Low cost magnets and magnetic devices manufactured from ferromagnetic conductively doped resin-based materials

• US 20060208383A1
• Filed: 03/17/2006
• Published: 09/21/2006
• Est. Priority Date: 03/17/2005
• Status: Abandoned Application

• Current Assignee: Thomas Aisenbrey
• Original Assignee: Thomas Aisenbrey
• Inventors: Aisenbrey, Thomas
• Application Number:
  US11/378,068
• Publication Number:
  US 20060208383A1
• Time in Patent Office: Days
• US Class Current: 264/104
• CPC Class Codes: H01F 1/083 in a bonding agent
• CPC Class Codes: H01F 1/113 in a bonding agent
• CPC Class Codes: H01F 41/0273 Imparting anisotropy methods and devices for magnetising permanent magnets H01F13/003

Abstract

Magnetic devices are formed of a ferromagnetic conductively doped resin-based material. The ferromagnetic conductively doped resin-based material comprises ferromagnetic micron conductive powder(s), ferromagnetic micron conductive fiber(s), or combinations thereof in a base resin host. The percentage by weight of the ferromagnetic micron conductive powder(s), ferromagnetic micron conductive fiber(s), or combinations is between about 20% and 50% of the weight of the ferromagnetic conductively doped resin-based material.

Claims

1. A magnetic device comprising a ferromagnetic conductively doped, resin-based material comprising ferromagnetic micron conductive fiber in a base resin host wherein said ferromagnetic micron conductive fiber is magnetically polarized.

2. The device according to claim 1 wherein the percent by weight of said ferromagnetic micron conductive fiber is between about 20% and about 50% of the total weight of said ferromagnetic conductively doped resin-based material.

3. The device according to claim 1 further comprising ferromagnetic micron conductive powder.

4. The device according to claim 1 further comprising non-ferromagnetic micron conductive fiber.

5. The device according to claim 1 further comprising non-ferromagnetic micron conductive powder.

6. The device according to claim 1 wherein said ferromagnetic micron conductive fiber comprises a core material onto which is plated a metal.

7. The device according to claim 1 wherein said ferromagnetic micron conductive fiber comprises ferrite.

8. The device according to claim 1 wherein said ferromagnetic micron conductive fiber comprises ceramic.

9. The device according to claim 1 wherein said ferromagnetic micron conductive fiber comprises nickel zinc or manganese zinc.

10. The device according to claim 1 wherein said ferromagnetic micron conductive fiber comprises a combination of iron, boron, or strontium.

11. The device according to claim 1 wherein said ferromagnetic micron conductive fiber is a rare earth element.

12. The device according to claim 1 wherein said ferromagnetic conductively doped resin-based material is metal plated.

13. The device according to claim 1 wherein said ferromagnetic micron conductive fiber has a diameter of between about 3 μ

m and about 12 μ

m and a length of between about 2 mm and about 14 mm.

14. A magnetic device comprising a ferromagnetic conductively doped, resin-based material comprising ferromagnetic micron conductive fiber in a base resin host wherein said ferromagnetic micron conductive fiber is magnetically polarized and wherein said ferromagnetic micron conductive fiber is between about 20% and about 50% of the total weight of said ferromagnetic conductively doped resin-based material.

15. The device according to claim 14 further comprising ferromagnetic micron conductive powder.

16. The device according to claim 15 wherein said ferromagnetic micron conductive powder comprises a ferrite, a ceramic, or a rare earth element.

17. The device according to claim 14 wherein said ferromagnetic micron conductive fiber comprises a core material onto which is plated a metal.

18. The device according to claim 14 wherein said ferromagnetic conductively doped resin-based material is metal plated.

19. The device according to claim 14 wherein said ferromagnetic micron conductive fiber has a diameter of between about 3 μ

m and about 12 μ

m and a length of between about 2 mm and about 14 mm.

20. The device according to claim 14 wherein said ferromagnetic conductively doped resin-based material is flexible.

21. A method to form a magnetic device, said method comprising:

providing a ferromagnetic conductively doped, resin-based material comprising ferromagnetic micron conductive fiber in a resin-based host;

molding said ferromagnetic conductively doped, resin-based material; and

magnetically polarizing said ferromagnetic micron conductive fiber.

22. The method according to claim 21 wherein the percent by weight of said ferromagnetic micron conductive fiber is between about 20% and about 50% of the total weight of said ferromagnetic conductively doped resin-based material.

23. The method according to claim 21 wherein said ferromagnetic conductively doped, resin-based material further comprises ferromagnetic micron conductive powder.

24. The method according to claim 21 wherein said ferromagnetic micron conductive fiber comprises a core material onto which is plated a metal.

25. The method according to claim 21 further comprising a step of plating metal onto said magnetic device.

26. The method according to claim 21 wherein said step of molding comprises:

injecting said ferromagnetic conductively doped, resin-based material into a mold;

curing said ferromagnetic conductively doped, resin-based material; and

removing said ferromagnetic conductively doped, resin-based material from said mold.

27. The method according to claim 21 wherein said step of molding comprises:

loading said ferromagnetic conductively doped, resin-based material into a chamber;

extruding said ferromagnetic conductively doped, resin-based material out of said chamber through a shaping outlet; and

curing said ferromagnetic conductively doped, resin-based material.

28. The method according to claim 27 further comprising a step of cutting said ferromagnetic conductively doped, resin-based material.

29. The method according to claim 21 wherein said step of magnetically polarizing is performed concurrent with said step of molding.

30. The method according to claim 21 wherein said step of magnetically polarizing is performed after said step of molding.