Patents by Inventor Sho TATSUOKA
Sho TATSUOKA 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: 11278967Abstract: A surface-coated cutting tool has a hard coating layer including an upper layer ?, an adhesion layer ?, and a lower layer ?. The upper layer ? is formed of an ?-Al2O3 layer formed under low temperature conditions. The adhesion layer ? includes a TiCN layer having a thickness of 0.5 ?m or more in an outermost layer and contains 0.5 to 3 ?m to a maximum depth of 0.5 ?m toward the inside in a layer thickness direction of the TiCN layer from the interface between the TiCN layer and the upper layer ?. The lower layer ? is formed of (Ti1-XAlX)(CYN1-Y) of a single phase of a NaCl type face-centered cubic structure, in which an average content ratio Xavg of Al and an average content ratio Yavg of C in this composition formula satisfy 0.60?Xavg?0.95 and 0?Yavg?0.005.Type: GrantFiled: March 29, 2017Date of Patent: March 22, 2022Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Kousuke Yanagisawa, Sho Tatsuoka, Kenichi Sato, Shin Nishida
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Publication number: 20210220919Abstract: A surface-coated cutting tool has a hard coating layer including an upper layer ?, an adhesion layer ?, and a lower layer ?. The upper layer ? is formed of an ?-Al2O3 layer formed under low temperature conditions. The adhesion layer ? includes a TiCN layer having a thickness of 0.5 ?m or more in an outermost layer and contains 0.5 to 3 ?m to a maximum depth of 0.5 ?m toward the inside in a layer thickness direction of the TiCN layer from the interface between the TiCN layer and the upper layer ?. The lower layer ? is formed of (Ti1-XAlX)(CYN1-Y) of a single phase of a NaCl type face-centered cubic structure, in which an average content ratio Xavg of Al and an average content ratio Yavg of C in this composition formula satisfy 0.60?Xavg?0.95 and 0?Yavg?0.005.Type: ApplicationFiled: March 29, 2017Publication date: July 22, 2021Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kousuke YANAGISAWA, Sho TATSUOKA, Kenichi SATO, Shin NISHIDA
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Patent number: 11040402Abstract: A surface-coated cutting tool including at least a TiAlCN layer, in which the layer is expressed by a composition formula: (Ti1-XAlX)(CYN1-Y), an average content ratio X of Al and an average content ratio Y of C (here, X and Y are atomic ratios) satisfy 0.60?X?0.95 and 0?Y?0.005, respectively, an average content ratio Z of Cl in the total amount of atoms configuring the TiAlCN phase (here, Z is an atomic ratio) satisfies 0.0001?Z?0.004, plane spacings d(111) and d(200) are respectively calculated from X-ray diffraction spectra of (111) plane and (200) plane of crystal grains having a NaCl type face-centered cubic structure in the TiAlCN layer measured by using an X-ray diffraction device, and an absolute value ?A=|A(111)?A(200)| defined as A(111)=31/2d(111) and A(200)=2d(200) satisfies 0.007 ???A?0.05.Type: GrantFiled: January 17, 2018Date of Patent: June 22, 2021Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Takuya Ishigaki, Sho Tatsuoka, Kenichi Sato, Kousuke Yanagisawa, Shin Nishida
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Patent number: 10710168Abstract: The hard coating layer of the cutting tool includes a complex nitride or complex carbonitride layer expressed by the composition formula: (Ti1-xAlx)(CyN1-y). xavg and yavg satisfy 0.60?xavg?0.95 and 0?yavg?0.005. xavg is an average content ratio of Al in a total amount of Ti and Al, and yavg is an average content ratio of C in a total amount of C and N. Some crystal grains composing the complex nitride or complex carbonitride layer have a cubic structure. In crystal grains having the cubic structure, the average crystal grain misorientaion is 1 degree or more; or 2 degrees or more, based on analysis of the polished surface perpendicular to a surface of the layer. A peak exists in 1-2 degrees of the average crystal grain misorientation in the frequency distribution of the average crystal grain misorientation and the area ratio.Type: GrantFiled: August 31, 2016Date of Patent: July 14, 2020Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
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Patent number: 10625347Abstract: In a hard coating layer that contains at least any of a layer of a complex nitride or a complex carbonitride (composition formula: (Ti1-xAlx)(CyN1-y)) of chemically-vapor-deposited Ti and Al, a layer of a complex nitride or a complex carbonitride (composition formula: (Ti1-?-?Al?Mr?)(C?Ni1-?)) of Ti, Al, and Me, and a layer of a complex nitride or a complex carbonitride (composition formula: (Cr1-pAlp)(CqN1-q) of Cr and Al in a surface-coated cutting tool, some crystal grains that form the layer of a complex nitride or a complex carbonitride have cubic structures, and a predetermined average crystal grain misorientation and inclined angle frequency distribution are present in the crystal grains that have cubic structures.Type: GrantFiled: October 31, 2016Date of Patent: April 21, 2020Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenichi Sato, Kousuke Yanagisawa, Shin Nishida
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Patent number: 10618115Abstract: In this surface-coated cutting tool, a hard coating layer includes at least a layer of a complex nitride or complex carbonitride expressed by a composition formula: (Cr1-xAlx)(CyN1-y) or a layer of a complex nitride or complex carbonitride expressed by a composition formula: (Ti1-?-?Al?Me?)(C?N1-?), crystal grains configuring the layer of a complex nitride or complex carbonitride having an NaCl type face-centered cubic structure are present, and predetermined average crystal grain misorientation and inclined angle frequency distribution are present in the crystal grains having an NaCl type face-centered cubic structure.Type: GrantFiled: October 31, 2016Date of Patent: April 14, 2020Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenichi Sato, Kousuke Yanagisawa, Shin Nishida
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Publication number: 20190358711Abstract: A surface-coated cutting tool including at least a TiAlCN layer, in which the layer is expressed by a composition formula: (Ti1-XAlX)(CYN1-Y), an average content ratio X of Al and an average content ratio Y of C (here, X and Y are atomic ratios) satisfy 0.60?X?0.95 and 0?Y?0.005, respectively, an average content ratio Z of Cl in the total amount of atoms configuring the TiAlCN phase (here, Z is an atomic ratio) satisfies 0.0001?Z?0.004, plane spacings d(111) and d(200) are respectively calculated from X-ray diffraction spectra of (111) plane and (200) plane of crystal grains having a NaCl type face-centered cubic structure in the TiAlCN layer measured by using an X-ray diffraction device, and an absolute value ?A=|A(111)?A(200)| defined as A(111)=31/2d(111) and A(200)=2d(200) satisfies 0.007 ???A?0.05.Type: ApplicationFiled: January 17, 2018Publication date: November 28, 2019Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Takuya ISHIGAKI, Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
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Patent number: 10456842Abstract: A surface-coated cutting tool has a hard coating layer on a tool body. The hard coating layer includes a (Ti1?xAlx)(CyN1?y) layer (the average amount Xavg of Al and the average amount Yavg of C satisfy 0.60?Xavg?0.95 and 0?Yavg?0.005). Crystal grains having an NaCl type face-centered cubic structure in the layer have {111} orientation, a columnar structure in which the average grain width of the individual crystal grains having an NaCl type face-centered cubic structure is 0.1 ?m to 2.0 ?m and the average aspect ratio is 2 to 10 is included, and in the individual crystal grains having an NaCl type face-centered cubic structure, a periodic compositional variation in Ti and Al in the composition formula: (Ti1?xAlx)(CyN1?y) is present and the difference between the average of maximum values of x and the average of minimum values thereof is 0.03 to 0.25.Type: GrantFiled: September 18, 2015Date of Patent: October 29, 2019Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
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Patent number: 10456841Abstract: A coated tool includes a hard coating layer that is formed with a (Ti,Al)(C,N) layer on its surface, the layer including an upper layer where a periodic compositional variation in Ti and Al is present in crystal grains having an NaCl type face-centered cubic structure, and a lower layer where a periodic compositional variation in Ti and Al is not present. The upper layer has a high Al amount, while the lower layer has a low Al amount. A value of I(200)/I(111) of the upper layer is greater than 10 and that of the lower layer is less than 3. The lower layer has a composition inclined structure where the Al amount increases from a tool body side towards an upper layer side. The lower layer contains multiple layers, where the Al amount of each layer can increase from the tool body side towards the upper layer side.Type: GrantFiled: March 11, 2016Date of Patent: October 29, 2019Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Kenichi Sato, Sho Tatsuoka, Kenji Yamaguchi
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Patent number: 10329671Abstract: The hard coating layer includes at least a complex nitride or complex carbonitride layer expressed by the composition formula (Ti1-xAlx)(CyN1-y). The average Al content ratio xavg the average C content ratio yavg satisfy 0.60?xavg?0.95 and 0?yavg?0.005, respectively, each of the xavg and yavg is in atomic ratio. The crystal grains constituting the complex nitride or complex carbonitride layer include a crystal grain having the cubic structure. Predetermined average crystal grain misorientation and inclined angle distribution exist in the crystal grains having the cubic structure.Type: GrantFiled: May 28, 2015Date of Patent: June 25, 2019Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenji Yamaguchi
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Patent number: 10307830Abstract: The hard coating layer includes at least a complex nitride or complex carbonitride layer expressed by the composition formula (Ti1-xAlx)(CyN1-y). The average Al content ratio xavg the average C content ratio yavg satisfy 0.60?xavg?0.95 and 0?yavg?0.005, respectively, each of the xavg and yavg is in atomic ratio. The crystal grains constituting the complex nitride or complex carbonitride layer include a crystal grain having the NaCl face-centered cubic structure. A predetermined average crystal grain misorientation exists in the crystal grains having the NaCl face-centered cubic structure.Type: GrantFiled: April 23, 2015Date of Patent: June 4, 2019Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenji Yamaguchi
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Patent number: 10265785Abstract: A surface-coated cutting tool of the present invention includes: a cutting tool body; and a hard coating layer provided on a surface of the cutting tool body, in which the hard coating layer includes a complex nitride or carbonitride layer, which is expressed by a composition formula: (Ti1-xAlx)(CyN1-y), the average content ratio Xavg of Al and the average content ratio Yavg of C in the complex nitride or carbonitride layer satisfy 0.60?Xavg?0.95 and 0?Yavg?0.005, provided that each of Xavg and Yavg is in atomic ratio, the complex nitride or carbonitride layer includes crystal grains with a cubic structure, and in the crystal grains with the cubic structure, a composition of Ti and Al is periodically changed in a direction of the normal line to the surface of the cutting tool body.Type: GrantFiled: March 26, 2015Date of Patent: April 23, 2019Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
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Publication number: 20180311745Abstract: In this surface-coated cutting tool, a hard coating layer includes at least a layer of a complex nitride or complex carbonitride expressed by a composition formula: (Cr1-xAlx)(CyN1-y) or a layer of a complex nitride or complex carbonitride expressed by a composition formula: (Ti1-?-?Al?Me?)(C?N1-?), crystal grains configuring the layer of a complex nitride or complex carbonitride having an NaCl type face-centered cubic structure are present, and predetermined average crystal grain misorientation and inclined angle frequency distribution are present in the crystal grains having an NaCl type face-centered cubic structure.Type: ApplicationFiled: October 31, 2016Publication date: November 1, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
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Publication number: 20180311742Abstract: In a hard coating layer that contains at least any of a layer of a complex nitride or a complex carbonitride (composition formula: (Ti1-xAlx)(CyN1-y)) of chemically-vapor-deposited Ti and Al, a layer of a complex nitride or a complex carbonitride (composition formula: (Ti1-?-?Al?Mr?)(C?Ni1-?)) of Ti, Al, and Me, and a layer of a complex nitride or a complex carbonitride (composition formula: (Cr1-pAlp)(CqN1-q) of Cr and Al in a surface-coated cutting tool, some crystal grains that form the layer of a complex nitride or a complex carbonitride have cubic structures, and a predetermined average crystal grain misorientation and inclined angle frequency distribution are present in the crystal grains that have cubic structures.Type: ApplicationFiled: October 31, 2016Publication date: November 1, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
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Publication number: 20180257147Abstract: The hard coating layer of the cutting tool includes a complex nitride or complex carbonitride layer expressed by the composition formula: (Ti1-xAlx)(CyN1-y). xavg and yavg satisfy 0.60?xavg?0.95 and 0?yavg?0.005. xavg is an average content ratio of Al in a total amount of Ti and Al, and yavg is an average content ratio of C in a total amount of C and N. Some crystal grains composing the complex nitride or complex carbonitride layer have a cubic structure. In crystal grains having the cubic structure, the average crystal grain misorientaion is 1 degree or more; or 2 degrees or more, based on analysis of the polished surface perpendicular to a surface of the layer. A peak exists in 1-2 degrees of the average crystal grain misorientation in the frequency distribution of the average crystal grain misorientation and the area ratio.Type: ApplicationFiled: August 31, 2016Publication date: September 13, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
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Publication number: 20180195172Abstract: A chemical vapor deposition apparatus includes a reaction chamber in which a deposition material is accommodated, a gas supply tube provided in the reaction chamber, and a rotary drive device that rotates the gas supply tube around a rotation axis in the reaction chamber, in which an inside of the gas supply tube is partitioned into the first and second gas flowing sections extending along the rotation axis, a set of gas ejection ports including at least three or more the gas ejection ports disposed, lying next to each other in the circumferential direction is installed on the tube wall, and the set of gas ejection ports includes at least one of a first gas ejection port ejecting the first gas flowing through the first gas flowing section, and at least one of the second gas ejection port ejecting a second gas flowing through the second gas flowing section.Type: ApplicationFiled: July 8, 2016Publication date: July 12, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20180154463Abstract: A coated tool has a hard coating layer including a layer of a complex nitride or complex carbonitride expressed by (Ti1-xAlx)(CyN1-y). A periodic concentration variation is present in crystal grains of a complex nitride or complex carbonitride having a NaCl type face-centered cubic structure in the layer. The periodic concentration variation direction includes a direction at 30 degrees or less with respect to a surface of a tool body. An area percentage of a periodic concentration variation of Ti and Al is 40% or more. The concentration variation period is 1 to 10 nm. A difference between an average of local maximums and an average of local minimums of a periodically varying amount x of Al is 0.01 to 0.1. Fine crystal grains having a hexagonal structure with an average grain size of 0.01 to 0.3 ?m are present at grain boundaries in 5% or less of the area.Type: ApplicationFiled: May 25, 2016Publication date: June 7, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kousuke YANAGISAWA, Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
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Publication number: 20180071830Abstract: A coated tool includes a hard coating layer that is formed with a (Ti,Al)(C,N) layer on its surface, the layer including an upper layer where a periodic compositional variation in Ti and Al is present in crystal grains having an NaCl type face-centered cubic structure, and a lower layer where a periodic compositional variation in Ti and Al is not present. The upper layer has a high Al amount, while the lower layer has a low Al amount. A value of I(200)/I(111) of the upper layer is greater than 10 and that of the lower layer is less than 3. The lower layer has a composition inclined structure where the Al amount increases from a tool body side towards an upper layer side. The lower layer contains multiple layers, where the Al amount of each layer can increase from the tool body side towards the upper layer side.Type: ApplicationFiled: March 11, 2016Publication date: March 15, 2018Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20170342552Abstract: A surface-coated cutting tool with a hard coating layer is provided. The hard coating layer includes at least a complex nitride or carbonitride layer (2) expressed by a composition formula: (Ti1-x-yAlxMey)(CzN1-z), Me being an element selected from Si, Zr, B, V, and Cr. The average content ratio Xavg, the average content ratio Yavg, and the average content ratio Zavg satisfy 0.60?Xavg, 0.005?Yavg?0.10, 0?Zavg?0.005, and 0.605?xavg+yavg?0.95. There are crystal grains having a cubic structure in the crystal grains constituting the complex nitride or carbonitride layer (2). A predetermined periodic content ratio change of Ti, Al and Me exists in the crystal grains having the cubic structure.Type: ApplicationFiled: November 27, 2015Publication date: November 30, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20170321322Abstract: The hard coating layer includes at least a complex nitride or carbonitride layer (2) expressed by a composition formula: (Ti1-x-yAlxMey)(CzN1-z), Me being an element selected from Si, Zr, B, V, and Cr. The average content ratio X, the average content ratio Y, and the average content ratio Z satisfy 0.60?xavg, 0.005?yavg?0.10, 0?zavg?0.005, and 0.605?xavg+yavg?0.95. There are crystal grains having a cubic structure in the crystal grains constituting the complex nitride or carbonitride layer (2). A predetermined periodic content ratio change of Ti, Al and Me exists in the crystal grains having the cubic structure.Type: ApplicationFiled: October 27, 2015Publication date: November 9, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI