Design ofthermoplastic composites with magnetic properties as filament raw material for use in 3D printers

Abstract

This patent application involves the appropriate use of thermoplastic materials with magnetic properties for 3D printers. Specifically, it focuses on sustainable technologies on how these materials can be used in various industrial, medical, automotive and other application areas, replacing conventional magnets. This technical field involves many interdisciplinary studies, such as polymer science and engineering, materials technologies and the production and application of magnetic materials. The patent involves the production and use of thermoplastic raw materials with magnetic properties through the special composition and processing of magnetic additives with thermoplastic polymers. The patent application focuses on the use of materials with magnetic properties as alternatives to magnets. These materials are lighter, more flexible, and more economical. The technical field of thermoplastic materials with magnetic properties offers potential for innovative use in various industries by combining materials science, engineering, and industrial applications.

Description

[0001] DESIGN OF THERMOPLASTIC COMPOSITES WITH MAGNETIC PROPERTIES AS FILAMENT RAW MATERIAL FOR USE IN 3D PRINTERS

[0002] Technical Field

[0003] This patent application involves the appropriate use of thermoplastic materials with magnetic properties for 3D printers. Specifically, it focuses on sustainable technologies on how these materials can be used in various industrial, medical, automotive and other application areas, replacing conventional magnets. This technical field involves many interdisciplinary studies, such as polymer science and engineering, materials technologies and the production and application of magnetic materials. The patent involves the production and use of thermoplastic raw materials with magnetic properties through the special composition and processing of magnetic additives with thermoplastic polymers. The patent application focuses on the use of materials with magnetic properties as alternatives to magnets. These materials are lighter, more flexible, and more economical. The technical field of thermoplastic materials with magnetic properties offers potential for innovative use in various industries by combining materials science, engineering, and industrial applications.

[0004] Previous Art

[0005] Magnetism is a physical phenomenon that is widespread in nature and is a fundamental property for many technological applications. Materials with magnetic properties are engineering materials that have this property and are used in many automotive, electronic and medical fields. These materials can generate magnetic fields and / or release their magnetic properties under the influence of a magnetic field, making them valuable in a range of applications.

[0006] Magnetic materials can basically be divided into four main classes: ferromagnetic, antiferromagnetic, ferrimagnetic and diaferromagnetic. Ferromagnetic materials (for example, iron and nickel) have a strong magnetic response to magnetic fields and have permanent magnet properties. In antiferromagnetic materials, atoms align in opposite magnetic directions, resulting in a neutral response to magnetic fields. Ferrimagnetic materials are similar to ferromagnetic materials, but their magnetic moments are oriented in opposite directions. Diaferromagnetic materials are typically non-magnetized. The applications of magnetic materials are highly diverse, with one of the most common being in magnetic storage technologies. Devices like magnetic tapes, hard disk drives, and magnetic cards utilize materials with magnetic properties for data storage and retrieval processes. Magnetic materials also form the basis of the operating principles of electric motors, employed in various applications from household appliances to industrial machinery and transportation vehicles. Additionally, magnetic materials play a significant role in the healthcare sector, contributing to medical devices, magnetic resonance imaging (MRI) machines, and magnetic drug delivery systems. The use of magnetic materials is optimized based on the properties of the materials and the requirements of specific applications. Magnetic materials are also used in filtration and membrane technology.

[0007] Materials with magnetic properties play a fundamental role in many aspects of modern technology. However, there are some significant disadvantages encountered in the use of these materials. These disadvantages, particularly in the fields where magnetic materials are applied, encourage engineering and technology experts to overcome current limitations and find more efficient solutions. There are significant challenges in the development and application of magnetic materials, including high temperature sensitivity, susceptibility to corrosion, power loss and processing issues. However, with new technological innovations and advances in materials science, these disadvantages also present opportunities.

[0008] Corrosion, a major concern in many applications using magnetic materials, is a primary disadvantage. Specifically, iron-based magnetic materials may be prone to oxidation over time, reducing material durability and longevity. Therefore, various coating and corrosion prevention methods continue to be developed to enhance the corrosion resistance of magnetic materials used in industries such as maritime, automotive, and construction. The information is provided in the article titled 'Study on Corrosion Behaviors of Sintered Nd-Fe-B Magnets in Different Environmental Conditions,' Published in The Journal of Applied Physics."

[0009] Weight, particularly in the aerospace and space industries, is one of the disadvantage of magnetic materials. The high density of permanent magnetic materials can pose a disadvantage in lightweight and high-performance applications such as aircraft and rockets. Consequently, continuous research is conducted in these industries to develop lightweight and durable magnetic materials.

[0010] Processability refers to the shaping and processing capabilities of magnetic materials. Some magnetic materials may be challenging and costly to process, posing a problem for industries attempting to optimize production processes. Ongoing efforts aim to make progress in this area by developing new techniques and manufacturing methods to enhance the processability of magnetic materials. A comprehensive review titled "Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review," published in the Materials journal in 2023, provides updated information on this topic.

[0011] The prevalent production methods for magnetic materials in our era are listed as follows:

[0012] • Pultrusion (Extrusion): Pultrusion is a commonly used method in the production of long, constant cross-sectional profiles of magnetic materials. In this method, the material mixture is passed through a special mold and then extruded under temperature and pressure. As a result, long rods, pipes, or other profiles are obtained. Pultrusion is employed to optimize the durability and magnetization properties of magnetic materials. This method is frequently used in the production of magnetic tapes, rods, and various magnetic profiles.

[0013] • Powder Metallurgy: Powder metallurgy is a method that allows the production of magnetic materials in the form of fine powders of metal or alloys by compressing and sintering. Powder metallurgy enables the production of magnetic materials in complex shapes and ensures the attainment of homogeneous materials. This method is commonly used in the production of magnetic cores, magnets, and transformers.

[0014] • Sintering: Sintering is the process of heating and compressing metal powders or mixtures of magnetic materials at high temperatures. As a result of this process, the material becomes bulk and more durable. Sintering is widely used in the production of magnetic materials, especially in the manufacturing of materials like magnetic ceramics and ferrites. Aim of the Invention

[0015] Magnetic materials are successfully used in a number of applications, playing an important role in modern technology. However, there is significant potential for extensive research in the future of material science towards innovative polymer- based materials to meet constantly changing and evolving industrial needs. The flexibility, light weight and processability of polymers could make them a potential composite magnetic material. Magnetic materials based on polymers have many benefits and could revolutionize sectors from electronics to medicine.

[0016] The potential of polymer-based magnetic materials includes advantages such as lighter and more flexible magnets, as well as energy efficiency and ease of production. These materials, when used in nanotechnology and biomedical applications, may contribute to the development of next-generation medical devices. The use of polymer-based magnetic materials could lead to advancements in sustainable energy technologies, such as the electrical and electronics sector, electric vehicles, and energy storage systems.

[0017] The application of these innovative materials has the potential to fundamentally alter industrial design and manufacturing processes. Polymer-based magnetic materials, possessing advantages in both cost and processability, can provide more efficient and sustainable solutions in future production processes.

[0018] Thermoplastics can be defined as a compatible material for imparting magnetic properties. Thermoplastic polymers are large-molecular-weight polymeric materials composed of long molecular chains. These polymers soften as the temperature increases (130°C-360°C) and solidify again upon cooling. This characteristic, one of the most significant features, enables the shaping and reshaping of thermoplastic polymers.

[0019] These polymers are generally produced through polymerization, a process involving the connection of small carbon-based molecules called monomers, forming long chain-like polymer molecules. Polymerization reactions typically occur under the influence of heat and catalysts.

[0020] One distinctive feature of thermoplastic polymers is their amorphous or crystalline structures. In amorphous polymers, molecular chains are irregularly arranged, often contributing to the flexibility of the polymer. Crystalline polymers, on the other hand, have molecular chains arranged in a specific order, typically providing higher strength and hardness.

[0021] Another significant feature of thermoplastic polymers is their melting points. When heated, the attractive forces between molecular chains decrease, causing the polymer to melt. This feature allows thermoplastic polymers to be molded and reshaped, offering a substantial advantage in the production of innovative materials.

[0022] These polymers find widespread applications in packaging materials, textile fibers, automotive components, medical devices, and various industrial applications. The broad usage of thermoplastic polymers is based on advantages such as moldability, durability, and recyclability.

[0023] For the production of thermoplastic matrix magnetic composite materials, the extrusion method involves adding magnetic fillers or / and additives into the thermoplastic matrix. In this process, magnetic particles are typically integrated into the extrusion process and uniformly distributed within the matrix material. Extrusion, occurring under high temperature and pressure, allows for shaping the material and obtaining the desired form. Composite materials with magnetic properties produced through extrusion are used in electromagnetic applications, radio frequency tagging systems, and industrial applications requiring electromagnetic compatibility. The advantages of these composite materials include lightweight, excellent processability, low cost, and flexibility in various application areas. This versatility allows extrusion-produced thermoplastic matrix magnetic composite materials to be customized and optimized for use in many industrial sectors.

[0024] Detailed Description of the Invention

[0025] Thermoplastic-based composite materials with magnetic properties represent a unique class of materials in which magnetic particles are dispersed in a thermoplastic matrix. These composite materials provide a balance between the flexibility, processability and light weight of the thermoplastic polymer matrix and the magnetisable properties of the magnetic particles. Typically, magnetic particles having ferromagnetic or ferrimagnetic properties are homogeneously integrated into the thermoplastic matrix. This integration enables the controllable manipulation of the material's magnetic properties. Thermoplastic-based magnetic composite materials have a broad potential for use in industrial applications, electromagnetic devices, and magnetic sensors. The production processes of these materials often involve thermoplastic processing methods such as extrusion or injection molding. These processes allow for shaping the material and adapting it to various form factors. As a result, thermoplastic-based magnetic composite materials offer innovation potential across various industries by combining magnetizable properties with the advantages of thermoplastic polymers.

[0026] As for the thermoplastic matrix in polymer-based composite materials, at least one type of thermoplastic matrix material is used, including Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyethylene terephthalate (PET or PTFE), Polyamide (PA) (Nylon), Polyvinyl chloride (PVC), Polyvinylidene fluoride (PVDF), Polycarbonate (PC), Acrylonitrile butadiene styrene (ABS), Polyvinylidene chloride (PVDC), Polybutylene Terephthalate (PBT), Polyphenylene Sulfide (PPS), Syndiotactic Polystyrene (SPS), Polyether ether ketone (PEEK), Polyketones (POK), and others.

[0027] Additi ves / fi I lers with magnetic properties as additive materials; ferrite (iron oxide), ferrite-based ceramics, magnetic nanoparticles, magnetic polymers, nanomagnetic polymers, magnetic metal powders, magnetic ceramic powders, magnetic elastomers, magnetic carbon nanotubes, magnetic biopolymers can be used.

[0028] The main mechanisms involved in an extrusion process are feeding, melting, and homogenous mixing. Twin-screw extrusion is a method used for melting and shaping thermoplastic materials. In this method, the material is passed through a twin-screw extruder, and the rotating motion of the screws melts the material. The molten material is extruded onto a plane, cooled, shaped, and cut. Twin-screw extrusion offers advantages in terms of high production speeds and homogeneous material properties. The length-to-diameter ratio (U / D ratio) of the screws affects the mixing and homogeneity of the output. The extrusion output speed depends on factors such as screw rotation, barrel temperature, screw configuration, and melt viscosity.

[0029] Explaining the method for the suitability of the raw material to be used for filament processing; Material Preparation: Firstly, the thermoplastic material to be used is prepared in granular or powdered form. Melting: The material is melted inside a extruder and extrude into a desired form during this process. The filament obtained through cooling is solidified and cut to the desired diameter. Winding: Filaments are wound onto spools and, if necessary, vacuum-packaged for sale. This production method allows thermoplastic materials to be transformed into filaments with different diameters and properties. These filaments are then used in various applications with 3D printers or extrusion methods.

[0030] The product produced using any of these methods or a combination of several methods will be suitable for use in automotive, electronic, and / or medical fields.

Claims

CLAIMS1. A 3D printer filament having magnetic properties, characterized by;- comprising at least one thermoplastic matrix, selected from Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyethylene terephthalate (PET or PTFE), Polyamide (PA) (Nylon), Polyvinyl chloride (PVC), Polyvinylidene fluoride (PVDF), Polycarbonate (PC), Acrylonitrile butadiene styrene (ABS), Polyvinylidene chloride (PVDC), Polybutylene terephthalate (PBT), Polyphenylene sulfide (PPS), Syndiotactic Polystyrene (SPS), Polyether ether ketone (PEEK), Polyketones (POK) in a ratio of 20%- 80%,- comprising at least one magnetic additive selected from Ferite (Iron Oxide), Ferrite-Based Ceramics, Magnetic Nanoparticles, Magnetic Polymers, Nanomagnetic Polymers, Magnetic Metal Powder, Magnetic Ceramic Powder, Magnetic Elastomers, Magnetic Carbon Nanotubes, Magnetic Biopolymers, in a ratio of 40%-80%,- being a polymer-based composite material containing additives, fillers, and / or reinforcement materials in a ratio of l%-30%.

2. A method for producing a 3D printer filament having magnetic properties, characterized by;- preparing the thermoplastic material in granule or powder form,- melting the mentioned material within an extrusion machine and forming it into a flat shape to achieve the desired form,- cooling the formed material and cutting it to the desired diameter,- involving steps of winding onto a spool, bobbin, or coil.