Patents by Inventor Eiji Okamoto

Eiji Okamoto 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).

  • Patent number: 11951686
    Abstract: A method for manufacturing a three-dimensional shaped object includes: a plasticizing step of plasticizing at least a part of a shaping material containing a thermoplastic resin to generate a plasticized material; a fiber introducing step including at least one of a step of introducing a covered fiber material, which is a fiber material covered with a covering material, into the plasticized material after being discharged from the nozzle opening, and a step of introducing the covered fiber material into the shaping material or the plasticized material before being discharged from the nozzle opening; and a shaping step of shaping a three-dimensional shaped object including the covered fiber material.
    Type: Grant
    Filed: February 23, 2022
    Date of Patent: April 9, 2024
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11911962
    Abstract: A three-dimensionally shaped article production member is a member used in a three-dimensionally shaped article production apparatus for producing a three-dimensionally shaped article by stacking a layer formed using a composition containing particles. The member is placed on a stage and comes in contact with the layer, and has a portion provided with pores in a contact surface with the layer.
    Type: Grant
    Filed: September 16, 2021
    Date of Patent: February 27, 2024
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Shinichi Nakamura, Koki Hirata
  • Patent number: 11878460
    Abstract: A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.
    Type: Grant
    Filed: December 5, 2022
    Date of Patent: January 23, 2024
    Assignee: Seiko Epson Corporation
    Inventors: Masaya Ishida, Eiji Okamoto, Hiroshi Wada, Toshimitsu Hirai
  • Patent number: 11766827
    Abstract: A three-dimensional shaped object manufacturing device includes a shaping table, layer forming portions configured to form a powder layer on the shaping table, a head 3 configured to discharge, from a nozzle, a liquid containing a binder to a shaping region of a three-dimensional shaped object in the powder layer, and a control unit configured to control a movement of the head with respect to the shaping table and a drive of the head by applying a voltage, in which the control unit performs control to, after the liquid is discharged to the shaping region, execute a flushing operation of discharging the liquid from the nozzle to a flushing position different from the shaping region, and set an applied voltage during the flushing operation higher than an applied voltage when the liquid is discharged to the shaping region.
    Type: Grant
    Filed: June 30, 2020
    Date of Patent: September 26, 2023
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11745418
    Abstract: A method of manufacturing a three-dimensionally formed object includes: forming a layer using a flowable composition including constituent material particles of a three-dimensionally formed object and a flowable composition including support portion-forming particles for forming a support portion which supports the three-dimensionally formed object during the formation of the three-dimensionally formed object; and imparting energy to the constituent material particles and the support portion-forming particles, in which in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a melting point of the constituent material particles and are lower than a melting point of the support portion-forming particles.
    Type: Grant
    Filed: February 2, 2021
    Date of Patent: September 5, 2023
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Masaya Ishida, Toshimitsu Hirai
  • Patent number: 11717984
    Abstract: A manufacturing method for three-dimensional structure has a layer forming step of supplying a flowable composition containing a powder and an organic material to form a unit layer, an organic material removing step of performing a treatment of removing the organic material on the unit layer, and an energy applying step of applying energy to the unit layer after the organic material removing step to form a molten layer or sintered layer, wherein the layer forming step, the organic material removing step, and the energy applying step are repeated with respect to the molten layer or sintered layer in a stacking direction as appropriate.
    Type: Grant
    Filed: December 2, 2020
    Date of Patent: August 8, 2023
    Assignee: Seiko Epson Corporation
    Inventors: Masaya Ishida, Tomoyuki Kamakura, Takeshi Miyashita, Eiji Okamoto
  • Patent number: 11707885
    Abstract: In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a shaping table is moved in a direction separating from the unit after discharging the liquid is ended and before a second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region from the head, and the shaping table is moved in the direction separating from the unit after discharging the liquid to the shaping region is ended and before the first layer forming portion faces the shaping region.
    Type: Grant
    Filed: September 9, 2022
    Date of Patent: July 25, 2023
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11648728
    Abstract: A three-dimensional shaped article producing composition is provided and contains a plurality of particles, a solvent for dispersing the particles, and a binder having a function to temporarily bind the particles to one another in a state where the solvent is removed, wherein a volume-based average particle diameter of the particles is 0.1 ?m or more and less than 50 ?m, and a content ratio of the binder is 1.5 vol % or more and 10 vol % or less.
    Type: Grant
    Filed: January 18, 2018
    Date of Patent: May 16, 2023
    Inventors: Takeshi Miyashita, Eiji Okamoto, Akihiko Tsunoya, Naoko Shima, Makoto Kato
  • Publication number: 20230111896
    Abstract: A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.
    Type: Application
    Filed: December 5, 2022
    Publication date: April 13, 2023
    Inventors: Masaya ISHIDA, Eiji OKAMOTO, Hiroshi WADA, Toshimitsu HIRAI
  • Patent number: 11577470
    Abstract: Provided is a three-dimensional shaping apparatus in which surface of a three-dimensional shaped object can be prevented from being roughened. The three-dimensional shaping apparatus that shapes a three-dimensional shaped object by stacking layers of a material includes: a stage; a discharge unit that has a nozzle surface in which a nozzle hole is formed; a moving unit that is configured to change a relative position between the stage and the nozzle surface; and a control unit that is configured to control the moving unit. The control unit drives the moving unit such that a relation between a gap G between the nozzle surface and the stage or the layer of the material when the material is discharged from the discharge unit and an outer diameter Dp of the nozzle surface satisfies a following relation (1). Dp?20×G+0.
    Type: Grant
    Filed: November 25, 2020
    Date of Patent: February 14, 2023
    Inventors: Manabu Watanabe, Eiji Okamoto, Akihiko Tsunoya, Koji Fujimori, Kazuhide Nakamura
  • Patent number: 11565314
    Abstract: A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.
    Type: Grant
    Filed: September 14, 2020
    Date of Patent: January 31, 2023
    Assignee: Seiko Epson Corporation
    Inventors: Masaya Ishida, Eiji Okamoto, Hiroshi Wada, Toshimitsu Hirai
  • Publication number: 20230001636
    Abstract: In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a shaping table is moved in a direction separating from the unit after discharging the liquid is ended and before a second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region from the head, and the shaping table is moved in the direction separating from the unit after discharging the liquid to the shaping region is ended and before the first layer forming portion faces the shaping region.
    Type: Application
    Filed: September 9, 2022
    Publication date: January 5, 2023
    Inventors: Eiji OKAMOTO, Akihiko TSUNOYA
  • Patent number: 11534826
    Abstract: A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.
    Type: Grant
    Filed: July 24, 2020
    Date of Patent: December 27, 2022
    Inventors: Eiji Okamoto, Ichiro Uechi
  • Patent number: 11534964
    Abstract: Provided is a method which includes a first layer formation step of forming a first layer by using a first composition that contains a constituent material powder, a first powder, and a binder of a three-dimensional shaped article; a second layer formation step of forming a second layer by using a second composition that contains a second powder and a binder; a degreasing step of a stack containing the first layer and the second layer; and a sintering step of the stack, a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer, a decomposition point of the second powder is higher than the decomposition point of the first powder, and a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder.
    Type: Grant
    Filed: November 29, 2018
    Date of Patent: December 27, 2022
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11518107
    Abstract: In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a second layer forming portion is moved in a direction separating from a shaping table before the second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region P from the head, and a first layer forming portion is moved in a direction separating from the shaping table before the first layer forming portion faces the shaping region.
    Type: Grant
    Filed: July 1, 2020
    Date of Patent: December 6, 2022
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11440248
    Abstract: In a three-dimensional shaped object manufacturing device, when a unit is moved in a forward direction, powder is supplied from a first supply portion, a powder layer is formed by a first layer forming portion, a liquid is discharged to a shaping region from a head, and a shaping table is moved in a direction separating from the unit after discharging the liquid is ended and before a second layer forming portion faces the shaping region, and when the unit is moved in a backward direction, the powder is supplied from a second supply portion, the powder layer is formed by the second layer forming portion, the liquid is discharged to the shaping region from the head, and the shaping table is moved in the direction separating from the unit after discharging the liquid to the shaping region is ended and before the first layer forming portion faces the shaping region.
    Type: Grant
    Filed: July 1, 2020
    Date of Patent: September 13, 2022
    Assignee: Seiko Epson Corporation
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Publication number: 20220274316
    Abstract: A method for manufacturing a three-dimensional shaped object according to the present disclosure includes: a plasticizing step of plasticizing at least a part of a shaping material including a first fiber material and a thermoplastic resin to generate a plasticized material to be discharged from a nozzle opening for shaping a three-dimensional shaped object; a fiber introducing step including either a step of introducing a second fiber material longer than the first fiber material into the shaping material or the plasticized material before being discharged from the nozzle opening, or a step of introducing the second fiber material into the plasticized material after being discharged from the nozzle opening; and a shaping step of shaping the three-dimensional shaped object including the first fiber material and the second fiber material.
    Type: Application
    Filed: February 23, 2022
    Publication date: September 1, 2022
    Inventors: Eiji OKAMOTO, Akihiko TSUNOYA
  • Publication number: 20220274342
    Abstract: A method for manufacturing a three-dimensional shaped object is a method for manufacturing a three-dimensional shaped object by laminating a shaping layer. The method includes a selection step of selecting a fiber material corresponding to a thickness of the shaping layer from a plurality of types of fiber materials having different fiber diameters, and a shaping step of forming the shaping layer by discharging a shaping material that includes the fiber material selected in the selection step from a nozzle opening.
    Type: Application
    Filed: February 24, 2022
    Publication date: September 1, 2022
    Inventors: Eiji OKAMOTO, Akihiko TSUNOYA
  • Publication number: 20220274337
    Abstract: A method for manufacturing a three-dimensional shaped object includes: a plasticizing step of plasticizing at least a part of a shaping material containing a thermoplastic resin to generate a plasticized material; a fiber introducing step including at least one of a step of introducing a covered fiber material, which is a fiber material covered with a covering material, into the plasticized material after being discharged from the nozzle opening, and a step of introducing the covered fiber material into the shaping material or the plasticized material before being discharged from the nozzle opening; and a shaping step of shaping a three-dimensional shaped object including the covered fiber material.
    Type: Application
    Filed: February 23, 2022
    Publication date: September 1, 2022
    Inventors: Eiji OKAMOTO, Akihiko TSUNOYA
  • Publication number: 20220274333
    Abstract: A three-dimensional shaping device includes: an ejection head including a nozzle configured to eject a binder containing water, a water-soluble resin, and a wetting agent, an individual liquid chamber communicating with the nozzle, an inflow path configured to flow the binder into the individual liquid chamber, and an outflow path configured to flow the binder out of the individual liquid chamber; and a circulation flow path configured to circulate the binder flowing out of the outflow path to the inflow path.
    Type: Application
    Filed: February 23, 2022
    Publication date: September 1, 2022
    Inventors: Eiji Okamoto, Toshimitsu Hirai, Kaoru Momose, Takayuki Yokoyama