manufacturing method of the three-dimensional shaped object, the method being capable of reducing an undesirable phenomenon associated with the contamination of the light transmission window with the fume substance. The manufacturing method according to an embodiment of the present invention is a method for manufacturing a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming, wherein the irradiation with light beam for the solidified-layer forming is performed by directing the light beam into the chamber through a light transmission window of the chamber, and wherein a gas blow is supplied to the light transmission window by use of a movable gas supply device, the light transmission window having been contaminated with a fume generated upon the formation of the solidified layer.Type: ApplicationFiled: December 22, 2015Publication date: November 30, 2017Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi ABE, Isao FUWA, Masataka TAKENAMI, Mikio MORI
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Publication number: 20170282462Abstract: In order to provide the method for manufacturing the three-dimensional shaped object which is capable of preventing the occurrence of the raised portion at the sintered portion or the melted and subsequently solidified portion by the irradiation of the light beam, there is provided a method for manufacturing a three-dimensional shaped object by alternate repetition of a step (i) forming a powder-layer and a step (ii) forming a solidified layer by irradiating a predetermined portion of the powder layer with a light beam, wherein the light beam-irradiated portion is vibrated in the step (ii).Type: ApplicationFiled: September 30, 2015Publication date: October 5, 2017Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LT D.Inventors: Satoshi ABE, Isao FUWA, Masataka TAKENAMI
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Patent number: 9724758Abstract: An apparatus for producing a laminated object, includes a powder layer forming unit for forming a powder layer of a powdery material, a material supply unit for feeding the powdery material to the powder layer forming unit; and a solidified layer forming unit for forming a solidified layer by irradiating a light beam on a specified portion of the powder layer and sintering or melting the specified portion of the powder layer. The apparatus is configured to produce an integrally laminated three-dimensional object by repeating formation of the powder layer and formation of the solidified layer. The material supply unit includes a cartridge unit charged with the powdery material, the cartridge unit being configured to allow the powdery material to drop downwards.Type: GrantFiled: July 23, 2015Date of Patent: August 8, 2017Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Yoshikazu Higashi, Isao Fuwa, Masataka Takenami, Norio Yoshida
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Patent number: 9597836Abstract: There is provided a manufacturing method of the three-dimensional shaped object, the method being capable of suitably reducing the local raised portion which can occur during the light beam irradiation under the condition of the divided sub-irradiation paths. The manufacturing method of the present invention is performed by repetition of a powder-layer forming and a solidified-layer forming, wherein an irradiation path of the light beam is divided into a plurality of sub-irradiation paths including a short sub-irradiation path with its length being shorter than a predetermined length and a long sub-irradiation path with its length being the predetermined length or longer, and wherein an irradiation mode of the light beam is changed depending on the lengths of the sub-irradiation paths.Type: GrantFiled: March 6, 2013Date of Patent: March 21, 2017Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Isamu Matsumoto, Masataka Takenami, Masaki Kondo, Isao Fuwa, Yoshiyuki Uchinono
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Patent number: 9592554Abstract: A method for manufacturing a three-dimensional shaped object, comprising: (i) forming a powder layer on a base plate by a sliding movement of a squeegee blade, followed by forming a solidified layer by irradiating a predetermined portion of the powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, steps (i) and (ii) being repeatedly performed, wherein machining is performed at least once on an outer surface of a shaped object precursor obtained during manufacturing, and after machining, at least one solidified layer is formed, and followed by upper face machining to remove a raised solidified portion generated at a peripheral edge of the solidified layer.Type: GrantFiled: May 22, 2012Date of Patent: March 14, 2017Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Isamu Matsumoto, Masataka Takenami, Isao Fuwa, Yoshikazu Higashi, Yoshiyuki Uchinono, Norio Yoshida
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Publication number: 20150321256Abstract: An apparatus for producing a laminated object, includes a powder layer forming unit for forming a powder layer of a powdery material, a material supply unit for feeding the powdery material to the powder layer forming unit; and a solidified layer forming unit for forming a solidified layer by irradiating a light beam on a specified portion of the powder layer and sintering or melting the specified portion of the powder layer. The apparatus is configured to produce an integrally laminated three-dimensional object by repeating formation of the powder layer and formation of the solidified layer. The material supply unit includes a cartridge unit charged with the powdery material, the cartridge unit being configured to allow the powdery material to drop downwards.Type: ApplicationFiled: July 23, 2015Publication date: November 12, 2015Inventors: Satoshi ABE, Yoshikazu HIGASHI, Isao FUWA, Masataka TAKENAMI, Norio YOSHIDA
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Patent number: 9156056Abstract: An apparatus for producing a laminated object, includes a powder layer forming unit for forming a powder layer of a powdery material, a material supply unit for feeding the powdery material to the powder layer forming unit; and a solidified layer forming unit for forming a solidified layer by irradiating a light beam on a specified portion of the powder layer and sintering or melting the specified portion of the powder layer. The apparatus is configured to produce an integrally laminated three-dimensional object by repeating formation of the powder layer and formation of the solidified layer. The material supply unit includes a cartridge unit charged with the powdery material, the cartridge unit being configured to allow the powdery material to drop downwards.Type: GrantFiled: August 4, 2009Date of Patent: October 13, 2015Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Yoshikazu Higashi, Isao Fuwa, Masataka Takenami, Norio Yoshida
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Patent number: 9073264Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed in a chamber; wherein a localized gas flow is provided in the chamber, and at least a part of a fume generated by the irradiation of the light beam is entrained by the localized gas flow.Type: GrantFiled: October 20, 2010Date of Patent: July 7, 2015Assignee: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Norio Yoshida, Isao Fuwa, Yoshikazu Higashi
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Publication number: 20150183165Abstract: There is provided a manufacturing method of the three-dimensional shaped object, the method being capable of suitably reducing the local raised portion which can occur during the light beam irradiation under the condition of the divided sub-irradiation paths. The manufacturing method of the present invention is performed by repetition of a powder-layer forming and a solidified-layer forming, wherein an irradiation path of the light beam is divided into a plurality of sub-irradiation paths including a short sub-irradiation path with its length being shorter than a predetermined length and a long sub-irradiation path with its length being the predetermined length or longer, and wherein an irradiation mode of the light beam is changed depending on the lengths of the sub-irradiation paths.Type: ApplicationFiled: March 6, 2013Publication date: July 2, 2015Applicant: PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.Inventors: Satoshi Abe, Isamu Matsumoto, Masataka Takenami, Masaki Kondo, Isao Fuwa, Yoshiyuki Uchinono
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Patent number: 9005513Abstract: An object of the present invention is to easily eliminate fumes inside a chamber, so as to improve a positional accuracy of irradiation with a light beam and a machining accuracy in a method for manufacturing a three-dimensional shaped object. A stacked-layers forming device 1 includes a powder layer forming unit 3, a light beam irradiating unit 4, a base 22 which is fixed and on which a powder layer 32 is formed, a lifting/lowering frame 34 which surrounds the circumference of the base 22 and is freely capable of being lifted and lowered, a cover frame 36 which has a window 36a allowing transmission of light beam in its top surface, and whose bottom surface is opened, and which is disposed on the lifting/lowering frame 34 to form a chamber C, and a gas tank 71 for supplying an ambient gas. The lifting/lowering frame 34 is lowered to reduce the volume of the chamber C, so as to discharge fumes generated inside the cover frame 36, which performs replacement with the ambient gas.Type: GrantFiled: May 14, 2010Date of Patent: April 14, 2015Assignee: Panasonic Intellectual Property Management Co., Ltd.Inventors: Satoshi Abe, Norio Yoshida, Yoshikazu Higashi, Isao Fuwa
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Patent number: 8999222Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a part of a surface portion of the three-dimensional shaped object is formed as a low-density solidified portion whose solidified density ranges from 50% to 90% so that an application of pressure can be performed by a gas flowing through the low-density solidified portion.Type: GrantFiled: June 9, 2011Date of Patent: April 7, 2015Assignees: Panasonic Corporation, OPM Laboratory Co., LtdInventors: Satoshi Abe, Yoshiyuki Uchinono, Isao Fuwa, Norio Yoshida, Kazuho Morimoto
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Patent number: 8974727Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a heater element is disposed on the solidified layer during the repeated steps (i) and (ii), and thereby the heater element is situated within the three-dimensional shaped object.Type: GrantFiled: June 9, 2011Date of Patent: March 10, 2015Assignees: Panasonic Corporation, OPM Laboratory Co., LtdInventors: Satoshi Abe, Yoshiyuki Uchinono, Isao Fuwa, Norio Yoshida, Kazuho Morimoto