Patents by Inventor Koichiro Hayashi

Koichiro Hayashi 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: 6852143
    Abstract: A turbo component for a turbocharger in which heat resistance, corrosion resistance, and wear resistance is superior, and in which the cost is further lowered, is provided. In the turbo component, the overall composition is, in ratio by mass, Cr: 23.8 to 44.3%, Mo: 1.0 to 3.0%, Si: 1.0 to 3.0%, P: 0.1 to 1.0%, C: 1.0 to 3.0%, and the balance of Fe and inevitable impurities, and carbide is dispersed in the matrix at a density ratio of 95% or more.
    Type: Grant
    Filed: January 17, 2002
    Date of Patent: February 8, 2005
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichiro Hayashi, Michiharu Mogami
  • Publication number: 20040220337
    Abstract: A fuel tank produced in such a manner that an upper shell and a lower shell melt-molded as two split molded parts from a PPS resin composition are welded to each other at a welding portion. The PPS resin composition contains (a) 60% by weight to 95% by weight of a PPS resin, and (b) 5% by weight to 40% by weight of an olefin resin. The (a) PPS resin contains (a-1) a PPS resin having an MFR of 90 g/10 min to 350 g/10 min and an amount of extracts by chloroform of 2.2% by weight to 4.5% by weight. The (b) olefin resin contains (b-1) a specific olefin copolymer, and (b-2) an ethylene-&agr;-olefin copolymer. The MFR of the PPS resin composition is 15 g/10 min to 50 g/10 min.
    Type: Application
    Filed: April 15, 2004
    Publication date: November 4, 2004
    Applicants: TOYODA GOSEI CO., LTD., FTS CO., LTD.
    Inventors: Daisuke Tsutsumi, Junji Koizumi, Koichiro Hayashi, Joji Kasugai, Masahide Kobayashi
  • Patent number: 6660056
    Abstract: A valve seat is provided in which wear resistance can be ensured by optimizing the matrix structure without dispersing of expensive hard particles, and therefore the machinability can be improved and the holding down of cost can be achieved. The valve seat exhibits a metallographic structure consisting of only bainite single phase or only a mixed phase of bainite and martensite, has an area ratio of bainite and martensite in cross section of 100:0 to 50:50, and has a matrix hardness of 250 to 850 Hv.
    Type: Grant
    Filed: May 1, 2001
    Date of Patent: December 9, 2003
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichiro Hayashi, Hideaki Kawata, Toru Tsuboi
  • Patent number: 6616726
    Abstract: Disclosed is a sintered alloy material for valve guides, containing: 1.5% to 4% by mass of carbon; 1% to 20% by mass of copper; 0.1% to 2% by mass of tin; 0.01% or more than 0.01% and less than 0.1% by mass of phosphorus; and an iron base. The metallographic structure of the sintered alloy material has a matrix phase composed mainly of pearlite, and a free carbon phase being dispersed in the matrix phase.
    Type: Grant
    Filed: August 30, 2001
    Date of Patent: September 9, 2003
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Katsunao Chikahata, Koichiro Hayashi
  • Patent number: 6562098
    Abstract: A wear resistant sintered member exhibits superior wear resistance at the same level as those of the conventional materials without using a Co-based hard phase is provided. A first hard phase comprising Mo silicide particles dispersed in an Fe-based alloy matrix of the first hard phase and a second hard phase comprising a ferrite phase or a mixed phase of ferrite and austenite having a higher Cr concentration than the Fe-based alloy matrix surrounding a core consisting of Cr carbide particles, are diffused in an Fe-based alloy matrix, the Mo silicide particles are contained in the first hard phase in an amount of 3 to 25 % by area, and the Cr carbide particles are contained in the second hard phase in an amount of 3 to 30 % by area.
    Type: Grant
    Filed: August 5, 2002
    Date of Patent: May 13, 2003
    Assignees: Hitachi Powdered Metals Co., Ltd., Nissan Motor Co., Ltd.
    Inventors: Hiroki Fujitsuka, Hideaki Kawata, Koichiro Hayashi, Tomonori Miyazawa, Koji Koyanagi, Akira Fujiki, Hideki Muramatsu, Kunio Maki, Yoshio Okada, Shin Nomura
  • Publication number: 20020139448
    Abstract: A turbo component for a turbocharger in which heat resistance, corrosion resistance, and wear resistance is superior, and in which the cost is further lowered, is provided. In the turbo component, the overall composition is, in ratio by mass, Cr: 23.8 to 44.3%, Mo: 1.0 to 3.0%, Si: 1.0 to 3.0%, P: 0.1 to 1.0%, C: 1.0 to 3.0%, and the balance of Fe and inevitable impurities, and carbide is dispersed in the matrix at a density ratio of 95% or more.
    Type: Application
    Filed: January 17, 2002
    Publication date: October 3, 2002
    Applicant: HITACHI POWDERED METALS CO., LTD.
    Inventors: Koichiro Hayashi, Michiharu Mogami
  • Publication number: 20020023518
    Abstract: Disclosed is a sintered alloy material for valve guides, containing: 1.5% to 4% by mass of carbon; 1% to 20% by mass of copper; 0.1% to 2% by mass of tin; 0.01% or more than 0.01% and less than 0.1% by mass of phosphorus; and an iron base. The metallographic structure of the sintered alloy material has a matrix phase composed mainly of pearlite, and a free carbon phase being dispersed in the matrix phase.
    Type: Application
    Filed: August 30, 2001
    Publication date: February 28, 2002
    Inventors: Katsunao Chikahata, Koichiro Hayashi
  • Patent number: 6340377
    Abstract: The invention relates to an iron-based high-temperature wear-resistant sintered alloy. This alloy contains 3.74-13.36 wt % W, 0.39-5.58 wt % V, 0.2-5.78 wt % Cr, 0.1-0.6 wt % Si, 0.39-1.99 wt % Mn, 0.21-1.18 wt % S, and up to 2.16 wt % C. This alloy includes 20-80 wt % of a first phase and 80-20 wt % of a second phase, each distributed therein, in the form of spots. The first phase contains 3-7 wt % W, up to 1 wt % Cr, 0.1-0.6 wt % Si, 0.2-1 wt % Mn, 0.1-0.6 wt % S, and up to 2.2 wt % C. The first phase may contain 0.5-1.5 wt % V, and in this case the vanadium content of the alloy becomes 0.79-5.88 wt %. The second phase contains 7-15 wt % W, 2-7 wt % V, 1-7 wt % Cr, 0.1-0.6 wt % Si, 0.2-1 wt % Mn, 0.1-0.6 wt % S, and up to 2.2 wt % of C. Each phase contains 0.3-1.6 wt % MnS and a carbide of at least tungsten, which are dispersed therein. The second phase further contains 10-20 areal % tungsten carbide (particle diameter: ≧1 &mgr;m) dispersed therein. The alloy further contains 0.
    Type: Grant
    Filed: April 11, 2000
    Date of Patent: January 22, 2002
    Assignees: Hitachi Powdered Metals Co., Ltd., Nissan Motor Co., Ltd.
    Inventors: Hideaki Kawata, Kei Ishii, Koichiro Hayashi, Yoshimasa Aoki, Atsushi Ehira, Kunio Maki, Masaki Toriumi
  • Publication number: 20010037842
    Abstract: A valve seat is provided in which wear resistance can be ensured by optimizing the matrix structure without dispersing of expensive hard particles, and therefore the machinability can be improved and the holding down of cost can be achieved. The valve seat exhibits a metallographic structure consisting of only bainite single phase or only a mixed phase of bainite and martensite, has an area ratio of bainite and martensite in cross section of 100:0 to 50:50, and has a matrix hardness of 250 to 850 Hv.
    Type: Application
    Filed: May 1, 2001
    Publication date: November 8, 2001
    Inventors: Koichiro Hayashi, Hideaki Kawata, Toru Tsuboi
  • Patent number: 6302937
    Abstract: The present invention provides a sintered material having high mechanical strength and superior wear resistance, and to a process of manufacture therefor. A sintered alloy having superior wear resistance has an overall composition consisting of, in percent by weight, Ni in an amount of 6.0 to 25.0%, Cr in an amount of 0.6 to 8.75%, C in an amount of 0.54 to 2.24%, and balance consisting of Fe, the sintered alloy exhibiting a metallographic structure in which the following hard phase is dispersed in a mixed structure of martensite and austenite, the hard phase comprising a core consisting of Cr carbide and a ferrite phase diffused Cr, or a mixed phase of ferrite and austenite diffused Cr, surrounding the core, and an area ratio of austenite in the mixed structure in the metallographic structure ranging from 5 to 30%.
    Type: Grant
    Filed: November 29, 1999
    Date of Patent: October 16, 2001
    Assignee: Hitachi Powdered Metals, Co., Ltd.
    Inventors: Koichiro Hayashi, Yoshimasa Aoki, Koichi Aonuma
  • Patent number: 6251157
    Abstract: A sintered alloy having superb wear resistance comprising: composite phases dispersed in a matrix of the sintered alloy; the composite phase consisting of; a particle group in which Cr carbide particles and Cr sulfide particles exist in a mixed condition; and a ferrite phase or a mixture phase of ferrite and austenite surrounding the particle group as a core.
    Type: Grant
    Filed: August 18, 1999
    Date of Patent: June 26, 2001
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Yoshimasa Aoki, Koichiro Hayashi, Koichi Aonuma, Toru Tsuboi
  • Patent number: 6012703
    Abstract: Disclosed is a valve guide which is manufactured by a sintered alloy and used for an engine, and more particularly, to a valve guide which has high wear resistance and can prevent appearance of scuffing on a surface of a valve stem associated with the valve guide, and to a process for manufacturing the valve guide. The valve guide comprises an inner surface sliding with a valve stem, the inner surface finished by machining and exposing pores. Area-ratio of the pores with respect to the inner surface is 2.7 to 10.7%, and at least one pore having pore size of not less than 80 .mu.m exists per 1 mm.sup.2 of the inner surface.
    Type: Grant
    Filed: July 9, 1997
    Date of Patent: January 11, 2000
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichiro Hayashi, Katsunao Chikahata
  • Patent number: 5952590
    Abstract: A sintered alloy having superb wear resistance consisting, percent by weight of, as a whole, Ni in the amount of 1.35 to 19.61%, Cr in the amount of 0.9 to 11.05%, Mo in the amount of 1.44 to 9.09%, Co in the amount of 3.6 to 20.05%, V in the amount of 0.018 to 0.26%, Si in the amount of 0.1 to 0.75%, C in the amount of 0.35 to 1.5%, and the balance of Fe, and the sintered alloy exhibiting a metallographic structure in which the following hard phases are dispersed in a mixed structure of martensite, sorbite, and austenite: a first hard phase comprising, a hard phase as a core mainly consisting of Mo suicide, and a diffused phase including diffused Co surrounding the hard phase; and a second hard phase comprising, a hard phase as a core consisting of Cr carbide, and a mixed phase of ferrite and austenite surrounding the hard phase.
    Type: Grant
    Filed: January 30, 1998
    Date of Patent: September 14, 1999
    Assignees: Hitachi Powdered Metals Co., Ltd., Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Hideaki Kawata, Koichiro Hayashi, Katsuaki Sato, Tsutomu Saka
  • Patent number: 5949003
    Abstract: The invention relates to a sintered alloy. This sintered alloy includes 3-13.4 wt % of W, 0.4-5.6 wt % or 0.8-5.9 wt % of V, 0.2-5.6 wt % of Cr, 0.1-0.6 wt % or 0.6-5.0 wt % of Si, 0.1-0.6 wt % or 0.2-1.0 wt % of Mn, 0.6-2.2 wt % of C, and a balance of Fe. The sintered alloy includes first and second phase which are distributed therein, in a form of spots, respectively. The second phase is in an amount of from 20 to 80 wt %, based on the total weight of the first and second phases. The first phase contains 3-7 wt % of W, 0.5-1.5 wt % of optional V, up to 1 wt % of Cr, 0.1-0.6 wt % or 0.6-5.0 wt % of Si, 0.1-0.6 wt % or 0.2-1.0 wt % of Mn, up to 2.2 wt % of C, and a balance of Fe. The second phase contains 3-15 wt % of W, 2-7 wt % of V, 1-7 wt % of Cr, 0.1-0.6 wt % or 0.6-5.0 wt % of Si, 0.1-0.6 wt % or 0.2-1.0 wt % of Mn, up to 2.2 wt % of C, and a balance of Fe. When the manganese contents of the first and second phases and the total of the sintered alloy are respectively in a range of from 0.2 to 1.
    Type: Grant
    Filed: April 14, 1997
    Date of Patent: September 7, 1999
    Assignees: Nissan Motor Co., Ltd., Hitachi Powdered Metals Co., Ltd.
    Inventors: Yoshimasa Aoki, Kei Ishii, Koichiro Hayashi, Kouichi Aonuma, Hideaki Kawata, Kunio Maki, Atsushi Ehira, Akira Fujiki, Sadayuki Abo, Seigo Sato
  • Patent number: 5834664
    Abstract: The present invention provides a valve seat having a suitable degree of wear resistance, which can be produced without recourse to expensive elements represented by cobalt and at a cost lower than ever before. This valve seat is formed of a wear-resistant sintered alloy having a general composition consisting essentially of, in weight ratio, 0.736 to 5.79% of nickel, 0.12 to 6.25% of chromium, 0.294 to 0.965% of molybdenum, and 0.508 to 2.0% of carbon with the balance being iron, and inevitable impurities, and having a micro structure wherein a bainite matrix structure or a mixed bainite and sorbite matrix structure includes a nucleus having a hard phase composed mainly of chromium carbide, and a ferrite surrounding said nucleus and having a high chromium concentration and a martensite surrounding said ferrite are dispersed.
    Type: Grant
    Filed: January 7, 1997
    Date of Patent: November 10, 1998
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichi Aonuma, Yoshimasa Aoki, Koichiro Hayashi
  • Patent number: 5824922
    Abstract: The invention provides a valve seat having a suitable degree of wear resistance, which can be produced without recourse to expensive elements represented by cobalt and at a cost lower than ever before. This valve seat is formed of a wear-resistant sintered alloy having a general composition consisting essentially of, in weight ratio, 0.736 to 9.65% of nickel, 0.736 to 2.895% of copper, 0.294 to 0.965% of molybdenum, 0.12 to 6.25% of chromium, and 0.508 to 2.0% of carbon with the balance being iron, and inevitable impurities, and having a metallic structure in which there are dispersed (1) a martensite, (2) a bainite having a nucleus of sorbite and/or upper bainite and surrounding said nucleus, (3) an austenite having a high nickel concentration, and (4) a hard phase surrounding with a ferrite having a high chromium concentration and composed mainly of a chromium carbide.
    Type: Grant
    Filed: January 7, 1997
    Date of Patent: October 20, 1998
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichi Aonuma, Yoshimasa Aoki, Koichiro Hayashi
  • Patent number: 5326526
    Abstract: Sintered iron alloy composition and method of manufacturing the same, the sintered alloy composition comprising: about 1.5 to about 2.5% carbon by weight; about 0.5 to about 0.9% manganese by weight; about 0.1 to about 0.2% sulfur by weight; about 1.9 to about 2.5% chromium by weight; about 0.15 to about 0.3% molybdenum by weight; about 2 to about 6% copper by weight; not more than about 0.3% by weight of a metal element material comprising at least one member selected from the group consisting of tungsten and vanadium; an effective content of a first solid lubricant material comprising at least one member selected from the group consisting of magnesium metasilicate minerals and magnesium orthosilicate minerals; and balance iron. This alloy composition is preferably used for making machine parts, such as slide members of valve operating systems for internal combustion engines.
    Type: Grant
    Filed: September 30, 1991
    Date of Patent: July 5, 1994
    Assignees: Hitachi Powdered Metals Co., Ltd., Nissan Motor Co., Ltd.
    Inventors: Yutaka Ikenoue, Koichiro Hayashi, Makoto Kano, Akira Fujiki
  • Patent number: 5259860
    Abstract: A sintered metal part has a magnesium metasilicate mineral, or a magnesium metasilicate mineral and a magnesium orthosilicate mineral, or at least one of a magnesium metasilicate mineral and a magnesium orthosilicate mineral and at least one of boron nitride and manganese sulfide dispersed throughout the metal matrix. An iron-based sintered sliding member is of a structure that free graphite and an intercrystalline inclusion have been dispersed throughout the metal matrix that consists essentially of, in weight ratio, 1.5 to 4% of carbon, 1 to 5% of copper, 0.1 to 2% of tin, 0.1 to 0.5% of phosphorus, 0.
    Type: Grant
    Filed: October 9, 1991
    Date of Patent: November 9, 1993
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Yutaka Ikenoue, Ryoji Satoh, Koichiro Hayashi, Katsunao Chikahata
  • Patent number: 4049867
    Abstract: A novel thermosetting resin composition comprising at least one [(2,3-epoxypropoxy)alkyl]trialkoxysilane and at least one selected from polymers, prepolymers, copolymers and coprepolymers of epoxy-group-containing vinyl monomers, which may further contain at least one selected from polymers, prepolymers, copolymers and coprepolymers of vinyl monomers containing no epoxy group, is disclosed. This composition is cured by heating with addition of a ring-opening polymerization catalyst and remarkably improves surface hardness, abrasion resistance, weathering resistance, chemical resistances, heat resistances, etc. of acrylic resins and many other plastic materials without imparing the inherent transparency and other optical properties of these materials when it is applied on the surface of them and cured.
    Type: Grant
    Filed: December 23, 1975
    Date of Patent: September 20, 1977
    Assignees: Japan Atomic Energy Research Institute, Tokyo Optical Company, Ltd.
    Inventors: Akihiko Ito, Isao Kaetsu, Hiroshi Okubo, Masamichi Kato, Koichiro Hayashi, Yuji Maeda
  • Patent number: 4049518
    Abstract: A multi-step process of producing polyoxymethylenes by solid state polymerization of trioxane is disclosed.Trioxane is irradiated with ionizing radiation within a temperature range in which no polymerization of trioxane takes place. The irradiated trioxane is then polymerized by raising the temperature to a value at which polymerization of trioxane takes place, said temperature value being at least 15.degree. C above the first mentioned temperature. The polymerization is effected in the presence of an amount of alkyl acetal. The polymerized product thus obtained is then again irradiated, whereupon further polymerization of the irradiated product takes place.The resulting polyoxymethylenes are snow white and exhibit excellent thermal stability. They also have high molecular weights.
    Type: Grant
    Filed: August 15, 1974
    Date of Patent: September 20, 1977
    Assignee: Japan Atomic Energy Research Institute
    Inventors: Akihiko Ito, Akira Shimizu, Koichiro Hayashi