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).
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Patent number: 9186728Abstract: A cutting tool having excellent chip treatability and adhesion resistance is provided. The cutting tool includes a hard sintered body in at least a cutting edge and has a rake face and a flank face. The rake face has a chip breaker in a protruded or uneven shape. The hard sintered body contains at least 20% by volume of cubic boron nitride. A region of not more than 20 ?m from a surface of the hard sintered body on the rake face side includes A-structures made of cubic boron nitride and B-structures made of at least one selected from the group consisting of hexagonal boron nitride, amorphous boron nitride, and boron oxide. The volume ratio of the B-structures to the sum of the A-structures and B-structures, B/(A+B), is not less than 5% by volume and not more than 90% by volume.Type: GrantFiled: August 30, 2011Date of Patent: November 17, 2015Assignee: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Makoto Setoyama, Satoru Kukino
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Patent number: 9056437Abstract: 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: GrantFiled: August 30, 2011Date of Patent: June 16, 2015Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Makoto Setoyama, Katsumi Okamura, Nozomi Tsukihara
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Patent number: 8999511Abstract: A cBN sintered body tool has the following feature. In at least one cross sectional surface of the cBN sintered body tool taken along a plane perpendicular to a joining surface having the largest area in joining surfaces between the cBN sintered body and the joining layer, a point C and a point D are assumed to represent points away by ¼ of the length of a line segment connecting a point A and a point B shown in a figure. A value obtained when an area of a region surrounded by a line segment connecting the point C and the point D, the first cBN particle, the second cBN particle, and the binder phase is divided by the length of the line segment connecting the point A and point B to each other is 0.14-0.6 ?m.Type: GrantFiled: April 3, 2012Date of Patent: April 7, 2015Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Yasunori Kobayashi, Satoru Kukino, Makoto Setoyama
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Patent number: 8871340Abstract: There is provided a surface-coated sintered body formed of a sintered body of cubic boron nitride with a sufficiently adhesive surface coating layer thereon. The present surface-coated sintered body includes a sintered body of cubic boron nitride and a surface coating layer formed on a surface thereof, the sintered body of cubic boron nitride including 20-99.5% by volume of cubic boron nitride 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 including at least W, and being formed to cover a surface of the sintered body of cubic boron nitride, the hard coating layer being formed to coat the adhesion layer, the adhesion layer being configured of an amorphous state and/or ultrafine particles having an average particle size equal to or smaller than 5 nm.Type: GrantFiled: June 1, 2011Date of Patent: October 28, 2014Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Makoto Setoyama, Katsumi Okamura, Nozomi Tsukihara
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Publication number: 20140193623Abstract: 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: ApplicationFiled: June 24, 2013Publication date: July 10, 2014Inventors: Makoto Setoyama, Akihiko Shibata, Yinxue Xiao, Akira Kobayashi
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Publication number: 20130260165Abstract: A cBN sintered body tool has the following feature. In at least one cross sectional surface of the cBN sintered body tool taken along a plane perpendicular to a joining surface having the largest area in joining surfaces between the cBN sintered body and the joining layer, a point C and a point D are assumed to represent points away by ¼ of the length of a line segment connecting a point A and a point B shown in a figure. A value obtained when an area of a region surrounded by a line segment connecting the point C and the point D, the first cBN particle, the second cBN particle, and the binder phase is divided by the length of the line segment connecting the point A and point B to each other is 0.14-0.6 ?m.Type: ApplicationFiled: April 3, 2012Publication date: October 3, 2013Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Yasunori Kobayashi, Satoru Kukino, Makoto Setoyama
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Publication number: 20130199351Abstract: 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: ApplicationFiled: August 30, 2011Publication date: August 8, 2013Applicant: SUMITOMO ELECTRIC HARDMETAL CORPInventors: Makoto Setoyama, Katsumi Okamura, Nozomi Tsukihara
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Patent number: 8389108Abstract: A surface-coated cutting tool of the present invention includes a substrate and a coated layer formed on the substrate, and the coated layer is a physical-vapor-deposition layer having a thickness of 10 ?m or more. A surface region having a thickness of 1 ?m from a surface of the coated layer includes a first region whose integrated residual stress is a compressive stress and a second region whose integrated residual stress is a tensile stress, and the integrated residual stress of the surface region falls within the range of ?1.5 to 1.5 GPa in any region included in the surface region.Type: GrantFiled: April 24, 2009Date of Patent: March 5, 2013Assignees: Sumitomo Electric Industries, Ltd., Sumitomo Electric Hardmetal Corp.Inventors: Hideki Moriguchi, Makoto Setoyama, Miki Miyanaga, Junya Okida, Sachiko Koike, Daiji Tabayashi
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Publication number: 20130000213Abstract: 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: ApplicationFiled: October 29, 2010Publication date: January 3, 2013Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Katsumi Okamura, Makoto Setoyama, Satoru Kukino
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Publication number: 20120282050Abstract: There is provided a surface-coated sintered body formed of a sintered body of cubic boron nitride with a sufficiently adhesive surface coating layer thereon. The present surface-coated sintered body includes a sintered body of cubic boron nitride and a surface coating layer formed on a surface thereof, the sintered body of cubic boron nitride including 20-99.5% by volume of cubic boron nitride 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 including at least W, and being formed to cover a surface of the sintered body of cubic boron nitride, the hard coating layer being formed to coat the adhesion layer, the adhesion layer being configured of an amorphous state and/or ultrafine particles having an average particle size equal to or smaller than 5 nm.Type: ApplicationFiled: June 1, 2011Publication date: November 8, 2012Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Makoto Setoyama, Katsumi Okamura, Nozomi Tsukihara
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Publication number: 20120213601Abstract: A cutting tool having excellent chip treatability and adhesion resistance is provided. The cutting tool includes a hard sintered body in at least a cutting edge and has a rake face and a flank face. The rake face has a chip breaker in a protruded or uneven shape. The hard sintered body contains at least 20% by volume of cubic boron nitride. A region of not more than 20 ?m from a surface of the hard sintered body on the rake face side includes A-structures made of cubic boron nitride and B-structures made of at least one selected from the group consisting of hexagonal boron nitride, amorphous boron nitride, and boron oxide. The volume ratio of the B-structures to the sum of the A-structures and B-structures, B/(A+B), is not less than 5% by volume and not more than 90% by volume.Type: ApplicationFiled: August 30, 2011Publication date: August 23, 2012Applicant: SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Makoto Setoyama, Satoru Kukino
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Patent number: 8071211Abstract: A surface-coated cutting tool according to the present invention includes a base material and a coating film formed on the base material. The coating film includes one or more hard layer and one or more oxygen-rich hard layer. The hard layer is crystalline in its entirety or crystalline with a part thereof being amorphous. The oxygen-rich hard layer and the hard layer are stacked and the oxygen-rich hard layer is amorphous in a region of interface with the hard layer.Type: GrantFiled: July 18, 2007Date of Patent: December 6, 2011Assignees: Sumitomo Electric Industries, Ltd., Sumitomo Electric Hardmetal Corp.Inventors: Sachiko Koike, Makoto Setoyama, Hideki Moriguchi
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Patent number: 7901796Abstract: A coated cutting tool and its manufacturing method are provided. The coated cutting tool includes a base material and a coating layer formed on a surface of the base material. The coating layer includes an alternate layer having at least one layer of each of an A layer and a B layer stacked one on another alternately. The A layer is made of a nitride containing Al and Cr, and when the total number of metal atoms constituting the A layer is represented as 1, a ratio of the number of Cr atoms is more than 0 and not more than 0.4. The B layer is made of a nitride containing Ti and Al, and when the total number of metal atoms constituting the B layer is represented as 1, a ratio of the number of Al atoms is more than 0 and not more than 0.7.Type: GrantFiled: December 26, 2005Date of Patent: March 8, 2011Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Haruyo Fukui, Naoya Omori, Shinya Imamura, Hideki Moriguchi, Makoto Setoyama, Akihiko Shibata
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Publication number: 20100260561Abstract: A surface-coated cutting tool of the present invention includes a substrate and a coated layer formed on the substrate, and the coated layer is a physical-vapor-deposition layer having a thickness of 10 ?m or more. A surface region having a thickness of 1 ?m from a surface of the coated layer includes a first region whose integrated residual stress is a compressive stress and a second region whose integrated residual stress is a tensile stress, and the integrated residual stress of the surface region falls within the range of ?1.5 to 1.5 GPa in any region included in the surface region.Type: ApplicationFiled: April 24, 2009Publication date: October 14, 2010Applicants: SUMITOMO ELECTRIC INDUSTRIES, LTD., SUMITOMO ELECTRIC HARDMETAL CORP.Inventors: Hideki Moriguchi, Makoto Setoyama, Miki Miyanaga, Junya Okida, Sachiko Koike, Daiji Tabayashi
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Publication number: 20090202312Abstract: A surface-coated cutting tool according to the present invention includes a base material and a coating film formed on the base material. The coating film includes one or more hard layer and one or more oxygen-rich hard layer. The hard layer is crystalline in its entirety or crystalline with a part thereof being amorphous. The oxygen-rich hard layer and the hard layer are stacked and the oxygen-rich hard layer is amorphous in a region of interface with the hard layer.Type: ApplicationFiled: July 18, 2007Publication date: August 13, 2009Inventors: Sachiko Koike, Makoto Setoyama, Hideki Moriguchi
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Patent number: 7527457Abstract: A surface-coated cutting tool includes a base material on which formed an inner layer composed of a compound containing Al, at least one of elements Cr and V and at least one element selected from the group consisting of nitrogen, carbon and oxygen, and an outermost layer composed of a carbonitride of TiSi is further formed on the inner layer. The surface-coated cutting tool is appropriately used for such tools as drill, end mill, throwaway tips for milling and turning, metal saw, gear cutting tool, reamer, and tap. The surface-coated cutting tool improved in peeling resistance and wear resistance as compared with conventional tools can thus be provided.Type: GrantFiled: March 16, 2005Date of Patent: May 5, 2009Assignees: Sumitomo Electric Hardmetal Corp., Sumitomo Electric Industries, Ltd.Inventors: Hideki Moriguchi, Haruyo Fukui, Naoya Omori, Shinya Imamura, Makoto Setoyama
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Patent number: 7498089Abstract: The present invention relates to a coated cutting tool equipped with a substrate and a coating formed on the substrate. The coating includes: a compound formed from elements Al and/or Cr and at least one element selected from a group consisting of carbon, nitrogen, oxygen, and boron; and chlorine.Type: GrantFiled: September 6, 2005Date of Patent: March 3, 2009Assignee: Sumitomo Electric Hardmetal Corp.Inventors: Naoya Omori, Shinya Imamura, Hideki Moriguchi, Haruyo Fukui, Makoto Setoyama
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Publication number: 20080253850Abstract: A surface-coated cutting tool includes a base material on which formed an inner layer composed of a compound containing Al, at least one of elements Cr and V and at least one element selected from the group consisting of nitrogen, carbon and oxygen, and an outermost layer composed of a carbonitride of TiSi is further formed on the inner layer. The surface-coated cutting tool is appropriately used for such tools as drill, end mill, throwaway tips for milling and turning, metal saw, gear cutting tool, reamer, and tap. The surface-coated cutting tool improved in peeling resistance and wear resistance as compared with conventional tools can thus be provided.Type: ApplicationFiled: March 16, 2005Publication date: October 16, 2008Inventors: Hideki Moriguchi, Haruyo Fukui, Naoya Omori, Shinya Imamura, Makoto Setoyama
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Publication number: 20070269610Abstract: A coated cutting tool and its manufacturing method are provided. The coated cutting tool includes a base material and a coating layer formed on a surface of the base material. The coating layer includes an alternate layer having at least one layer of each of an A layer and a B layer stacked one on another alternately. The A layer is made of a nitride containing Al and Cr, and when the total number of metal atoms constituting the A layer is represented as 1, a ratio of the number of Cr atoms is more than 0 and not more than 0.4. The B layer is made of a nitride containing Ti and Al, and when the total number of metal atoms constituting the B layer is represented as 1, a ratio of the number of Al atoms is more than 0 and not more than 0.7.Type: ApplicationFiled: December 26, 2005Publication date: November 22, 2007Inventors: Haruyo Fukui, Naoya Omori, Shinya Imamura, Hideki Moriguchi, Makoto Setoyama, Akihiko Shibata
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Publication number: 20070172675Abstract: The present invention relates to a coated cutting tool equipped with a substrate and a coating formed on the substrate. The coating includes: a compound formed from elements Al and/or Cr and at least one element selected from a group consisting of carbon, nitrogen, oxygen, and boron; and chlorine.Type: ApplicationFiled: September 6, 2005Publication date: July 26, 2007Applicant: Sumitomo Electric Hardmetal Corp.Inventors: Naoya Omori, Shinya Imamura, Hideki Moriguchi, Haruyo Fukui, Makoto Setoyama