Silicon Containing Patents (Class 148/307)
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Patent number: 7799147Abstract: The performance index ??×Q of a magnetic core member, in which an Fe—Si—Cr alloy is used, is further improved. A flaky soft magnetic metal powder, which is used in a magnetic core member for an RFID antenna comprising the above flaky soft magnetic metal powder and a binder, wherein it is composed of an Fe—Si—Cr alloy having an Ms (saturation magnetization)/Hc (coercive force) of 0.8 to 1.5 (mT/Am?1) in an applied magnetic field of 398 kA/m. In the present invention, it is preferable that the flaky soft magnetic metal powder consists of 7 to 23 at % of Si, 15 at % or less of Cr (excluding 0), and the balance being Fe and inevitable impurities, and that it has a weight-average particle size D50 of 5 to 30 ?m and an average thickness of 0.1 to 1 ?m.Type: GrantFiled: March 15, 2007Date of Patent: September 21, 2010Assignee: TDK CorporationInventors: Atsuhito Matsukawa, Katsuhiko Wakayama, Yoshihito Hirai
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Patent number: 7767035Abstract: A metallic magnetic material for magnetic element for magnetic element of a choke coil and an SMD choke power coil for accommodating low voltage and high current in a personal computer, graphic card, high frequency power supply, etc, is prepared by baking a powder of Fe—Si—Al alloy sendust, obtained by an atomization process and having an average particle diameter of 10 to 70 ?m, at 600° C. to 1000° C. in air or in an oxidizing atmosphere and mixing the baked sendust with 3 to 45 wt % of a carbonyl iron powder with an average particle diameter of 1 to 10 ?m. The metallic magnetic material for magnetic element according to the present invention is used in a coil-embedded SMD power choke coil having a square or rectangular shape with a height of 1 mm to 7 mm and with a length of one side being 3 mm to 13 mm.Type: GrantFiled: November 30, 2007Date of Patent: August 3, 2010Assignee: Sekisin Industry Co., Ltd.Inventors: Namio Sato, Yotaro Toyoshima, Katsutoshi Yamamoto
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Patent number: 7763122Abstract: The invention relates to a non-oriented electrical steel sheet, widely used as an iron core in electric devices, and to a method of manufacturing the same. The non-oriented electrical sheet includes 0.004 wt. % or less C; 1.0-3.5 wt. % Si; 0.02 wt. % or less P; 0.001 wt. % or less S; 0.2˜2.5 wt. % Al; 0.003 wt. % or less N; 0.004 wt. % or less Ti; Mn, in which the amount thereof is represented by the following formula (1): 0.10+100×S(wt. %)?Mn(wt. %)?0.21+200×S(wt. %)—(1); a balance of iron; and inevitable impurities.Type: GrantFiled: December 18, 2006Date of Patent: July 27, 2010Assignee: POSCO Co., Ltd.Inventors: Byung-Keun Bae, Jae-Kwan Kim
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Patent number: 7744702Abstract: A soft magnetic alloy powder containing Fe—Ni-based crystal particles is provided as one capable of adequately reducing core loss of a powder magnetic core and achieving satisfactory magnetic characteristics at an effective operating temperature of an element. The present invention provides a soft magnetic alloy powder containing Fe—Ni-based crystal particles containing 45 to 55 mass % Fe and 45 to 55 mass % Ni, relative to a total mass of Fe and Ni, and containing 1 to 12 mass % Co and 1.2 to 6.5 mass % Si, relative to a total mass of Fe, Ni, Co, and Si.Type: GrantFiled: October 19, 2007Date of Patent: June 29, 2010Assignee: TDK CorporationInventors: Hiroshi Tomita, Hideharu Moro, Kesaharu Takatoh, Koyu Enda
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Patent number: 7740796Abstract: Provided is iron silicide powder in which the content of oxygen as the gas component is 1500 ppm or less, and a method of manufacturing such iron silicide powder including the steps of reducing iron oxide with hydrogen to prepare iron powder, heating the iron powder and Si powder in a non-oxidizing atmosphere to prepare synthetic powder containing FeSi as its primary component, and adding and mixing Si powder once again thereto and heating this in a non-oxidizing atmosphere to prepare iron silicide powder containing FeSi2 as its primary component. The content of oxygen as the gas component contained in the iron silicide powder will decrease, and the iron silicide powder can be easily pulverized as a result thereof. Thus, the mixture of impurities when the pulverization is unsatisfactory will be reduced, the specific surface area of the iron silicide powder will increase, and the density can be enhanced upon sintering the iron silicide powder.Type: GrantFiled: September 1, 2003Date of Patent: June 22, 2010Assignee: Nippon Mining & Metals Co., LtdInventors: Kunihiro Oda, Ryo Suzuki
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Patent number: 7736444Abstract: Grain oriented electrical steel is made in a manner that the grains are selectively grown to obtain a crystal structure known as cube-on-edge and the grains are largely aligned in the rolling direction. Selection of chemistry and process route along with thin slab continuous casting enables the production of Grain oriented electrical steel such that less energy is consumed in the process, certain process steps can be combined, yield is better and the product can be manufactured within a wider process control tolerance.Type: GrantFiled: April 16, 2007Date of Patent: June 15, 2010Assignee: Silicon Steel Technology, Inc.Inventors: Vladimir Pavlovich Shumilov, Alexandr G. Shalimov, Leonard Mironov, Urij Christiakov
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Publication number: 20100132846Abstract: Spring element, in particular spring rail for wipers, in particular of motor vehicles, with a low tendency to vibrate or a high attenuation, made from a ferritic chromium steel comprising 0.03 to 0.12% of carbon, 0.2 to 0.9% of silicon, 0.3 to 1% of manganese, 13 to 20% of chromium, 0.1 to 2.0% of molybdenum, 0.05 to 1.0% of copper, 0.02 to 0.05% of nitrogen, less than 0.01% of titanium, 0.01 to 0.10% of niobium and 0.02 to 0.25% of vanadium, remainder iron.Type: ApplicationFiled: February 4, 2010Publication date: June 3, 2010Applicant: Stahlwerk Ergste Westig GmbHInventors: OSKAR PACHER, Gisbert Kloss-Ulitzka, Victor Castro
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Patent number: 7678204Abstract: The present invention: provides a good-workability and high-strength cold-rolled steel sheet excellent in post-painting corrosion resistance to the extent of securing excellent resistance to salt warm water immersion which is a good-workability and high-strength cold-rolled steel sheet excellent in post-painting corrosion resistance characterized in that: said steel sheet contains, in mass, 0.16 to 0.19% C, 1.10 to 1.30% Si, 1.50 to 1.60% Mn, not more than 0.1% P and 0.015 to 0.050% Al, with the balance consisting of Fe and unavoidable impurities; the average of the amount of Si incrassating on the surface of said steel sheet is not more than 20 times the Si concentration in said steel sheet; and the area percentage of the portions where the ratio of the Si concentration on the surface of said steel sheet to the Si concentration in said steel sheet is not less than 10 is not more than 95%.Type: GrantFiled: December 9, 2003Date of Patent: March 16, 2010Assignees: Nippon Steel Corporation, Honda Motor Co., Ltd.Inventors: Toshiyuki Katsumi, Kazuhiko Honda, Koki Tanaka, Kaoru Yamazaki, Takahiro Tanae, Katsuyoshi Kaneko, Yoshikazu Umeno, Yoshitaka Okitsu
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Patent number: 7670443Abstract: A method of making a magnetic alloy material includes the steps of: preparing a melt of an alloy material having a predetermined composition; rapidly cooling and solidifying the melt to obtain a rapidly solidified alloy represented by: Fe100-a-b-cREaAbTMc where RE is at least one rare-earth element selected from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er and Tm and including at least about 90 at % of La; A is at least one element selected from Al, Si, Ga, Ge and Sn; TM is at least one transition metal element selected from Sc, Ti, V, Cr, Mn, Co, Ni, Cu and Zn; and 5 at %?a?10 at %, 4.7 at %?b?18 at % and 0 at %?c?9 at %; and producing a compound phase having an NaZn13-type crystal structure in at least about 70 vol % of the rapidly solidified alloy.Type: GrantFiled: February 12, 2007Date of Patent: March 2, 2010Assignee: Hitachi Metals, Ltd.Inventors: Ryosuke Kogure, Hirokazu Kanekiyo, Takeshi Nishiuchi, Satoshi Hirosawa
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Publication number: 20100043927Abstract: An alloy composition of FeaBbSicPxCyCuz. Parameters meet the following conditions: 79?a?86 atomic %; 5?b?13 atomic %; 0?c?8 atomic %; 1?x?8 atomic %; 0?y?5 atomic %, 0.4?z?1.4 atomic %; and 0.08?z/x?0.8. Or, parameters meet the following conditions: 81?a?86 atomic %; 6?b?10 atomic %; 2?c?8 atomic %; 2?x?5 atomic %; 0?y?4 atomic %; 0.4?z?1.4 atomic %, and 0.08?z/x?0.8.Type: ApplicationFiled: August 20, 2009Publication date: February 25, 2010Inventor: Akihiro MAKINO
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Patent number: 7662242Abstract: Non-oriented electrical steel sheet superior in core loss characterized by containing, by mass %, C: 0.01% or less, Si: 0.1% to 7.0%, Al: 0.1% to 3.0%, Mn: 0.1% to 2.0%, N: 0.005% or less, Ti: 0.02% or less, REM: 0.05% or less, S: 0.005% or less, O: 0.005% or less, and a balance of iron and unavoidable impurities and having a mass % of S shown by [S], a mass % of O shown by [O], a mass % of REM shown by [REM], a mass % of Ti shown by [Ti], and a mass % of N shown by [N] satisfying [Formula 1] and [Formula 2]: [REM]2×[O]2×[S]?1×10?15??[Formula 1] ([REM]2×[O]2×[S])÷([Ti]×[N])?1×10?10??[Formula 2].Type: GrantFiled: September 28, 2005Date of Patent: February 16, 2010Assignee: Nippon Steel CorporationInventors: Masafumi Miyazaki, Wataru Ohashi, Yousuke Kurosaki, Takeshi Kubota, Hiroshi Harada, Tomohiro Konno, Yutaka Matsumoto, Koichi Kirishiki
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Patent number: 7658807Abstract: The present invention relates to a hot-rolled steel strip for further processing to form non-grain oriented electrical sheet with the following composition (in % by weight) C: <0.02%, Mn: ?1.2%, Si: 0.1-4.4%, Al 0.1-4.4%, wherein the sum formed from the Si content and twice the Al content is <5%, P: <0.15%, Sn: ?0.20%, Sb: ?0.20%, the remainder iron and unavoidable impurities, with a strip thickness which is at most 1.8 mm, and with a partially softened structure which is characterised by a high intensity for the ? fibre (fibre representation of orientation distribution functions) in the region of 0° to 60°, wherein the ratio I112/I001 formed from the intensity I112 of the position (112) <110> to the intensity I001 of the position (001) <110> is >0.4 and the ratio I111/I001 formed from the intensity I111 of the position (111) <110> to the intensity I001 of the position (001) <110> is >0.2.Type: GrantFiled: October 23, 2002Date of Patent: February 9, 2010Assignee: ThyssenKrupp Steel AGInventors: Karl Ernst Friedrich, Wolfgang Rasim, Joergen Schneider, Rudolf Kawalla, Carl-Dieter Wuppermann
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Publication number: 20090320961Abstract: A magnet core is required to be particularly dense, made of alloys produced in a rapid solidification process and have a minimal coercitive field strength. To achieve these aims, a coarse-grain powder fraction is first produced from an amorphous strip of a soft magnetic alloy. In addition, at least one fine-grain powder fraction is produced from a nanocrystalline strip of a soft magnetic alloy. The particle fractions are then mixed to produce a multi-modal powder, wherein the particles of the coarse-grain particle fraction have an amorphous structure and the particles of the fine-grain powder fraction have a nanocrystalline structure. The multi-modal powder is then pressed to produce a magnet core.Type: ApplicationFiled: July 11, 2007Publication date: December 31, 2009Applicant: VACUUMSHMELZE GMBH & CO.KGInventor: Markus Brunner
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Patent number: 7608154Abstract: A nonoriented electrical steel sheet excellent in core loss comprising copper sulfides with a sphere-equivalent radius of 100 nm or less, wherein the number density of the copper sulfides is less than 1×1010 [inclusions/mm3]. Preferably, the percentage of the number of copper sulfides with a (major axis)/(minor axis) ratio of more than 2 per total number of copper sulfides is 30% or less. The steel preferably further comprises Cu of 0.5 mass % or less and REM of 0.0005% or more and 0.03% or less, wherein the following expression (1) or expressions (1) and (2) are met: [REM]×[Cu]3?7.5×10?11??(1), ([REM]?0.003)0.1×[Cu]2?1.25×10?4??(2).Type: GrantFiled: September 9, 2005Date of Patent: October 27, 2009Assignee: Nippon Steel CorporationInventors: Wataru O-hashi, Masafumi Miyazaki, Yousuke Kurosaki, Takeshi Kubota
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Patent number: 7601229Abstract: A method for making soft magnetic material includes: a first heat treatment step applying a temperature of at least 400 deg C. and less than 900 deg C. to metal magnetic particles; a step for forming a plurality of compound magnetic particles in which said metal magnetic particles are surrounded by insulation film; and a step for forming a shaped body by compacting a plurality of compound magnetic particles. This provides a method for making soft magnetic material that provides desired magnetic properties.Type: GrantFiled: October 1, 2004Date of Patent: October 13, 2009Assignee: Sumitomo Electric Industries Ltd.Inventors: Haruhisa Toyoda, Hirokazu Kugai, Kazuhiro Hirose, Naoto Igarashi, Takao Nishioka
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Publication number: 20090220372Abstract: Disclosed is a low cost, low magnetostriction body which is decreased only in magnetostriction while maintaining magnetic characteristics such as loss and saturation magnetization at desired values. Also disclosed is a dust core using such a low magnetostriction body. Specifically disclosed is a low magnetostriction body obtained by shaping a soft magnetic material powder added with an organic compound having an effect of changing the magnetostriction of the soft magnetic material when combined with it, and heat-treating a green compact in an inert atmosphere. The absolute value of the magnetostriction ?O-P (1 T/50 Hz) of the low magnetostriction body is not more than 1.0×10?6. Also specifically disclosed is a dust core using such a low magnetostriction body.Type: ApplicationFiled: May 23, 2006Publication date: September 3, 2009Inventors: Takeshi Hattori, Shin Tajima, Masaki Sugiyama, Hidefumi Kishimoto, Toshiya Yamaguchi, Tadayoshi Kikkou
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Publication number: 20090184790Abstract: A soft magnetic alloy consists essentially of 5 percent by weight?Co?30 percent by weight, 1 percent by weight?Cr?20 percent by weight, 0.1 percent by weight?Al?2 percent by weight, 0 percent by weight?Si?1.5 percent by weight, 0.017 percent by weight?Mn?0.2 percent by weight, 0.01 percent by weight?S?0.05 percent by weight where Mn/S is >1.7, 0 percent by weight?O?0.0015 percent by weight, und 0.0003 percent by weight?Ce?0.05 percent by weight, 0 percent by weight?Ca?0.005 percent by weight and the remainder iron, where 0.117 percent by weight?(Al+Si+Mn+V+Mo+W+Nb+Ti+Ni)?5 percent by weight.Type: ApplicationFiled: July 24, 2008Publication date: July 23, 2009Applicant: Vacuumschmelze GmbH & Co. KGInventors: Witold Pieper, Joachim Gerster
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Publication number: 20090145522Abstract: Disclosed are soft magnetic alloys that consist essentially of 10% by weight?Co?22% by weight, 0% by weight?V?4% by weight, 1.5% by weight?Cr?5% by weight, 1% by weight?Mn?2% by weight, 0% by weight?Mo?1% by weight, 0.5% by weight?Si?1.5% by weight, 0.1% by weight?Al?1.0% by weight, rest iron. Also disclosed are methods of making the alloys, and products containing them, such as actuator systems, electric motors, and the like.Type: ApplicationFiled: July 27, 2007Publication date: June 11, 2009Applicant: Vacuumschmelze GmbH & Co. KGInventors: Witold Pieper, Joachim Gerster
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Patent number: 7540927Abstract: A soft magnetic steel has, on the mass basis, a carbon content of 0.0015% to 0.02%, a manganese content of 0.15% to 0.5%, and a sulfur content of 0.015% to 0.1%, has a ratio Mn/S of 5.7 or more, and contains a single-phase ferrite microstructure as its metallographic structure, in which the density of precipitated FeS grains having a major axis of 0.1 ?m or more is 5000 grains/mm2 or less. This steel ensures excellent magnetic properties with less variation after magnetic annealing, exhibits excellent machinability and cold forgeability during production processes, and can thereby yield a steel part even having a complicated shape and a large size in a high yield.Type: GrantFiled: July 10, 2006Date of Patent: June 2, 2009Assignee: Kobe Steel, Ltd.Inventor: Masamichi Chiba
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Patent number: 7513959Abstract: When a non-oriented electrical steel sheet is manufactured, simultaneously having superior magnetic properties and high strengths, a composition containing 0.02% or less of C, 4.5% or less of Si, 5.0% or less (including 0) of Ni, and 0.2% to 4.0% of Cu is used, and a solute Cu is allowed to appropriately remain in finish annealing. In the steel sheet thus obtained, finely shaped Cu is precipitated by aging treatment, and while the magnetic properties are not degraded, the yield stress is increased to not less than CYS (MPa) represented by the following formula: note CYS=180+5,600[% C]+95[% Si]+50[% Mn]+37[% Al]+435[% P]+25[% Ni]+22d?1/2 where d is an average grain diameter (mm) of crystal grains.Type: GrantFiled: December 3, 2003Date of Patent: April 7, 2009Assignee: JFE Steel CorporationInventors: Minoru Takashima, Masaaki Kohno, Katsumi Yamada, Masaki Kawano, Kaoru Sato
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Patent number: 7501029Abstract: A high-strength, high-permeability steel sheet for picture tube band comprises, in mass percent, C: 0.003-0.010%, Si: 0.5-1.0%, Mn: 1.0-2.0%, P: 0.04-0.15%, S: not more than 0.02%, Al: not more than 0.030%, N: not more than 0.004% and the balance of Fe and unavoidable impurities, has a chemical composition satisfying C×Mn×P?2.5×10?4, and has a ferrite crystal grain diameter of 10-100 ?m and a yield stress of 300 N/mm2 or higher, and preferably has a specific permeability ?0.35 in a DC magnetic field of 0.35 Oe of 400 or higher. The steel sheet can be produced by regulating the hot-rolling coiling temperature to 600-700° C. and selecting an appropriate combination of the cold rolling reduction ratio and a final annealing temperature in the range of 750-900° C.Type: GrantFiled: April 12, 2004Date of Patent: March 10, 2009Assignee: Nisshin Steel Co., Ltd.Inventors: Tsunetoshi Suzaki, Kentaro Hirata, Yuichi Higo
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Publication number: 20090044881Abstract: Reheating a grain-oriented electrical steel sheet slab comprising predetermined components to 1280° C. or more and a solid solution temperature of inhibitor substances or more, hot rolling, annealing, and cold rolling it, decarburization annealing it, nitriding it in a strip running state, coating an annealing separator, and finish annealing it during which making a precipitation ratio of N as AlN after hot rolling 20% or less, making a mean grain size of primary recrystallization 7 ?m to less than 20 ?m, and making a nitrogen increase ?N in the nitridation within a range of Equation (1) and making nitrogen contents ?N1 and ?N2 (front and back, mass %) of a 20% thickness portion of one surface of the steel strip (sheet) within a range of Equation (2): 0.007?([N]?14/48×[Ti])??N?[solAl]×14/27?([N]?14/48×[Ti])+0.0025??Equation (1) |?N1??N2|/?N?0.Type: ApplicationFiled: May 19, 2006Publication date: February 19, 2009Inventors: Tomoji Kumano, Kenichi Murakami, Yoshiyuki Ushigami
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Publication number: 20090039994Abstract: A soft magnetic alloy consists essentially of 10 percent by weight ?Co?22 percent by weight, 0 percent by weight ?V?4 percent by weight, 1.5 percent by weight ?Cr?5 percent by weight, 0 percent by weight <Mn<1 percent by weight, 0 percent by weight ?Mo?1 percent by weight, 0.5 percent by weight ?Si?1.5 percent by weight, 0.1 percent by weight ?Al?1.0 percent by weight and the remainder iron, the content of the elements chromium and manganese and molybdenum and aluminium and silicon and vanadium being 4.0 percent by weight ?(Cr+Mn+Mo+Al+Si+V)?9.0 percent by weight.Type: ApplicationFiled: July 24, 2008Publication date: February 12, 2009Applicant: Vacuumschmelze GmbH & Co. KGInventors: Witold Pieper, Joachim Gerster
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Patent number: 7465364Abstract: An Fe—Cr—Si based non-oriented electrical steel sheet contains 2.5% to 10% by mass of Si, 1.5% to 20% by mass of Cr, 0.006% by mass or less of C, 0.002% by mass or less of N, 0.005% by mass or less of S, 0.005% by mass or less of Ti, 0.005% by mass or less of Nb, and as necessary, 0.1% to 2% by mass of Al and at least one of 0.005% to 1% by mass of Sb and 0.005% to 1% by mass of Sn, and the balance being Fe and incidental impurities, wherein the electrical resistivity of the steel is 60 ??cm or more, and the number of nitrides containing chromium per mm2 in the interior of the steel sheet is 2,500 or less. Consequently, the problem that high electrical resistance resulting from the high Si content and high Cr content is not satisfactorily utilized is advantageously solved, and it is possible to provide a non-oriented electrical steel sheet having excellent magnetic properties in the high-frequency range, in particular, in a frequency range of 1 kHz or more.Type: GrantFiled: December 18, 2003Date of Patent: December 16, 2008Assignee: JFE Steel CorporationInventors: Takeshi Omura, Masaaki Kohno, Masaki Kawano
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Patent number: 7442263Abstract: The invention relates to a transductor regulator with a magnetic core which is made up of a nanocrystalline alloy which is almost free of magnetorestriction. The core has as low cyclic magnetization losses as possible and as rectangular a hysterisis cycle as possible. Said alloy has the composition: FeaCobCucM?dSixByM?z, M? representing an element from the group V, Nb, Ta, Ti, Mo, W, Zr, Hf or a combination of these and M? representing an element from the group C, P, Ge, As, Sb, In, O, N or a combination of these and the following conditions applying: a+b+c+d+x+y+z=100%, with a=100%?b?c?d?x?y?z, 0?b?15, 0.5?c?2, 0.1?d?6, 2?x?20, 2?y?18, 0?z?10 and x+y>18. The inventive transductor regulators are particularly advantageously used in motor vehicle voltage supplies, rail power supplies or in aircraft power supplies.Type: GrantFiled: September 7, 2001Date of Patent: October 28, 2008Assignee: Vacuumschmelze GmbH & Co. KGInventors: Wulf Günther, Roman Klinger, Werner Loges, Jörg Petzold
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Patent number: 7399369Abstract: The present invention is a grain-oriented electrical steel sheet characterized in that Bi is present at 0.01 to less than 1,000 ppm in terms of mass at the interface of the substrate steel and the primary film of the grain-oriented electrical steel sheet. The grain-oriented electrical steel sheet is produced by any of the processes of: before decarburization annealing, applying preliminary annealing for 1 to 20 sec. at 700° C. or higher and controlling an atmosphere in the temperature range; controlling the maximum attaining temperature B (° C.) before final cold rolling so that the maximum attaining temperature B may satisfy the expression, ?10×ln(A)+1,100?B?10×ln(A)+1,220, in accordance with a Bi content A (ppm) and at the same time heating the steel sheet cold rolled to the final thickness to 700° C. or higher within 10 sec. or at a heating rate of 100° C./sec. or more before decarburization annealing, or immediately thereafter applying preliminary annealing for 1 to 20 sec. at 700° C.Type: GrantFiled: July 16, 2002Date of Patent: July 15, 2008Assignee: Nippon Steel CorporationInventors: Eiichi Nanba, Katsuyuki Yanagihara, Satoshi Arai, Shuichi Yamazaki, Fumikazu Ando, Kazutoshi Takeda, Yousuke Kurosaki, Nobuo Tachibana
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Publication number: 20080121314Abstract: The present invention relates to technology for manufacturing electrical steel sheets having excellent magnetic properties through the control of a hot-rolled texture using the phase transformation of steel. More particularly, it relates to a non-oriented electrical steel sheet that has reduced iron loss and increased magnetic flux density by controlling alloy component elements and optimizing hot-rolling conditions, even though hot-rolled sheet annealing is not carried out, as well as a manufacturing method thereof. More specifically, the invention provides a non-oriented electrical steel sheet which has excellent magnetic properties while hot-rolled sheet annealing can be omitted, the steel sheet being comprised of 0.005 wt % or less of C, 1.0-3.0 w % of Si, 0.1-2.0 wt % of Mn, 0.1 wt % or less of P, 0.1-1.5 wt % of Al, and a remainder of Fe and other inevitable impurities, in which the relationship between the elements Mn and Al satisfies an equation of ?0.2 <m(=Mn?Al)<1.Type: ApplicationFiled: December 20, 2005Publication date: May 29, 2008Inventors: Jae-Young Choi, Byung-Keun Bae, Jong-Tae Park, Jae-Kwan Kim, Chel-Min Park
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Patent number: 7377986Abstract: The present invention relates to a method for producing a non-oriented electrical steel with improved magnetic properties and improved resistance to ridging, brittleness, nozzle clogging and magnetic aging. The chromium bearing steel is produced from a steel melt which is cast as a thin slab or conventional slab, cooled, hot rolled and/or cold rolled into a finished strip. The finished strip is further subjected to at least one annealing treatment wherein the magnetic properties are developed, making the steel sheet of the present invention suitable for use in electrical machinery such as motors or transformers.Type: GrantFiled: July 27, 2006Date of Patent: May 27, 2008Assignee: AK Steel Properties, Inc.Inventors: Jerry W. Schoen, Robert J. Comstock, Jr.
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Patent number: 7371271Abstract: An object of the present invention is to provide a composite soft magnetic sintered material that has high density, high mechanical strength and high relative magnetic permeability at high frequencies and, in order to achieve this object, the present invention provides a method of producing the composite soft magnetic sintered material, which comprises mixing a composite soft magnetic powder, that consists of iron powder, Fe—Si based soft magnetic iron alloy powder, Fe—Al based soft magnetic iron alloy powder, Fe—Si—Al based soft magnetic iron alloy powder, Fe—Cr based soft magnetic iron alloy powder or nickel-based soft magnetic alloy powder (hereinafter these powders are referred to as soft magnetic metal powder) of which particles arc coated with a ferrite layer which has a spinel structure, with 0.05 to 1.Type: GrantFiled: March 29, 2002Date of Patent: May 13, 2008Assignee: Mitsubishi Materials PMG CorporationInventors: Kazunori Igarashi, Ryoji Nakayama, Koichiro Morimoto, Muneaki Watanabe
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Publication number: 20080099106Abstract: Disclosed are soft magnetic alloys that consist essentially of 10% by weight?Co?22% by weight, 0% by weight?V?4% by weight, 1.5% by weight?Cr?5% by weight, 1% by weight?Mn?2% by weight, 0% by weight?Mo?1% by weight, 0.5% by weight?Si?1.5% by weight, 0.1% by weight?Al?1.0% by weight, rest iron. Also disclosed are methods of making the alloys, and products containing them, such as actuator systems, electric motors, and the like.Type: ApplicationFiled: July 27, 2007Publication date: May 1, 2008Applicant: Vacuumschmelze GmbH & Co. KGInventors: Witold Pieper, Joachim Gerster
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Publication number: 20070221297Abstract: The performance index ??×Q of a magnetic core member, in which an Fe—Si—Cr alloy is used, is further improved. A flaky soft magnetic metal powder, which is used in a magnetic core member for an RFID antenna comprising the above flaky soft magnetic metal powder and a binder, wherein it is composed of an Fe—Si—Cr alloy having an Ms (saturation magnetization)/Hc (coercive force) of 0.8 to 1.5 (mT/Am?1) in an applied magnetic field of 398 kA/m. In the present invention, it is preferable that the flaky soft magnetic metal powder consists of 7 to 23 at % of Si, 15 at % or less of Cr (excluding 0), and the balance being Fe and inevitable impurities, and that it has a weight-average particle size D50 of 5 to 30 ?m and an average thickness of 0.1 to 1 ?m.Type: ApplicationFiled: March 15, 2007Publication date: September 27, 2007Applicant: TDK CORPORATIONInventors: Atsuhito Matsukawa, Katsuhiko Wakayama, Yoshihito Hirai
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Patent number: 7195680Abstract: The invention relates to a soft magnetic alloy with the following composition in wt. %: 28%?Ni?34%, 0%?Co?4%, 0%?Cu?4%, 1%?Cr, 0%?Mo?8%, 0%?Nb?1%, 0%?Mn?2%, 0%?V?5%, 0%?W?5%, 0%?Si?4%, 0%?Al?4%, 0%?C?0.4%, optionally one or several elements selected from magnesium and calcium the content of which is such as to remain below 0.1%, the rest being iron and impurities from production. The chemical composition furthermore satisfies the following relationships: 180.5?6×Ni2.5×(Cr+Mo+V+W+Si+Al)+4×(Co+Cu)?197.5 et Co+Cu?4%. The invention relates to the use thereof for production of a stator for use in a motor for clock-making.Type: GrantFiled: February 14, 2003Date of Patent: March 27, 2007Assignee: Imphy AlloysInventors: Thierry Waeckerle, Hervë Fraisse, Bruno Boulogne
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Patent number: 7141127Abstract: A low core loss magnetic alloy with a high saturation magnetic flux density, which has a composition represented by the general formula: (Fel-aCoa)100-y-cM?yX?c(atomic %) where M? represents at least one element selected from V, Ti, Zr, Nb, Mo, Hf, Ta, and W, X? represents Si and B, an Si content (atomic %) is smaller than a B content (atomic %), the B content is from 4 to 12 atomic %, and the Si content is from 0.01 to 5 atomic %, a, y, and c satisfy respectively 0.2<a<0.6, 6.5?y?15, 2?c?15, and 7?(y+c)?20, at least a part of an alloy structure being occupied by crystal grains having grain size of not larger than 50 nm, a saturation magnetic flux density Bs being not less than 1.65 T, and a core loss Pcm per unit volume in conditions at 80° C., f=20 kHz, and Bm=0.2 T being not more than 15 W/kg.Type: GrantFiled: January 14, 2004Date of Patent: November 28, 2006Assignee: Hitachi Metals, Ltd.Inventor: Yoshihito Yoshizawa
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Patent number: 7063754Abstract: The magnetic material for magnetic refrigeration according to the present invention has an NaZn13-type crystalline structure and comprises iron (Fe) as a principal element (more specifically, Fe is substituted for the position of “Zn”) and hydrogen (H) in an amount of 2 to 18 atomic % based on all constitutional elements. Preferably, the magnetic material for magnetic refrigeration preferably contains 61 to 87 atomic % of Fe, 4 to 18 atomic % of a total amount of Si and Al, 5 to 7 atomic % of La. The magnetic material for magnetic refrigeration exhibits a large entropy change in a room temperature region and no thermal hysteresis in a magnetic phase transition. Therefore, when a magnetic refrigeration cycle is configured using the magnetic material for magnetic refrigeration, a stable operation can be performed.Type: GrantFiled: April 1, 2003Date of Patent: June 20, 2006Assignee: Kabushiki Kaisha ToshibaInventors: Kazuaki Fukamichi, Asaya Fujita, Yoshiaki Iijima, Akiko Saito, Tadahiko Kobayashi, Masashi Sahashi
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Patent number: 7041148Abstract: High-permeability, low-core-loss soft magnetic composite materials, compositions containing the same, and methods for making the same are described. These magnetic materials are made by forming fiber or flake shaped particles from a ferromagnetic material, annealing the particles, and then coating an insulating material on the particles. These particles can then be compacted to form an article that has high permeability, high saturation, low core loss, and is a suitable replacement for laminations in various applications, such as motors.Type: GrantFiled: March 3, 2003Date of Patent: May 9, 2006Assignee: General Electric CompanyInventors: Luana Emiliana Iorio, Paul Alfred Siemers, Gerald Burt Kliman, Krishnamurthy Anand, Amitabh Verma
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Patent number: 6942740Abstract: A grain oriented electromagnetic steel sheet is free from an undercoating mainly composed of forsterite (Mg2SiO4), excellent in processability and magnetic properties and useful to production cost, and has a composition containing, by % by mass, 2.0 to 8.0% of Si, wherein secondary recrystallized grains contains fine crystal grains having a grain diameter of 0.15 mm to 0.50 mm at a rate of 2 grains/cm2 or more. In the process of producing the steel sheet, inhibitors are not utilized, and the fine crystal grains are achieved by high purification and low temperature final annealing.Type: GrantFiled: January 17, 2002Date of Patent: September 13, 2005Assignee: JFE Steel CorporationInventors: Yasuyuki Hayakawa, Mitsumasa Kurosawa, Seiji Okabe, Takeshi Imamura
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Patent number: 6938324Abstract: A motor stator core for achieving improved magnetizing feature in lower magnetic fields and reduced iron loss, and improving motor power. The stator core fabriated out of non-oriented electrical steel sheets is annealed by applying a magnetic field to the heated stator core at least in the temperature range from a temperature immediately above a Curie point thereof to 300° C. in the process of cooling the stator core. The magnetic field has the same direction as the direction of exitation of a stator in the motor when used to drive a motor. This increases the magnetic induction in lower magnetic fields in particular and reduces the hysteresis loss, with a reduction in the total iron loss of the stator. A motor using this stator core increases in saturation induction under exciting currents of higher frequncies, allowing enhanced motor power.Type: GrantFiled: October 21, 2003Date of Patent: September 6, 2005Assignees: Toyo Tessin Kogyo Co., Ltd., Hi-Z Co., Ltd.Inventors: Hiromichi Koshiishi, Tomiya Ogata, Shigeki Eguchi, Hideo Hasegawa
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Patent number: 6852174Abstract: There is disclosed a powder magnetic core in which a permeability does not easily drop even when an applied magnetic field intensifies, comprising: a bulk body containing a main component of a powder of an Fe-base alloy having a soft magnetic property, and the balance substantially including a heat-treated insulation binder and a void, wherein an aspect ratio of the powder is in a range of 1 to 1.5, and a volume ratio of the powder in the bulk body is in a range of 40 to 60 volume %, and an initial permeability (?0) has a value which satisfies 6??0?20, and a relation of ?/?0?0.5 is established between K and A, when the permeability is ? with an applied magnetic field of 24 kA/m.Type: GrantFiled: August 12, 2002Date of Patent: February 8, 2005Assignee: Daido Tokushuko Kabushiki KaishaInventors: Satoshi Takemoto, Takanobu Saito
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Publication number: 20040231752Abstract: The present invention is a grain-oriented electrical steel sheet characterized in that Bi is present at 0.01 to less than 1,000 ppm in terms of mass at the interface of the substrate steel and the primary film of the grain-oriented electrical steel sheet. The grain-oriented electrical steel sheet is produced by any of the processes of: before decarburization annealing, applying preliminary annealing for 1 to 20 sec. at 700° C. or higher and controlling an atmosphere in the temperature range; controlling the maximum attaining temperature B (° C.) before final cold rolling so that the maximum attaining temperature B may satisfy the expression, −10×ln(A)+1,100≦B≦10×ln(A)+1,220, in accordance with a Bi content A (ppm) and at the same time heating the steel sheet cold rolled to the final thickness to 700° C. or higher within 10 sec. or at a heating rate of 100° C./sec.Type: ApplicationFiled: June 22, 2004Publication date: November 25, 2004Inventors: Eiichi Nanba, Katsuyuki Yanagihara, Satoshi Arai, Shuichi Yamazaki, Fumikazu Ando, Kazutoshi Takeda
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Patent number: 6811900Abstract: When plural-layer ceramic coatings are formed on a surface of an grain-oriented silicon steel sheet after finish annealing according to the invention, TiNO coating is formed as a first coating layer by a hollow cathode process under an application of a high bias voltage to the steel sheet, whereby ceramic tension coatings having excellent coating adhesion property and hence tension applying effect can be formed. As a result, ultra-low iron loss grain-oriented silicon steel sheets having an excellent iron loss property even after stress relief annealing at high temperatures for a long time can be stably obtained.Type: GrantFiled: January 28, 2003Date of Patent: November 2, 2004Assignee: JFE Steel CorporationInventor: Yukio Inokuti
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Patent number: 6800146Abstract: A magnetic circuit member contains a matrix portion including iron and silicon; and graphite particles in the matrix. Each of the graphite particles has either a spherical shape or a compact vermicular shape. The inclusion of graphite particles having a relatively low conductivity in the matrix portion having a good magnetic property prevents eddy currents from forming in the magnetic circuit member in an alternating magnetic field, thus preserving the original magnetic property found in the absence of the alternating magnetic field. Each of the graphite particles has a spherical or compact vermicular shape that does not intercept magnetic flux passing through the material forming the magnetic circuit member. The graphite contained in the material improves liquidity of the melted material in casting, thus the magnetic circuit member can be manufactured by casting.Type: GrantFiled: March 19, 2002Date of Patent: October 5, 2004Assignee: Aisin Seiki Kabushiki KaishaInventors: Akikazu Matsumoto, Wataru Yagi
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Patent number: 6797410Abstract: A steel composition, in which, Si content is regulated to a given range and Nb and Cu or Ni, Mo are compositively added, and a recrystallization annealing is carried out to form an internal oxide layer just beneath a surface of a steel sheet and a surface oxide simultaneously formed on the surface of the steel sheet is removed by pickling. As a result, the formation of oxides of Si, Mn and the like is considerably decreased on the surface of the steel sheet in a subsequent heating before plating because the above internal oxide layer acts as a diffusion barrier. Thus, there can be obtained high tensile strength hot-dipped steel sheets having a considerably excellent plating property.Type: GrantFiled: May 13, 2002Date of Patent: September 28, 2004Assignee: JFE Steel CorporationInventors: Kazuhide Ishii, Kazuaki Kyono, Chiaki Kato, Kazuo Mochizuki
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Publication number: 20040149355Abstract: The present invention provides a non-oriented electrical steel sheet containing:Type: ApplicationFiled: December 24, 2003Publication date: August 5, 2004Inventors: Masaaki Kohno, Masaki Kawano, Atsuhito Honda, Akio Fujita
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Patent number: 6758915Abstract: The invention is a grain-oriented magnetic steel sheet having extremely low iron loss, suitable for use as an iron core material for transformers and power generators, and a method for producing the same. The method includes forming a coating layer on a surface of a steel sheet having a thickness of 0.27 mm or less by vapor deposition in a low oxidizing atmosphere with an oxygen partial pressure (Po2) of less than 0.1 atm and a total pressure of 0.1 atm or more. The steel sheet has extremely low iron loss with a thickness of 0.27 mm or less and includes a coating layer formed by vapor deposition on a matrix surface.Type: GrantFiled: December 5, 2002Date of Patent: July 6, 2004Assignee: JFE Steel CorporationInventors: Minoru Takashima, Mineo Muraki, Hiroi Yamaguchi, Mitsumasa Kurosawa, Michiro Komatsubara
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Patent number: 6723179Abstract: A soft magnetism metal powder having a majority of particles, each of which, when cross-sectioned, has no greater than ten crystal particles on average, may be coated on an outer surface of each of the particles with a resistive material having a higher resistivity than the underlying parent phase. The soft magnetism metal powder may be prepared by heating a soft magnetism metal powder to a high temperature in a high temperature atmosphere, thereby reducing the number of crystal particles in each of the soft magnetism metal powder particles. A soft magnetism metal formed body may be prepared by pressing the soft magnetism metal particles at a sufficient temperature and pressure.Type: GrantFiled: October 16, 2001Date of Patent: April 20, 2004Assignee: Aisin Seiki Kabushiki KaishaInventors: Wataru Yagi, Kota Maruyama, Yoshiharu Iyoda, Aiko Nakashima, Toshihisa Terazawa, Naoki Kamiya
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Patent number: 6723914Abstract: There is provided a composite magnetic tape which can be easily applied irrespective of the inside or outside of an electronic equipment, prevent radiation of undesired electromagnetic waves from the inside of the equipment and reflection into the inside of the equipment, and shield electromagnetic noise from the outside of the equipment. The tape may be in the form of an adhesive tape or a self-welding tape. The tape is constituted of a composite magnetic layer formed by dispersing soft magnetic powder into an organic binding agent. Alternatively, it may have a stacked structure of a composite magnetic layer and a conductor layer.Type: GrantFiled: February 23, 2000Date of Patent: April 20, 2004Assignee: NEC Tokin CorpInventors: Koji Kamei, Norihiko Ono, Mitsuharu Sato
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Publication number: 20040069377Abstract: Process for the production of oriented grain electrical steel strips, in which a silicon steel, comprising at least 30 ppm of S, is directly cast as strip 1.5-4.5 mm thick and cold rolled to a final thickness of between 1.0 and 0.15 mm; characterised by the following staged: Cooling and deformation of the solidified strip to obtain a second phases distribution in which 600 cm−1<Iz<1500 cm−1 and Iy=1.9 Fv/r (cm−1), Fv being the volume fraction of second phases stable at temperatures of less than 800° C., and r being the precipitates mean radius, in cm.; Hot rolling between solidification and coiling of the strip at a temperature of not less than 750° C., with a reduction ratio of between 15 and 60%; Cold rolling with reduction ratio of 60-92%; Cold rolled strip annealing at 750-1100° C., with increase of the nitrogen content of at least 30 ppm with respect to the initial composition at the strip core, in nitriding atmosphere.Type: ApplicationFiled: November 13, 2003Publication date: April 15, 2004Inventors: Stefano Fortunati, Stefano Cicale, Claudia Rocchi, Giuseppe Abbruzzese
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Patent number: 6714114Abstract: A magnetic sticking sheet comprising a non-magnetic base and a magnetic layer formed on the non-magnetic base by coating a magnetic coating material containing ferromagnetic particles and a binder, the magnetic layer having a thickness of 0.03 to 0.10 mm, oriented longitudinally to give a squareness ratio of 80 to 90%, and multipolar-magnetized longitudinally; the sheet having a total thickness of 0.08 to 0.25 mm and flexibility for rolling; the magnetic layer having a surface magnetic flux density of 35 to 100G; and the sheet having a magnetic sticking force, required for removing a magnetic sticking sheet fixed magnetically on a magnetic surface via the magnetic layer while keeping the magnetic surface and the sheet parallel, of 0.4 to 0.9 gf/cm2.Type: GrantFiled: June 2, 2003Date of Patent: March 30, 2004Assignee: Sony CorporationInventors: Shinichi Matsumura, Miki Sudo, Kazuto Kawamata, Eiji Ohta
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Publication number: 20040040629Abstract: A low core loss grain-oriented electrical steel sheet that does not have a significant deterioration in a magnetic flux density and a decrease of a space factor, and which may withstand stress-relieving annealing is provided. Melted and re-solidified layers can be formed on either or both of the surfaces of the grain-oriented electrical steel sheet that extend in a direction that is perpendicular to the rolling direction (e.g., in the direction of the width thereof), at a cyclic interval of not less than approximately 2 mm to less than approximately 5 mm in the rolling direction. The melted and re-solidified layers may be provided on each surface of the grain-oriented electrical steel sheet, and can have an aspect ratio that is a ratio of the depth to the width of the melted and re-solidified layer of not less than approximately 0.20 and a depth of not less than approximately 15 &mgr;m. In addition, the melted and re-solidified layers can be formed by using a laser.Type: ApplicationFiled: May 30, 2003Publication date: March 4, 2004Inventors: Hideyuki Hamamura, Tatsuhiko Sakai, Naoya Hamada
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Patent number: 6635125Abstract: A grain-oriented electrical steel sheet excellent in film and iron loss characteristics. The steel sheet contains up to 0.005% of C, 2.0 to 7.0& Si in terms of weight % and the balance iron and unavoidable impurities. An oxide film which mainly contains forsterite is formed on the surface and an insulating coating is formed on the oxide film. The peak intensity of Si obtained by glow discharge spectral analysis (GDS analysis) from the oxide film surface is at least ½ of that of Al, and the depth of the peak position of Si from the oxide film surface us up to {fraction (1/10)} of the depth of that of Al. The sheet satisfies the formulas for a ratio y(%) with which peeling of the oxide film does not take place when subjected to a bending test with a curvature of 20 mm and for core loss characteristic W (W/kg): y(%)≧−122.45t+112.55 W (W/kg)≦2.37t+0.280 wherein t represents a sheet thickness in terms of mm.Type: GrantFiled: March 27, 2002Date of Patent: October 21, 2003Assignee: Nippon Steel CorporationInventors: Kenji Kosuge, Kishio Mochinaga, Eiichi Nanba, Nobuo Tachibana, Shinya Ishii, Naoki Yagi