Patents by Inventor Katsumi Okamura

Katsumi Okamura 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: 9346716
    Abstract: A tool made of a cubic boron nitride sintered body which has a long life in a stable manner in any application of cutting and plastic working is provided. The tool made of the cubic boron nitride sintered body according to the present invention includes a cubic boron nitride sintered body at least at a tool working point and it is characterized by satisfying an Equation (I) and any one of an Equation (II) and an Equation (III) 20?X?98??(I) Y?0.6×X+3 (where 20?X<88)??(II) Y?5.8×X?455 (where 88?X?98)??(III) where a ratio of cubic boron nitride contained in the cubic boron nitride sintered body is denoted as X volume % and thermal conductivity of the cubic boron nitride sintered body is denoted as Y (W/m·K).
    Type: Grant
    Filed: October 29, 2010
    Date of Patent: May 24, 2016
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Katsumi Okamura, Makoto Setoyama, Satoru Kukino
  • Publication number: 20160136735
    Abstract: A surface-coated boron nitride sintered body tool is provided, in which a cutting edge portion includes a compound sintered body and a coating layer. The compound sintered body includes cBN particles. The compound sintered body includes 45-80 vol % of cBN particles. A first particle size distribution curve of the cBN particles has one or more peaks in a range in which a particle size is 0.1-0.7 ?m. A second particle size distribution curve of the cBN particles has a first peak having a maximum peak height in a range in which the particle size is 2.0-7.0 ?m. An integral value ratio (Io/It×100) is 1-20, in the second particle size distribution curve, the integral value Io being in the range in which the particle size is 0.1-0.7 ?m, and the integral value It being in an entire range.
    Type: Application
    Filed: March 20, 2015
    Publication date: May 19, 2016
    Inventors: Yusuke MATSUDA, Katsumi OKAMURA, Kenta SANO, Nozomi TSUKIHARA, Makoto SETOYAMA
  • Publication number: 20160115087
    Abstract: A surface-coated boron nitride sintered body tool is provided, in which at least a cutting edge portion includes a cubic boron nitride sintered body and a coating film formed on the cubic boron nitride sintered body. The coating film includes an A layer, a B layer and a C layer. The C layer is provided between the A layer and the B layer. The A layer contains Ti and the like. The B layer is formed by alternately stacking a B1 compound layer containing Ti, Si and the like and a B2 compound layer containing Al and the like. The C layer includes McLczc (Mc represents one or more of group 4 elements, group 5 elements and group 6 elements in a periodic table, Al and Si; Lc represents one or more of B, C, N, and O; and zc is 0.05 or more and 0.85 or less).
    Type: Application
    Filed: June 5, 2014
    Publication date: April 28, 2016
    Inventors: Yoshiaki SORAI, Katsumi OKAMURA, Nozomi TSUKIHARA, Makoto SETOYAMA
  • Publication number: 20160114400
    Abstract: A surface-coated boron nitride sintered body tool is provided, in which at least a cutting edge portion includes a cubic boron nitride sintered body and a coating film formed on a surface of the cubic boron nitride sintered body. The coating film contains Si and includes a B layer formed by alternately stacking one or more of each of a B1 compound layer and a B2 compound layer that are different in composition. A ratio between an average thickness t1 of the B1 compound layers and an average thickness t2 of the B2 compound layers is defined as t2/t1 that satisfies a relation of 0.5<t2/t1?10.
    Type: Application
    Filed: June 5, 2014
    Publication date: April 28, 2016
    Inventors: Nozomi Tsukihara, Katsumi Okamura, Makoto Setoyama
  • Patent number: 9308707
    Abstract: A joined product has a cemented carbide sintered compact serving as a first material to be joined and a cBN sintered compact serving as a second material to be joined, wherein: the first material to be joined and the second material to be joined are joined together via a joining material disposed therebetween and containing titanium (Ti); and a titanium nitride (TiN) compound layer having a thickness of 10-300 nm is produced at an interface between the second material to be joined and the joining material.
    Type: Grant
    Filed: November 22, 2011
    Date of Patent: April 12, 2016
    Assignees: Sumitomo Electric Industries, Ltd., Sumitomo Electric Hardmetal Corp., National Institute of Advanced Industrial Science and Technology
    Inventors: Tomoyuki Ishida, Hideki Moriguchi, Takeru Nakashima, Satoru Kukino, Shinichiro Yurugi, Teruhiro Enami, Katsumi Okamura, Yusuke Matsuda, Koji Sano, Keizo Kobayashi, Kimihiro Ozaki
  • Publication number: 20160068449
    Abstract: A cutting tool includes a base material and a coating formed on the base material. The base material is a sintered body containing 30 to 80% by volume of cubic boron nitride, and a binder. The surface in contact with the coating, of the base material, has a plurality of convex portions made of the cubic boron nitride and a plurality of concave portions made of the binder. A surface roughness Rsub of the surface in contact with the base material, is 0.1 to 0.4 ?m. A surface roughness Rsurf of an outermost surface of the coating is 0 to 0.15 ?m. A surface roughness Rasurf of the outermost surface of the coating is 0 to 0.1 ?m. The surface roughness Rsub of the surface in contact with the coating, of the base material, is greater than the surface roughness Rsurf of the outermost surface of the coating.
    Type: Application
    Filed: November 25, 2014
    Publication date: March 10, 2016
    Inventors: Nozomi TSUKIHARA, Makoto SETOYAMA, Katsumi OKAMURA
  • Publication number: 20160052827
    Abstract: Provided is a cubic boron nitride sintered body having good wear resistance and fracture resistance. A method for manufacturing a cubic boron nitride sintered body of the present invention is a method for manufacturing a cubic boron nitride sintered body having a cubic boron nitride particle content of 80% by volume or more and 99% by volume or less. The method includes a first step of preparing cubic boron nitride particles; a second step of coating surfaces of the cubic boron nitride particles with a coating material so as to obtain coated particles; a third step of mixing the coated particles and a binder to obtain a mixture; and a fourth step of sintering the mixture.
    Type: Application
    Filed: March 12, 2014
    Publication date: February 25, 2016
    Inventors: Yusuke MATSUDA, Katsumi OKAMURA, Tsutomu HIRANO, Tomohiro FUKAYA
  • Publication number: 20160047031
    Abstract: In a surface-coated boron nitride sintered body tool, at least a cutting edge portion includes a cubic boron nitride sintered body and a coating layer formed on a surface of the cubic boron nitride sintered body. A layer B of the coating layer is formed by alternately laminating one or more layers of each of two or more thin-film layers having different compositions. A B1 thin-film layer as one of the thin-film layers has a thickness more than 30 nm and less than 200 nm. A B2 thin-film layer as one of the thin-film layers different from the B1 thin-film layer is formed by alternately laminating one or more layers of each of two or more compound layers having different compositions. Each of the compound layers has a thickness not less than 0.5 nm and less than 30 nm.
    Type: Application
    Filed: February 26, 2014
    Publication date: February 18, 2016
    Inventors: Katsumi OKAMURA, Nozomi TSUKIHARA, Makoto SETOYAMA
  • Publication number: 20160039010
    Abstract: In a surface-coated boron nitride sintered body tool, at least a cutting edge portion contains a cubic boron nitride sintered body and a coating layer formed on a surface of the cubic boron nitride sintered body. A layer B of the coating layer is formed by alternately laminating one or more layers of each of two or more compound layers having different compositions. Each of the compound layers has a thickness not less than 0.5 nm and less than 30 nm.
    Type: Application
    Filed: February 26, 2014
    Publication date: February 11, 2016
    Inventors: Makoto SETOYAMA, Katsumi OKAMURA, Nozomi TSUKIHARA
  • Publication number: 20160040279
    Abstract: In a surface-coated boron nitride sintered body tool, at least a cutting edge portion contains a cubic boron nitride sintered body and a coating layer formed on a surface of the cubic boron nitride sintered body. A layer B of the coating layer is formed by alternately laminating one or more layers of each of two or more thin-film layers having different compositions. A B1 thin-film layer as one of the thin-film layers is formed by alternately laminating one or more layers of each of two or more compound layers having different compositions. Each of the compound layers has a thickness not less than 0.5 nm and less than 30 nm. A B2 thin-film layer as one of the thin-film layers different from the B1 thin-film layer has a thickness more than 30 nm and less than 200 nm.
    Type: Application
    Filed: February 26, 2014
    Publication date: February 11, 2016
    Inventors: Makoto SETOYAMA, Katsumi OKAMURA, Nozomi TSUKIHARA
  • Publication number: 20150328691
    Abstract: A composite sintered body according to the present invention contains at least cubic boron nitride and a binder. Cubic boron nitride has a continuous skeleton structure as a result of bonding of a plurality of first cubic boron nitride particles to each other. The binder has a continuous structure as a result of bonding of a plurality of binder particles to each other, that are present in a region except for a bonding interface where the first cubic boron nitride particles are bonded to each other. Second cubic boron nitride particles isolated from the first cubic boron nitride particles forming the skeleton structure are dispersed in the continuous structure of the binder particles.
    Type: Application
    Filed: January 6, 2015
    Publication date: November 19, 2015
    Inventors: Katsumi OKAMURA, Satoru KUKINO, Tomohiro FUKAYA
  • Publication number: 20150291478
    Abstract: A cubic boron nitride sintered body includes cubic boron nitride, a binder, and a metal catalyst element, a content by percentage of the cubic boron nitride is 50 vol % or more and 85 vol % or less, a content by percentage of the catalyst is 0.5 mass % or more and 5 mass % or less. A sum of a detected peak value of nitrogen and a detected peak value of boron at each of arbitrary measurement points on line segments is calculated, a measurement point at which the sum is a half or less of a maximum value among the sums at all measurement points respectively is identified as a binder-portion measurement point, and a ratio of the number of measurement points at which the catalyst element is not detected among the binder-portion measurement points, to a total number of all binder-portion measurement points, is 30% or less.
    Type: Application
    Filed: October 10, 2013
    Publication date: October 15, 2015
    Inventors: Yoshiaki Sorai, Katsumi Okamura, Tomohiro Fukaya
  • Publication number: 20150266100
    Abstract: A cutting tool includes a cutting insert that is held in a holder in a detachable manner. The cutting insert has a substantially regular quadrangular shape in plan view and includes four round corners. The cutting insert is formed of CBN sinter as a whole. The cutting insert includes two principal surfaces that are upper and lower surfaces opposite to each other, and four side surfaces that are arranged so as to connect the principal surfaces to each other. A boundary portion (ridge line portion) between each of the principal surfaces and each of the side surfaces forms a cutting edge. In a central portion of each of the side surfaces of the cutting insert, a groove for absorbing a crack, having a substantially V-shape in cross section, is formed all around the cutting insert so as to be recessed with respect to the side surfaces.
    Type: Application
    Filed: October 9, 2013
    Publication date: September 24, 2015
    Inventors: Katsumi Okamura, Yosuke Korogi, Naoki Watanobe, Nozomi Tsukihara, Hiroki Yonekura
  • Patent number: 9120707
    Abstract: cBN sintered body includes cBN and a binder phase, wherein a content of the cBN is 82-98 volume %, and in a cross section of the cBN sintered body, an isolated binder phase having an area of 0.05-0.5 ?m2 has a protrusion of two or more steps, and assuming that in a first-step protrusion, A1 represents a side length which is perpendicular in a tip direction, and B1 represents a side length which is parallel in the tip direction; and in a second-step protrusion, A2 represents a side length which is perpendicular in the tip direction, and B2 represents a side length which is parallel in the tip direction, an area ratio of an isolated binder phase having a protrusion in which A1/B1 is 1-10 times of A2/B2, to the whole of the binder phase having the area of 0.05-0.5 ?m2, is 25% or more.
    Type: Grant
    Filed: October 18, 2011
    Date of Patent: September 1, 2015
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Yusuke Matsuda, Katsumi Okamura, Satoru Kukino
  • Publication number: 20150239050
    Abstract: An object is to prolong the life of a cubic boron nitride cutting tool used for cutting a heat-resistant alloy. A cubic boron nitride cutting tool includes an edge tip made of a sintered cubic boron nitride compact having a thermal conductivity within the range of 20 to 70 W/m·K and including cubic boron nitride particles having an average particle diameter within the range of 0.5 ?m to 2 ?m; and a base metal that holds the edge tip at a corner portion of the base metal, wherein a cutting edge formed on the edge tip of the tool has a positive rake angle.
    Type: Application
    Filed: March 25, 2014
    Publication date: August 27, 2015
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Tsutomu Hirano, Katsumi Okamura, Naoki Watanobe
  • Publication number: 20150202730
    Abstract: A method for manufacturing a cubic boron nitride cutting tool including a base metal and sintered cubic boron nitride compact at a corner portion of the base metal, capable of improving the accuracy of the center height and reducing the angle of inclination or width of a negative rake face; and the cubic boron nitride cutting tool. The method includes grinding the compact by pressing it against an end face of a grindstone of a grinder to form flank and rake faces on the compact while the base metal of the cutting tool is held by a chuck of the grinder, so that the compact is substantially ground. The rake face is formed to be recessed from a top face of the base metal or only a portion of the compact that protrudes from a base-metal rake face is ground while the tool is continuously held by the chuck.
    Type: Application
    Filed: December 27, 2013
    Publication date: July 23, 2015
    Inventors: Naoki Watanobe, Katsumi Okamura, Hiroki Yonekura, Yosuke Korogi
  • Patent number: 9056437
    Abstract: A surface-coated sintered body includes a sintered body of cubic boron nitride (cBN) and a surface coating layer formed on a surface thereof, the sintered body of cBN containing 20 to 99.5% by volume of cBN and a binder, the surface coating layer including an adhesion layer and at least one hard coating layer, the adhesion layer being a metal layer containing at least W and being formed to cover a portion of the surface of the sintered body of cBN, the hard coating layer being formed to cover the sintered body of cBN and the adhesion layer, a ratio of cBN particles in contact with the adhesion layer to a total number of cBN particles in contact with the adhesion layer or the hard coating layer in the surface of the sintered body of cBN being 0.01 to 20%.
    Type: Grant
    Filed: August 30, 2011
    Date of Patent: June 16, 2015
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Makoto Setoyama, Katsumi Okamura, Nozomi Tsukihara
  • Patent number: 9016987
    Abstract: In a pilot hole of a workpiece made of a difficult-to-cut cast iron, a cutting tool having a leading end to which a cutting insert is attached is inserted to cut the surface of the wall of the pilot hole. At this time, the cutting tool rotates about an axis (?) and also revolves about another axis (?), so that contouring is performed on the workpiece by the tool. The cutting insert is formed of a sintered body having a CBN content of not less than 85% by volume, and the cutting insert has a thermal conductivity of not less than 100 W/(mK).
    Type: Grant
    Filed: October 28, 2010
    Date of Patent: April 28, 2015
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Katsumi Okamura, Satoru Kukino, Tomohiro Fukaya
  • Patent number: 8999023
    Abstract: A composite sintered body according to the present invention contains at least cubic boron nitride and a binder. Cubic boron nitride has a continuous skeleton structure as a result of bonding of a plurality of first cubic boron nitride particles to each other. The binder has a continuous structure as a result of bonding of a plurality of binder particles to each other, that are present in a region except for a bonding interface where the first cubic boron nitride particles are bonded to each other. Second cubic boron nitride particles isolated from the first cubic boron nitride particles forming the skeleton structure are dispersed in the continuous structure of the binder particles.
    Type: Grant
    Filed: May 28, 2007
    Date of Patent: April 7, 2015
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Katsumi Okamura, Satoru Kukino, Tomohiro Fukaya
  • Patent number: 8993132
    Abstract: A cubic boron nitride sintered body tool has, at least at a cutting edge, a cubic boron nitride sintered body composed of a cubic boron nitride particle and a binder phase. The binder phase contains at least Al2O3 and a Zr compound. On any straight line in the sintered body, the mean value of a continuous distance occupied by Al2O3 is 0.1-1.0 ?m, and the standard deviation of the continuous distance occupied by Al2O3 is not more than 0.8. On the straight line, X/Y is 0.1-1 where X represents the number of points of contact between Al2O3 and the Zr compound, and Y represents the sum of the number of points of contact between Al2O3 and cBN and the number of points of contact between Al2O3 and binder phase component(s) other than Al2O3 and the Zr compound.
    Type: Grant
    Filed: July 25, 2011
    Date of Patent: March 31, 2015
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Katsumi Okamura, Machiko Abe, Satoru Kukino