Patents by Inventor Makoto Setoyama

Makoto Setoyama 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).

  • Publication number: 20210213539
    Abstract: A cutting tool comprises a rake face and a flank face, the cutting tool being composed of a substrate made of a cubic boron nitride sintered material and a coating provided on the substrate, the coating including a MAIN layer, the MAIN layer including crystal grains of MxAl1-xN in the cubic crystal system, nF<nR being satisfied, where nF represents a number of voids per 100 ?m in length of the MAIN layer on the flank face in a cross section of the MAIN layer, and nR represents a number of voids per 100 ?m in length of the MAIN layer on the rake face in a cross section of the MAIN layer, nD being 3 or less, where nD represents a number of droplets per 100 ?m in length of the MAIN layer on the flank face in a cross section of the MAIN layer.
    Type: Application
    Filed: July 16, 2020
    Publication date: July 15, 2021
    Applicant: Sumitomo Electric Hardmetal Corp.
    Inventors: Momoko IIDA, Makoto SETOYAMA, Haruyo FUKUI
  • Patent number: 11059105
    Abstract: Provided is a surface-coated cutting tool including a base material and a coating including a super-multilayer-structure layer where A layers and B layers different from the A layers in composition are alternately laminated. The super-multilayer-structure layer includes an X area and a Y area those are alternately repeated. In the X area, A layers having a thickness AX and B layers having a thickness BX are alternately laminated. In the Y area, A layers having a thickness AY and B layers having a thickness BY are alternately laminated. The thickness AX is larger than the thickness AY, and the thickness BX is smaller than the thickness BY. Each of the A layers and the B layers comprising one or more elements selected from a group consisting of Ti, Al, Cr, Si, Ta, Nb, and W, and one or more elements selected from a group consisting of C and N.
    Type: Grant
    Filed: September 20, 2017
    Date of Patent: July 13, 2021
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Keizo Tanaka, Makoto Setoyama, Yutaka Kobayashi, Akira Kobayashi
  • Patent number: 10994341
    Abstract: A surface-coated cutting tool includes a base material and a coating film provided on a surface of the base material, wherein the coating film includes a first alternating layer provided on the base material and a second alternating layer provided on the first alternating layer, the first alternating layer includes A and B layers, the second alternating layer includes C and D layers, each of one or plurality of the A layers is composed of a nitride or carbonitride of AlaCrbM1(1-a-b), each of one or plurality of the B layers is composed of a nitride or carbonitride of AlcTidM2(1-c-d), each of one or plurality of the C layers is composed of a nitride or carbonitride of TieSifM3(1-e-f), and each of one or plurality of the D layers is composed of a nitride or carbonitride of TigSihM4(1-g-h).
    Type: Grant
    Filed: March 8, 2019
    Date of Patent: May 4, 2021
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Hiroki Takeshita, Makoto Setoyama, Haruyo Fukui
  • Patent number: 10994339
    Abstract: A surface-coated cutting tool includes a substrate composed of cemented carbide and a coating film. The coating film includes an intermediate layer in contact with the substrate and an upper layer formed on the intermediate layer. The upper layer is made up of a single layer consisting of an upper base layer which is a layer in contact with the intermediate layer or multiple layers constituted of two or more layers. A mismatch in lattice interplanar spacing in an interface region between the substrate and the intermediate layer is not higher than 65% of a theoretical value of a mismatch in lattice interplanar spacing between the substrate and the upper base layer. A mismatch in lattice interplanar spacing in an interface region between the intermediate layer and the upper base layer is not higher than 65% of the theoretical value of the mismatch in lattice interplanar spacing between the substrate and the upper base layer.
    Type: Grant
    Filed: November 22, 2017
    Date of Patent: May 4, 2021
    Assignees: Sumitomo Electric Hardmetal Corp., Sumitomo Electric Industries, Ltd.
    Inventors: Keizo Tanaka, Makoto Setoyama, Haruyo Fukui, Akira Kobayashi, Koji Kuramochi
  • Publication number: 20210069794
    Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and aluminum, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the aluminum being larger than 0.40 and not more than 0.70.
    Type: Application
    Filed: October 16, 2018
    Publication date: March 11, 2021
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA, Kouhei YOSHIMURA
  • Publication number: 20210001410
    Abstract: A surface-coated cutting tool includes a base material and a coating film provided on a surface of the base material, wherein the coating film includes a first alternating layer provided on the base material and a second alternating layer provided on the first alternating layer, the first alternating layer includes A and B layers, the second alternating layer includes C and D layers, each of one or plurality of the A layers is composed of a nitride or carbonitride of AlaCrbM1(l-a-b), each of one or plurality of the B layers is composed of a nitride or carbonitride of AlcTidM2(l-c-d), each of one or plurality of the C layers is composed of a nitride or carbonitride of TieSifM3(l-e-f), and each of one or plurality of the D layers is composed of a nitride or carbonitride of TigSihM4(l-g-h).
    Type: Application
    Filed: March 8, 2019
    Publication date: January 7, 2021
    Applicant: Sumitomo Electric Hardmetal Corp.
    Inventors: Hiroki Takeshita, Makoto Setoyama, Haruyo Fukui
  • Publication number: 20200406364
    Abstract: A cutting tool includes: a substrate; and a coating film formed on the substrate, wherein the coating film includes a first layer formed on the substrate, and a second layer formed on the first layer, the first layer is composed of a boride including titanium as a component element, and the second layer is composed of a nitride including zirconium as a component element.
    Type: Application
    Filed: July 10, 2019
    Publication date: December 31, 2020
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
  • Publication number: 20200406365
    Abstract: A cutting tool includes: a substrate; and a coating film formed on the substrate, wherein the coating film includes a first layer formed on the substrate, and a second layer formed on the first layer, the first layer is composed of a boride including zirconium as a component element, and the second layer is composed of a nitride including zirconium as a component element.
    Type: Application
    Filed: July 10, 2019
    Publication date: December 31, 2020
    Applicants: SUMITOMO ELECTRIC HARDMETAL CORP., SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
  • Publication number: 20200368822
    Abstract: A surface coated cutting tool comprises a base material and a coating layer that coats the base material, the coating layer including an alternate layer composed of a first unit layer and a second unit layer alternately stacked, the first unit layer being composed of a nitride containing aluminum and zirconium, in the first unit layer, when the total number of metal atoms constituting the first unit layer is represented as 1, a ratio thereto of the number of atoms of the zirconium being not less than 0.65 and not more than 0.95, the second unit layer being composed of a nitride containing titanium and silicon, in the second unit layer, when the total number of metal atoms constituting the second unit layer is represented as 1, a ratio thereto of the number of atoms of the silicon being larger than 0 and not more than 0.20.
    Type: Application
    Filed: October 30, 2018
    Publication date: November 26, 2020
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA, Kouhei YOSHIMURA
  • Publication number: 20200331071
    Abstract: A surface-coated cutting tool includes: a substrate including a rake face and a flank face; a first coating film that coats the rake face; and a second coating film that coats the flank face, wherein the first coating film includes a first composite nitride layer at a region d1 on the rake face, the second coating film includes a second composite nitride layer at a region d2 on the flank face, the first composite nitride layer includes Ti1-x1-y1Alx1Tay1C?1N?1, the second composite nitride layer includes Ti1-x2-y2Alx2Tay2C?2N?2.
    Type: Application
    Filed: January 30, 2019
    Publication date: October 22, 2020
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Kouhei YOSHIMURA, Haruyo FUKUI, Makoto SETOYAMA, Keizo TANAKA
  • Publication number: 20200055790
    Abstract: A surface-coated cutting tool including a substrate including a rake face and a flank face and a coating which covers a surface of the substrate is provided. The substrate is made of a cBN sintered material or a ceramic sintered material. The coating includes an alternating layer. The alternating layer is made by alternately stacking a first layer and a second layer different in composition from the first layer. The first layer contains Al, Cr, and N. The second layer contains Ti, Al, and N. A ratio T1/T2 between a thickness Ti of the first layer and a thickness T2 of the second layer is not lower than 0.1 and lower than 1. There are thirty or more interfaces at which the first layer and the second layer are in contact with each other.
    Type: Application
    Filed: September 20, 2017
    Publication date: February 20, 2020
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Makoto Setoyama, Nozomi Tsukihara, Yuki Tsutsumiuchi, Satoru Kukino, Yusuke Matsuda, Hironari Moroguchi
  • Publication number: 20190247930
    Abstract: Provided is a surface-coated cutting tool including a base material and a coating including a super-multilayer-structure layer where A layers and B layers different from the A layers in composition are alternately laminated. The super-multilayer-structure layer includes an X area and a Y area those are alternately repeated. In the X area, A layers having a thickness AX and B layers having a thickness BX are alternately laminated. In the Y area, A layers having a thickness AY and B layers having a thickness BY are alternately laminated. The thickness AX is larger than the thickness AY, and the thickness BX is smaller than the thickness BY. Each of the A layers and the B layers comprising one or more elements selected from a group consisting of Ti, Al, Cr, Si, Ta, Nb, and W, and one or more elements selected from a group consisting of C and N.
    Type: Application
    Filed: September 20, 2017
    Publication date: August 15, 2019
    Inventors: Keizo Tanaka, Makoto Setoyama, Yutaka Kobayashi, Akira Kobayashi
  • Publication number: 20190247927
    Abstract: A cutting tool includes a base material, and a coating film covering the base material in contact with the base material. The base material is a cubic boron nitride sintered material. The coating film is a ceramic. An amount of oxygen in the coating film is less than or equal to 0.040 mass percent.
    Type: Application
    Filed: December 14, 2017
    Publication date: August 15, 2019
    Inventors: Katsumi Okamura, Satoru Kukino, Makoto Setoyama
  • Publication number: 20190232386
    Abstract: A cutting tool includes a substrate and a coating film provided on the substrate, wherein the substrate is a cBN sintered material including more than or equal to 30 volume % and less than 80 volume % of cBN and a binder, the coating film includes a compound layer constituted of a composition of Ti1-xAlxC1-aNa, where 0.70?X?0.95 and 0<a?1, and the compound layer has a NaCl type crystal structure in a whole or part of the compound layer.
    Type: Application
    Filed: September 1, 2017
    Publication date: August 1, 2019
    Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Nozomi Tsukihara, Makoto Setoyama, Anongsack Paseuth
  • Patent number: 10272498
    Abstract: A composite sintered material contains cubic boron nitride particles and binder particles. The composite sintered material contains 40 vol % or more and 80 vol % or less of the cubic boron nitride particles. The binder particles contain TiCN particles. The composite sintered material shows a first peak belonging to a (200) plane of the TiCN particles in a range in which a Bragg angle 2? is 41.7° or more and 42.6° or less in an X-ray diffraction spectrum measured using a Cu-K? ray as a ray source.
    Type: Grant
    Filed: March 20, 2015
    Date of Patent: April 30, 2019
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Naoki Watanobe, Yusuke Matsuda, Katsumi Okamura, Nozomi Tsukihara, Makoto Setoyama
  • Publication number: 20190022763
    Abstract: A surface-coated cutting tool includes a substrate composed of cemented carbide and a coating film. The coating film includes an intermediate layer in contact with the substrate and an upper layer formed on the intermediate layer. The upper layer is made up of a single layer consisting of an upper base layer which is a layer in contact with the intermediate layer or multiple layers constituted of two or more layers. A mismatch in lattice interplanar spacing in an interface region between the substrate and the intermediate layer is not higher than 65% of a theoretical value of a mismatch in lattice interplanar spacing between the substrate and the upper base layer. A mismatch in lattice interplanar spacing in an interface region between the intermediate layer and the upper base layer is not higher than 65% of the theoretical value of the mismatch in lattice interplanar spacing between the substrate and the upper base layer.
    Type: Application
    Filed: November 22, 2017
    Publication date: January 24, 2019
    Inventors: Keizo Tanaka, Makoto Setoyama, Haruyo Fukui, Akira Kobayashi, Koji Kuramochi
  • Patent number: 10030299
    Abstract: A surface-coated boron nitride sintered body tool includes a cubic boron nitride sintered body and a coating film formed thereon. The coating film includes an A layer and a C layer. The A layer is formed of Ti1-xaMaxaC1-yaNya (where Ma is one or more of Cr, Nb and W; 0?xa?0.7; 0?ya?1). The C layer is formed of Al1-(xc+yc)CrxcMcycN (where Mc is one or more of Ti, V and Si; 0.2?xc?0.8; 0?yc?0.6; 0.2?xc+yc?0.8). The A layer is formed on an outermost surface of the coating film or between the outermost surface of the coating film and the C layer. A distance between the outermost surface of the coating film and an upper surface of the C layer is 0.1 ?m or more and 1.0 ?m or less.
    Type: Grant
    Filed: September 19, 2014
    Date of Patent: July 24, 2018
    Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Nozomi Tsukihara, Makoto Setoyama, Katsumi Okamura
  • Patent number: 10016813
    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: Grant
    Filed: June 5, 2014
    Date of Patent: July 10, 2018
    Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Nozomi Tsukihara, Katsumi Okamura, Makoto Setoyama
  • Publication number: 20180117678
    Abstract: The surface-coated cBN sintered material includes a cBN sintered material containing cBN particles and a binder, and a coating. A proportion of the cBN particles in the cBN sintered material is 80 to 98% by volume, the binder contains a first compound including at least one element of Al and Cr and at least one element of N, B and O. The coating contains a layer A in contact with the cBN sintered material. The layer A is constituted of Alx1Cry1Mz1Ca1Nbb1Oc1 (provided that M is at least one element of Ti, V, Nb and Si, and 0.25?x1?0.75, 0.25?y1?0.75, 0?z1?0.5, x1+y1+z1=1, 0?a1?0.5, 0.5?b1?1, 0?c1?0.1, and a1+b1+c1=1 are satisfied).
    Type: Application
    Filed: December 2, 2016
    Publication date: May 3, 2018
    Inventors: Kazushi Takahama, Makoto Setoyama, Katsumi Okamura
  • Patent number: 9943911
    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: Grant
    Filed: March 20, 2015
    Date of Patent: April 17, 2018
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Yusuke Matsuda, Katsumi Okamura, Kenta Sano, Nozomi Tsukihara, Makoto Setoyama