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1. 发明授权

US07766543B2 Method for controlling an expandable mixture 有权
标题翻译：控制可膨胀混合物的方法
公开(公告)号：US07766543B2
公开(公告)日：2010-08-03
申请号：US11921956
申请日：2006-06-09
申请人： Yusuke Kato , Toshihiko Zenpo , Norihiro Asano , Kazuyuki Nishikawa
发明人： Yusuke Kato , Toshihiko Zenpo , Norihiro Asano , Kazuyuki Nishikawa
IPC分类号： G01K11/00 , G01K11/06 , B29C44/34
CPC分类号： B22C5/14 , B22C5/04 , B22C9/02 , B22C19/04
摘要： 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.
摘要翻译：公开了一种在将可注射的混合物注入模具之前监测和控制可膨胀混合物的状态并保持填充条件以制造具有均匀强度的铸模的方法。该方法包括（a）测量可膨胀混合物的温度的步骤，（b）基于测量的温度确定显示可膨胀混合物的特性的一个或多个特征参数的每个参考值的步骤，以及可膨胀混合物的特性与其温度之间的预定关系，（c）测量显示可膨胀混合物混合条件的一个或多个特性参数的步骤，（d）确定每个特征参数在相应的参考值内，以及（e）确定可膨胀混合物是否在正常条件下制成或者需要调整的步骤。

2. 发明申请

US20070137825A1 Process for producing cast item 审中-公开
标题翻译：铸造件生产流程
公开(公告)号：US20070137825A1
公开(公告)日：2007-06-21
申请号：US10590354
申请日：2005-02-23
申请人： Yusuke Kato , Toshihiko Zenpo , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
发明人： Yusuke Kato , Toshihiko Zenpo , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
IPC分类号： B22C5/18 , B22C1/16 , B22D29/00
CPC分类号： B22C1/10 , B22C1/188 , B22C9/02 , B22C9/10 , B22D29/005
摘要： A casting process that employs a collapse-prone core is disclosed. The process includes the steps of mixing one or more kind of an aggregate granular material, one or more kind of a water-soluble binder, and water, to form a mixture of the aggregate granular material, and stirring the mixture to cause it to foam. Such a mixture prevents the generation of undesirable gases when molding a mold and pouring molten metal into the mold. The process also includes the steps of charging the foamed mixture into a molding space, evaporating the moisture within the charged mixture to harden the charged mixture to mold a mold with the hardened mixture, assembling at least one mold that is cast in the hardened mixture with the mating mold to form a completed mold, pouring molten metal into the completed mold, removing the completed mold from a cast article that is composed of the solidified molten metal during a process of cooling the cast article after the molten metal is solidified, and applying a heat treatment to the cast article.
摘要翻译：公开了一种采用易崩溃的芯的铸造工艺。该方法包括将一种或多种聚集体颗粒材料，一种或多种水溶性粘合剂和水混合以形成聚集体颗粒材料的混合物，并搅拌混合物使其发泡的步骤。这样的混合物防止在模制模具并将熔融金属倒入模具中时产生不需要的气体。该方法还包括以下步骤：将发泡混合物装入模制空间中，蒸发装入的混合物中的水分，使装入的混合物硬化以用硬化的混合物模制模具，将至少一个浇铸在硬化混合物中的模具组装成配合模具以形成完成的模具，将熔融金属浇注到完成的模具中，在熔融金属固化后的冷却铸造工艺的过程中，从由凝固的熔融金属组成的铸造制品中除去完成的模具，并施加对铸造件进行热处理。

3. 发明授权

US07906049B2 Method for filling a foam mixture in a cavity of a metal mold and an apparatus for molding a mold 有权
标题翻译：将泡沫混合物填充在金属模具的空腔中的方法和用于模制模具的装置
公开(公告)号：US07906049B2
公开(公告)日：2011-03-15
申请号：US12096427
申请日：2006-11-08
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Kazuyuki Nishikawa , Toshio Kanno , Shinji Sonoyama
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Kazuyuki Nishikawa , Toshio Kanno , Shinji Sonoyama
IPC分类号： B32B37/00
CPC分类号： B22C5/12 , B22C15/245
摘要： A method for filling a foam mixture in a cavity of a metal mold, which can provide a mold without defects. This method for filling a foam mixture in a cavity of a horizontally-split metal mold by pressurizing a mixture of granular aggregate, water-soluble binders, and water, and injecting the mixture into the cavity of the metal mold includes: a step for preparing the horizontally-split metal mold having a filling port communicating with the cavity, which port is disposed at a side and near abutting surfaces of the horizontally-split metal mold; a step for connecting a discharging port of a device for injecting the foam mixture to the filling port of the horizontally-split metal mold, wherein the device for injecting the foam mixture includes a mixing bath to accommodate and mix the granular aggregate, the water-soluble binders, and the water, and a mechanism for pushing up the mixture in the mixing bath, wherein the mixing bath is cylindrical and has an opening at its upper end, a bottom plate at its lower end, and the discharging port at its side; a step for pushing up the foam mixture in the mixing bath by driving the mechanism for pushing up the mixture; a step for discharging the foam mixture from the discharging port, and for injecting the mixture into the filling port; and a step for filling the cavity with the foam mixture while the mixture pushes out air in the cavity.
摘要翻译：一种用于将泡沫混合物填充在金属模具的空腔中的方法，其可以提供没有缺陷的模具。这种通过对颗粒状聚集体，水溶性粘合剂和水的混合物进行加压以及将混合物注入到金属模具的腔体中来将泡沫混合物填充在水平分割的金属模具的空腔中的方法包括：所述水平分割的金属模具具有与所述空腔连通的填充口，所述端口设置在所述横向分割的金属模具的一侧和邻近表面处; 用于将用于将泡沫混合物注入的装置的排出口连接到水平分割的金属模具的填充口的步骤，其中用于注入泡沫混合物的装置包括用于容纳和混合颗粒状聚集体的混合槽，可溶性粘合剂和水，以及用于在混合槽中推出混合物的机构，其中混合浴是圆柱形的，并且在其上端具有开口，在其下端具有底板，在其下侧具有排出口 ; 通过驱动用于将混合物推起的机构来推动混合槽中的泡沫混合物的步骤; 从排出口排出泡沫混合物并将混合物注入到填充口中的步骤; 以及在混合物推出空腔中的空气的同时用泡沫混合物填充空腔的步骤。

4. 发明申请

US20070196529A1 Apparatus For Molding A Mold And A Metal Used Therefor 有权
标题翻译：用于成型模具和用于其的金属的装置
公开(公告)号：US20070196529A1
公开(公告)日：2007-08-23
申请号：US10593591
申请日：2005-03-22
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa , Motoyasu Tanaka
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa , Motoyasu Tanaka
IPC分类号： B29C44/58 , B29C45/00 , B29C44/60
CPC分类号： B22C19/04 , B22C5/12 , B22C15/245
摘要： This invention relates to an apparatus for molding a mold by pressurizing a foam mixture composed of particles of aggregate, water-soluble binders, and water, and injecting it into a cavity of a heated metal mold. This invention provides an apparatus which can use a foam mixture effectively, can fill the cavity of the metal mold with enough of a foam mixture, and can shorten the time to harden the foam mixture. To achieve these effects, the apparatus for molding a mold is comprised of a hollow rectangular-parallelepiped body 12 having a bottom plate 14, the bottom plate 14 having an injection hole 13 to inject the foam mixture, a means 10 for containing the foam mixture having functions as a mixing bath to mix particles of aggregate, water-soluble binders, and water, and as a pressurized vessel to inject the foam mixture into a metal mold, and a means 22 for closing and opening the injection hole 13. The apparatus is further provided with any means or any combination of means for measuring a temperature of the particles of aggregate or the foam mixture, viscosity of the foam mixture, and moisture of the foam mixture. Further, the means for communicating gases from the cavity of the metal mold to the outside of the mold so that the particles of aggregate cannot pass through it is disposed in the metal mold.
摘要翻译：本发明涉及一种通过对由聚集体，水溶性粘合剂和水的颗粒组成的泡沫混合物进行加压并将其注入加热的金属模的空腔中来模制模具的装置。本发明提供了一种可以有效地使用泡沫混合物的装置，可以用足够的泡沫混合物填充金属模具的空腔，并且可以缩短泡沫混合物硬化的时间。为了实现这些效果，用于模制成型的装置包括具有底板14的中空的长方体12，底板14具有用于注射泡沫混合物的注射孔13，用于容纳泡沫混合物的装置10 具有作为混合槽的功能，以混合骨料，水溶性粘合剂和水的颗粒，以及作为加压容器将泡沫混合物注入金属模具中，以及用于关闭和打开注射孔13的装置22。该装置还具有用于测量聚集体颗粒或泡沫混合物的温度，泡沫混合物的粘度和泡沫混合物的湿度的任何方法或任何组合的装置。此外，用于将气体从金属模具的空腔连通到模具外部的装置，使得聚集体颗粒不能通过它的装置设置在金属模具中。

5. 发明申请

US20060071364A1 Dry aggregate mixture, method of foundry molding using dry aggregate mixture and casting core 审中-公开
标题翻译：干骨料混合物，使用干骨料混合物和铸芯的铸造成型方法
公开(公告)号：US20060071364A1
公开(公告)日：2006-04-06
申请号：US10534032
申请日：2003-03-20
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
IPC分类号： B29C33/40 , B22C1/22
CPC分类号： B22C1/22 , B22C5/12 , B22C9/10 , B22C9/126 , B22C15/23 , B22C15/24
摘要： 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.
摘要翻译：提供了一种干骨料混合物，其中粘合剂甚至在加热时不会产生对人体健康有害的不愉快的气味或气体; 一种铸造成型方法，其中可以令人满意地填充由粘合剂和颗粒状聚集体组成的骨料混合物，其中用于铸造成型的空间至少其一部分，以及铸模成型方法，其中用于模塑由粘合剂和粒状聚集体组成的骨料混合物的模具即使在高湿度下也能保持令人满意的性能。在铸造成型的方法中，通过使用通过提供由颗粒状聚集体，水溶性粘合剂和水构成的骨料混合物而获得的干混合物形成模具，并通过加热，减压或蒸发蒸发聚集体混合物中的水同时进行混合以实现分离成单颗粒，或者向其中加入润滑剂和交联剂。

6. 发明授权

US08490677B2 Method for forming molds and core for casting metal 有权
标题翻译：用于铸造金属的模具和芯的方法
公开(公告)号：US08490677B2
公开(公告)日：2013-07-23
申请号：US10570273
申请日：2004-08-31
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
IPC分类号： B22C1/20 , B22C1/26
CPC分类号： B22C1/20 , B22C1/26 , B22C9/02 , B22C15/08
摘要： 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.
摘要翻译：本发明提供了一种用于在粘合剂加热时形成模具和芯体的方法，该方法不产生对人体有不良影响的气体。特别地，本发明提供了一种用于形成模具和芯的方法，所述方法包括由粒状骨料组成的骨料混合物，其中所述水性粘合剂和水在搅拌下发泡，填充到用于成型模具的空间中，并且用蒸发水分。在一个实施方案中，通过在从成型空间取出之前和之后加入交联剂可以进一步固化模具。此外，提供了用于本发明的模具成型方法的模具用骨料混合物。

7. 发明授权

US08109319B2 Molding process and the resulting mold 有权
标题翻译：成型工艺和所得模具
公开(公告)号：US08109319B2
公开(公告)日：2012-02-07
申请号：US11631115
申请日：2005-06-29
申请人： Norihiro Asano , Toshihiko Zenpo , Masaya Hotta , Kazuyuki Nishikawa
发明人： Norihiro Asano , Toshihiko Zenpo , Masaya Hotta , Kazuyuki Nishikawa
IPC分类号： B22C9/00 , B22C1/22
CPC分类号： B22C9/02 , B22C1/2253 , B22C1/24 , B22C1/26
摘要： 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.
摘要翻译：一种模塑方法，其包括将颗粒聚集体，多种水溶性粘合剂，引起与粘合剂的交联反应的交联剂，酚醛树脂和水混合在一起，搅拌所得混合物以制备鼓泡的流体聚集体混合物，骨料混合物成型成模腔，并通过从混合物中蒸发水来固化骨料混合物，得到由混合物制成的模具。

8. 发明授权

US08029614B2 Dry mixture of an aggregate material, a molding process using the same, and a core mold 失效
标题翻译：骨料的干混合物，使用其的成型方法和芯模
公开(公告)号：US08029614B2
公开(公告)日：2011-10-04
申请号：US12585074
申请日：2009-09-02
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa
IPC分类号： B28B7/36 , C04B35/66 , B22C9/00 , B22C1/02 , B22C1/16 , B22C1/22
CPC分类号： B22C1/22 , B22C5/12 , B22C9/10 , B22C9/126 , B22C15/23 , B22C15/24
摘要： 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.
摘要翻译：提供了一种干骨料混合物，其中粘合剂甚至在加热时不会产生对人体健康有害的不愉快的气味或气体; 一种铸造成型方法，其中可以令人满意地填充由粘合剂和颗粒状聚集体组成的骨料混合物，其中用于铸造成型的空间至少其一部分，以及铸模成型方法，其中用于模塑由粘合剂和粒状聚集体组成的骨料混合物的模具即使在高湿度下也能保持令人满意的性能。在铸造成型的方法中，通过使用通过提供由颗粒状聚集体，水溶性粘合剂和水构成的骨料混合物而获得的干混合物形成模具，并通过加热，减压或蒸发蒸发聚集体混合物中的水同时进行混合以实现分离成单颗粒，或者向其中加入润滑剂和交联剂。

9. 发明授权

US07500840B2 Apparatus for molding a mold and a metal used therefor 有权
标题翻译：用于模制模具和用于其的金属的装置
公开(公告)号：US07500840B2
公开(公告)日：2009-03-10
申请号：US10593591
申请日：2005-03-22
申请人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa , Motoyasu Tanaka
发明人： Toshihiko Zenpo , Yusuke Kato , Norihiro Asano , Masahiko Nagasaka , Kazuyuki Nishikawa , Motoyasu Tanaka
IPC分类号： B29C44/34 , B29C44/58
CPC分类号： B22C19/04 , B22C5/12 , B22C15/245
摘要： An apparatus for molding a mold by pressurizing a foam mixture composed of particles of aggregate, water-soluble binders, and water, and injecting it into a cavity of a heated metal mold that includes a hollow rectangular-parallelepiped body 12 having a bottom plate 14, the bottom plate 14 having an injection hole 13 to inject the foam mixture, a device 10 for containing the foam mixture having functions as a mixing bath to mix particles of aggregate, water-soluble binders, and water, and as a pressurized vessel to inject the foam mixture into the metal mold, and a device 22 for closing and opening the injection hole 13. The apparatus is further provided with a device for measuring a temperature of the particles of aggregate or the foam mixture, the viscosity, and the moisture and a device for communicating gases from the cavity of the metal mold to the outside of the mold so that the particles of aggregate cannot pass through it.
摘要翻译：一种用于通过对由聚集体，水溶性粘合剂和水的颗粒组成的泡沫混合物加压并将其注入加热的金属模具的空腔中来模制模具的装置，所述加热的金属模具包括具有底板14的中空的长方体12 底板14具有用于注入泡沫混合物的注入孔13，用于容纳泡沫混合物的装置10具有作为混合槽的功能，以混合骨料，水溶性粘结剂和水的颗粒，以及作为加压容器，将泡沫混合物注入到金属模具中，以及用于关闭和打开注射孔13的装置22.该装置还设置有用于测量骨料或泡沫混合物颗粒的温度，粘度和水分的装置以及用于将气体从金属模的空腔传递到模具外部的装置，使得聚集体颗粒不能通过。

10. 发明授权

US09314837B2 Method for molding sand mold and sand mold 有权
标题翻译：砂模和砂模成型方法
公开(公告)号：US09314837B2
公开(公告)日：2016-04-19
申请号：US14360577
申请日：2012-11-27
申请人： Masaomi Mitsutake , Hirotsune Watanabe , Tomokazu Suda , Yusuke Kato , Toshihiko Zenpo
发明人： Masaomi Mitsutake , Hirotsune Watanabe , Tomokazu Suda , Yusuke Kato , Toshihiko Zenpo
IPC分类号： B22C1/00 , B22C1/18 , B22C9/02 , B22C7/06
CPC分类号： B22C1/00 , B22C1/188 , B22C7/06 , B22C9/02
摘要： 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.
摘要翻译：通过混合，搅拌和捏合作为粘合剂的水玻璃（11），产生砂（7），表面活性剂（9）和水（10），发泡砂（S）。将发泡砂（S）包装在金属模具的空腔中并固化以形成砂模。通过使用砂模，铸铝。通过使用无机粘合剂的水玻璃，在铸造时不会产生有害气体和气味。此外，当水玻璃（Na 2 O nSiO 2·mH 2 O）的摩尔比n调整在0.65〜1.30的范围内时，可以抑制通过在浇铸时用高温熔体加热水玻璃而产生的水（H 2 O）的量。由此，能够抑制水（H 2 O）与铝（Al）的反应的氢气（H 2）的产生，能够提高铸造品质。

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