Nanoparticle coating method

• US 11,384,422 B2
• Filed: 11/27/2017
• Issued: 07/12/2022
• Est. Priority Date: 11/29/2016
• Status: Active Grant

• Current Assignee: Magnetic Laminates Limited
• Original Assignee: Magnetic Laminates Limited
• Inventors: Kinmont, Patrick William John, Binns, Robert Davidson, Binns, Christopher Robin
• Primary Examiner(s): Su, Xiaowei
• Application Number:
  US16/465,143
• Publication Number:
  US 20190330732A1
• Time in Patent Office: 1,688 Days
• Field of Search: None
• CPC Class Codes: C23C 14/165 by cathodic sputtering
• CPC Class Codes: C23C 14/223 specially adapted for coating particles
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: H01F 1/0018 Diamagnetic or paramagnetic materials, i.e. materials with low susceptibility and no hysteresis H01F1/0036 takes precedence
• CPC Class Codes: H01F 1/0063 in a non-magnetic matrix, e.g. granular solids granular films H01F10/007
• CPC Class Codes: H01F 1/147 Alloys characterised by their composition treatment thereof for enhancing their electromagnetic properties C21D8/12
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0213 Manufacturing of magnetic circuits made from strip(s) or ribbon(s) magnetic cores made by winding a ribbon H01F27/25
• CPC Class Codes: H01F 41/0233 Manufacturing of magnetic circuits made from sheets magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H02K 1/02 characterised by the magnetic material

Abstract

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.

Claims

1. A method for producing a magnetic nanoparticle-coated laminate material comprising:

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 matrix material to thereby form a matrix and subsequently depositing magnetic nanoparticles onto the matrix as the matrix forms, to thereby embed the magnetic nanoparticles in the matrix, in which each magnetic nanoparticle is 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;

stacking the coated film portions on top of each other such that each at least one coated surface of each film portion is located between adjacent film portions; and

compressing the stacked coated film portions together to form a nanoparticle-coated laminate material.

2. A method as claimed in claim 1, in which the film portions are provided by a continuous film, and in which the method further comprises cutting the coated continuous film into separate coated film portions of predetermined dimensions prior to stacking.

3. A method as claimed claim 1, in which the coated laminate material is further machined to form a nanoparticle-containing coated component of an electromagnetic apparatus.

4. A method as claimed in claim 1, in which one or more of the stacking, and/or compressing and/or machining steps is carried out at ambient temperature.

5. A method as claimed in claim 1, in which one or more of the coiling or stacking, and/or compressing and/or machining steps is carried out under vacuum.

6. A method as claimed claim 1, in which the film portions have a thickness of no more than 2 mm.

7. A method as claimed in claim 1, in which the film portions have a thickness of at least 0.01 mm.

8. A method as claimed in claim 1, in which the film portions have a thickness of about 0.2 mm.

9. A method as claimed in claim 1, in which the nanoparticles-containing coating on each surface has a thickness of no more than 1 mm.

10. A method as claimed claim 1, in which the nanoparticles-containing coating on each surface has a thickness of at least 0.005 mm.

11. A method as claimed in claim 1, in which the volume fraction of coating to film portions within the coated laminate material is about 50%.

12. A method as claimed in claim 1, in which each surface of a pair of opposed surfaces of a plurality of steel or iron/cobalt (Fe/Co) alloy film portions is coated with a magnetic nanoparticle-containing coating.

13. A method as claimed in claim 1, in which the nanoparticles each comprise a shell and core, and in which the shell and core of each nanoparticle 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.

14. A method for producing a magnetic nanoparticle-coated laminate material comprising:

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 in which the coating is deposited in the presence of an electromagnetic field, and in which each magnetic nanoparticle is 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;

stacking the coated film portions on top of each other such that each at least one coated surface of each film portion is located between adjacent film portions; and

compressing the stacked coated film portions together to form a nanoparticle-coated laminate material.

15. A method for producing a magnetic nanoparticle-coated coiled material comprising:

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 matrix material to thereby form a matrix, and subsequently depositing magnetic nanoparticles onto the matrix as the matrix forms, to thereby embed the magnetic nanoparticles in the matrix, in which each magnetic nanoparticle is 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

coiling the coated film portions such that each at least one coated surface of each film portion is located between adjacent film portions; and

compressing the coiled coated film portions together to form a nanoparticle-coated coiled material.

16. A method as claimed in claim 15, in which the film portions are provided by a continuous film, and in which the method further comprises cutting the coated continuous film into separate coated film portions of predetermined dimensions prior to coiling.

17. A method as claimed claim 15, in which the coated coiled material is further machined to form a nanoparticle-containing coated component of an electromagnetic apparatus.

18. A method as claimed in claim 15, in which one or more of the coiling, and/or compressing and/or machining steps is carried out at ambient temperature.

19. A method as claimed in claim 15, in which the volume fraction of coating to film portions within the coated coiled material is about 50%.