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).

  • Patent number: 10710168
    Abstract: 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: Grant
    Filed: August 31, 2016
    Date of Patent: July 14, 2020
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
  • Patent number: 10625347
    Abstract: 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: Grant
    Filed: October 31, 2016
    Date of Patent: April 21, 2020
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenichi Sato, Kousuke Yanagisawa, Shin Nishida
  • Patent number: 10618115
    Abstract: 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: Grant
    Filed: October 31, 2016
    Date of Patent: April 14, 2020
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenichi Sato, Kousuke Yanagisawa, Shin Nishida
  • Publication number: 20190358711
    Abstract: 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: Application
    Filed: January 17, 2018
    Publication date: November 28, 2019
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Takuya ISHIGAKI, Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
  • Patent number: 10456841
    Abstract: 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: Grant
    Filed: March 11, 2016
    Date of Patent: October 29, 2019
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Kenichi Sato, Sho Tatsuoka, Kenji Yamaguchi
  • Patent number: 10456842
    Abstract: 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: Grant
    Filed: September 18, 2015
    Date of Patent: October 29, 2019
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
  • Patent number: 10329671
    Abstract: 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: Grant
    Filed: May 28, 2015
    Date of Patent: June 25, 2019
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenji Yamaguchi
  • Patent number: 10307830
    Abstract: 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: Grant
    Filed: April 23, 2015
    Date of Patent: June 4, 2019
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenji Yamaguchi
  • Patent number: 10265785
    Abstract: 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: Grant
    Filed: March 26, 2015
    Date of Patent: April 23, 2019
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenichi Sato, Kenji Yamaguchi
  • Publication number: 20180311745
    Abstract: 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: Application
    Filed: October 31, 2016
    Publication date: November 1, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
  • Publication number: 20180311742
    Abstract: 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: Application
    Filed: October 31, 2016
    Publication date: November 1, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenichi SATO, Kousuke YANAGISAWA, Shin NISHIDA
  • Publication number: 20180257147
    Abstract: 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: Application
    Filed: August 31, 2016
    Publication date: September 13, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
  • Publication number: 20180195172
    Abstract: 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: Application
    Filed: July 8, 2016
    Publication date: July 12, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenji YAMAGUCHI
  • Publication number: 20180154463
    Abstract: 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: Application
    Filed: May 25, 2016
    Publication date: June 7, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Kousuke YANAGISAWA, Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
  • Publication number: 20180071830
    Abstract: 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: Application
    Filed: March 11, 2016
    Publication date: March 15, 2018
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
  • Publication number: 20170342552
    Abstract: 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: Application
    Filed: November 27, 2015
    Publication date: November 30, 2017
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
  • Publication number: 20170321322
    Abstract: 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: Application
    Filed: October 27, 2015
    Publication date: November 9, 2017
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
  • Patent number: 9797040
    Abstract: A hard coating layer on a cutting tool includes at least a Ti and Al complex nitride or carbonitride layer and has an average layer thickness of 1 to 20 ?m. In a case where a composition of the complex nitride or carbonitride layer is expressed by: (Ti1-xAlx)(CyN1-y), a content ratio x and a content ratio y satisfy 0.60?x?0.95 and 0?y?0.005, where x and y are in atomic ratio. Crystal grains constituting the complex nitride or carbonitride layer include cubic phase crystal grains and hexagonal phase crystal grains. An area ratio occupied by the cubic phase crystal grains is 30-80%. An average grain width W is 0.05-1.0 ?m. An average aspect ratio A of the crystal grains with the cubic grain structure is 5 or less. A periodic content ratio change of Ti and Al in (Ti1-xAlx)(CyN1-y) exists in each of the cubic phase crystal grains.
    Type: Grant
    Filed: April 1, 2014
    Date of Patent: October 24, 2017
    Assignee: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho Tatsuoka, Kenji Yamaguchi, Akira Osada
  • Publication number: 20170297117
    Abstract: 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: Application
    Filed: September 18, 2015
    Publication date: October 19, 2017
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
  • Publication number: 20170298505
    Abstract: Provided is a coated tool in which a hard coating layer has excellent hardness and toughness and exhibits chipping resistance and defect resistance during long-term use. The hard coating layer includes at least a layer of a complex nitride or complex carbonitride expressed by the composition formula: (Ti1-x-yAlxMey) (CzN1-x) (here, Me is one element selected from among Si, Zr, B, V, and Cr), an average amount Xavg of Al, an average amount Yavg of Me, and an average amount Zavg of C satisfy 0.60?Xavg, 0.005?Yavg?0.10, 0?Zavg?0.005, and 0.605?Xavg+Yavg?0.95, crystal grains having a cubic structure are present in crystal grains constituting the layer of a complex nitride or complex carbonitride, and in the crystal grains having a cubic structure, a predetermined periodic concentration variation of Ti, Al, and Me is present, whereby the problems are solved.
    Type: Application
    Filed: September 18, 2015
    Publication date: October 19, 2017
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI