Nanoparticle-Coated Laminate for High Saturation Magnetization
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Solution Overview
Problem
Current technologies for producing magnetic materials are limited by the Slater-Pauling limit, restricting the saturation magnetization of transition metal alloys, which hinders the efficiency of electro-mechanical apparatus like motors and generators, and have only been able to produce thin films with enhanced magnetism, not bulk components.
Innovation Solution
A method involving coating steel or iron/cobalt alloy film portions with magnetic nanoparticles, specifically iron, cobalt, nickel, or their alloys, and embedding them in a matrix to create a nanoparticle-coated laminate or coiled material, which exceeds the Slater-Pauling limit by enhancing the magnetic moment per atom and preventing phase separation through core-shell nanoparticles, allowing for the production of bulk components with improved magnetism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional transition metal alloys are used, then the material structure is simple and easy to manufacture, but the saturation magnetization is limited by the Slater-Pauling limit
Solution Approach 1:
The patent uses composite materials by combining magnetic nanoparticles (Fe, Co, Ni or their alloys) with a matrix material to create a nanoparticle-coated laminate or coiled structure. This composite approach allows achieving saturation magnetization exceeding the Slater-Pauling limit (greater than 2.45 μB per atom) while maintaining manufacturability through coating processes on steel or iron/cobalt alloy film portions.
2Quantity of substance
If thin films with enhanced magnetism are produced, then the magnetic moment per atom is improved, but the component size remains limited and cannot produce bulk components
Solution Approach 1:
The patent applies the nesting principle by coating film portions with nanoparticle layers, creating a nested structure where nanoparticles are embedded in a matrix on the film surfaces. This allows bulk components (laminate or coiled structures) to be constructed from multiple coated film portions stacked or coiled together, thereby achieving both enhanced magnetization and bulk component dimensions.
Solution Approach 2:
The patent transitions from two-dimensional thin films to three-dimensional bulk components by stacking multiple coated film portions into laminate structures or coiling them into cylindrical forms. This dimensional transformation enables the production of bulk components with improved magnetism while maintaining the nanoparticle coating architecture.
3Quantity of substance
If Fe volume fraction is increased to enhance magnetization, then the magnetic moment increases, but phase separation occurs leading to aggregation of Fe nanoparticles and reduced magnetization
Solution Approach 1:
The patent uses a matrix material as an intermediary between Fe nanoparticles, preventing direct contact and aggregation between iron particles. This matrix embedding approach stabilizes the nanoparticle distribution and prevents phase separation even at higher Fe volume fractions, maintaining the enhanced magnetic moment while avoiding the formation of macroscopic grains.
Solution Approach 2:
The patent applies local quality by creating a heterogeneous structure where Fe nanoparticles are locally distributed within the matrix rather than forming uniform bulk phases. This localized nanoparticle arrangement within the matrix prevents macroscopic phase separation while maintaining high magnetic moment per atom through the nanoparticle effect.
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 method enables the production of bulk components with significantly higher magnetic moments, reducing the weight and dimensions of electromagnetic apparatus while increasing efficiency, allowing for smaller-scale, cost-effective, and energy-efficient manufacturing of components like motors and generators.
Implementation Method 1
coating at least one surface of a pair of opposed surfaces of a plurality of steel or iron/cobalt (Fe/Co) alloy film portions with a magnetic nanoparticle-containing coating
Implementation Method 2
preventing phase separation through core-shell nanoparticles, allowing for the production of bulk components with improved magnetism
Implementation Method 3
compressing the stacked coated film portions together to form a nanoparticle-coated laminate material
Data Source
AI summary
The present invention provides a method for producing a magnetic nanoparticle-coated laminate material. The method comprises coating a pair of opposed surfaces of a plurality of steel or iron/cobalt (Fe/Co) alloy film portions with a magnetic nanoparticle-containing coating. Each magnetic nanoparticle comprises a core and a shell covering at least a portion of the core. The shell and core are made of different materials selected from one or more of: iron, cobalt, nickel; and/or alloys comprising two or more of: iron, cobalt and/or nickel; and/or magnetic rare earth metals; and/or diamagnetic transition metals. The method further comprises stacking the coated film portions on top of each other such that a or each coated surface of each film portion is located adjacent a further coated surface of an adjacent film portion; and compressing the stacked coated film portions together to form a nanoparticle-coated laminate material.