Patents by Inventor Katsumi Nakayama
Katsumi Nakayama 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: 9120147Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.Type: GrantFiled: May 12, 2014Date of Patent: September 1, 2015Assignee: Nucor CorporationInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Patent number: 8875777Abstract: A method of continuously casting steel strip includes steps of providing rails positioned beneath a casting position and extending in opposite directions there from to discharge stations, supporting first and second scrap receptacles movable along the rails, engaging a seal between the first scrap receptacle and an enclosure enabling support of a protective atmosphere beneath a pair of casting rolls, disengaging the seal between the first scrap receptacle and the enclosure and moving the first scrap receptacle along the rails in a direction away from the second scrap receptacle to a discharge station, and moving the second scrap receptacle into the casting position and sealingly engaging the second scrap receptacle and the enclosure.Type: GrantFiled: March 13, 2013Date of Patent: November 4, 2014Assignee: Nucor CorporationInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Publication number: 20140246164Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.Type: ApplicationFiled: May 12, 2014Publication date: September 4, 2014Applicant: NUCOR CORPORATIONInventors: Jay Jon ONDROVIC, Eric FULBRIGHT, Katsumi NAKAYAMA
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Patent number: 8631853Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.Type: GrantFiled: December 2, 2011Date of Patent: January 21, 2014Assignee: Nucor CorporationInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Patent number: 8499820Abstract: An apparatus for casting metal strip includes a pair of counter-rotatable casting rolls having casting surfaces laterally positioned to form a nip therebetween through which cast strip can be cast, and on which a casting pool of molten metal can be formed supported on the casting surfaces above the nip, a pair of molten metal delivery nozzles disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, a pair of side dams adjacent ends of the pair of casting rolls capable of confining the casting pool, a pair of delivery nozzle actuators capable of positioning the delivery nozzles independently of the side dams and a pair of side dam actuators capable of positioning the side dams independently of the delivery nozzles during casting, and a control system capable of controlling desired distance between the delivery nozzles and the side dams.Type: GrantFiled: July 26, 2012Date of Patent: August 6, 2013Assignee: Nucor CorporationInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Publication number: 20130186587Abstract: A method of continuously casting steel strip includes steps of providing rails positioned beneath a casting position and extending in opposite directions there from to discharge stations, supporting first and second scrap receptacles movable along the rails, engaging a seal between the first scrap receptacle and an enclosure enabling support of a protective atmosphere beneath a pair of casting rolls, disengaging the seal between the first scrap receptacle and the enclosure and moving the first scrap receptacle along the rails in a direction away from the second scrap receptacle to a discharge station, and moving the second scrap receptacle into the casting position and sealingly engaging the second scrap receptacle and the enclosure.Type: ApplicationFiled: March 13, 2013Publication date: July 25, 2013Applicant: NUCOR CORPORATIONInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Patent number: 8397794Abstract: Described herein is a twin roll caster including a pair of casting rolls arranged parallel to one another with a gap between the casting rolls and side dams parallel to one another forming a pool between the casting rolls and side dams. A side dam support is provided that applies a compression force on at least one of the side dams at a compression angle relative to the axis of the casting rolls.Type: GrantFiled: April 3, 2012Date of Patent: March 19, 2013Assignee: Castrip, LLCInventors: Katsumi Nakayama, Atsushi Hirata, Kiroyuki Otsuka, Hisahiko Fukase
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Patent number: 8316920Abstract: A metal strip casting apparatus and method of casting metal strip include assembling a pair of counter-rotatable casting rolls positioned laterally forming a nip between for casting, and assembling a pair of brush rolls, each of the brush rolls associated with one of each of the casting rolls. Each brush roll includes at least one spaced apart brush line extending substantially along the axial length of the casting roll. The brush lines may form a spiral, zigzag, wave or crisscross array about the brush roll. The brush roll may include one or more staggered rings with regularly or irregularly spaced apart bristles which form the brush lines. The brush lines may be between 10 to 50 mm apart and separated by between 2 mm to 45 mm of open space. The brush lines may be one line per 10 mm to 90 mm of axial length of brush roll.Type: GrantFiled: November 20, 2009Date of Patent: November 27, 2012Assignee: Nucor CorporationInventors: Hiroyuki Otsuka, Hiroki Yoshizawa, Katsumi Nakayama, Kazuo Miyoshi
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Patent number: 8316681Abstract: A rolling mill, including: a casting device that casts molten metal to form a slab with a predetermined width; a pair of finishing milling rolls that shape the slab by rolling; and a movement device capable of moving the finishing milling rolls along respective axis directions thereof, in which a contour of a peripheral surface of each of the finishing milling rolls has a shape in which a first contour and a second contour are overlapped, the first contour including: edge regions with a shape in accordance with an average value of thickness variation in edge portions so as to make uniform a rolling reduction in a width direction for the slab with an edge thickness equal to the average value; and a central region that is interposed between the edge regions, and the second contour including edge regions which have an inclination angle steeper with respect to the axis direction than a central region so that the distance between facing edge portions of one of the pair of finishing milling rolls and the other of tType: GrantFiled: February 6, 2009Date of Patent: November 27, 2012Assignee: IHI CorporationInventors: Katsumi Nakayama, Hisashi Honjou
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Publication number: 20120285651Abstract: An apparatus for casting metal strip includes a pair of counter-rotatable casting rolls having casting surfaces laterally positioned to form a nip therebetween through which cast strip can be cast, and on which a casting pool of molten metal can be formed supported on the casting surfaces above the nip, a pair of molten metal delivery nozzles disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, a pair of side dams adjacent ends of the pair of casting rolls capable of confining the casting pool, a pair of delivery nozzle actuators capable of positioning the delivery nozzles independently of the side dams and a pair of side dam actuators capable of positioning the side dams independently of the delivery nozzles during casting, and a control system capable of controlling desired distance between the delivery nozzles and the side dams.Type: ApplicationFiled: July 26, 2012Publication date: November 15, 2012Applicant: NUCOR CORPORATIONInventors: Jay Jon ONDROVIC, Eric FULBRIGHT, Katsumi NAKAYAMA
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Publication number: 20120273156Abstract: Described herein is a twin roll caster including a pair of casting rolls arranged parallel to one another with a gap between the casting rolls and side dams parallel to one another forming a pool between the casting rolls and side dams. A side dam support is provided that applies a compression force on at least one of the side dams at a compression angle relative to the axis of the casting rolls.Type: ApplicationFiled: April 3, 2012Publication date: November 1, 2012Applicant: CASTRIP, LLCInventors: Katsumi Nakayama, Atsushi Hirata, Hiroyuki Otsuka, Hisahiko Fukase
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Patent number: 8251127Abstract: An apparatus for casting metal strip includes a pair of counter-rotatable casting rolls having casting surfaces laterally positioned to form a nip therebetween through which cast strip can be cast, and on which a casting pool of molten metal can be formed supported on the casting surfaces above the nip, a pair of molten metal delivery nozzles disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, a pair of side dams adjacent ends of the pair of casting rolls capable of confining the casting pool, a pair of delivery nozzle actuators capable of positioning the delivery nozzles independently of the side dams and a pair of side dam actuators capable of positioning the side dams independently of the delivery nozzles during casting, and a control system capable of controlling desired distance between the delivery nozzles and the side dams.Type: GrantFiled: June 24, 2008Date of Patent: August 28, 2012Assignee: Nucor CorporationInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Publication number: 20120073780Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.Type: ApplicationFiled: December 2, 2011Publication date: March 29, 2012Applicant: NUCOR CORPORATIONInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Patent number: 8113267Abstract: Provided is a twin-roll casting machine capable of suppressing irregularities in crosswise thickness distribution of a strip. The twin-roll casting machine comprises chilled rolls, side weirs, and nozzle pieces. A plurality of openings for supply of molten metal to between the chilled rolls are formed alternately on portions of each of the nozzle pieces adjacent to the one and the other rolls, respectively, and are spaced apart from each other axially of the rolls.Type: GrantFiled: June 18, 2008Date of Patent: February 14, 2012Assignee: IHI CorporationInventors: Hiroyuki Otsuka, Katsumi Nakayama
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Publication number: 20120012273Abstract: An operation to acquire a strip with less thickness even if arcuate worn steps are formed on side weirs is disclosed. During an operation of a twin-roll casting machine with arcuate worn steps developing on side weirs due to rotational sliding contact of chilled rolls, the thickness of a steel strip from a nip is reduced, and the center-to-center distance between the rolls is increased with the side weirs in contact with ends of the rolls being displaced upward. This prevents interference of outer peripheries of the rolls with boundary surfaces adjacent to the arcuate worn steps of the side weirs.Type: ApplicationFiled: September 22, 2011Publication date: January 19, 2012Applicant: IHI CorporationInventors: Hiroyuki OTSUKA, Katsumi Nakayama, Hiroki Yoshizawa
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Patent number: 8087448Abstract: A roll polishing apparatus that can suppress cracks on a strip. The roll polishing apparatus includes brush rolls which face outer periphery of chilled rolls over an axial length of the chilled rolls, respectively, cylinders which urge the brush rolls wholly to the chilled rolls, respectively, and cylinders which deform the brush rolls in conformity to crowns of the chilled rolls, respectively. By these elements, wires of the brush rolls are uniformly contacted on outer peripheries of the chilled rolls to wipe off oxides adhering to the outer peripheries of the chilled rolls.Type: GrantFiled: March 21, 2008Date of Patent: January 3, 2012Assignee: IHI CorporationInventors: Katsumi Nakayama, Hiroyuki Otsuka, Shiro Osada, Hisahiko Fukase
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Publication number: 20110284180Abstract: A casting roll having an outer periphery capable of being efficiently cooled is disclosed. The casting roll has a roll body on which side weirs abut, short tube-shaped supports each coaxially with and protruding from the roll body, a stub axle fitted into the support, a sleeve fitted over the support and a flange contiguous with the stub axle and abutting on the sleeve on a side away from the roll body. The roll body is formed with longitudinal cooling passages passing through the roll from one end to the other end of the roll as well as radial cooling passages each adjacent to a corresponding end of the roll and extending from an inner periphery of the roll to a corresponding longitudinal cooling passage. A plug is fitted into each end of the longitudinal cooling passages and abuts on the sleeve. With a distance between the longitudinal cooling passages and the outer periphery of the roll body being reduced as much as possible, cooling water is passed through a portion of the roll body.Type: ApplicationFiled: August 3, 2011Publication date: November 24, 2011Applicant: IHI CorporationInventors: Katsumi NAKAYAMA, Hiroyuki Otsuka, Hisahiko Fukase
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Patent number: 8051895Abstract: An operation to acquire a strip with less thickness even if arcuate worn steps are formed on side weirs is disclosed. During an operation of a twin-roll casting machine with arcuate worn steps developing on side weirs due to rotational sliding contact of chilled rolls, the thickness of a steel strip from a nip is reduced, and the center-to-center distance between the rolls is increased with the side weirs in contact with ends of the rolls being displaced upward. This prevents interference of outer peripheries of the rolls with boundary surfaces adjacent to the arcuate worn steps of the side weirs.Type: GrantFiled: January 31, 2008Date of Patent: November 8, 2011Assignee: IHI CorporationInventors: Hiroyuki Otsuka, Katsumi Nakayama, Hiroki Yoshizawa
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Patent number: 8006742Abstract: A casting roll having an outer periphery capable of being efficiently cooled is disclosed. The casting roll has a roll body on which side weirs abut, short tube-shaped supports each coaxially with and protruding from the roll body, a stub axle fitted into the support, a sleeve fitted over the support and a flange contiguous with the stub axle and abutting on the sleeve on a side away from the roll body. The roll body is formed with longitudinal cooling passages passing through the roll from one end to the other end of the roll as well as radial cooling passages each adjacent to a corresponding end of the roll and extending from an inner periphery of the roll to a corresponding longitudinal cooling passage. A plug is fitted into each end of the longitudinal cooling passages and abuts on the sleeve. With a distance between the longitudinal cooling passages and the outer periphery of the roll body being reduced as much as possible, cooling water is passed through a portion of the roll body.Type: GrantFiled: February 22, 2008Date of Patent: August 30, 2011Assignee: IHI CorporationInventors: Katsumi Nakayama, Hiroyuki Otsuka, Hisahiko Fukase
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Publication number: 20110119858Abstract: A roll polishing apparatus that can suppress cracks on a strip. The roll polishing apparatus includes brush rolls which face outer periphery of chilled rolls over an axial length of the chilled rolls, respectively, cylinders which urge the brush rolls wholly to the chilled rolls, respectively, and cylinders which deform the brush rolls in conformity to crowns of the chilled rolls, respectively. By these elements, wires of the brush rolls are uniformly contacted on outer peripheries of the chilled rolls to wipe off oxides adhering to the outer peripheries of the chilled rolls.Type: ApplicationFiled: March 21, 2008Publication date: May 26, 2011Applicant: IHI CORPORATIONInventors: Katsumi Nakayama, Hiroyuki Otsuka, Shiro Osada, Hisahiko Fukase