Magnetic Sinterable Powder Composition for 3D Printed Objects
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Solution Overview
Problem
Current methods for manufacturing permanent magnets, such as laser sintering of pure metals or compounding with thermoplastics, face challenges in achieving a balance between magnetic and mechanical properties, especially for complex geometries, with high costs and limited mechanical strength or oxidation resistance.
Innovation Solution
A composition of sinterable magnetic powder comprising 50-95% magnet powder, 5-50% thermoplastic polymer, and a flow agent, with a D50 of less than 100 μm, processed through mixing, grinding, and optional addition of additives, enabling layer-by-layer sintering for producing dense magnetic objects with improved mechanical and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser sintering of pure metal is used, then magnetic properties are improved, but mechanical strength and oxidation resistance are limited
Solution Approach 1:
The patent applies composite materials by combining magnetic powder (providing magnetic properties) with thermoplastic polymer (providing mechanical strength and oxidation resistance). This composite powder composition enables the sintered object to simultaneously achieve good magnetic properties and enhanced mechanical properties including impact resistance and oxidation resistance that pure metal sintering cannot provide.
2Strength
If compounding with thermoplastic is used, then mechanical properties are improved, but magnetic properties are lowered
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio of magnetic powder to thermoplastic polymer, controlling particle size distribution (D50 less than 100 μm), and adjusting processing parameters during sintering. These parameter optimizations enable the composite material to achieve a balance where both mechanical properties and magnetic properties are satisfactory, overcoming the limitation of conventional compounding methods.
3Reliability
If high magnetic particle content (more than 95%) is used, then magnetic properties are improved, but mechanical strength decreases and recycling becomes difficult
Solution Approach 1:
The patent applies parameter changes by optimizing the magnetic particle content to a specific range (50-95%) rather than using extreme high concentrations. This optimized parameter range, combined with controlled particle size distribution, ensures sufficient magnetic properties while maintaining adequate mechanical strength and enabling recyclability of the sintered objects.
4Ease of manufacture
If larger particle size is used, then ease of manufacture is improved, but manufacturing precision and surface quality deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution with a specific parameter (D50 less than 100 μm). This optimized particle size parameter enables good flowability and ease of manufacture during the sintering process while simultaneously achieving precise definition and smooth surface appearance in the final sintered objects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for the creation of magnetic objects with precise definition, smooth surface, and enhanced mechanical properties like impact resistance and flexibility, while maintaining magnetic properties, suitable for complex geometries and reducing development time.
Implementation Method 1
The agglomeration of powders by fusion (referred to below as 'sintering') is caused by radiation such as, for example, a laser beam (laser sintering), infrared radiation, UV radiation or any source of electromagnetic radiation. allowing the powder to be melted layer by layer to make objects.
Implementation Method 2
The agglomeration of powders by fusion (referred to below as 'sintering') is caused by radiation such as, for example, a laser beam (laser sintering), infrared radiation, UV radiation or any source of electromagnetic radiation.
Data Source
AI summary
The present invention relates to a sinterable magnetic powder composition comprising 50 wt% to 95 wt% of at least one powder magnet and 5 wt% to 50 wt% of at least one thermoplastic polymer, out of the total weight of the composition, said powder composition having a D50 in the range of 0.1 µm to 100 µm. The present invention relates, in particular, to the use of said composition in processes for agglomerating powder, layer by layer, by fusion or sintering, in order to manufacture magnetic three-dimensional objects.