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: 9797040Abstract: 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: GrantFiled: April 1, 2014Date of Patent: October 24, 2017Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Kenji Yamaguchi, Akira Osada
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Publication number: 20170298505Abstract: 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: ApplicationFiled: September 18, 2015Publication date: October 19, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
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Publication number: 20170297117Abstract: 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: ApplicationFiled: September 18, 2015Publication date: October 19, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
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Publication number: 20170216930Abstract: A surface-coated cutting tool has a hard coating layer and a tool body, which is coated with a lower layer including a TiCN layer having at least an NaCl type face-centered cubic crystal structure and an upper layer formed of a TiAlCN layer having a single phase crystal structure of NaCl type face-centered cubic crystals or a mixed phase crystal structure of NaCl type face-centered cubic crystals and hexagonal crystals. The tool body is further coated with an outermost surface layer including an Al2O3 layer, when the layer of a complex nitride or complex carbonitride of Ti and Al is expressed by the composition formula: (Ti1-xAlx)(CyN1-y), the average amount Xave of Al in Ti and Al and the average amount Yave of C in C and N (both Xave and Yave are atomic ratios) respectively satisfy 0.60?Xave?0.95 and 0?Yave?0.005.Type: ApplicationFiled: September 29, 2015Publication date: August 3, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Kenichi SATO, Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20170198400Abstract: 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: ApplicationFiled: May 28, 2015Publication date: July 13, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20170165758Abstract: 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: ApplicationFiled: April 23, 2015Publication date: June 15, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenji YAMAGUCHI
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Publication number: 20170113285Abstract: 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: ApplicationFiled: March 26, 2015Publication date: April 27, 2017Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenichi SATO, Kenji YAMAGUCHI
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Publication number: 20160333478Abstract: A chemical vapor deposition apparatus includes: a reaction chamber in which deposition materials are housed a gas supply tube provided in the reaction chamber and a rotary drive device that rotates the gas supply tube about a rotation axis. A an inside of the gas supply tube is divided into a first gas flowing section and a second gas flowing section both of which extend along the rotation axis. A first gas ejection port ejects a first gas flowing in the first gas flowing section into the reaction chamber, and a second gas ejection port ejects a second gas flowing in the second gas flowing section into the reaction chamber. The first port and the second port form an ejection port pair in a plane perpendicular to the rotation axis.Type: ApplicationFiled: January 9, 2015Publication date: November 17, 2016Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenji YAMAGUCHI
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Patent number: 9452478Abstract: A surface-coated cutting tool includes a body and a hard coating layer coating the cutting tool body. In the surface-coated cutting tool, the (Ti1-XAlX)(CYN1-Y) layer with a cubic crystal structure (X and Y are atomic ratio, and satisfy 0.60?X?0.90 and 0.0005?Y?0.005, respectively) is vapor-deposited on the body by a chemical vapor deposition method. The Al content XL is 0.55?XL?0.70, and the grain size DL is 0.1 ?m or less in the (Ti1-XAlX)(CYN1-Y) layer near the interface between the body and the complex carbonitride layer. The Al content XH 0.80?XH?0.95 and the average grain size DH is 0.5 ?m to 2 ?m in the (Ti1-XAlX)(CYN1-Y) layer near the outer surface side. Furthermore, the Al content ratio and the grain size in the (Ti1-XAlX)(CYN1-Y) layer gradually increase to the outer surface side.Type: GrantFiled: March 11, 2013Date of Patent: September 27, 2016Assignee: MITSUBISHI MATERIALS CORPORATIONInventors: Makoto Igarashi, Sho Tatsuoka, Naoyuki Iwasaki, Akira Osada
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Patent number: 9415446Abstract: A coated tool with a hard coating layer, which has an excellent hardness and heat insulating effect; and exhibits an excellent chipping resistance and an excellent fracturing resistance for a long-term usage, is provided. The hard coating layer included in the coated tool has a chemically vapor deposited alternate laminated structure, which is made of: a region A layer and a region B layer, each of which is expressed by the composition formula of (Ti1-xAlx)(CyN1-y); and has the average total layer thickness of 1-10 ?m. In the region A layer, relationships, 0.70?x?0.80 and 0.0005?y?0.005, are satisfied; the average grain width W is 0.1 ?m or less; and the average grain length L is 0.1 ?m or less. In the region B layer, relationships, 0.85?x?0.95 and 0.0005?y?0.005, are satisfied; the average grain width W is 0.1-2.0 ?m; and the average grain length L is 0.5-5.0 ?m.Type: GrantFiled: August 28, 2013Date of Patent: August 16, 2016Assignee: Mitsubishi Materials CorporationInventors: Sho Tatsuoka, Naoyuki Iwasaki, Kenji Yamaguchi, Akira Osada
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Publication number: 20160040285Abstract: 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: ApplicationFiled: April 1, 2014Publication date: February 11, 2016Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho TATSUOKA, Kenji YAMAGUCHI, Akira OSADA
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Publication number: 20150217378Abstract: A coated tool with a hard coating layer, which has an excellent hardness and heat insulating effect; and exhibits an excellent chipping resistance and an excellent fracturing resistance for a long-term usage, is provided. The hard coating layer included in the coated tool has a chemically vapor deposited alternate laminated structure, which is made of: a region A layer and a region B layer, each of which is expressed by the composition formula of (Ti1-xAlx)(CYN1-y); and has the average total layer thickness of 1-10 ?m. In the region A layer, relationships, 0.70?x?0.80 and 0.0005?y?0.005, are satisfied; the average grain width W is 0.1 ?m or less; and the average grain length L is 0.1 ?m or less. In the region B layer, relationships, 0.85?x?0.95 and 0.0005?y?0.005, are satisfied; the average grain width W is 0.1-2.0 ?m; and the average grain length L is 0.5-5.0 ?m.Type: ApplicationFiled: August 28, 2013Publication date: August 6, 2015Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Sho Tatsuoka, Naoyuki Iwasaki, Kenji Yamaguchi, Akira Osada
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Publication number: 20150158094Abstract: A surface-coated cutting tool includes a body and a hard coating layer coating the cutting tool body. In the surface-coated cutting tool, the (Ti1-XAlX)(CYN1-Y) layer with a cubic crystal structure (X and Y are atomic ratio, and satisfy 0.600?X?0.90 and 0.0005?Y?0.005, respectively) is vapor-deposited on the body by a chemical vapor deposition method. The Al content XL is 0.55?XL?0.70, and the grain size DL is 0.1 ?m or less in the (Ti1-XAlX)(CYN1-Y) layer near the interface between the body and the complex carbonitride layer. The Al content XH 0.80?XH?0.95 and the average grain size DH is 0.5 ?m to 2 ?m in the (Ti1-XAlX)(CYN1-Y) layer near the outer surface side. Furthermore, the Al content ratio and the grain size in the (Ti1-XAlX)(CYN1-Y) layer gradually increase to the outer surface side.Type: ApplicationFiled: March 11, 2013Publication date: June 11, 2015Applicant: MITSUBISHI MATERIALS CORPORATIONInventors: Makoto Igarashi, Sho Tatsuoka, Naoyuki Iwasaki, Akira Osada
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Patent number: 8962126Abstract: A surface-coated cutting tool, which has a hard-coating layer with excellent chipping and fracturing resistances in a high speed intermittent cutting work, is provided. The surface-coated cutting tool includes a cutting tool body, which is made of WC cemented carbide or TiCN-based cermet, and a hard-coating layer, which is vapor deposited on the cutting tool body and has a lower layer and an upper layer. The lower layer is a Ti compound layer, and the upper layer is an aluminum oxide layer. There is a micropore-rich layer in the lower layer in the vicinity of the interface between the lower and upper layers. There are micropores with diameters of 2 to 70 nm in the micropore-rich layer. The diameters of the micropores in the micropore-rich layer shows a bimodal distribution pattern.Type: GrantFiled: February 2, 2012Date of Patent: February 24, 2015Assignee: Mitsubishi Materials CorporationInventors: Sho Tatsuoka, Kohei Tomita, Akira Osada, Eiji Nakamura
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Publication number: 20120202032Abstract: A surface-coated cutting tool, which has a hard-coating layer with excellent chipping and fracturing resistances in a high speed intermittent cutting work, is provided. The surface-coated cutting tool includes a cutting tool body, which is made of WC cemented carbide or TiCN-based cermet, and a hard-coating layer, which is vapor deposited on the cutting tool body and has a lower layer and an upper layer. The lower layer is a Ti compound layer, and the upper layer is an aluminum oxide layer. There is a micropore-rich layer in the lower layer in the vicinity of the interface between the lower and upper layers. There are micropores with diameters of 2 to 70 nm in the micropore-rich layer. The diameters of the micropores in the micropore-rich layer shows a bimodal distribution pattern.Type: ApplicationFiled: February 2, 2012Publication date: August 9, 2012Applicant: Mitsubishi Materials CorporationInventors: Sho TATSUOKA, Kohei TOMITA, Akira OSADA, Eiji NAKAMURA