Patents by Inventor Kenji KUMAI

Kenji KUMAI 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: 12343802
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. An average distance between the plurality of first protrusions is 70-120 nm. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Grant
    Filed: July 28, 2020
    Date of Patent: July 1, 2025
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Hirotoshi Ito, Kenji Kumai, Takanori Sugiyama, Tadashi Katsuma
  • Patent number: 12318845
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. At least one of the plurality of first protrusions is a composite protrusion including second protrusions protruding in a direction intersecting with a protruding direction of the first protrusions. An average number of the second protrusions in the composite protrusion is 1.4 or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Grant
    Filed: July 28, 2020
    Date of Patent: June 3, 2025
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Hirotoshi Ito, Kenji Kumai, Takanori Sugiyama, Tadashi Katsuma
  • Patent number: 12246385
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. At least one of the plurality of first protrusions is a composite protrusion including second protrusions protruding in a direction intersecting with a protruding direction of the first protrusions. A percentage of the composite protrusions in the plurality of first protrusions is 30% or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Grant
    Filed: July 28, 2020
    Date of Patent: March 11, 2025
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Hirotoshi Ito, Kenji Kumai, Takanori Sugiyama, Tadashi Katsuma
  • Patent number: 12194543
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes a TiCN layer, an intermediate layer including Ti, and an Al2O3 layer in this order from a side of the base. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. An average area of the plurality of first protrusions is 1700 nm2 or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Grant
    Filed: July 28, 2020
    Date of Patent: January 14, 2025
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Hirotoshi Ito, Kenji Kumai, Takanori Sugiyama, Tadashi Katsuma
  • Patent number: 12103089
    Abstract: A coated tool includes a base and a coating layer on the base. The coating layer includes a first layer including Al2O3 particles, and a second layer on the first layer. The second layer includes, sequentially from the base, a first film, a second film in contact with the first film, and a third film in contact with the second film. The first to third films individually include Ti. The first film, the second film and the third film individually include at least one kind selected from C and N. The coated tool satisfies a relationship of a first N content>a third N content>a second N content, in which the first N content is an N content in the first film, the second N content is an N content in the second film, and the third N content is an N content in the third film.
    Type: Grant
    Filed: March 24, 2021
    Date of Patent: October 1, 2024
    Assignee: KYOCERA CORPORATION
    Inventors: Yuusaku Sugawa, Hayato Kubo, Kenji Kumai, Hiroyuki Kinjo
  • Patent number: 11969801
    Abstract: A coated tool in a non-limiting embodiment of the present disclosure includes a base and a coating layer located on the base. The coated tool includes a first surface, a second surface adjacent to the first surface, and a cutting edge located on at least a part of a ridge part of the first surface and the second surface. The coating layer includes a Ti-based coating layer. If a fracture toughness value of the Ti-based coating layer is measured on a surface of the coating layer parallel to a surface of the base, the Ti-based coating layer includes a first region where the fracture toughness value is 10 MPa·m0.5 or more.
    Type: Grant
    Filed: June 23, 2021
    Date of Patent: April 30, 2024
    Assignee: KYOCERA CORPORATION
    Inventor: Kenji Kumai
  • Publication number: 20230234142
    Abstract: A coated tool in a non-limiting embodiment of the present disclosure includes a base and a coating layer located on the base. The coated tool includes a first surface, a second surface adjacent to the first surface, and a cutting edge located on at least a part of a ridge part of the first surface and the second surface. The coating layer includes a Ti-based coating layer. If a fracture toughness value of the Ti-based coating layer is measured on a surface of the coating layer parallel to a surface of the base, the Ti-based coating layer includes a first region where the fracture toughness value is 10 MPa·m0.5 or more.
    Type: Application
    Filed: June 23, 2021
    Publication date: July 27, 2023
    Inventor: Kenji KUMAI
  • Publication number: 20230219144
    Abstract: A coated tool in a non-limiting embodiment of the present disclosure includes a base and a coating layer located on the base. The coated tool includes a first surface, a second surface adjacent to the first surface, and a cutting edge located on at least a part of a ridge part of the first surface and the second surface. The coating layer includes an Al2O3 layer. If a fracture toughness value of the Al2O3 layer is measured on a surface of the coating layer parallel to a surface of the base, the Al2O3 layer includes a first region where the fracture toughness value is 5 MPa·m0.5 or more.
    Type: Application
    Filed: June 23, 2021
    Publication date: July 13, 2023
    Inventor: Kenji KUMAI
  • Publication number: 20230126815
    Abstract: A coated tool includes a base and a coating layer on the base. The coating layer includes a first layer including Al2O3 particles, and a second layer on the first layer. The second layer includes, sequentially from the base, a first film, a second film in contact with the first film, and a third film in contact with the second film. The first to third films individually include Ti. The first film, the second film and the third film individually include at least one kind selected from C and N. The coated tool satisfies a relationship of a first N content>a third N content>a second N content, in which the first N content is an N content in the first film, the second N content is an N content in the second film, and the third N content is an N content in the third film.
    Type: Application
    Filed: March 24, 2021
    Publication date: April 27, 2023
    Inventors: Yuusaku SUGAWA, Hayato KUBO, Kenji KUMAI, Hiroyuki KINJO
  • Patent number: 11541468
    Abstract: A coated tool of the present disclosure is provided with a base member and a coating layer located on a surface of the base member. The coating layer includes a TiCNO layer and an Al2O3 layer. The Al2O3 layer is located in contact with the TiCNO layer at a position farther from the base member than the TiCNO layer is. The TiCNO layer includes a plurality of first protrusions that project toward the Al2O3 layer, and a beam that extends in a direction intersecting a direction in which the first protrusions project, to connect the first protrusions. A cutting tool of the present disclosure is provided with: a holder extending from a first end toward a second end and including a pocket on a side of the first end; and the above-described coated tool located in the pocket.
    Type: Grant
    Filed: January 28, 2019
    Date of Patent: January 3, 2023
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Yoshikazu Kodama, Kenji Kumai, Takanori Sugiyama, Hirotoshi Itoh
  • Patent number: 11534835
    Abstract: A coated tool of the present disclosure is provided with a base member and a coating layer located on a surface of the base member. The coating layer includes a TiCNO layer and an Al2O3 layer. The Al2O3 layer is located in contact with the TiCNO layer at a position farther from the base member than the TiCNO layer is. The TiCNO layer includes a first composite protrusion including a first protrusion that projects toward the Al2O3 layer and a second protrusion that projects from the first protrusion in a direction intersecting a direction in which the first protrusion projects. A cutting tool of the present disclosure is provided with: a holder extending from a first end toward a second end and including a pocket on a side of the first end; and the above-described coated tool located in the pocket.
    Type: Grant
    Filed: January 28, 2019
    Date of Patent: December 27, 2022
    Assignee: KYOCERA Corporation
    Inventors: Yuusaku Sugawa, Yoshikazu Kodama, Kenji Kumai, Takanori Sugiyama, Hirotoshi Itoh
  • Patent number: 11517966
    Abstract: A coated tool of the present disclosure is provided with a base member and a coating layer located on a surface of the base member. The coating layer includes a TiCNO layer and an Al2O3 layer. The Al2O3 layer is located in contact with the TiCNO layer at a position farther from the base member than the TiCNO layer is. The TiCNO layer includes a composite protrusion including a first protrusion that projects toward the Al2O3 layer, a second protrusion that projects from the first protrusion in a direction intersecting a direction in which the first protrusion projects, and a third protrusion that projects from the second protrusion in a direction intersecting the direction in which the second protrusion projects.
    Type: Grant
    Filed: January 28, 2019
    Date of Patent: December 6, 2022
    Assignee: KYOCERA CORPORATION
    Inventors: Yuusaku Sugawa, Yoshikazu Kodama, Kenji Kumai, Takanori Sugiyama, Hirotoshi Itoh
  • Patent number: 11478857
    Abstract: A cutting insert may include a base member and a coating layer thereon. The coating layer may include a first layer including a titanium compound on the base member, a second layer including alumina and an upper surface on the first layer, and a third layer including a titanium compound on the upper surface. The coating layer may include a crack at a top surface and therein. In a cross section orthogonal to the top surface, the crack may be present in the third layer and the second layer; in the third layer it may have a width of 1 ?m or more. In the upper surface it may have a width of 0.5 ?m or more—smaller than the width of the crack in the third layer. Another part may have a width of 0.2 ?m or less closer to the base member than the upper surface.
    Type: Grant
    Filed: December 25, 2017
    Date of Patent: October 25, 2022
    Assignee: KYOCERA Corporation
    Inventors: Kou Ri, Kenji Kumai
  • Publication number: 20220258253
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. An average distance between the plurality of first protrusions is 70-120 nm. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Application
    Filed: July 28, 2020
    Publication date: August 18, 2022
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Hirotoshi ITO, Kenji KUMAI, Takanori SUGIYAMA, Tadashi KATSUMA
  • Publication number: 20220250162
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. At least one of the plurality of first protrusions is a composite protrusion including second protrusions protruding in a direction intersecting with a protruding direction of the first protrusions. A percentage of the composite protrusions in the plurality of first protrusions is 30% or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Application
    Filed: July 28, 2020
    Publication date: August 11, 2022
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Hirotoshi ITO, Kenji KUMAI, Takanori SUGIYAMA, Tadashi KATSUMA
  • Publication number: 20220250163
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes an intermediate layer including Ti, and an Al2O3 layer. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. At least one of the plurality of first protrusions is a composite protrusion including second protrusions protruding in a direction intersecting with a protruding direction of the first protrusions. An average number of the second protrusions in the composite protrusion is 1.4 or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Application
    Filed: July 28, 2020
    Publication date: August 11, 2022
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Hirotoshi ITO, Kenji KUMAI, Takanori SUGIYAMA, Tadashi KATSUMA
  • Publication number: 20220250161
    Abstract: A coated tool in the present disclosure includes a base and a coating layer located on a surface of the base. The coating layer includes a TiCN layer, an intermediate layer including Ti, and an Al2O3 layer in this order from a side of the base. The Al2O3 layer is located in contact with the intermediate layer at a position further away from the base than the intermediate layer. The intermediate layer includes a plurality of first protrusions protruding toward the Al2O3 layer. An average area of the plurality of first protrusions is 1700 nm2 or less. A cutting tool in the present disclosure includes a holder which is extended from a first end toward a second end and includes a pocket on a side of the first end, and the coated tool located in the pocket.
    Type: Application
    Filed: July 28, 2020
    Publication date: August 11, 2022
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Hirotoshi ITO, Kenji KUMAI, Takanori SUGIYAMA, Tadashi KATSUMA
  • Patent number: 11241743
    Abstract: A coated tool may include a base member having a first surface and a coating layer may be located on the first surface. The coating layer may include a first layer having a plurality of ?-Al2O3 crystal particles. At least one of the ?-Al2O3 crystal particles has at least two regions with different orientations from each other.
    Type: Grant
    Filed: June 20, 2018
    Date of Patent: February 8, 2022
    Assignee: KYOCERA Corporation
    Inventors: Yoshikazu Kodama, Kenji Kumai, Yuusaku Sugawa
  • Publication number: 20210114121
    Abstract: A coated tool of the present disclosure is provided with a base member and a coating layer located on a surface of the base member. The coating layer includes a TiCNO layer and an Al2O3 layer. The Al2O3 layer is located in contact with the TiCNO layer at a position farther from the base member than the TiCNO layer is. The TiCNO layer includes a plurality of first protrusions that project toward the Al2O3 layer, and a beam that extends in a direction intersecting a direction in which the first protrusions project, to connect the first protrusions. A cutting tool of the present disclosure is provided with: a holder extending from a first end toward a second end and including a pocket on a side of the first end; and the above-described coated tool located in the pocket.
    Type: Application
    Filed: January 28, 2019
    Publication date: April 22, 2021
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Yoshikazu KODAMA, Kenji KUMAI, Takanori SUGIYAMA, Hirotoshi ITOH
  • Publication number: 20210114114
    Abstract: A coated tool of the present disclosure is provided with a base member and a coating layer located on a surface of the base member. The coating layer includes a TiCNO layer and an Al2O3 layer. The Al2O3 layer is located in contact with the TiCNO layer at a position farther from the base member than the TiCNO layer is. The TiCNO layer includes a first composite protrusion including a first protrusion that projects toward the Al2O3 layer and a second protrusion that projects from the first protrusion in a direction intersecting a direction in which the first protrusion projects. A cutting tool of the present disclosure is provided with: a holder extending from a first end toward a second end and including a pocket on a side of the first end; and the above-described coated tool located in the pocket.
    Type: Application
    Filed: January 28, 2019
    Publication date: April 22, 2021
    Applicant: KYOCERA Corporation
    Inventors: Yuusaku SUGAWA, Yoshikazu KODAMA, Kenji KUMAI, Takanori SUGIYAMA, Hirotoshi ITOH