Patents by Inventor Akio Kobayashi

Akio Kobayashi 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).

  • Patent number: 11884996
    Abstract: Provided is an iron-based alloy sintered body having a tensile strength of 800 MPa or more, excellent machinability, a microstructure with an average Vickers hardness of 300 Hv or more and 900 Hv or less and a standard deviation of Vickers hardness of 200 Hv or less, and an average pore circularity of 0.30 or more.
    Type: Grant
    Filed: April 10, 2020
    Date of Patent: January 30, 2024
    Assignee: JFE STEEL CORPORATION
    Inventors: Nao Nasu, Takuya Takashita, Akio Kobayashi
  • Patent number: 11795532
    Abstract: A production method for water-atomized metal powder includes: in a region in which the average temperature of a molten metal stream is higher than the melting point by 100° C. or more, spraying primary cooling water from a plurality of directions at a convergence angle of 10° to 25°, where the convergence angle is an angle between an impact direction on the molten metal stream of the primary cooling water from one direction and an impact direction on the molten metal stream of the primary cooling water from any other direction; and in a region in which 0.0004 seconds or more have passed after an impact of the primary cooling water and the average temperature of metal powder is the melting point or higher and (the melting point+50° C.) or lower, spraying secondary cooling water on the metal powder under conditions of an impact pressure of 10 MPa or more.
    Type: Grant
    Filed: October 10, 2019
    Date of Patent: October 24, 2023
    Assignee: JFE Steel Corporation
    Inventors: Makoto Nakaseko, Shigeru Unami, Akio Kobayashi, Takuya Takashita
  • Publication number: 20230212719
    Abstract: Provided is an Fe-based nanocrystalline alloy powder. The Fe-based nanocrystalline alloy powder has a chemical composition, excluding inevitable impurities, represented by a composition formula of FeaSibBcPdCueMf, where the M in the composition formula is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, C, Al, S, O, and N, 79 at %?a?84.5 at %, 0 at %?b<6 at %, 0 at %<c?10 at %, 4 at %<d?11 at %, 0.2 at %?e?0.53 at %, 0 at %?f?4 at %, a+b+c+d+e+f=100 at %, a degree of crystallinity is more than 10% by volume, and an Fe crystallite diameter of the Fe-based nanocrystalline alloy powder is 50 nm or less.
    Type: Application
    Filed: February 27, 2023
    Publication date: July 6, 2023
    Applicant: JFE STEEL CORPORATION
    Inventors: Naoki YAMAMOTO, Takuya TAKASHITA, Makoto NAKASEKO, Akio KOBAYASHI, Akiri URATA, Miho CHIBA
  • Patent number: 11654487
    Abstract: A production method for water-atomized metal powder includes: in a region in which the average temperature of a molten metal stream having an Fe concentration of 76.0 at % or more and less than 82.9 at % is 100° C. or more higher than the melting point, spraying primary cooling water at a convergence angle of 10° to 25°, where the convergence angle is an angle between an impact direction on the molten metal stream from one direction and an impact direction on the molten metal stream from any other direction; and in a region in which 0.0004 seconds or more have passed after an impact of the primary cooling water and the average temperature of metal powder is the melting point or higher and (the melting point+100° C.) or lower, spraying secondary cooling water on the metal powder under conditions of an impact pressure of 10 MPa or more.
    Type: Grant
    Filed: October 10, 2019
    Date of Patent: May 23, 2023
    Assignee: JFE STEEL CORPORATION
    Inventors: Makoto Nakaseko, Naomichi Nakamura, Akio Kobayashi, Takuya Takashita
  • Patent number: 11600414
    Abstract: Provided is a soft magnetic powder that can produce a dust core having excellent magnetic properties. The soft magnetic powder has a chemical composition, excluding inevitable impurities, represented by a composition formula of FeaSibBcPdCueMf, where the M is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, C, Al, S, O, and N, 79 at %?a?84.5 at %, 0 at %?b<6 at %, 0 at %<c?10 at %, 4 at %<d?11 at %, 0.2 at %?e?0.53 at %, 0 at %?f?4 at %, a+b+c+d+e+f=100 at %, a particle size is 1 mm or less, and a median of circularity of particles constituting the soft magnetic powder is 0.4 or more and 1.0 or less.
    Type: Grant
    Filed: July 25, 2019
    Date of Patent: March 7, 2023
    Assignee: JFE STEEL CORPORATION
    Inventors: Naoki Yamamoto, Takuya Takashita, Makoto Nakaseko, Akio Kobayashi, Akiri Urata, Miho Chiba
  • Patent number: 11542579
    Abstract: The present disclosure relates to an iron-based prealloy powder having excellent strength and processability, and an iron-based alloy powder for powder metallurgy and a sinter-forged member using the same. The iron-based prealloy powder for powder metallurgy according to an embodiment of the present disclosure includes 0.5 to 5.0 wt % of Cu, 0.1 to 0.5 wt % of Mo, and a balance of Fe and other inevitable impurities. A Cu content (Cu %) and a Mo content (Mo %) satisfy the following Relational Equation (1): 0.3×Cu %+3×Mo %?2.7??(1).
    Type: Grant
    Filed: March 26, 2020
    Date of Patent: January 3, 2023
    Assignees: HYUNDAI MOTOR COMPANY, KIA MOTORS CORPORATION, JFE STEEL CORPORATION
    Inventors: Hak Soo Kim, Kohsuke Ashizuka, Akio Kobayashi, Naomichi Nakamura, Masashi Fujinaga, Toshio Maetani, Hirofumi Enokido, Hisashi Sudo
  • Patent number: 11505854
    Abstract: The present disclosure relates to an iron-based prealloy powder having excellent strength and processability, and an iron-based alloy powder for powder metallurgy and a sinter-forged member using the same. The iron-based prealloy powder for powder metallurgy according to an embodiment of the present disclosure includes 0.5 to 5.0 wt % of Cu, 0.1 to 0.5 wt % of Mo, and a balance of Fe and other inevitable impurities. A Cu content (Cu %) and a Mo content (Mo %) satisfy the following Relational Equation (1): 0.3×Cu %+3×Mo %?2.7??(1).
    Type: Grant
    Filed: March 26, 2020
    Date of Patent: November 22, 2022
    Assignees: HYUNDAI MOTOR COMPANY, KIA MOTORS CORPORATION, JFE STEEL CORPORATION
    Inventors: Hak Soo Kim, Kohsuke Ashizuka, Akio Kobayashi, Naomichi Nakamura, Masashi Fujinaga, Toshio Maetani, Hirofumi Enokido, Hisashi Sudo
  • Patent number: 11441212
    Abstract: Provided is alloyed steel powder having excellent fluidity, formability, and compressibility without containing Ni, Cr, or Si. The alloyed steel powder includes iron-based alloy containing Mo, in which Mo content is 0.4 mass % to 1.8 mass %, a weight-based median size D50 is 40 ?m or more, and among particles contained in the alloyed steel powder, those particles having an equivalent circular diameter of 50 ?m to 200 ?m have a number average of solidity of 0.70 to 0.86, the solidity being defined as (particle cross-sectional area/envelope-inside area).
    Type: Grant
    Filed: November 30, 2018
    Date of Patent: September 13, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Takuya Takashita, Akio Kobayashi, Naomichi Nakamura
  • Patent number: 11414731
    Abstract: Disclosed is a mixed powder for powder metallurgy including: (a) an iron-based powder containing Si in an amount of 0 mass % to 0.2 mass % and Mn in an amount of 0 mass % to 0.4 mass %, with the balance being Fe and inevitable impurities; and (b) an alloyed steel powder containing Mo in an amount of 0.3 mass % to 4.5 mass %, Si in an amount of 0 mass % to 0.2 mass %, and Mn in an amount of 0 mass % to 0.4 mass %, with the balance being Fe and inevitable impurities, wherein a ratio of (b) the alloyed steel powder to a total of (a) the iron-based powder and (b) the alloyed steel powder is from 50 mass % to 90 mass %, and a ratio of Mo to the total of (a) the iron-based powder and (b) the alloyed steel powder is 0.20 mass % or more and less than 2.20 mass %.
    Type: Grant
    Filed: January 26, 2018
    Date of Patent: August 16, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Akio Kobayashi, Naomichi Nakamura
  • Publication number: 20220219229
    Abstract: Provided is an iron-based alloy sintered body having a tensile strength of 800 MPa or more, excellent machinability, a microstructure with an average Vickers hardness of 300 Hv or more and 900 Hv or less and a standard deviation of Vickers hardness of 200 Hv or less, and an average pore circularity of 0.30 or more.
    Type: Application
    Filed: April 10, 2020
    Publication date: July 14, 2022
    Applicant: JFE STEEL CORPORATION
    Inventors: Nao NASU, Takuya TAKASHITA, Akio KOBAYASHI
  • Patent number: 11364541
    Abstract: Disclosed is a partially diffusion-alloyed steel powder having excellent fluidity, formability, and compressibility without containing Ni, Cr, and Si. A partially diffusion-alloyed steel powder having excellent fluidity, formability, and compressibility that includes an iron-based powder and Mo diffusionally adhered to a surface of the iron-based powder, in which Mo content is 0.2 mass % to 2.0 mass %, a weight-based median diameter D50 is 40 ?m or more, and among particles contained in the partially diffusion-alloyed steel powder, those particles having an equivalent circular diameter of 50 ?m to 200 ?m have a number average of solidity of 0.70 to 0.86, the solidity being defined as (particle cross-sectional area/envelope-inside area).
    Type: Grant
    Filed: November 30, 2018
    Date of Patent: June 21, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Takuya Takashita, Akio Kobayashi, Naomichi Nakamura
  • Publication number: 20220161321
    Abstract: Provided is a steel strip joining method that can appropriately evaluate risk of a fracture in a joined part and prevent a fracture more reliably. An iron-based mixed powder for powder metallurgy comprises: an iron-based alloy powder; and an alloying powder, wherein the iron-based alloy powder contains Mo: 0.2 mass % or more and 1.5 mass % or less, the alloying powder contains a graphite powder and a copper powder, a ratio of a mass of the graphite powder to a total mass of the iron-based alloy powder and the alloying powder is 0.10 mass % to 1.0 mass %, a ratio of a mass of the copper powder to the total mass of the iron-based alloy powder and the alloying powder is 0.5 mass % to 3.0 mass %, and the copper powder has an average particle size of 25 ?m or less, and a specific surface area of 0.30 m2/g or more.
    Type: Application
    Filed: February 10, 2020
    Publication date: May 26, 2022
    Applicant: JFE STEEL CORPORATION
    Inventors: Takuya TAKASHITA, Nao NASU, Akio KOBAYASHI
  • Publication number: 20220044859
    Abstract: Provided is an iron-based powder for dust cores that has high apparent density and enables producing dust cores having high green density. An iron-based powder for dust cores comprises a maximum particle size of 1 mm or less, wherein a median circularity of particles constituting the iron-based powder for dust cores is 0.40 or more, and a uniformity number in Rosin-Rammler equation is 0.30 or more and 90.0 or less.
    Type: Application
    Filed: February 10, 2020
    Publication date: February 10, 2022
    Applicant: JFE STEEL CORPORATION
    Inventors: Naoki YAMAMOTO, Takuya TAKASHITA, Makoto NAKASEKO, Akio KOBAYASHI, Shigeru UNAMI
  • Patent number: 11236411
    Abstract: Disclosed is an alloyed steel powder for powder metallurgy from which sintered parts that do not contain expensive Ni, or Cr or Mn susceptible to oxidation, that have excellent compressibility, and that have high strength in an as-sintered state can be obtained. The alloyed steel powder for powder metallurgy has: a chemical composition containing Mo: 0.5 mass % to 2.0 mass % and Cu: 1.0 mass % to 8.0 mass %, with the balance being Fe and inevitable impurities; and a microstructure in which an FCC phase is present at a volume fraction of 0.5% to 10.0%.
    Type: Grant
    Filed: March 22, 2019
    Date of Patent: February 1, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Nao Nasu, Takuya Takashita, Akio Kobayashi
  • Publication number: 20210379658
    Abstract: A production method for water-atomized metal powder includes: in a region in which the average temperature of a molten metal stream is higher than the melting point by 100° C. or more, spraying primary cooling water from a plurality of directions at a convergence angle of 10° to 25°, where the convergence angle is an angle between an impact direction on the molten metal stream of the primary cooling water from one direction and an impact direction on the molten metal stream of the primary cooling water from any other direction; and in a region in which 0.0004 seconds or more have passed after an impact of the primary cooling water and the average temperature of metal powder is the melting point or higher and (the melting point+50° C.) or lower, spraying secondary cooling water on the metal powder under conditions of an impact pressure of 10 MPa or more.
    Type: Application
    Filed: October 10, 2019
    Publication date: December 9, 2021
    Applicant: JFE Steel Corporation
    Inventors: Makoto Nakaseko, Shigeru Unami, Akio Kobayashi, Takuya Takashita
  • Publication number: 20210379657
    Abstract: A production method for water-atomized metal powder includes: in a region in which the average temperature of a molten metal stream having an Fe concentration of 76.0 at % or more and less than 82.9 at % is 100° C. or more higher than the melting point, spraying primary cooling water at a convergence angle of 10° to 25°, where the convergence angle is an angle between an impact direction on the molten metal stream from one direction and an impact direction on the molten metal stream from any other direction; and in a region in which 0.0004 seconds or more have passed after an impact of the primary cooling water and the average temperature of metal powder is the melting point or higher and (the melting point+100° C.) or lower, spraying secondary cooling water on the metal powder under conditions of an impact pressure of 10 MPa or more.
    Type: Application
    Filed: October 10, 2019
    Publication date: December 9, 2021
    Applicant: JFE Steel Corporation
    Inventors: Makoto Nakaseko, Naomichi Nakamura, Akio Kobayashi, Takuya Takashita
  • Publication number: 20210310656
    Abstract: A heater of the disclosure includes: a rod-like ceramic body; a heat-generating resistor including an embedded portion embedded in the ceramic body and an exposed portion drawn out to an outer periphery face of the ceramic body; a metallic member electrically connected to the heat-generating resistor; and a conductive joining member including titanium, the conductive joining member being configured to join the exposed portion and the metallic member together. The conductive joining member includes a first portion in layer form, in which titanium exists in segregation condition, located along an interface with the exposed portion; and at least one second portion in granular form, in which titanium exists in segregation condition, located away from the first portion.
    Type: Application
    Filed: September 27, 2019
    Publication date: October 7, 2021
    Applicant: KYOCERA Corporation
    Inventor: Akio KOBAYASHI
  • Publication number: 20210313101
    Abstract: Provided is a soft magnetic powder that can produce a dust core having excellent magnetic properties. The soft magnetic powder has a chemical composition, excluding inevitable impurities, represented by a composition formula of FeaSibBcPdCueMf, where the M is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, C, Al, S, O, and N, 79 at %?a?84.5 at %, 0 at %?b<6 at %, 0 at %<c?10 at %, 4 at %<d?11 at %, 0.2 at %?e?0.53 at %, 0 at %?f?4 at %, a+b+c+d+e+f=100 at %, a particle size is 1 mm or less, and a median of circularity of particles constituting the soft magnetic powder is 0.4 or more and 1.0 or less.
    Type: Application
    Filed: July 25, 2019
    Publication date: October 7, 2021
    Applicant: JFE STEEL CORPORATION
    Inventors: Naoki YAMAMOTO, Takuya TAKASHITA, Makoto NAKASEKO, Akio KOBAYASHI, Akiri URATA, Miho CHIBA
  • Publication number: 20210180164
    Abstract: Provided is alloyed steel powder having excellent fluidity, formability, and compressibility without containing Ni, Cr, or Si. The alloyed steel powder includes iron-based alloy containing Mo, in which Mo content is 0.4 mass % to 1.8 mass %, a weight-based median size D50 is 40 ?m or more, and among particles contained in the alloyed steel powder, those particles having an equivalent circular diameter of 50 ?m to 200 ?m have a number average of solidity of 0.70 to 0.86, the solidity being defined as (particle cross-sectional area/envelope-inside area).
    Type: Application
    Filed: November 30, 2018
    Publication date: June 17, 2021
    Applicant: JFE STEEL CORPORATION
    Inventors: Takuya TAKASHITA, Akio KOBAYASHI, Naomichi NAKAMURA
  • Publication number: 20210138547
    Abstract: Disclosed is a partially diffusion-alloyed steel powder having excellent fluidity, formability, and compressibility without containing Ni, Cr, and Si. A partially diffusion-alloyed steel powder having excellent fluidity, formability, and compressibility that includes an iron-based powder and Mo diffusionally adhered to a surface of the iron-based powder, in which Mo content is 0.2 mass % to 2.0 mass %, a weight-based median diameter D50 is 40 ?m or more, and among particles contained in the partially diffusion-alloyed steel powder, those particles having an equivalent circular diameter of 50 ?m to 200 ?m have a number average of solidity of 0.70 to 0.86, the solidity being defined as (particle cross-sectional area/envelope-inside area).
    Type: Application
    Filed: November 30, 2018
    Publication date: May 13, 2021
    Applicant: JFE STEEL CORPORATION
    Inventors: Takuya TAKASHITA, Akio KOBAYASHI, Naomichi NAKAMURA