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).

  • 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
  • Patent number: 9884790
    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: Grant
    Filed: November 25, 2014
    Date of Patent: February 6, 2018
    Assignee: Sumitomo Electric Hardmetal Corp.
    Inventors: Nozomi Tsukihara, Makoto Setoyama, Katsumi Okamura
  • Patent number: 9850177
    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 includes an A layer and a B layer. The A layer is formed of columnar crystals each having a particle size of 10 nm or more and 400 nm or less. The B layer is formed of columnar crystals each having a particle size of 5 nm or more and 70 nm or less. The B layer is formed by alternately stacking two or more compound layers having different compositions. The compound layers each have a thickness of 0.5 nm or more and 300 nm or less.
    Type: Grant
    Filed: June 5, 2014
    Date of Patent: December 26, 2017
    Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Nozomi Tsukihara, Katsumi Okamura, Makoto Setoyama
  • Publication number: 20170014915
    Abstract: A compound sintered body contains cubic boron nitride particles and binder particles. The composite sintered body 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 body 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: Application
    Filed: March 20, 2015
    Publication date: January 19, 2017
    Inventors: Naoki Watanobe, Yusuke Matsuda, Katsumi Okamura, Nozomi Tsukihara, Makoto Setoyama
  • Publication number: 20160265098
    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: Application
    Filed: September 19, 2014
    Publication date: September 15, 2016
    Inventors: Nozomi TSUKIHARA, Makoto SETOYAMA, Katsumi OKAMURA
  • Publication number: 20160194254
    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 includes an A layer and a B layer. The A layer is formed of columnar crystals each having a particle size of 10 nm or more and 400 nm or less. The B layer is formed of columnar crystals each having a particle size of 5 nm or more and 70 nm or less. The B layer is formed by alternately stacking two or more compound layers having different compositions. The compound layers each have a thickness of 0.5 nm or more and 300 nm or less.
    Type: Application
    Filed: June 5, 2014
    Publication date: July 7, 2016
    Inventors: Nozomi TSUKIHARA, Katsumi OKAMURA, Makoto SETOYAMA
  • 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
  • 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: 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: 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: 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
  • Patent number: 9211588
    Abstract: A surface-coated cutting tool according to the present invention is a surface-coated cutting tool including a base material and a coating film formed on the base material, wherein the coating film includes at least a wear-resistant layer and an adhesion-resistant layer, the wear-resistant layer has a multilayer structure in which an A layer of a nitride containing Ti and Al as well as a B layer of a nitride containing Al and Cr are alternately stacked, and has a cubic crystal structure, and the adhesion-resistant layer is located at an outermost surface of the coating film, is composed of a nitride expressed by (AlaCrbTi1-a-b)N (wherein a+b<0.99, b>0.01, and 0.2b+0.7<a), and has a wurtzite-type crystal structure.
    Type: Grant
    Filed: June 24, 2013
    Date of Patent: December 15, 2015
    Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.
    Inventors: Makoto Setoyama, Akihiko Shibata, Yinxue Xiao, Akira Kobayashi