Patents by Inventor Toshihiko Zenpo
Toshihiko Zenpo 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: 20240042513Abstract: A sand mold-forming additive capable of making a sand mold-forming composition having excellent forming property and a sand mold having excellent moisture resistance is provided. The sand mold-forming additive contains 0.01-2.00 parts by weight of an inorganic alkali metal compound (B) per 100 parts by weight of anionic surfactant (A). The inorganic alkali metal compound (B) is at least one selected from sodium chloride and sodium sulfate. The ionic surfactant (A) is preferably at least one selected from alkyl sulfonic acid metal salts (A1), alkyl sulfuric acid metal salts (A2), and polyoxyalkylene alkyl ether sulfuric acid ester metal salts (A3).Type: ApplicationFiled: February 9, 2022Publication date: February 8, 2024Applicants: SINTOKOGIO, LTD., TAKEMOTO YUSHI KABUSHIKI KAISHAInventors: Yusuke KATO, Toshihiko ZENPO, Tomohiro AOKI, Shumma SATO
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Patent number: 10099278Abstract: A mold-making device may include a stirring device including a stirring tank and at least one stirring blade. The stirring device may further include a packing port that is configured to open and close on a bottom of the stirring tank. The stirring device may stir a particulate aggregate and at least one additive by rotating the at least one stirring blade within the stirring tank to yield an admixture. A forming mold may communicate with the packing port and mold the admixture into a predetermined shape. A packing device may compress a surface of the admixture within the stirring tank and pack the admixture into the forming mold via the packing port.Type: GrantFiled: February 7, 2014Date of Patent: October 16, 2018Assignee: Sintokogio, Ltd.Inventors: Kazumasa Uchida, Masaomi Mitsutake, Hirotsune Watanabe, Takumi Maegawa, Masashi Morikawa, So Nakayama, Tomokazu Suda, Toshihiko Zenpo
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Patent number: 10035181Abstract: To provide an apparatus for reclaiming foundry sand and a method for reclaiming foundry sand that can effectively remove binders and so on that attach to returned foundry sand that has been used. Foundry sand that has been used is supplied from a chute for feeding sand 14A to a rotor 16. The rotor 16 is rotated by a driver 20 so that frictional force is generated on the sand in the rotor 16. Then, the sand in the rotor 16 is dropped into the container for washing with water 30 that is located below the rotor 16. In the container for washing with water 30, an agitator 34 is rotated by the driver 20 so that the sand in the container for washing with water 30 is agitated and washed with water.Type: GrantFiled: April 12, 2013Date of Patent: July 31, 2018Assignee: SINTOKOGIO, LTD.Inventors: Yusuke Kato, Toshihiko Zenpo, Tomohiro Aoki, Takehiko Matsumoto, Takumi Maegawa, Hirotsune Watanabe, Tomokazu Suda, Masaomi Mitsutake, Hisao Nakane
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Patent number: 9962868Abstract: First, a supply device supplies a foamed kneaded material into a cylinder. Then, in a state in which an internal space of the cylinder is communicated with a pattern forming space of a mold, the piston disposed in the cylinder is moved toward the foamed kneaded material side while opening a gas release hole formed piercing through the piston. Then, at a timing when the piston has reached an expected position where the piston is expected to be on contacting the foamed kneaded material supplied into the cylinder, the gas release hole is closed by an open-close plug. Then, the foamed kneaded material supplied into the cylinder is pressed toward the pattern forming space side of the mold by moving the piston toward the foamed kneaded material side.Type: GrantFiled: April 11, 2013Date of Patent: May 8, 2018Assignees: SINTOKOGIO, LTD., TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Yusuke Kato, Toshihiko Zenpo, Toshio Kanno, Hirotsune Watanabe, Tomokazu Suda, Yasutake Nagata, Masaomi Mitsutake, Takumi Maegawa
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Patent number: 9789533Abstract: Sand for a casting mold including sand, a binder, and an inorganic compound particle having poor water solubility and generating a gas, which is at least one of water vapor or carbon dioxide gas, by heat from a molten metal.Type: GrantFiled: November 8, 2013Date of Patent: October 17, 2017Assignees: SINTOKOGIO, LTD., TOYOTA JIDOSHA KABUSHIKI KAISHAInventors: Tomohiro Aoki, Yusuke Kato, Takehiko Matsumoto, Kenichiro Mori, Toshihiko Zenpo, Tomokazu Suda, Masaomi Mitsutake, Takumi Maegawa, So Nakayama, Masashi Morikawa, Hirotsune Watanabe
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Publication number: 20160121388Abstract: Sand for a casting mold including sand, a binder, and an inorganic compound particle having poor water solubility and generating a gas, which is at least one of water vapor or carbon dioxide gas, by heat from a molten metal.Type: ApplicationFiled: November 8, 2013Publication date: May 5, 2016Inventors: Tomohiro AOKI, Yusuke KATO, Takehiko MATSUMOTO, Kenichiro MORI, Toshihiko ZENPO, Tomokazu SUDA, Masaomi MITSUTAKE, Takumi MAEGAWA, So NAKAYAMA, Masashi MORIKAWA, Hirotsune WATANABE
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Patent number: 9314837Abstract: By mixing, stirring and kneading, with water glass (11) as a binder, sand (7), a surfactant (9), and water (10), foamed sand (S) is generated. The foamed sand (S) is packed in a cavity of a metallic mold and solidified to form a sand mold. By using the sand mold, aluminum is cast. By using water glass that is an inorganic binder, during casting, harmful gas and odor are not generated. Further, when a molar ratio n of water glass (Na2O nSiO2 mH2O) is adjusted in the range of 0.65 to 1.30, a quantity of water (H2O) generated by heating water glass with a high temperature melt during casting can be suppressed. Thereby, hydrogen gas (H2) according to a reaction between water (H2O) and aluminum (Al) can be suppressed from being generated and casting quality can be improved.Type: GrantFiled: November 27, 2012Date of Patent: April 19, 2016Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, SINTOKOGIO, LTD.Inventors: Masaomi Mitsutake, Hirotsune Watanabe, Tomokazu Suda, Yusuke Kato, Toshihiko Zenpo
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Publication number: 20160052047Abstract: A mold-making device may include a stirring device including a stirring tank and at least one stirring blade. The stirring device may further include a packing port that is configured to open and close on a bottom of the stirring tank. The stirring device may stir a particulate aggregate and at least one additive by rotating the at least one stirring blade within the stirring tank to yield an admixture. A forming mold may communicate with the packing port and mold the admixture into a predetermined shape. A packing device may compress a surface of the admixture within the stirring tank and pack the admixture into the forming mold via the packing port.Type: ApplicationFiled: February 7, 2014Publication date: February 25, 2016Inventors: Kazumasa Uchida, Massaomi Mitsutake, Hirotsune Watanabe, Takumi Maegawa, Masashi Morikawa, So Nakayama, Tomokazu Suda, Toshihiko Zenpo
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Publication number: 20150197044Abstract: First, a supply device supplies a foamed kneaded material into a cylinder. Then, in a state in which an internal space of the cylinder is communicated with a pattern forming space of a mold, the piston disposed in the cylinder is moved toward the foamed kneaded material side while opening a gas release hole formed piercing through the piston. Then, at a timing when the piston has reached an expected position where the piston is expected to be on contacting the foamed kneaded material supplied into the cylinder, the gas release hole is closed by an open-close plug. Then, the foamed kneaded material supplied into the cylinder is pressed toward the pattern forming space side of the mold by moving the piston toward the foamed kneaded material side.Type: ApplicationFiled: April 11, 2013Publication date: July 16, 2015Inventors: Yusuke Kato, Toshihiko Zenpo, Toshio Kanno, Hirotsune Watanabe, Tomokazu Suda, Yasutake Nagata, Masaomi Mitsutake, Takumi Maegawa
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Publication number: 20150096594Abstract: To provide an apparatus for reclaiming foundry sand and a method for reclaiming foundry sand that can effectively remove binders and so on that attach to returned foundry sand that has been used. Foundry sand that has been used is supplied from a chute for feeding sand 14A to a rotor 16. The rotor 16 is rotated by a driver 20 so that frictional force is generated on the sand in the rotor 16. Then, the sand in the rotor 16 is dropped into the container for washing with water 30 that is located below the rotor 16. In the container for washing with water 30, an agitator 34 is rotated by the driver 20 so that the sand in the container for washing with water 30 is agitated and washed with water.Type: ApplicationFiled: April 12, 2013Publication date: April 9, 2015Inventors: Yusuke Kato, Toshihiko Zenpo, Tomohiro Aoki, Takehiko Matsumoto, Takumi Maegawa, Hirotsune Watanabe, Tomokazu Suda, Masaomi Mitsutake, Hisao Nakane
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Publication number: 20140284015Abstract: By mixing, stirring and kneading, with water glass (11) as a binder, sand (7), a surfactant (9), and water (10), foamed sand (S) is generated. The foamed sand (S) is packed in a cavity of a metallic mold and solidified to form a sand mold. By using the sand mold, aluminum is cast. By using water glass that is an inorganic binder, during casting, harmful gas and odor are not generated. Further, when a molar ratio n of water glass (Na20 nSiO2 mH2O) is adjusted in the range of 0.65 to 1.30, a quantity of water (H2O) generated by heating water glass with a high temperature melt during casting can be suppressed. Thereby, hydrogen gas (H2) according to a reaction between water (H2O) and aluminum (Al) can be suppressed from being generated and casting quality can be improved.Type: ApplicationFiled: November 27, 2012Publication date: September 25, 2014Applicants: TOYOTA JIDOSHA KABUSHIKI KAISHA, SINTOKOGIO, LTD.Inventors: Masaomi Mitsutake, Hirotsune Watanabe, Tomokazu Suda, Yusuke Kato, Toshihiko Zenpo
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Patent number: 8528626Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.Type: GrantFiled: November 2, 2011Date of Patent: September 10, 2013Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 8490677Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.Type: GrantFiled: August 31, 2004Date of Patent: July 23, 2013Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Publication number: 20120048503Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.Type: ApplicationFiled: November 2, 2011Publication date: March 1, 2012Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 8109319Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.Type: GrantFiled: June 29, 2005Date of Patent: February 7, 2012Assignee: Sintokogio, Ltd.Inventors: Norihiro Asano, Toshihiko Zenpo, Masaya Hotta, Kazuyuki Nishikawa
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Patent number: 8034265Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.Type: GrantFiled: January 7, 2009Date of Patent: October 11, 2011Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 8029614Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.Type: GrantFiled: September 2, 2009Date of Patent: October 4, 2011Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 7906049Abstract: A method for filling a foam mixture in a cavity of a metal mold, which can provide a mold without defects.Type: GrantFiled: November 8, 2006Date of Patent: March 15, 2011Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Kazuyuki Nishikawa, Toshio Kanno, Shinji Sonoyama
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Patent number: 7766543Abstract: A method is disclosed that monitors and controls the condition of an expandable mixture before injecting it in a mold and that maintains the conditions for filling so as to make a casting mold having a uniform strength. The method comprises (a) a step of measuring the temperature of the expandable mixture, (b) a step of determining each reference value of the one or more characteristic parameters that show a characteristic property of the expandable mixture based on the measured temperature and the predetermined relationship between a characteristic property of an expandable mixture and its temperature, (c) a step of measuring the one or more characteristic parameters that show the condition of the mixing of the expandable mixture, (d) a step of determining whether each characteristic parameter is within the corresponding reference value, and (e) a step of determining whether the expandable mixture has been made under the normal condition or if it needs to be adjusted.Type: GrantFiled: June 9, 2006Date of Patent: August 3, 2010Assignee: Sintokogio, Ltd.Inventors: Yusuke Kato, Toshihiko Zenpo, Norihiro Asano, Kazuyuki Nishikawa
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Publication number: 20100064935Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.Type: ApplicationFiled: September 2, 2009Publication date: March 18, 2010Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa