Patents by Inventor Kai Funaki
Kai Funaki 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: 20230391677Abstract: According to an embodiment, a silicon nitride sintered body includes silicon nitride crystal grains and a grain boundary phase. In a case where Raman spectroscopy of a 20 ?m×20 ?m region at any cross section of the silicon nitride sintered body is performed, seven or more peaks are detected within a range of not less than 400 cm?1 and not more than 1200 cm?1, and the most intense peak of the seven or more peaks is not in a range of not less than 515 cm?1 and not more than 525 cm?1. Favorably, at least three of the seven or more peaks exist within a range of not less than 530 cm?1 and not more than 830 cm?1. It is favorable for at least one of the seven or more peaks to be within a range of not less than 440 cm?1 and not more than 460 cm?1.Type: ApplicationFiled: August 17, 2023Publication date: December 7, 2023Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Shoya SANO, Katsuyuki AOKI, Kai FUNAKI, Kazuya OOKUBO
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Patent number: 11813693Abstract: A friction stir welding tool member according to the present embodiment has a shoulder portion and a probe portion concentrically projecting from an upper surface of the shoulder portion. The shoulder portion includes a curved surface processed portion that is curved to have a curved shape on an outer peripheral edge of the shoulder portion. A space occupancy occupied by the two-dimensional space in which neither the shoulder portion nor the probe portion exists is in a range of 30% to 70%, the space occupancy being determined based on a projection drawing of a side surface region surrounded from a tip of the probe portion to the curved surface processed portion of the shoulder portion.Type: GrantFiled: April 14, 2021Date of Patent: November 14, 2023Assignees: OSAKA UNIVERSITY, TOSHIBA MATERIALS CO., LTD.Inventors: Hidetoshi Fujii, Yoshiaki Morisada, Kai Funaki, Masahiro Kato, Takayuki Fukasawa, Yutaka Abe
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Publication number: 20230332644Abstract: A ceramic ball material according to the present embodiment includes a spherical portion, and a band-shaped portion formed over a circumference of a surface of the spherical portion. The band-shaped portion has a width in a range of 0.5 mm or more and 4.0 mm or less, both shoulders of which are provided with an R section having a radius of curvature of 0.02 mm or more. Any one of aluminum oxide, silicon nitride, boron nitride, and zirconium oxide is used as the ceramic.Type: ApplicationFiled: June 23, 2023Publication date: October 19, 2023Inventors: Kai FUNAKI, Shoya SANO
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Publication number: 20230093291Abstract: A silicon nitride sintered body includes a silicon nitride crystal grains and grain boundary phases. Further, when D stands for width of the silicon nitride sintered body before being subjected to surface processing, relations between an average grain diameter dA and an average aspect ratio rA of the silicon nitride crystal grain in a first region from an outermost surface to a depth of 0 to 0.01D and an average grain diameter dB and an average aspect ratio rB of the silicon nitride crystal grain in a second region inside the first region satisfy the inequalities: 0.8? dA/dB? 1.2; and 0.8? rA/rB? 1.2.Type: ApplicationFiled: November 22, 2022Publication date: March 23, 2023Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventor: Kai FUNAKI
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Publication number: 20230080570Abstract: A silicon nitride sintered body includes at least one black portion with a major axis of 10 ?m or more in a field of view with a unit area of 5 mm×5 mm, when observing an arbitrary cross-section of the silicon nitride sintered body using a metallurgical microscope. A major axis of the black portion is Preferably 500 ?m or less. The number of the black portion within the field of view with a unit area of 5 mm×5 mm is preferably 2 or more and 10 or less. A segregation portion of Fe is preferably included in the black portion.Type: ApplicationFiled: November 18, 2022Publication date: March 16, 2023Inventors: Katsuyuki AOKI, Kai FUNAKI, Takayuki FUKASAWA, Shoya SANO
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Patent number: 11130194Abstract: The friction stir welding tool member according to the present invention is made of a ceramic member in which a shoulder portion and a probe portion are integrally formed, wherein a root portion of the probe portion and an end portion of the shoulder portion have a curved surface shape; and the friction stir welding tool member has a ratio (R1/D) of 0.02 or more and 0.20 or less when a curvature radius of the end portion of the shoulder portion is defined as R1 (mm) and an outer diameter of the shoulder portion is defined as D (mm). In addition, the ceramic member is preferably made of a silicon nitride sintered body having a Vickers hardness of 1400 HV1 or more. According to the above-described configuration, a friction stir welding tool member having excellent durability can be provided.Type: GrantFiled: August 4, 2017Date of Patent: September 28, 2021Assignees: OSAKA UNIVERSITY, TOSHIBA MATERIALS CO., LTD.Inventors: Hidetoshi Fujii, Yoshiaki Morisada, Kai Funaki, Isao Ikeda, Yutaka Abe, Masahiro Kato
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Publication number: 20210261467Abstract: The sliding member according to the embodiment includes a silicon nitride sintered body that includes silicon nitride crystal grains and a grain boundary phase, in which a percentage of a number of the silicon nitride crystal grains including dislocation defect portions inside the silicon nitride crystal grains among any 50 of the silicon nitride crystal grains having completely visible contours in a 50 ?m×50 ?m observation region of any cross section or surface of the silicon nitride sintered body is not less than 0% and not more than 10%. The percentage is more preferably not less than 0% and not more than 3%.Type: ApplicationFiled: April 21, 2021Publication date: August 26, 2021Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Kai FUNAKI, Katsuyuki AOKI, Haruhiko YAMAGUTI, Minoru TAKAO, Yutaka ABE
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Patent number: 11097374Abstract: The friction stir welding tool member according to the present invention is made of a silicon nitride sintered body, wherein the silicon nitride sintered body contains 15% by mass or less of additive components except silicon nitride in such a manner that the additive components include at least one element selected from lanthanoid elements and at least one element selected from Mg, Ti, Hf, and Mo. In addition, it is preferable that the additive components further include at least one element selected from Al, Si, and C. According to the above-described configuration, a friction stir welding tool member having an excellent durability can be provided.Type: GrantFiled: August 4, 2017Date of Patent: August 24, 2021Assignees: OSAKA UNIVERSITY, TOSHIBA MATERIALS CO., LTD.Inventors: Hidetoshi Fujii, Yoshiaki Morisada, Kai Funaki, Isao Ikeda, Yutaka Abe, Masahiro Kato
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Patent number: 10787393Abstract: The present invention provides a silicon nitride sintered body including silicon nitride crystal grains and a grain boundary phase, wherein the silicon nitride crystal grains are covered with the grain boundary phase and width of the grain boundary phase is 0.2 nm or more. It is preferable that the width of the grain boundary phase is 0.2 nm to 5 nm. Additionally, it is preferable that the silicon nitride sintered body includes 15% by mass or less of the grain boundary phase. According to the above-described configuration, it is possible to provide a high-temperature-resistant silicon nitride sintered body in which degradation of the grain boundary phase under high temperature environment is suppressed. This silicon nitride sintered body is suitable for constituent material of a high-temperature-resistant member, use environment of which is 300° C. or higher.Type: GrantFiled: March 28, 2016Date of Patent: September 29, 2020Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Isao Ikeda, Kai Funaki, Yutaka Abe
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Patent number: 10744592Abstract: The present invention provides a welding tool member for friction stir welding comprising a silicon nitride sintered body, wherein the silicon nitride sintered body includes an additive component other than silicon nitride in a content of 15% by mass or less, and the additive component includes three or more elements selected from Y, Al, Mg, Si, Ti, Hf, Mo and C. It is preferable that the content of the additive component is 3% by mass or more and 12.5% by mass or less. It is also preferable that the additive component includes four or more elements selected from Y, Al, Mg, Si, Ti, Hf, Mo and C. Due to above structure, there can be provided a welding tool member for friction stir welding having a high durability.Type: GrantFiled: August 28, 2015Date of Patent: August 18, 2020Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Isao Ikeda, Kai Funaki, Yutaka Abe
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Publication number: 20190210149Abstract: The friction stir welding tool member according to the present invention is made of a ceramic member in which a shoulder portion and a probe portion are integrally formed, wherein a root portion of the probe portion and an end portion of the shoulder portion have a curved surface shape; and the friction stir welding tool member has a ratio (R1/D) of 0.02 or more and 0.20 or less when a curvature radius of the end portion of the shoulder portion is defined as R1 (mm) and an outer diameter of the shoulder portion is defined as D (mm). In addition, the ceramic member is preferably made of a silicon nitride sintered body having a Vickers hardness of 1400 HV1 or more. According to the above-described configuration, a friction stir welding tool member having excellent durability can be provided.Type: ApplicationFiled: August 4, 2017Publication date: July 11, 2019Applicants: OSAKA UNIVERSITY, TOSHIBA MATERIALS CO., LTD.Inventors: Hidetoshi FUJII, Yoshiaki MORISADA, Kai FUNAKI, Isao IKEDA, Yutaka ABE, Masahiro KATO
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Publication number: 20190168337Abstract: The friction stir welding tool member according to the present invention is made of a silicon nitride sintered body, wherein the silicon nitride sintered body contains 15% by mass or less of additive components except silicon nitride in such a manner that the additive components include at least one element selected from lanthanoid elements and at least one element selected from Mg, Ti, Hf, and Mo. In addition, it is preferable that the additive components further include at least one element selected from Al, Si, and C. According to the above-described configuration, a friction stir welding tool member having an excellent durability can be provided.Type: ApplicationFiled: August 4, 2017Publication date: June 6, 2019Applicants: OSAKA UNIVERSITY, TOSHIBA MATERIALS CO., LTD.Inventors: Hidetoshi FUJII, Yoshiaki MORISADA, Kai FUNAKI, Isao IKEDA, Yutaka ABE, Masahiro KATO
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Publication number: 20180134626Abstract: The present invention provides a silicon nitride sintered body including silicon nitride crystal grains and a grain boundary phase, wherein the silicon nitride crystal grains are covered with the grain boundary phase and width of the grain boundary phase is 0.2 nm or more. It is preferable that the width of the grain boundary phase is 0.2 nm to 5 nm. Additionally, it is preferable that the silicon nitride sintered body includes 15% by mass or less of the grain boundary phase. According to the above-described configuration, it is possible to provide a high-temperature-resistant silicon nitride sintered body in which degradation of the grain boundary phase under high temperature environment is suppressed. This silicon nitride sintered body is suitable for constituent material of a high-temperature-resistant member, use environment of which is 300° C. or higher.Type: ApplicationFiled: March 28, 2016Publication date: May 17, 2018Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Isao IKEDA, Kai FUNAKI, Yutaka ABE
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Publication number: 20170297141Abstract: The present invention provides a welding tool member for friction stir welding comprising a silicon nitride sintered body, wherein the silicon nitride sintered body includes an additive component other than silicon nitride in a content of 15% by mass or less, and the additive component includes three or more elements selected from Y, Al, Mg, Si, Ti, Hf, Mo and C. It is preferable that the content of the additive component is 3% by mass or more and 12.5% by mass or less. It is also preferable that the additive component includes four or more elements selected from Y, Al, Mg, Si, Ti, Hf, Mo and C. Due to above structure, there can be provided a welding tool member for friction stir welding having a high durability.Type: ApplicationFiled: August 28, 2015Publication date: October 19, 2017Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Isao IKEDA, Kai FUNAKI, Yutaka ABE
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Patent number: 9440887Abstract: The present invention provides a silicon nitride sintered body comprising a silicon nitride crystalline particle and a grain boundary phase, the silicon nitride sintered body having an area ratio of the grain boundary phase per 100 ?m×100 ?m unit area of 15 to 35% when an arbitrary cross section thereof is photographed. Further, it is preferable that the area ratio of the grain boundary phase per 100 ?m×100 ?m unit area is 15 to 25%. Furthermore, the silicon nitride sintered body is suitable for a wear resistant member. Due to above structure, there can be provided a silicon nitride sintered body and a wear resistant member having a high processability (workability) and an excellent sliding property.Type: GrantFiled: October 21, 2013Date of Patent: September 13, 2016Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Kai Funaki, Michiyasu Komatsu, Haruhiko Yamaguti, Katsuyuki Aoki
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Publication number: 20150251957Abstract: The present invention provides a silicon nitride sintered body comprising a silicon nitride crystalline particle and a grain boundary phase, the silicon nitride sintered body having an area ratio of the grain boundary phase per 100 ?m×100 ?m unit area of 15 to 35% when an arbitrary cross section thereof is photographed. Further, it is preferable that the area ratio of the grain boundary phase per 100 ?m×100 ?m unit area is 15 to 25%. Furthermore, the silicon nitride sintered body is suitable for a wear resistant member. Due to above structure, there can be provided a silicon nitride sintered body and a wear resistant member having a high processability (workability) and an excellent sliding property.Type: ApplicationFiled: October 21, 2013Publication date: September 10, 2015Applicants: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.Inventors: Kai Funaki, Michiyasu Komatsu, Haruhiko Yamaguti, Katsuyuki Aoki
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Publication number: 20130157445Abstract: There is provided a polycrystalline aluminum nitride base material having a linear expansion coefficient similar to GaN. The polycrystalline aluminum nitride base material as a substrate material for crystal growth of GaN-base semiconductors has a mean linear expansion coefficient of 4.9×10?6/K to 6.1×10?6/K between 20° C. and 600° C. and 5.5×10?6/K to 6.6×10?6/K between 20° C. and 1100° C.Type: ApplicationFiled: August 3, 2011Publication date: June 20, 2013Inventors: Kimiya Miyashita, Michiyasu Komatsu, Katsuyuki Aoki, Kai Funaki