Patents by Inventor Makoto Setoyama
Makoto Setoyama 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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Patent number: 11534836Abstract: A surface-coated cutting tool includes: a substrate including a rake face and a flank face; a first coating film that coats the rake face; and a second coating film that coats the flank face, wherein the first coating film includes a first composite nitride layer at a region d1 on the rake face, the second coating film includes a second composite nitride layer at a region d2 on the flank face, the first composite nitride layer includes Ti1-x1-y1Alx1Tay1C?1N?1, the second composite nitride layer includes Ti1-x2-y2Alx2Tay2C?2N?2.Type: GrantFiled: January 30, 2019Date of Patent: December 27, 2022Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Kouhei Yoshimura, Haruyo Fukui, Makoto Setoyama, Keizo Tanaka
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Patent number: 11426801Abstract: A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAlN layer, the MAlN layer including crystal grains of MxAl1-xN in the cubic crystal system, nF<nR being satisfied, where nF represents a number of voids per 100 ?m in length of the MAlN layer on the flank face in a cross section of the MAlN layer, and nR represents a number of voids per 100 ?m in length of the MAlN layer on the rake face in a cross section of the MAlN layer, nD being 3 or less, where nD represents a number of droplets per 100 ?m in length of the MAlN layer on the flank face in a cross section of the MAlN layer.Type: GrantFiled: July 16, 2020Date of Patent: August 30, 2022Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Momoko Iida, Makoto Setoyama, Haruyo Fukui
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Publication number: 20220226907Abstract: A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAlN layer, when a cross section of the MAlN layer is subjected to an electron backscattering diffraction image analysis to determine a crystal orientation of each of the crystal grains of the MxAl1?xN and a color map is created based thereon, then on the color map, the flank face having the MAlN layer occupied in area by 45% to 75% by crystal grains of the MxAl1?xN having a (111) plane with a normal thereto extending in a direction within 25 degrees with respect to a direction in which a normal to the flank face extends, the MAlN layer having a residual stress of ?2 GPa to ?0.1 GPa.Type: ApplicationFiled: July 16, 2020Publication date: July 21, 2022Applicant: Sumitomo Electric Hardmetal Corp.Inventors: Makoto SETOYAMA, Momoko IIDA, Haruyo FUKUI
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Patent number: 11370033Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and silicon, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the silicon being larger than 0 and not more than 0.20.Type: GrantFiled: October 30, 2018Date of Patent: June 28, 2022Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo Fukui, Makoto Setoyama, Keizo Tanaka, Kouhei Yoshimura
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Patent number: 11338370Abstract: A cutting tool includes a base material, and a coating film covering the base material in contact with the base material. The base material is a cubic boron nitride sintered material. The coating film is a ceramic. An amount of oxygen in the coating film is less than or equal to 0.040 mass percent.Type: GrantFiled: December 14, 2017Date of Patent: May 24, 2022Assignees: Sumitomo Electric Industries, Ltd., Sumitomo Electric Hardmetal Corp.Inventors: Katsumi Okamura, Satoru Kukino, Makoto Setoyama
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Patent number: 11298748Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and aluminum, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the aluminum being larger than 0.40 and not more than 0.70.Type: GrantFiled: October 16, 2018Date of Patent: April 12, 2022Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo Fukui, Makoto Setoyama, Keizo Tanaka, Kouhei Yoshimura
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Publication number: 20210213539Abstract: A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAIN layer, the MAIN layer including crystal grains of MxAl1-xN in the cubic crystal system, nF<nR being satisfied, where nF represents a number of voids per 100 ?m in length of the MAIN layer on the flank face in a cross section of the MAIN layer, and nR represents a number of voids per 100 ?m in length of the MAIN layer on the rake face in a cross section of the MAIN layer, nD being 3 or less, where nD represents a number of droplets per 100 ?m in length of the MAIN layer on the flank face in a cross section of the MAIN layer.Type: ApplicationFiled: July 16, 2020Publication date: July 15, 2021Applicant: Sumitomo Electric Hardmetal Corp.Inventors: Momoko IIDA, Makoto SETOYAMA, Haruyo FUKUI
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Patent number: 11059105Abstract: Provided is a surface-coated cutting tool including a base material and a coating including a super-multilayer-structure layer where A layers and B layers different from the A layers in composition are alternately laminated. The super-multilayer-structure layer includes an X area and a Y area those are alternately repeated. In the X area, A layers having a thickness AX and B layers having a thickness BX are alternately laminated. In the Y area, A layers having a thickness AY and B layers having a thickness BY are alternately laminated. The thickness AX is larger than the thickness AY, and the thickness BX is smaller than the thickness BY. Each of the A layers and the B layers comprising one or more elements selected from a group consisting of Ti, Al, Cr, Si, Ta, Nb, and W, and one or more elements selected from a group consisting of C and N.Type: GrantFiled: September 20, 2017Date of Patent: July 13, 2021Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Keizo Tanaka, Makoto Setoyama, Yutaka Kobayashi, Akira Kobayashi
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Patent number: 10994339Abstract: A surface-coated cutting tool includes a substrate composed of cemented carbide and a coating film. The coating film includes an intermediate layer in contact with the substrate and an upper layer formed on the intermediate layer. The upper layer is made up of a single layer consisting of an upper base layer which is a layer in contact with the intermediate layer or multiple layers constituted of two or more layers. A mismatch in lattice interplanar spacing in an interface region between the substrate and the intermediate layer is not higher than 65% of a theoretical value of a mismatch in lattice interplanar spacing between the substrate and the upper base layer. A mismatch in lattice interplanar spacing in an interface region between the intermediate layer and the upper base layer is not higher than 65% of the theoretical value of the mismatch in lattice interplanar spacing between the substrate and the upper base layer.Type: GrantFiled: November 22, 2017Date of Patent: May 4, 2021Assignees: Sumitomo Electric Hardmetal Corp., Sumitomo Electric Industries, Ltd.Inventors: Keizo Tanaka, Makoto Setoyama, Haruyo Fukui, Akira Kobayashi, Koji Kuramochi
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Patent number: 10994341Abstract: A surface-coated cutting tool includes a base material and a coating film provided on a surface of the base material, wherein the coating film includes a first alternating layer provided on the base material and a second alternating layer provided on the first alternating layer, the first alternating layer includes A and B layers, the second alternating layer includes C and D layers, each of one or plurality of the A layers is composed of a nitride or carbonitride of AlaCrbM1(1-a-b), each of one or plurality of the B layers is composed of a nitride or carbonitride of AlcTidM2(1-c-d), each of one or plurality of the C layers is composed of a nitride or carbonitride of TieSifM3(1-e-f), and each of one or plurality of the D layers is composed of a nitride or carbonitride of TigSihM4(1-g-h).Type: GrantFiled: March 8, 2019Date of Patent: May 4, 2021Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Hiroki Takeshita, Makoto Setoyama, Haruyo Fukui
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Publication number: 20210069794Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and aluminum, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the aluminum being larger than 0.40 and not more than 0.70.Type: ApplicationFiled: October 16, 2018Publication date: March 11, 2021Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA, Kouhei YOSHIMURA
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Publication number: 20210001410Abstract: A surface-coated cutting tool includes a base material and a coating film provided on a surface of the base material, wherein the coating film includes a first alternating layer provided on the base material and a second alternating layer provided on the first alternating layer, the first alternating layer includes A and B layers, the second alternating layer includes C and D layers, each of one or plurality of the A layers is composed of a nitride or carbonitride of AlaCrbM1(l-a-b), each of one or plurality of the B layers is composed of a nitride or carbonitride of AlcTidM2(l-c-d), each of one or plurality of the C layers is composed of a nitride or carbonitride of TieSifM3(l-e-f), and each of one or plurality of the D layers is composed of a nitride or carbonitride of TigSihM4(l-g-h).Type: ApplicationFiled: March 8, 2019Publication date: January 7, 2021Applicant: Sumitomo Electric Hardmetal Corp.Inventors: Hiroki Takeshita, Makoto Setoyama, Haruyo Fukui
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Publication number: 20200406365Abstract: A cutting tool includes: a substrate; and a coating film formed on the substrate, wherein the coating film includes a first layer formed on the substrate, and a second layer formed on the first layer, the first layer is composed of a boride including zirconium as a component element, and the second layer is composed of a nitride including zirconium as a component element.Type: ApplicationFiled: July 10, 2019Publication date: December 31, 2020Applicants: SUMITOMO ELECTRIC HARDMETAL CORP., SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
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Publication number: 20200406364Abstract: A cutting tool includes: a substrate; and a coating film formed on the substrate, wherein the coating film includes a first layer formed on the substrate, and a second layer formed on the first layer, the first layer is composed of a boride including titanium as a component element, and the second layer is composed of a nitride including zirconium as a component element.Type: ApplicationFiled: July 10, 2019Publication date: December 31, 2020Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
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Publication number: 20200368822Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and silicon, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the silicon being larger than 0 and not more than 0.20.Type: ApplicationFiled: October 30, 2018Publication date: November 26, 2020Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA, Kouhei YOSHIMURA
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Publication number: 20200331071Abstract: A surface-coated cutting tool includes: a substrate including a rake face and a flank face; a first coating film that coats the rake face; and a second coating film that coats the flank face, wherein the first coating film includes a first composite nitride layer at a region d1 on the rake face, the second coating film includes a second composite nitride layer at a region d2 on the flank face, the first composite nitride layer includes Ti1-x1-y1Alx1Tay1C?1N?1, the second composite nitride layer includes Ti1-x2-y2Alx2Tay2C?2N?2.Type: ApplicationFiled: January 30, 2019Publication date: October 22, 2020Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Kouhei YOSHIMURA, Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
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Publication number: 20200055790Abstract: A surface-coated cutting tool including a substrate including a rake face and a flank face and a coating which covers a surface of the substrate is provided. The substrate is made of a cBN sintered material or a ceramic sintered material. The coating includes an alternating layer. The alternating layer is made by alternately stacking a first layer and a second layer different in composition from the first layer. The first layer contains Al, Cr, and N. The second layer contains Ti, Al, and N. A ratio T1/T2 between a thickness Ti of the first layer and a thickness T2 of the second layer is not lower than 0.1 and lower than 1. There are thirty or more interfaces at which the first layer and the second layer are in contact with each other.Type: ApplicationFiled: September 20, 2017Publication date: February 20, 2020Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Makoto Setoyama, Nozomi Tsukihara, Yuki Tsutsumiuchi, Satoru Kukino, Yusuke Matsuda, Hironari Moroguchi
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Publication number: 20190247930Abstract: Provided is a surface-coated cutting tool including a base material and a coating including a super-multilayer-structure layer where A layers and B layers different from the A layers in composition are alternately laminated. The super-multilayer-structure layer includes an X area and a Y area those are alternately repeated. In the X area, A layers having a thickness AX and B layers having a thickness BX are alternately laminated. In the Y area, A layers having a thickness AY and B layers having a thickness BY are alternately laminated. The thickness AX is larger than the thickness AY, and the thickness BX is smaller than the thickness BY. Each of the A layers and the B layers comprising one or more elements selected from a group consisting of Ti, Al, Cr, Si, Ta, Nb, and W, and one or more elements selected from a group consisting of C and N.Type: ApplicationFiled: September 20, 2017Publication date: August 15, 2019Inventors: Keizo Tanaka, Makoto Setoyama, Yutaka Kobayashi, Akira Kobayashi
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Publication number: 20190247927Abstract: A cutting tool includes a base material, and a coating film covering the base material in contact with the base material. The base material is a cubic boron nitride sintered material. The coating film is a ceramic. An amount of oxygen in the coating film is less than or equal to 0.040 mass percent.Type: ApplicationFiled: December 14, 2017Publication date: August 15, 2019Inventors: Katsumi Okamura, Satoru Kukino, Makoto Setoyama
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Publication number: 20190232386Abstract: A cutting tool includes a substrate and a coating film provided on the substrate, wherein the substrate is a cBN sintered material including more than or equal to 30 volume % and less than 80 volume % of cBN and a binder, the coating film includes a compound layer constituted of a composition of Ti1-xAlxC1-aNa, where 0.70?X?0.95 and 0<a?1, and the compound layer has a NaCl type crystal structure in a whole or part of the compound layer.Type: ApplicationFiled: September 1, 2017Publication date: August 1, 2019Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Nozomi Tsukihara, Makoto Setoyama, Anongsack Paseuth