Patents by Inventor Kouichi Amaya
Kouichi Amaya 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: 11465358Abstract: A three-dimensional object shaping method includes the steps of a powder layer forming step, a sliding step of a squeegee on the supplied powder, and a sintering step of irradiating the powder layer, all successively repeated, wherein after dividing shaping regions into a plurality of laminating units, each laminating unit of the plurality of laminating units is divided into an inside region including a maximum prearranged sintering region, and an outside region not including the maximum prearranged sintering region, and wherein the squeegee sliding speed in the outside region is set to be greater than the sliding speed in the inside region.Type: GrantFiled: August 2, 2017Date of Patent: October 11, 2022Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Kousuke Ishimoto
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Patent number: 11097497Abstract: A support for supporting a workpiece from below efficiently while reducing the amount of necessary materials, and a shaping method for shaping the workpiece and support efficiently includes a hollow state support for supporting a workpiece from below, and the hollow state support has a lattice form with crossing of straight linear or curved columnar bodies, wherein a sintered strength at a connecting region with the workpiece is lower than the sintered strength at the other regions.Type: GrantFiled: February 10, 2020Date of Patent: August 24, 2021Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Kousuke Ishimoto
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Patent number: 11077500Abstract: A three-dimensional shaping method in which the powder supplying blade 2 is able to travel without any problems, in which a control system stores in advance a fine sintered region 11 so that any one of a cross-sectional area or a mean diameter in the horizontal direction, a shaping width and an undercut angle at the end is equal to or less than a predetermined extent, or the control system makes a determination in a sintering step, for said each element, so in the case of the raised sintered portions 12 forming on the upper side of the sintered region 11, a rotating cutting tool 3 cuts the raised sintered portions 12 entirely or partially, thereby achieving the object.Type: GrantFiled: September 24, 2018Date of Patent: August 3, 2021Assignee: Matsuura Machinery CorporationInventors: Kousuke Ishimoto, Makoto Ichimura, Kouichi Amaya
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Patent number: 10946582Abstract: A method for producing a three-dimensional shaped product based on dispersion of powder by a squeegee and irradiation of the powder layer with a laser beam or electron beam, including the steps of installing a suction device that suctions fumes generated from the powder layer, in a state surrounding the entire periphery of a shaping table, and selecting a suction reference position at the shortest distance from the irradiation reference position currently moved and worked in a prescribed time range.Type: GrantFiled: November 1, 2019Date of Patent: March 16, 2021Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Seiichi Tomita
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Patent number: 10899088Abstract: A support for supporting a workpiece from below efficiently while reducing the amount of necessary materials, and a shaping method for shaping the workpiece and support efficiently includes a hollow state support for supporting a workpiece from below, and the hollow state support has a lattice form with crossing of straight linear or curved columnar bodies, wherein a sintered strength at a connecting region with the workpiece is lower than the sintered strength at the other regions.Type: GrantFiled: November 17, 2017Date of Patent: January 26, 2021Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Kousuke Ishimoto
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Patent number: 10773459Abstract: A three-dimensional shaping method utilizing a powder layer forming step, and a sintering step with a laser beam or electron beam, the method including the steps of a) measuring a light intensity of sparks and photographing the sparks generated with fly-off of powder caused by irradiation of the beam over the entire periphery of the sintering region, b) commanding to continue sintering within the next time unit or the next powder layer forming step, when it is detected that the region width and light intensity are within the standard ranges for a given time unit, and c) commanding to cancel sintering in the next time unit or the next powder layer forming step when a sintering defect has occurred, when it is detected that a condition has occurred in which the region width and light intensity deviate from the standard ranges for a given time unit.Type: GrantFiled: August 2, 2017Date of Patent: September 15, 2020Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Kousuke Ishimoto, Takeshi Yamada
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Publication number: 20200276754Abstract: A method for producing a three-dimensional shaped product based on dispersion of powder by a squeegee and irradiation of the powder layer with a laser beam or electron beam, including the steps of installing a suction device that suctions fumes generated from the powder layer, in a state surrounding the entire periphery of a shaping table, and selecting a suction reference position at the shortest distance from the irradiation reference position currently moved and worked in a prescribed time range.Type: ApplicationFiled: November 1, 2019Publication date: September 3, 2020Inventors: Kouichi Amaya, Seiichi Tomita
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Publication number: 20200180237Abstract: A support for supporting a workpiece from below efficiently while reducing the amount of necessary materials, and a shaping method for shaping the workpiece and support efficiently includes a hollow state support for supporting a workpiece from below, and the hollow state support has a lattice form with crossing of straight linear or curved columnar bodies, wherein a sintered strength at a connecting region with the workpiece is lower than the sintered strength at the other regions.Type: ApplicationFiled: February 10, 2020Publication date: June 11, 2020Inventors: Kouichi Amaya, Kousuke Ishimoto
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Patent number: 10663948Abstract: A method for a three-dimensional shaped product produced by lamination, irradiation-based sintering and cutting, when undercut regions are present, comprising the steps of: 1. setting a model for the three-dimensional shaped product; 2. selecting a standard of undercut angle; 3. rotating the model in angle units; 4. calculating a total projected area on a horizontal plane of the undercut regions having angles crossing the horizontal plane which are smaller angles than a standard of undercut angle; 5. selecting a rotation angle such that the total projected area is either smallest or a prescribed standard value is reached; 6. when a minimum total area in step 5 is larger than a predetermined standard value or all of the total projected area in step 4 is larger than the predetermined standard value, sending a command to set a shaping region of a support section for supporting the undercut region.Type: GrantFiled: February 21, 2018Date of Patent: May 26, 2020Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Jun Kobayashi, Tatsuya Kabeshita
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Patent number: 10576684Abstract: A three-dimensional shaping method utilizing a powder layer forming step, and a sintering step with a laser beam or electron beam, the method including the steps of a) measuring the reflection intensity of the beam irradiated in each sintering step, or the reflection intensity of other light, b) commanding to continue sintering within the next time unit, or when the next powder layer forming step is given, when it has been detected that the reflection intensity of the step a) is within a standard range for a given time unit, and, c) judging that a sintering defect has been produced, and commanding to cancel sintering in the next time unit, or when the next powder layer forming step is given, when it is detected that a condition has occurred in which the reflection intensity of step a) deviates from the standard range for a given time unit.Type: GrantFiled: August 2, 2017Date of Patent: March 3, 2020Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Kousuke Ishimoto, Takeshi Yamada
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Patent number: 10562111Abstract: A cutting tool 1 includes a cutting edge equipped with a helically curved groove 2 at a side outer periphery in the longitudinal direction, and a coolant passage pipe 3 extended internally and communicatively connected with ejection holes 4 of coolant arranged inside the groove 2 by way of a coolant passage pipe 31 branched from the coolant passage pipe 3 extended around a rotation center axis along the longitudinal direction or along the helically curved groove.Type: GrantFiled: December 28, 2018Date of Patent: February 18, 2020Assignee: Matsuura Machinery CorporationInventors: Kouichi Amaya, Ryuzo Tanaka, Yoshiaki Kano, Yasunori Takezawa, Tetsuya Igarashi
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Patent number: 10525530Abstract: A three-dimensional shaping apparatus includes a shaping table 31, a squeegee 32, a sintering device, a cutting device, transport pathways 4 through which metal powder and fumes that have been discharged to the outer side of a shaping tank 1 after cutting with the cutting device, and metal powder that has been discharged to the outer side of a chamber 2 surrounding the shaping tank 1 without forming part of the laminated layer, are transported to a sifter 5 located at the top of a powder tank 6, and supply devices for inert gas that does not react with the metal powder at an inlet 40 of each transport pathway 4, so as to suppress oxidation of metal powder in the transport pathway for collected metal powder and fumes, and also dust explosion due to sudden oxidation of the same.Type: GrantFiled: July 26, 2018Date of Patent: January 7, 2020Assignee: Matsuura Machinery Corp.Inventors: Kouichi Amaya, Toshihiko Kato, Tetsushi Midorikawa, Mitsuyoshi Yoshida, Kazuhiro Shimizu
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Publication number: 20190224760Abstract: A cutting tool 1 has cutting edges 2 formed by a plurality of side surfaces on both sides 21, 22 raised at a side portion along a longitudinal direction, and the cutting tool 1 in which a coolant passage pipe 30 is extended around a rotation center axis 5, and coolant passage pipes 31 branched from the extended coolant passage pipe 30 are projected along a direction of a raised side surface 21 on a rotating direction side of the raised side surfaces on both sides 21, 22.Type: ApplicationFiled: December 28, 2018Publication date: July 25, 2019Inventors: Kouichi Amaya, Ryuzo Tanaka, Yoshiaki Kano, Yasunori Takezawa, Tetsuya Igarashi
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Publication number: 20190224761Abstract: A cutting tool 1 includes a cutting edge equipped with a helically curved groove 2 at a side outer periphery in the longitudinal direction, and a coolant passage pipe 3 extended internally and communicatively connected with ejection holes 4 of coolant arranged inside the groove 2 by way of a coolant passage pipe 31 branched from the coolant passage pipe 3 extended around a rotation center axis along the longitudinal direction or along the helically curved groove.Type: ApplicationFiled: December 28, 2018Publication date: July 25, 2019Inventors: Kouichi Amaya, Ryuzo Tanaka, Yoshiaki Kano, Yasunori Takezawa, Tetsuya Igarashi
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Publication number: 20190152163Abstract: A support for supporting a workpiece from below efficiently while reducing the amount of necessary materials, and a shaping method for shaping the workpiece and support efficiently includes a hollow state support for supporting a workpiece from below, and the hollow state support has a lattice form with crossing of straight linear or curved columnar bodies, wherein a sintered strength at a connecting region with the workpiece is lower than the sintered strength at the other regions.Type: ApplicationFiled: November 17, 2017Publication date: May 23, 2019Inventors: Kouichi Amaya, Kousuke Ishimoto
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Publication number: 20190070662Abstract: A three-dimensional shaping apparatus includes a shaping table 31, a squeegee 32, a sintering device, a cutting device, transport pathways 4 through which metal powder and fumes that have been discharged to the outer side of a shaping tank 1 after cutting with the cutting device, and metal powder that has been discharged to the outer side of a chamber 2 surrounding the shaping tank 1 without forming part of the laminated layer, are transported to a sifter 5 located at the top of a powder tank 6, and supply devices for inert gas that does not react with the metal powder at an inlet 40 of each transport pathway 4, so as to suppress oxidation of metal powder in the transport pathway for collected metal powder and fumes, and also dust explosion due to sudden oxidation of the same.Type: ApplicationFiled: July 26, 2018Publication date: March 7, 2019Inventors: Kouichi Amaya, Toshihiko Kato, Tetsushi Midorikawa, Mitsuyoshi Yoshida, Kazuhiro Shimizu
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Publication number: 20190039287Abstract: A three-dimensional shaping method utilizing a powder layer forming step, and a sintering step with a laser beam or electron beam, the method including the steps of a) measuring the reflection intensity of the beam irradiated in each sintering step, or the reflection intensity of other light, b) commanding to continue sintering within the next time unit, or when the next powder layer forming step is given, when it has been detected that the reflection intensity of the step a) is within a standard range for a given time unit, and, c) judging that a sintering defect has been produced, and commanding to cancel sintering in the next time unit, or when the next powder layer forming step is given, when it is detected that a condition has occurred in which the reflection intensity of step a) deviates from the standard range for a given time unit.Type: ApplicationFiled: August 2, 2017Publication date: February 7, 2019Inventors: Kouichi Amaya, Kousuke Ishimoto, Takeshi Yamada
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Publication number: 20190039315Abstract: A three-dimensional object shaping method includes the steps of a powder layer forming step, a sliding step of a squeegee on the supplied powder, and a sintering step of irradiating the powder layer, all successively repeated, wherein after dividing shaping regions into a plurality of laminating units, each laminating unit of the plurality of laminating units is divided into an inside region including a maximum prearranged sintering region, and an outside region not including the maximum prearranged sintering region, and wherein the squeegee sliding speed in the outside region is set to be greater than the sliding speed in the inside region.Type: ApplicationFiled: August 2, 2017Publication date: February 7, 2019Inventors: Kouichi Amaya, Kousuke Ishimoto
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Publication number: 20190041827Abstract: A method for a three-dimensional shaped product produced by lamination, irradiation-based sintering and cutting, when undercut regions are present, comprising the steps of: 1. setting a model for the three-dimensional shaped product; 2. selecting a standard of undercut angle; 3. rotating the model in angle units; 4. calculating a total projected area on a horizontal plane of the undercut regions having angles crossing the horizontal plane which are smaller angles than a standard of undercut angle; 5. selecting a rotation angle such that the total projected area is either smallest or a prescribed standard value is reached; 6. when a minimum total area in step 5 is larger than a predetermined standard value or all of the total projected area in step 4 is larger than the predetermined standard value, sending a command to set a shaping region of a support section for supporting the undercut region.Type: ApplicationFiled: February 21, 2018Publication date: February 7, 2019Inventors: Kouichi Amaya, Jun Kobayashi, Tatsuya Kabeshita
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Publication number: 20190039314Abstract: A three-dimensional shaping method utilizing a powder layer forming step, and a sintering step with a laser beam or electron beam, the method including the steps of a) measuring a light intensity of sparks and photographing the sparks generated with fly-off of powder caused by irradiation of the beam over the entire periphery of the sintering region, b) commanding to continue sintering within the next time unit or the next powder layer forming step, when it is detected that the region width and light intensity are within the standard ranges for a given time unit, and c) commanding to cancel sintering in the next time unit or the next powder layer forming step when a sintering defect has occurred, when it is detected that a condition has occurred in which the region width and light intensity deviate from the standard ranges for a given time unit.Type: ApplicationFiled: August 2, 2017Publication date: February 7, 2019Inventors: Kouichi Amaya, Kousuke Ishimoto, Takeshi Yamada