Patents by Inventor Takaaki Ikari
Takaaki Ikari 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: 20210205875Abstract: The casting mold is provided with: the molding wall portion forming the internal space; and the filling ports that open to the molding wall portion and that allow the molten metal to flow into the internal space. In this configuration the channel center lines of the filling ports intersect the surface of the heater at the non-perpendicular contact angle.Type: ApplicationFiled: July 25, 2018Publication date: July 8, 2021Inventors: Naohisa Kamiyama, Toshihiko Kubo, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Patent number: 11052456Abstract: The casting mold is provided with: the molding wall portion forming the internal space; and the filling ports that open to the molding wall portion and that allow the molten metal to flow into the internal space. In this configuration the channel center lines of the filling ports intersect the surface of the heater at the non-perpendicular contact angle.Type: GrantFiled: July 25, 2018Date of Patent: July 6, 2021Assignee: Marelli Cabin Comfort Japan CorporationInventors: Naohisa Kamiyama, Toshihiko Kubo, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Patent number: 10981219Abstract: The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.Type: GrantFiled: July 25, 2018Date of Patent: April 20, 2021Assignee: Marelli Cabin Comfort Japan CorporationInventors: Naohisa Kamiyama, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Patent number: 10967424Abstract: The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.Type: GrantFiled: July 25, 2018Date of Patent: April 6, 2021Assignee: Marelli Cabin Comfort Japan CorporationInventors: Naohisa Kamiyama, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Publication number: 20210094093Abstract: The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.Type: ApplicationFiled: July 25, 2018Publication date: April 1, 2021Inventors: Naohisa Kamiyama, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Publication number: 20200164427Abstract: The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.Type: ApplicationFiled: July 25, 2018Publication date: May 28, 2020Inventors: Naohisa Kamiyama, Tetsuzo Nishimura, Makoto Murakami, Ikuo Kataoka, Shinya Sato, Takaaki Ikari
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Patent number: 9724754Abstract: There are provided a method of manufacturing an aluminum product and a method of manufacturing an aluminum brake caliper each using die casting, for improving flow and run of molten metal during casting and enhancing productivity and quality. In a method of manufacturing an aluminum product provided with opposing portions opposed to each other with a hollow portion interposed in between, and connecting portions connecting the opposing portions at two sides thereof, the method includes a die casting step of performing casting by pouring molten metal of an aluminum alloy from a gate for the molten metal formed in one of the opposing portions via the connecting portions and a bridge connecting the two opposing portions, and a bridge removing step of removing the bridge.Type: GrantFiled: December 4, 2012Date of Patent: August 8, 2017Assignee: NIPPON LIGHT METAL COMPANY, LTD.Inventors: Shinya Sato, Takaaki Ikari
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Publication number: 20140360633Abstract: There are provided a method of manufacturing an aluminum product and a method of manufacturing an aluminum brake caliper each using die casting, for improving flow and run of molten metal during casting and enhancing productivity and quality. In a method of manufacturing an aluminum product provided with opposing portions opposed to each other with a hollow portion interposed in between, and connecting portions connecting the opposing portions at two sides thereof, the method includes a die casting step of performing casting by pouring molten metal of an aluminum alloy from a gate for the molten metal formed in one of the opposing portions via the connecting portions and a bridge connecting the two opposing portions, and a bridge removing step of removing the bridge.Type: ApplicationFiled: December 4, 2012Publication date: December 11, 2014Inventors: Shinya Sato, Takaaki Ikari
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Patent number: 6866085Abstract: The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an ?-Al phase in a surface layer is of average grain size different by 50 ?m or less from an ?-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 ?m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20° C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.Type: GrantFiled: May 13, 2002Date of Patent: March 15, 2005Assignees: Nippon Light Metal Co., Ltd., Denso CorporationInventors: Akio Hashimoto, Takaaki Ikari, Hiromi Takagi, Sumi Yoshikawa
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Patent number: 6648054Abstract: The present invention provides a die-casting method comprising the steps of evacuating a cavity 30 defined by dies of a die-casting machine to provide therein a vacuum of 100 millibar or less during a first period, injecting a reactive gas from a sleeve of the die-casting machine into the cavity 30 during a second period which has a partial overlap period with the first period and follows the overlap period, so as to increase the inner pressure of the cavity to atmospheric pressure or more, pouring a molten aluminum alloy M into the sleeve 40 while keeping the injection of the reactive gas, and subsequently moving a plunger 42 in the sleeve forward to forcibly inject the molten aluminum alloy from the sleeve into the cavity 30 while re-evacuating the cavity 30. The evacuation, reactive-gas injection and re-evacuation operations can be performed with respective overlap periods therebetween.Type: GrantFiled: July 10, 2002Date of Patent: November 18, 2003Assignee: Nippon Light Metal Co., Ltd.Inventors: Yukio Kuramasu, Osamu Yoshida, Yoshihiro Tajima, Takaaki Ikari
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Publication number: 20030143101Abstract: An aluminum alloy for die casting, contains, in terms of mass percentage: Si in the range of 1.0˜3.5 %; Mg in the range of 2.5˜4.5 %; Mn in the range of 0.3˜1.5%; Fe in the range equal to or less than 0.15%; Ti in the range of equal to or less than 0.20%; and the balance of aluminum and inevitable impurities. A die cast product having good strength and elongation in a high strain rate region is produced from the aluminum alloy without the need for solution heat treatment.Type: ApplicationFiled: March 17, 2003Publication date: July 31, 2003Applicant: NISSAN MOTOR CO., LTDInventors: Sanji Kitaoka, Yukio Kuramasu, Syuichi Asakuno, Kenji Tsushima, Masahiko Shioda, Hiroshi Kambe, Shinichiro Sumi, Takaaki Ikari
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Publication number: 20030041993Abstract: The present invention provides a die-casting method comprising the steps of evacuating a cavity 30 defined by dies of a die-casting machine to provide therein a vacuum of 100 millibar or less during a first period, injecting a reactive gas from a sleeve of the die-casting machine into the cavity 30 during a second period which has a partial overlap period with the first period and follows the overlap period, so as to increase the inner pressure of the cavity to atmospheric pressure or more, pouring a molten aluminum alloy M into the sleeve 40 while keeping the injection of the reactive gas, and subsequently moving a plunger 42 in the sleeve forward to forcibly inject the molten aluminum alloy from the sleeve into the cavity 30 while re-evacuating the cavity 30. The evacuation, reactive-gas injection and re-evacuation operations can be performed with respective overlap periods therebetween.Type: ApplicationFiled: July 10, 2002Publication date: March 6, 2003Inventors: Yukio Kuramasu, Osamu Yoshida, Yoshihiro Tajima, Takaaki Ikari
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Publication number: 20030037848Abstract: The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an &agr;-Al phase in a surface layer is of average grain size different by 50 &mgr;m or less from an &agr;-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 &mgr;m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20° C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.Type: ApplicationFiled: May 13, 2002Publication date: February 27, 2003Applicant: Nippon Light Co., Ltd.Inventors: Akio Hashimoto, Takaaki Ikari, Hiromi Takagi, Sumi Yoshikawa
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Publication number: 20020088512Abstract: An aluminum alloy for die casting, contains, in terms of mass percentage: Si in the range of 1.0˜3.5%; Mg in the range of 2.5˜4.5%; Mn in the range of 0.3˜1.5%; Fe in the range equal to or less than 0.15%; Ti in the range of equal to or less than 0.20%; and the balance of aluminum and inevitable impurities. A die cast product having good strength and elongation in a high strain rate region is produced from the aluminum alloy without the need for solution heat treatment.Type: ApplicationFiled: October 22, 2001Publication date: July 11, 2002Applicant: Nissan Motor Company, LtdInventors: Sanji Kitaoka, Yukio Kuramasu, Syuichi Asakuno, Kenji Tsushima, Masahiko Shioda, Hiroshi Kambe, Shinichiro Sumi, Takaaki Ikari
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Publication number: 20010008155Abstract: The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an &agr;-Al phase in a surface layer is of average grain size different by 50 &mgr;m or less from an &agr;-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 &mgr;m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20° C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.Type: ApplicationFiled: January 10, 2001Publication date: July 19, 2001Applicant: NIPPON LIGHT METAL CO., LTDInventors: Akio Hashimoto, Takaaki Ikari, Hiromi Takagi, Sumi Yoshikawa
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Patent number: 6176294Abstract: After a cavity 2 of a die-casting mold 1 is evacuated to exclude gases, oxygen gas is blown into the cavity 2 until an internal pressure of the cavity exceeds the atmospheric pressure, and then a molten metal 5 is forcibly injected into the cavity 2. The cavity 2 is evacuated to a degree of vacuum less than 100 millibar through a suction nozzle 11. The oxygen gas is blown through a nozzle 14 into the cavity 2 so as to fill the cavity 2 with the oxygen gas at an internal pressure higher than the atmospheric pressure. When the molten metal 5 is injected into the cavity 2 clarified in this way, inclusion of gases is perfectly prohibited. As a result, obtained die-cast products are free from defects such as blowholes or porosity caused by inclusion of gases and so useful as functional members as well as structural members.Type: GrantFiled: July 13, 1999Date of Patent: January 23, 2001Assignee: Nippon Light Metal Co., Ltd.Inventors: Yukio Kuramasu, Takaaki Ikari