Magnetic composites

Abstract

The present invention discloses methods and magnetic material composites capable of withstanding one or more loads without the need for a substructure to provide structural support thereto. The magnetic composites are formable from composites such as epoxies, resins, plastics and the like together with rare earth or other magnetic or magnetizable compounds, or magnetic nano-particles to form structural magnetic composites. The magnetic composites have one or more portions with an aggregation of the magnetic material and one or more portions free of or substantially free of the magnetic material. The magnetic composites are suitable for use to form components of electrical motors, generators, pumps, fans, paints, coatings and parts or derivatives thereof.

Description

RELATED APPLICATIONS [0001] This application claims priority to Provisional Application Ser. No. 60 / 838,737, filed Aug. 18, 2006, the contents of which are hereby incorporated by reference.FIELD OF THE INVENTION [0002] The present invention relates to magnetic material composites. More particularly, the present invention relates to structural magnetic composites and illustrative methods and processes to form the same. BACKGROUND OF THE INVENTION [0003] Conventionally, magnets are formed by sintering or bonding compounds to form a magnet. Once formed, these magnets are attached to a mechanical element or member by a variety of methods, including mechanical fasteners, adhesives, lamination, or other means of affixation known in the art. The affixing of the magnets to the mechanical element is often to provide structural support to the magnet in order to overcome structural deficiencies in the magnetic material. The mechanical component, affixed through such conventional methods, may t...

AI Technical Summary

Benefits of technology

The present invention provides new magnetic material composites and methods of forming them that overcome deficiencies in the prior art. These composites have the desired properties of magnets without the limitations of conventional structural materials. They are moldable, formable, and can be worked into any desired shape or form. The use of these composites reduces the number of parts required to manufacture a motor or other article containing magnets and simplifies the manufacturing process. The magnetic material composites have interstitial spacing of the magnetic material reduced, improving the magnetic field strength. They can be used in various applications such as electric motors, generators, bearings, filters, fans, pumps, and coatings. The patent text also describes a mold and a method of manufacturing an article using the magnetic material composite.

Problems solved by technology

A drawback to such conventional magnet manufacturing processes is that sintered magnets tend to be brittle, and often break if machined or attached to a structural element by mechanical means.

As a result, conventionally bonded magnets often have a relatively weak magnetic field due to the dispersion of the magnetizable matter substantially through out the cured bonding agent.

Conventional bonded magnets also have limitations on how the evenly distributed magnetic material can be magnetized into complex pole patterns.

Despite known conventional techniques, magnetic components created using existing processes are limited due to required methods of attachment to substructures for structural support, and are often limited by the need for additional manufacturing steps and processes.

Additionally, known conventional techniques often use or distribute magnetic materials inefficiently.

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