Patents by Inventor Shintaro FUKADA
Shintaro FUKADA 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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Publication number: 20240075691Abstract: A joined assembly includes: a first member; a second member which has a facing part facing the first member in a thickness direction thereof; and joints lying along the facing part to join the first member and the second member to each other. The joints include: a pair of end joints respectively located at the opposite end portions of the facing part; and an intermediate joint located between the end joints and having a lower joining strength than the end joints. The end joint includes a fastening member mechanically joining the first member and the second member. The intermediate joint includes a friction-stirred part joining the first member and the second member by friction stir.Type: ApplicationFiled: March 28, 2022Publication date: March 7, 2024Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke HARUNA, Shintaro FUKADA, Ryoji OHASHI, Ryoichi HATANO
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Patent number: 11858060Abstract: A friction stir spot welder includes a controller configured to: drive a rotary actuator and an advancement/withdrawal actuator to cause a pin to press workpieces while rotating; after the pressing, drive the rotary actuator and the advancement/withdrawal actuator to cause the pin and a shoulder to press the workpieces while rotating; and after the pressing, drive the rotary actuator and the advancement/withdrawal actuator to cause the pin and/or the shoulder to plunge into a weld region of the workpieces while rotating and stir the weld region to weld the workpieces together.Type: GrantFiled: December 26, 2019Date of Patent: January 2, 2024Assignee: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Ryoichi Hatano, Shintaro Fukada
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Publication number: 20230241708Abstract: A double-acting tool for friction stir spot welding is used to weld a first member and a second member each formed of a thermoplastic resin molding by friction stir spot welding. An overlapping part of the first member and the second member is formed, and the tool is disposed against the overlapping part while rotating a pin and a shoulder about a rotation axis. The shoulder is plunged into the overlapping part to start friction stir. The plunging is continued until the shoulder penetrates the first member, and penetrates the second member or reaches a depth corresponding to a first thickness t1 or lager. Subsequently, the overlapping part is backfilled with a resin material overflowed due to the plunging.Type: ApplicationFiled: March 9, 2023Publication date: August 3, 2023Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Ryoichi HATANO, Kenichi KAMIMUKI, Shintaro FUKADA, Shunsuke HARUNA
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Publication number: 20230191710Abstract: A first member formed of a thermoplastic resin molding mixed with a fiber material and a second member formed of a molding containing at least a thermoplastic resin are welded by friction stir spot welding using a double-acting tool for friction stir spot welding. An overlapping part between the first member and the second member is formed, and the tool is disposed against the overlapping part while the pin and the shoulder are rotated about the rotation axis. The pin is plunged into the overlapping part, and friction stir is performed to cause extension fibers to remain around a plunging region of the pin while the shoulder is retracted to release an overflow material. The shoulder is brought closer to the overlapping part to wrap the extension fibers into the overflow material when the overflow material is backfilled while the pin is retracted from the overlapping part.Type: ApplicationFiled: February 22, 2023Publication date: June 22, 2023Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Ryoichi HATANO, Kenichi KAMIMUKI, Shintaro FUKADA, Shunsuke HARUNA
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Patent number: 11491576Abstract: A friction stir spot welding method includes a welding step of performing friction stir spot welding of a workpiece by using a pin member and a shoulder member while the workpiece is supported and pressed by the end face of a clamp member and a pressing step of causing a friction stir spot welding device to press an obverse surface and a reverse surface of at least one of a friction-stirred region of the workpiece and an adjacent region adjacent to the friction-stirred region of the workpiece from a rotary tool side and an opposite side after the welding step while the pin member and the shoulder member are accommodated in an accommodation space of the clamp member.Type: GrantFiled: September 3, 2018Date of Patent: November 8, 2022Assignee: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke Haruna, Shintaro Fukada, Takashi Ninomiya, Etsuko Yamada, Masaaki Hirano
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Publication number: 20220143739Abstract: A friction stir spot welding apparatus includes: a pin that is columnar; a shoulder that is cylindrical, the pin being within the shoulder; a rotary driver that rotates the pin and the shoulder about an axis that coincides with a center axis of the pin; and an advance-retreat driver that advances and retreats the pin and the shoulder along the axis. A first groove is formed at a tip end portion of an outer peripheral surface of the shoulder so as to extend in a direction along the center axis of the pin.Type: ApplicationFiled: February 28, 2020Publication date: May 12, 2022Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Ryoichi HATANO, Shintaro FUKADA, Yusuke YOSHIDA, Shunsuke HARUNA, Masahiro MIYAKE, Kengo MAEDA
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Patent number: 11292077Abstract: A friction stir spot welding method performs friction stir spot welding of a pair of workpieces having a coating film formed on at least one welding surface by using a refill friction stir spot welding device including rotary tools. The method includes removing the coating film by plunging a distal end of the shoulder member into one workpiece up to a position closer to the surface than the welding surface, while rotating the shoulder member as a rotary tool around the axis, and rotating the shoulder member in a state in which the surface of one of the pair of workpieces, with the welding surfaces being overlaid on each other, is pressed by the end face of the clamp member and performing friction stir spot welding of the pair of workpieces after the coating film removal by using the pin member and the shoulder member as rotary tools.Type: GrantFiled: September 3, 2018Date of Patent: April 5, 2022Assignee: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke Haruna, Shintaro Fukada, Noriyuki Taniyama
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Publication number: 20220072653Abstract: A friction stir spot welder includes a controller configured to: drive a rotary actuator and an advancement/withdrawal actuator to cause a pin to press workpieces while rotating; after the pressing, drive the rotary actuator and the advancement/withdrawal actuator to cause the pin and a shoulder to press the workpieces while rotating; and after the pressing, drive the rotary actuator and the advancement/withdrawal actuator to cause the pin and/or the shoulder to plunge into a weld region of the workpieces while rotating and stir the weld region to weld the workpieces together.Type: ApplicationFiled: December 26, 2019Publication date: March 10, 2022Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Ryoichi HATANO, Shintaro FUKADA
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Patent number: 11045898Abstract: A friction stir spot welding method according to one aspect of the present invention includes: performing a plunging process of moving a shoulder (28) toward a second workpiece (102) from a first workpiece (101) side while rotating a rotary tool to plunge the shoulder into the first and second workpieces; and performing a backfilling process of pushing stirred materials that have flowed into an inside of the shoulder in the plunging process out of the shoulder and backfilling a plunging hole with the stirred materials, the plunging hole being formed by the plunging of the shoulder. In the plunging process, the shoulder is plunged to a position that is shifted from a boundary between the first workpiece and the second workpiece to the second workpiece side by 1 mm or more, such that a component of a protective layer (104) is concentrated in a central portion of a stirred portion (105) when the backfilling process is completed.Type: GrantFiled: March 13, 2017Date of Patent: June 29, 2021Assignee: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke Haruna, Shintaro Fukada
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Publication number: 20200282491Abstract: A friction stir spot welding method performs friction stir spot welding of a pair of workpieces having a coating film formed on at least one welding surface by using a refill friction stir spot welding device including rotary tools. The method includes removing the coating film by plunging a distal end of the shoulder member into one workpiece up to a position closer to the surface than the welding surface, while rotating the shoulder member as a rotary tool around the axis, and rotating the shoulder member in a state in which the surface of one of the pair of workpieces, with the welding surfaces being overlaid on each other, is pressed by the end face of the clamp member and performing friction stir spot welding of the pair of workpieces after the coating film removal by using the pin member and the shoulder member as rotary tools.Type: ApplicationFiled: September 3, 2018Publication date: September 10, 2020Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke HARUNA, Shintaro FUKADA, Noriyuki TANIYAMA
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Publication number: 20200276666Abstract: A friction stir spot welding method includes a welding step of performing friction stir spot welding of a workpiece by using a pin member and a shoulder member while the workpiece is supported and pressed by the end face of a clamp member and a pressing step of causing a friction stir spot welding device to press an obverse surface and a reverse surface of at least one of a friction-stirred region of the workpiece and an adjacent region adjacent to the friction-stirred region of the workpiece from a rotary tool side and an opposite side after the welding step while the pin member and the shoulder member are accommodated in an accommodation space of the clamp member.Type: ApplicationFiled: September 3, 2018Publication date: September 3, 2020Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke HARUNA, Shintaro FUKADA, Takashi NINOMIYA, Etsuko YAMADA, Masaaki HIRANO
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Publication number: 20190070692Abstract: A friction stir spot welding method according to one aspect of the present invention includes: performing a plunging process of moving a shoulder (28) toward a second workpiece (102) from a first workpiece (101) side while rotating a rotary tool to plunge the shoulder into the first and second workpieces; and performing a backfilling process of pushing stirred materials that have flowed into an inside of the shoulder in the plunging process out of the shoulder and backfilling a plunging hole with the stirred materials, the plunging hole being formed by the plunging of the shoulder. In the plunging process, the shoulder is plunged to a position that is shifted from a boundary between the first workpiece and the second workpiece to the second workpiece side by 1 mm or more, such that a component of a protective layer (104) is concentrated in a central portion of a stirred portion (105) when the backfilling process is completed.Type: ApplicationFiled: March 13, 2017Publication date: March 7, 2019Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Shunsuke HARUNA, Shintaro FUKADA
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Patent number: 10201873Abstract: A friction stir spot welding device includes a pin member, a shoulder member, a rotation driving unit, a tool driving unit, a position detector, and a controller, wherein the controller sets as reference position of the tip end surface of the pin member or shoulder member at a time point when the pin member tip end surface or shoulder member contacts an obverse surface of an object and controls the tool driving unit reducing a pressing force to the object by the pin member and pressing force to the object by the shoulder member in a next welding process, and/ or controls the rotation driving unit reducing the pin member rotational speed and shoulder member rotational speed in the next welding process, in case where a first position is the position of the tip end surface of the pin member or the shoulder member is within a first region.Type: GrantFiled: October 22, 2015Date of Patent: February 12, 2019Assignee: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Hideki Okada, Shintaro Fukada
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Publication number: 20170304935Abstract: A friction stir spot welding device includes a pin member, a shoulder member, a rotation driving unit, a tool driving unit, a position detector, and a controller, wherein the controller sets as reference position of the tip end surface of the pin member or shoulder member at a time point when the pin member tip end surface or shoulder member contacts an obverse surface of an object and controls the tool driving unit reducing a pressing force to the object by the pin member and pressing force to the object by the shoulder member in a next welding process, and/or controls the rotation driving unit reducing the pin member rotational speed and shoulder member rotational speed in the next welding process, in case where a first position is the position of the tip end surface of the pin member or the shoulder member is within a first region.Type: ApplicationFiled: October 22, 2015Publication date: October 26, 2017Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHAInventors: Hideki OKADA, Shintaro FUKADA