Patents by Inventor Jun Yaokawa

Jun Yaokawa 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).

  • Publication number: 20220349026
    Abstract: A metal purifying method having: a local heating step of heating an aluminum-based molten metal in a first region on a molten metal surface of the aluminum-based molten metal; and a local low pressure step of lowering the pressure in a second region on the molten metal surface to a pressure lower than the pressure in the first region. The second region is different from the first region. This allows a specific element to be vaporized from the second region to purify the aluminum-based molten metal. The specific element is one or more of Zn, Mg, or Pb having a saturated vapor pressure higher than that of Al. This is effective not only in a purifying method for removing a specific element from an aluminum-based molten metal but also in a method of recovering a specific element, which can be a resource, from an aluminum-based molten metal.
    Type: Application
    Filed: April 14, 2022
    Publication date: November 3, 2022
    Applicants: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO, TOYOTA JIDOSHA KABUSHIKI KAISHA, TOYOTA TSUSHO CORPORATION
    Inventors: Hiroshi KAWAHARA, Jun YAOKAWA, Kazuma HIBI, Hiroyuki MORI, Yasushi IWATA, Takuma MINOURA, Hiroyuki ISHII, Daisuke SAKUMA, Yusei KUSAKA, Akira KANO, Kyosuke ITO, Satoshi NAKANO
  • Publication number: 20220140356
    Abstract: An object provides a power generation apparatus performing the purification of an Al alloy melt using scrap as raw material. A power generation apparatus includes: a container body with aluminum alloy melt and molten salt in a liquid junction with the aluminum alloy melt; an anode which is in contact with the aluminum alloy melt; and a cathode which is in contact with the molten salt. DC power is obtained from between the anode and the cathode by an anode reaction on the aluminum alloy melt side and a cathode reaction on the molten salt side. When the aluminum alloy melt and the molten salt are separated by a separator allowing ionic conduction between the aluminum alloy melt and molten salt, the power generation efficiency is enhanced. The amount of a reactant in the Al alloy melt is monitored by measuring the electrical quantity associated with the power generation.
    Type: Application
    Filed: June 15, 2021
    Publication date: May 5, 2022
    Applicant: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO
    Inventors: Jun YAOKAWA, Kazuma HIBI, Takuma MINOURA, Hiroshi KAWAHARA, Yasushi IWATA
  • Publication number: 20220106673
    Abstract: The present disclosure provides a method for manufacturing an aluminum alloy member capable of suppressing deterioration in ductility thereof. In the method for manufacturing an aluminum alloy member, an aluminum alloy casting material that contains 2.0 to 5.5 mass % of Cu, and 4.0 to 7.0 mass % of Si in which a content of Mg is 0.5 mass % or less, a content of Zn is 1.0 mass % or less, a content of Fe is 1.0 mass % or less, a content of Mn is 0.5 mass % or less and the balance is made of Al and inevitable impurities is used. The method for manufacturing an aluminum alloy member includes a heating and holding step of heating and holding the aluminum alloy casting material within a solid-liquid coexisting temperature region; and a quenching step of rapidly cooling the aluminum alloy casting material after performing the heating and holding step.
    Type: Application
    Filed: December 17, 2021
    Publication date: April 7, 2022
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yusuke YOKOTA, Hirotsune WATANABE, Makoto KIKUCHI, Hiroshi KAWAHARA, Yasushi IWATA, Jun YAOKAWA, Kazuma HIBI
  • Publication number: 20220106666
    Abstract: A recycling method for aluminum alloy is capable of offering a recycled Al alloy (melt), in which the Fe concentration is efficiently reduced, while using Al alloy scrap and the like as raw materials. The method includes: a preparation step of preparing a first melt by melting an Fe.Mn-containing material that contains Fe and Mn and an Al alloy raw material; a crystallization step of holding the first melt at a separation temperature at which an Fe compound crystallizes; and an extraction step of extracting a second melt obtained by removing at least part of the Fe compound crystallized from the first melt. The Fe.Mn-containing material preferably has a mass ratio of Mn to Fe (Mn/Fe) of, for example, 2 or more.
    Type: Application
    Filed: November 25, 2019
    Publication date: April 7, 2022
    Applicants: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO, TOYOTA JIDOSHA KABUSHIKI KAISHA, TOYOTA TSUSHO CORPORATION
    Inventors: Takuma MINOURA, Jun YAOKAWA, Yasushi IWATA, Hiroshi KAWAHARA, Kazuma HIBI, Noriyuki UENO, Akira KANO, Yusei KUSAKA, Kyosuke ITO, Tomoo MURATA
  • Patent number: 11214857
    Abstract: The present disclosure provides a method for manufacturing an aluminum alloy member capable of suppressing deterioration in ductility thereof. In the method for manufacturing an aluminum alloy member, an aluminum alloy casting material that contains 2.0 to 5.5 mass % of Cu, and 4.0 to 7.0 mass % of Si in which a content of Mg is 0.5 mass % or less, a content of Zn is 1.0 mass % or less, a content of Fe is 1.0 mass % or less, a content of Mn is 0.5 mass % or less and the balance is made of Al and inevitable impurities is used. The method for manufacturing an aluminum alloy member includes a heating and holding step of heating and holding the aluminum alloy casting material within a solid-liquid coexisting temperature region; and a quenching step of rapidly cooling the aluminum ally casting material after performing the heating and holding step.
    Type: Grant
    Filed: February 5, 2019
    Date of Patent: January 4, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yusuke Yokota, Hirotsune Watanabe, Makoto Kikuchi, Hiroshi Kawahara, Yasushi Iwata, Jun Yaokawa, Kazuma Hibi
  • Publication number: 20190284669
    Abstract: The present disclosure provides a method for manufacturing an aluminum alloy member capable of suppressing deterioration in ductility thereof. In the method for manufacturing an aluminum alloy member, an aluminum alloy casting material that contains 2.0 to 5.5 mass % of Cu, and 4.0 to 7.0 mass % of Si in which a content of Mg is 0.5 mass % or less, a content of Zn is 1.0 mass % or less, a content of Fe is 1.0 mass % or less, a content of Mn is 0.5 mass % or less and the balance is made of Al and inevitable impurities is used. The method for manufacturing an aluminum alloy member includes a heating and holding step of heating and holding the aluminum alloy casting material within a solid-liquid coexisting temperature region; and a quenching step of rapidly cooling the aluminum ally casting material after performing the heating and holding step.
    Type: Application
    Filed: February 5, 2019
    Publication date: September 19, 2019
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yusuke YOKOTA, Hirotsune WATANABE, Makoto KIKUCHI, Hiroshi KAWAHARA, Yasushi IWATA, Jun YAOKAWA, Kazuma HIBI
  • Patent number: 9713840
    Abstract: A method for manufacturing a pipe with a rib, in which a rib portion formed inside a pipe portion includes bent portions in accordance with bending of the pipe portion or a twisted portion in accordance with twisting of the pipe portion, includes drawing out molten metal held in a furnace by using a starter, from a surface of the molten metal, and drawing up the molten metal through a shape defining member defining a sectional shape of the pipe with the rib to be cast, and cooling and solidifying the molten metal passed through the shape defining member and drawn up. The bent portions are formed by moving at least one of the starter and the shape defining member in a horizontal direction. The twisted portion is formed by rotating at least one of the starter and the shape defining member about an axis extending along a vertical direction.
    Type: Grant
    Filed: February 10, 2016
    Date of Patent: July 25, 2017
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi Furukawa, Tsukasa Kato, Keiichi Morita, Tetsuya Nakajima, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Patent number: 9700935
    Abstract: There are provided a manufacturing method of a casting capable of easily manufacturing a casting having a complex form and of increasing the degree of freedom of form of the casting to be manufactured, a manufacturing device thereof and a casting. At the time of forming a casting by drawing out molten metal from a bath surface of a molten metal bath and solidifying the molten metal which has been drawn out, an outer contour unit configured from a plurality of outer contour defining members for defining the outer contour of a casting is arranged in a region between the bath surface of the molten meth bath and a solid region where the molten metal is solidified and the molten metal which has been drawn out from the bath surface is drawn out through a region determined by the outer contour unit, and the form of the casting is changed by moving at least one of the plurality of outer contour defining members according to the drawing out of the molten metal.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: July 11, 2017
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO
    Inventors: Yu Sasaki, Yuichi Furukawa, Norihiro Amano, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Publication number: 20160361761
    Abstract: A pulling-up-type continuous casting apparatus according to an aspect of the present invention includes a molten-metal holding furnace that holds molten metal, a shape defining member configured to define a cross-sectional shape of a hollowed cast-metal article to be casted as held molten metal drawn from the molten-metal surface passes through the shape defining member, a cooling unit that cools the held molten metal by blowing a cooling gas on an inner peripheral surface of the hollowed cast-metal article near an solidification interface, the drawn molten metal continuously extending to the cast-metal article through the solidification interface, and a blower unit that blows air to a negative pressure area formed in a space between a flow path through which the cooling gas blown from the cooling unit flows and a top surface of the shape defining member.
    Type: Application
    Filed: May 31, 2016
    Publication date: December 15, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Naoaki SUGIURA, Tokiharu FUKUDA, Masahiro KUNO, Jun YAOKAWA, Yasushi IWATA, Yoshio SUGIYAMA
  • Patent number: 9457396
    Abstract: A free casting method according to the present invention includes, a lead-out step for leading out molten metal from a lead-out area (P) provided in a source of supply, e.g. a surface level of the molten metal, to retain the molten metal temporarily by surface films (F) generated on an outer surface, and a forming step for obtaining a formed body by solidifying retained molten metal (MS) led out along a set passage (L1) depending on a desired casting shape, wherein the retained molten metal is solidified after being formed into the desired casting shape by applying an external force thereto at positions between an unrestrained root portion of the retained molten metal in vicinity of the surface level of the molten metal and a solidification interface defined as a boundary between the retained molten metal and the formed body in the forming step.
    Type: Grant
    Filed: March 11, 2015
    Date of Patent: October 4, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama, Hiroaki Iwahori, Norihiro Amano, Noriyuki Ueno, Takehito Kobayashi
  • Patent number: 9433998
    Abstract: A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer.
    Type: Grant
    Filed: January 6, 2014
    Date of Patent: September 6, 2016
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi Furukawa, Jun Yaokawa, Yasushi Iwata
  • Publication number: 20160158832
    Abstract: A method for manufacturing a pipe with a rib, in which a rib portion formed inside a pipe portion includes bent portions in accordance with bending of the pipe portion or a twisted portion in accordance with twisting of the pipe portion, includes drawing out molten metal held in a furnace by using a starter, from a surface of the molten metal, and drawing up the molten metal through a shape defining member defining a sectional shape of the pipe with the rib to be cast, and cooling and solidifying the molten metal passed through the shape defining member and drawn up. The bent portions are formed by moving at least one of the starter and the shape defining member in a horizontal direction. The twisted portion is formed by rotating at least one of the starter and the shape defining member about an axis extending along a vertical direction.
    Type: Application
    Filed: February 10, 2016
    Publication date: June 9, 2016
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi FURUKAWA, Tsukasa KATO, Keiichi MORITA, Tetsuya NAKAJIMA, Jun YAOKAWA, Yasushi IWATA, Yoshio SUGIYAMA
  • Patent number: 9120146
    Abstract: A free casting method according to the present invention includes, a lead-out step for leading out molten metal from a lead-out area provided in a source of supply, e.g. a surface level of the molten metal, to retain the molten metal temporarily by surface films generated on an outer surface, and a forming step for obtaining a formed body by solidifying retained molten metal led out along a set passage depending on a desired casting shape, wherein the retained molten metal is solidified after being formed into the desired casting shape by applying an external force thereto at positions between an unrestrained root portion of the retained molten metal in vicinity of the surface level of the molten metal and a solidification interface defined as a boundary between the retained molten metal and the formed body in the forming step.
    Type: Grant
    Filed: September 12, 2011
    Date of Patent: September 1, 2015
    Assignees: KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO, TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama, Hiroaki Iwahori, Norihiro Amano, Noriyuki Ueno, Takehito Kobayashi
  • Publication number: 20150239038
    Abstract: A free casting method according to the present invention includes, a lead-out step for leading out molten metal from a lead-out area (P) provided in a source of supply, e.g. a surface level of the molten metal, to retain the molten metal temporarily by surface films (F) generated on an outer surface, and a forming step for obtaining a formed body by solidifying retained molten metal (MS) led out along a set passage (L1) depending on a desired casting shape, wherein the retained molten metal is solidified after being formed into the desired casting shape by applying an external force thereto at positions between an unrestrained root portion of the retained molten metal in vicinity of the surface level of the molten metal and a solidification interface defined as a boundary between the retained molten metal and the formed body in the forming step.
    Type: Application
    Filed: March 11, 2015
    Publication date: August 27, 2015
    Inventors: Jun YAOKAWA, Yasushi IWATA, Yoshio SUGIYAMA, Hiroaki IWAHORI, Norihiro AMANO, Noriyuki UENO, Takehito KOBAYASHI
  • Publication number: 20150202681
    Abstract: An up-drawing continuous casting apparatus includes a holding furnace which holds molten metal, a guide-out member which guides the molten metal out from a surface of the molten metal held in the holding furnace, a shape determining member which is arranged to adjoin the surface of the molten metal and allows the molten metal guided out by the guide-out member to pass through the shape determining member to define a shape of a cross section of a casting, a cooling portion which cools the molten metal after the molten metal passes through the shape determining member, and an impact imparting portion which imparts an impact to the guide-out member or the casting.
    Type: Application
    Filed: October 11, 2013
    Publication date: July 23, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi Furukawa, Tsukasa Kato, Keiichi Morita, Tetsuya Nakajima, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Publication number: 20150196952
    Abstract: An up-thawing continuous casting apparatus includes a holding furnace that holds molten metal; a shape determining member that is arranged near a molten metal surface of a casting held in the holding furnace, and that determines a sectional shape of the molten metal by the molten metal passing through the shape determining member; a cooling portion that cools and solidifies the molten metal that has passed through the shape determining member; and a molten metal cooling portion that lowers a temperature of the molten metal held in the holding furnace.
    Type: Application
    Filed: September 13, 2013
    Publication date: July 16, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Tetsuya Nakajima, Yuichi Furukawa, Tsukasa Kato, Keiichi Morita, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Publication number: 20150122451
    Abstract: An up-drawing continuous casting apparatus includes a holding furnace that holds molten metal, a shape determining member that is arranged near a molten metal surface of the molten metal held in the holding furnace, and that determines a sectional shape of a casting by the molten metal passing through the shape determining member, and a cooling portion that cools the molten metal that has passed through the shape determining member. The shape determining member includes, on a main surface on the molten metal surface side, at least one of a protruding portion that protrudes from the main surface, or a recessed portion that is recessed from the main surface.
    Type: Application
    Filed: September 13, 2013
    Publication date: May 7, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Tetsuya Nakajima, Yuichi Furukawa, Tsukasa Kato, Keiichi Morita, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Publication number: 20150071817
    Abstract: There are provided a manufacturing method of a casting capable of easily manufacturing a casting having a complex form and of increasing the degree of freedom of form of the casting to be manufactured, a manufacturing device thereof and a casting. At the time of forming a casting by drawing out molten metal from a bath surface of a molten metal bath and solidifying the molten metal which has been drawn out, an outer contour unit configured from a plurality of outer contour defining members for defining the outer contour of a casting is arranged in a region between the bath surface of the molten meth bath and a solid region where the molten metal is solidified and the molten metal which has been drawn out from the bath surface is drawn out through a region determined by the outer contour unit, and the form of the casting is changed by moving at least one of the plurality of outer contour defining members according to the drawing out of the molten metal.
    Type: Application
    Filed: March 13, 2013
    Publication date: March 12, 2015
    Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO
    Inventors: Yu Sasaki, Yuichi Furukawa, Norihiro Amano, Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama
  • Publication number: 20140120250
    Abstract: A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer.
    Type: Application
    Filed: January 6, 2014
    Publication date: May 1, 2014
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi FURUKAWA, Jun YAOKAWA, Yasushi IWATA
  • Publication number: 20140116567
    Abstract: A pipe with a rib includes a pipe portion, and a rib portion formed inside the pipe portion. The rib portion includes a plurality of bent portions in accordance with bending of the pipe portion.
    Type: Application
    Filed: October 31, 2013
    Publication date: May 1, 2014
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yuichi FURUKAWA, Tsukasa KATO, Keiichi MORITA, Tetsuya NAKAJIMA, Jun YAOKAWA, Yasushi IWATA, Yoshio SUGIYAMA