Magnetic composites
First Claim
1. A magnetic material composite, comprising:
- a first structural material, a magnetic material admixed with the structural material to form the magnetic material composite, and a second structural material molecularly compatible with the first structural material, wherein the first structural material essentially encapsulates the magnetic material and the second magnetic material essentially encapsulate the first structural material and the magnetic material composite has at least one portion of the first structural material containing the magnetic material and at least one portion of the first structural material substantially free of the magnetic material.
1 Assignment
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Accused Products
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.
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Citations
42 Claims
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1. A magnetic material composite, comprising:
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a first structural material, a magnetic material admixed with the structural material to form the magnetic material composite, and a second structural material molecularly compatible with the first structural material, wherein the first structural material essentially encapsulates the magnetic material and the second magnetic material essentially encapsulate the first structural material and the magnetic material composite has at least one portion of the first structural material containing the magnetic material and at least one portion of the first structural material substantially free of the magnetic material. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A mold having at least one cavity for formation of a molded article comprising:
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a magnetic field generator configured to generate one or more discrete magnetic fields in said mold, and one or more control mechanisms programmed to control at least one of duration and strength of any of said magnetic fields applied in the mold to form an article from a structural magnetic composite comprising a magnetic material and a structural material. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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18. An article of manufacture comprising:
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one or more mechanical elements formed from a magnetic material composite comprising a magnetic material and structural material, wherein the magnetic material composite has at least one portion with an aggregation of the magnetic material and at least one portion substantially free of the magnetic material. - View Dependent Claims (19)
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20. A method of manufacturing an article, the method comprising the steps of:
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selecting a magnetic material, selecting a structural material, and mixing the magnetic material and the structural material to form a material composite having at least one portion containing an aggregation of the magnetic material and at least one portion substantially free of the magnetic material.
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33. A method of manufacturing an article of manufacture, comprising the steps of:
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providing a magnetic material composite having a magnetic material and another material; and
causing the magnetic material to migrate within the magnetic material composite and aggregate in at least one portion of the magnetic material composite, such that at least one portion of the magnetic material composite is substantially free of the magnetic material. - View Dependent Claims (34, 35, 36, 37)
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38. A method of manufacturing an article of manufacture, comprising the step of:
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providing a magnetic material composite having a structural material and a magnetic material, wherein the magnetic material composite includes at least one portion containing the magnetic material and at least one portion substantially free of the magnetic material; and
magnetizing the magnetic material. - View Dependent Claims (39)
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40. A molding system, comprising:
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a working material source;
a mold having a cavity;
a distribution means for distributing a working material from said working material source to the cavity of the mold; and
at least one magnet for applying a magnetic field to the cavity of the mold. - View Dependent Claims (41, 42)
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Specification