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

[0008] The present invention provides new magnetic material composites and illustrative methods and processes to form the same that overcome deficiencies in the prior art. These magnetic material composites of the illustrative embodiment of the invention provide the desired properties of magnets having sufficient magnetic strength without the conventional structural limitations. Additionally, the magnetic material composites have the beneficial properties of other composites such as epoxies, plastics, and other like composites. The resulting magnetic material composites have a concentration of magnetic material in one or more portions. As a result, the interstitial spacing of the magnetic material in the magnetic material composite is significantly reduced, as compared to conventionally bonded magnets, to improve the magnetic field strength thereof. Additionally, the magnetic material composites of the present invention may be moldable, formable, machinable, shapeable or otherwise workable into any desired shape or form. The present invention advantageously allows formation of monolithic magnetic material composites having a desired shape, weight, thickness, and magnetic properties.

[0009] The use of magnetic material composites in accordance with the teachings of the present invention may reduce the number of parts required to manufacture a motor, a generator or other article of manufacture containing a magnet or magnets. Additionally, magnetic material composites formed in accordance with the teachings herein may reduce the steps involved in assembly processes, and result in monolithic chemically bonded structures capable of providing desired properties of magnets and structural properties of other composites including epoxies, paints, and coatings. The magnetic material composites as taught herein use materials more efficiently, providing superior material control and reduced waste within manufacturing processes. That is, the magnetic material composites and methods of formation of magnetic material composites as taught herein avoid the need for additional processing to attach a substructure for mechanical support and may reduce the amount of magnetic material needed to form bonded magnets utilized therein.

[0011] In one aspect of the present invention, a magnetic material composite is provided. The magnetic material composite is formed from a first structural material a magnetic material and a second structural material. The first structural material essentially encapsulates the magnetic material to form the magnetic material composite, and the magnetic material composite has one or more portions containing the magnetic material and one or more portions substantially free of the magnetic material. The second structural material essentially encapsulates the first structural material and the magnetic material. The magnetic material composite may be able to withstand structural loads without being fastened or joined to a substructure for structural support.

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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