U.S. patent application number 11/894371 was filed with the patent office on 2008-02-21 for magnetic composites.
This patent application is currently assigned to Maglev Technologies, LLC. Invention is credited to Daniel Irvin, Robert J. Thibodeau, Christopher Williams.
Application Number | 20080044680 11/894371 |
Document ID | / |
Family ID | 38980956 |
Filed Date | 2008-02-21 |
United States Patent
Application |
20080044680 |
Kind Code |
A1 |
Thibodeau; Robert J. ; et
al. |
February 21, 2008 |
Magnetic composites
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.
Inventors: |
Thibodeau; Robert J.;
(Gloucester, MA) ; Williams; Christopher;
(Manchester, MA) ; Irvin; Daniel; (Prides
Crossing, MA) |
Correspondence
Address: |
LAHIVE & COCKFIELD, LLP
ONE POST OFFICE SQUARE
BOSTON
MA
02109-2127
US
|
Assignee: |
Maglev Technologies, LLC
Manchester
MA
|
Family ID: |
38980956 |
Appl. No.: |
11/894371 |
Filed: |
August 20, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60838737 |
Aug 18, 2006 |
|
|
|
Current U.S.
Class: |
428/547 ;
264/427; 264/437; 425/130; 425/3; 428/539.5 |
Current CPC
Class: |
Y10T 428/12021 20150115;
H01F 1/083 20130101; B29C 45/16 20130101; H01F 41/0273 20130101;
H02K 1/02 20130101; B29C 45/0013 20130101; B29K 2995/0008 20130101;
H01F 41/0246 20130101; H01F 1/26 20130101; H01F 13/00 20130101 |
Class at
Publication: |
428/547 ;
264/427; 264/437; 425/130; 425/003; 428/539.5 |
International
Class: |
B22F 7/06 20060101
B22F007/06 |
Claims
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.
2. The magnetic material composite of claim 1, wherein the
structural material comprises a polymeric material.
3. The magnetic material composite of claim 1, wherein the magnetic
material comprises at least one of: a magnetic particle, a
magnetizable particle, a magnetic compound, a magnetizable
compound, a magnetic nano-particle, a magnetizable nano-particle, a
magnetic nano-particle compound, a magnetizable nano-particle
compound and combinations thereof.
4. The magnetic material composite of claim 1, wherein said
magnetic material is magnetized prior to admixing with said
structural material.
5. The magnetic material composite of claim 1, wherein the at least
one portion containing the magnetic material comprises a surface of
the magnetic material composite, an end of the magnetic material
composite and a layer within the magnetic material composite.
6. The magnetic material composite of claim 1, wherein said
structural material is configured to provide structural support to
withstand a load placed on the magnetic material composite.
7. The magnetic material composite of claim 1, wherein the magnetic
material is stratified or concentrated in the magnetic material
composite.
8. A mold having at least one cavity for formation of a molded
article comprising: 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.
9. The mold of claim 8, wherein the one or more control mechanisms
are programmed to control at least one of the duration and the
strength of any of said magnetic fields in the mold as applied to
the structural magnetic composite sufficient to align a magnetic
polarity of said magnetic material contained in one of the cavities
of said mold.
10. The mold of claim 8, wherein the one or more control mechanisms
are programmed to control at least one of the duration and the
strength of any of said magnetic fields in the mold as applied to
the structural magnetic composite capable to magnetize the magnetic
material contained in one of the cavities of said mold.
11. The mold of claim 8, wherein the magnetic field generator
comprises one or more electromagnets responsive to the one or more
control mechanisms to generate any of the magnetic fields applied
to said mold.
12. The mold of claim 8, wherein the magnetic field generator
comprises at least one permanent magnet configured to generate any
of said magnetic fields applied to said mold.
13. The mold of claim 8, wherein two or more materials with
different magnetic or structural properties are separately
introduced to the mold to control the concentration and
distribution of magnetic and structural materials.
14. The mold of claim 13, wherein the two or more materials are
introduced to the mold simultaneously.
15. The mold of claim 13, wherein the two or more materials are
introduced to the mold in series.
16. The mold of claim 13, wherein the two or more materials are
introduced to the mold such as to ensure a unified chemical bond
between the magnetic compound and the non-magnetic compound.
17. The mold of claim 16, wherein the magnetic material is injected
into the mold, magnetizables are aligned, polarized and magnetized,
and the structural material is introduced into the mold before the
structural material substantially cures.
18. An article of manufacture comprising: 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.
19. The article of manufacture of claim 18, wherein the article
comprises any of a motor, a generator, a pump, or a fan having a
rotatable member formed in whole or in part from the magnetic
material composite.
20. A method of manufacturing an article, the method comprising the
steps of: 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.
21. The method of claim 15, further comprising the step of
injecting the material composite into a cavity of a mold.
22. The method of claim 15, further comprising the step of forming
a sheet of material from the material composite.
23. The method of claim 15, wherein the material composite
comprises a liquid having properties that allows the material
composite to be applied to a surface of an object with any of a
brush, a roller or a spray gun.
24. The method of claim 15, further comprising the step of forming
the material composite into a coating suitable for application to a
surface of an object.
25. The method of claim 16, further comprising the step of applying
an electrical current to said cavity of said mold.
26. The method of claim 16, further comprising the step of,
applying a magnetic field to said cavity of said mold.
27. The method of claim 21 further comprising the step of,
controlling at least one of a duration and a strength of said
magnetic field to stratify said magnetic material contained in said
cavity.
28. The method of claim 21, further comprising the step of
controlling at least one of a duration and a strength of said
magnetic field applied to align a magnetic polarity of said
magnetic material contained in the cavity of said mold.
29. The method of claim 15 further comprising the steps of,
removing the article from the cavity of the mold, placing the
article in a cavity of a second mold, and injecting the cavity of
the second mold with a magnetic neutral compound molecularly
compatible with the article.
30. The method of claim 25, wherein the magnetic neutral compound
molecularly compatible with the article bonds with the article
without additional preparation of the article.
31. The method of claim 15, further comprising the step of applying
an electrical field to the material composite.
32. The method of claim 15, further comprising the step of applying
a magnetic field to the material composite.
33. A method of manufacturing an article of manufacture, comprising
the steps of: 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.
34. The method of claim 33, wherein the step of causing the
magnetic material to migrate and aggregate comprises the step of
applying one of a magnetic field, an electrical field and
combinations thereof to the magnetic material composite.
35. The method of claim 33, further comprising the step of shaping
the magnetic material composite into a selected form.
36. The method of claim 33, further comprising the step of curing
the magnetic material composite into a solid phase.
37. The method of claim 33, wherein the magnetic material composite
further includes a catalyst to facilitate said step of curing.
38. A method of manufacturing an article of manufacture, comprising
the step of: 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.
39. The method of claim 38, wherein the step of magnetizing the
magnetic material comprises at least one of: applying a magnetic
field, an electrical field and a combination thereof to the
magnetic material composite.
40. A molding system, comprising: 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.
41. The molding system of claim 40, wherein the working material
source comprises a first material source and a second material
source, and the distribution means mixes the first material and
second material together to form a working material prior to
distributing the working material to the cavity of the mold.
42. The molding system of claim 40, further comprising a control
system for controlling the application of the magnetic material to
the cavity of the mold.
Description
RELATED APPLICATIONS
[0001] This application claims priority to Provisional Application
Ser. No. 60/838,737, filed Aug. 18, 2006, the contents of which are
hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to magnetic material
composites. More particularly, the present invention relates to
structural magnetic composites and illustrative methods and
processes to form the same.
BACKGROUND OF THE INVENTION
[0003] Conventionally, magnets are formed by sintering or bonding
compounds to form a magnet. Once formed, these magnets are attached
to a mechanical element or member by a variety of methods,
including mechanical fasteners, adhesives, lamination, or other
means of affixation known in the art. The affixing of the magnets
to the mechanical element is often to provide structural support to
the magnet in order to overcome structural deficiencies in the
magnetic material. The mechanical component, affixed through such
conventional methods, may thus provide structural support for the
magnet. The added structural support enables the magnet to support
or resist one or more loads in order to perform a desired task or
tasks, or to protect the magnet from breakage, degradation,
oxidation and/or perform other functions.
[0004] In a process of forming a magnet through sintering, a
compound to be magnetized is heated to align the molecules of the
compound, optimizing polarity. A drawback to such conventional
magnet manufacturing processes is that sintered magnets tend to be
brittle, and often break if machined or attached to a structural
element by mechanical means.
[0005] In a conventional bonding process for manufacturing a
magnet, a compound to be magnetized is mixed with a bonding agent,
such as an epoxy, a polymeric material, or the like, at an
approximate weight ratio of magnetizable matter to bonding agent of
between about 80:20 and about 98:2. In such a process, the
magnetizable matter tends to be uniformly dispersed through out the
bonding agent once cured. As a result, conventionally bonded
magnets often have a relatively weak magnetic field due to the
dispersion of the magnetizable matter substantially through out the
cured bonding agent.
[0006] Other processes designed to overcome structural inadequacies
of magnets include plating, laminating and coating, which often
have the same deficiencies of sintered magnets and conventionally
bonded magnets. Conventional bonded magnets also have limitations
on how the evenly distributed magnetic material can be magnetized
into complex pole patterns.
[0007] Despite known conventional techniques, magnetic components
created using existing processes are limited due to required
methods of attachment to substructures for structural support, and
are often limited by the need for additional manufacturing steps
and processes. Additionally, known conventional techniques often
use or distribute magnetic materials inefficiently.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides new magnetic material
composites and illustrative methods and processes to form the same
that overcome deficiencies in the prior art. These magnetic
material composites of the illustrative embodiment of the invention
provide the desired properties of magnets having sufficient
magnetic strength without the conventional structural limitations.
Additionally, the magnetic material composites have the beneficial
properties of other composites such as epoxies, plastics, and other
like composites. The resulting magnetic material composites have a
concentration of magnetic material in one or more portions. As a
result, the interstitial spacing of the magnetic material in the
magnetic material composite is significantly reduced, as compared
to conventionally bonded magnets, to improve the magnetic field
strength thereof. Additionally, the magnetic material composites of
the present invention may be moldable, formable, machinable,
shapeable or otherwise workable into any desired shape or form. The
present invention advantageously allows formation of monolithic
magnetic material composites having a desired shape, weight,
thickness, and magnetic properties.
[0009] The use of magnetic material composites in accordance with
the teachings of the present invention may reduce the number of
parts required to manufacture a motor, a generator or other article
of manufacture containing a magnet or magnets. Additionally,
magnetic material composites formed in accordance with the
teachings herein may reduce the steps involved in assembly
processes, and result in monolithic chemically bonded structures
capable of providing desired properties of magnets and structural
properties of other composites including epoxies, paints, and
coatings. The magnetic material composites as taught herein use
materials more efficiently, providing superior material control and
reduced waste within manufacturing processes. That is, the magnetic
material composites and methods of formation of magnetic material
composites as taught herein avoid the need for additional
processing to attach a substructure for mechanical support and may
reduce the amount of magnetic material needed to form bonded
magnets utilized therein.
[0010] Uses for magnetized material composites as taught herein
include electric motors and generators, bearings, filters, fans,
pumps, paints, coatings, nano-impregnation processes and many other
like structures, functions and operations having or involving
magnets known in the art.
[0011] In one aspect of the present invention, a magnetic material
composite is provided. The magnetic material composite is formed
from a first structural material a magnetic material and a second
structural material. The first structural material essentially
encapsulates the magnetic material to form the magnetic material
composite, and the magnetic material composite has one or more
portions containing the magnetic material and one or more portions
substantially free of the magnetic material. The second structural
material essentially encapsulates the first structural material and
the magnetic material. The magnetic material composite may be able
to withstand structural loads without being fastened or joined to a
substructure for structural support.
[0012] In another aspect of the present invention, a mold having
one or more cavities for formation of a molded article is
disclosed. A magnetic field generator associated with the mold is
configured to generate one or more discrete magnetic fields in the
mold. One or more control mechanisms associated with the mold is
programmed to control duration and strength of any magnetic fields
applied to the mold via the magnetic field generator. The magnetic
fields applied to the mold facilitate formation of an article from
a magnetic material composite having a magnetic material and a
structural material.
[0013] In one aspect of the present invention, an article of
manufacture is disclosed. The article of manufacture includes one
or more mechanical elements formed from a magnetic material
composite having a magnetic material and structural material. The
magnetic material composite has one or more portions with an
aggregation of the magnetic material and one or more portions
substantially free of the magnetic material.
[0014] In another aspect of the present inventions, a method of
manufacturing an article is disclosed. The method includes the
steps of selecting a magnetic material and selecting a structural
material. The method includes the step of mixing the magnetic
material and the structural material to form a material composite
having one or more portions containing an aggregation of the
magnetic material and one or more portions substantially free of
the magnetic material.
[0015] According to another aspect of the invention, a method of
manufacturing an article of manufacture comprises the steps of
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.
[0016] In still another aspect, a method of manufacturing an
article of manufacture comprises the steps of 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.
[0017] According to still another aspect, a molding system is
provided. The molding system comprises 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing and other objects, features and advantages of
the invention will be apparent from the following description and
apparent from the accompanying drawings in which like reference
characters refer to the same parts through-out the different views.
The drawings illustrate principles of the invention, and although
not to scale, show relative dimensions.
[0019] FIGS. 1A and 1B is an exemplary drawing depicting formation
of a magnetic material composite in accordance with an illustrative
embodiment of the present invention.
[0020] FIG. 2 is an exemplary block flow diagram depicting the
steps involved in the formation of a magnetic material composite in
accordance an illustrative embodiment of the present invention.
[0021] FIG. 3A is an exemplary diagram depicting a magnetic
material composite of the present invention with the magnetic
material substantially dispersed through out the structural
material.
[0022] FIG. 3B is an exemplary block diagram of a magnetic material
composite, depicting migration and aggregation of magnetic material
in a structural material according to an embodiment of the
invention.
[0023] FIG. 3C is another exemplary block diagram of a magnetic
material composite of an illustrative embodiment of the invention,
depicting migration and aggregation of a magnetic material in a
structural material in accordance with the teachings of the present
invention.
[0024] FIG. 3D is another exemplary block diagram of a magnetic
material composite, depicting migration and aggregation of a
magnetic material in a structural material in accordance with the
teachings of an illustrative embodiment of the present
invention.
[0025] FIG. 3E is an exemplary block diagram depicting
magnetization of a magnetic material in a structural material
forming a magnetic material composite according to an illustrative
embodiment of the invention.
[0026] FIG. 3F is an exemplary block diagram depicting magnetic
fields of a magnetic material in the structural material of a
magnetic material composite in accordance with an illustrative
embodiment of the invention.
[0027] FIG. 4 is an exemplary block diagram of a co-injection
system suitable for use in accordance with the teachings of the
present invention.
[0028] FIG. 5 is an exemplary block diagram depicting an injection
system suitable for use in accordance with the teachings of the
present invention.
[0029] FIG. 6 is an exemplary diagram of a rotational apparatus
formed in whole or part from a magnetic material composite as
taught by an illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0030] The present invention discloses a structural magnetic
composite, as well as methods and devices for forming the same. The
present invention will be described below relative to certain
illustrative embodiments. Those skilled in the art will appreciate
that the present invention may be implemented and executed in a
number of different applications and embodiments and is not
specifically limited to the particular embodiments depicted
herein.
[0031] The structural magnetic composite of the illustrative
embodiments of the invention may advantageously have one or more
portions with a concentration of magnetic material and one or more
portions with little or no magnetic particles. The ability to
concentrate the magnetic material in the structural magnetic
composite allows shaping of a magnetic field and shaping of a
magnetic field strength while minimizing an amount of magnetic
material, and allowing a structure formed from the structural
magnetic composite to withstand forces applied to the structure or
a component of the structure without the need to fasten the
structure to a substructure for structural support.
[0032] A structural magnetic composite according to the present
invention includes a first structural material, such as an epoxy,
plastic, or similar polymeric substance, a magnetic material, such
as a magnetic particle(s), magnetizable particle(s), a magnetic
compound, a magnetizable compound and/or a magnetic
nano-particle(s) and a second structural material, such as an
epoxy, plastic, or similar polymeric substance molecularly
compatible with the first structural material. The magnetic
material is introduced to and mixed with the first structural
material, preferably while the first structural material is at
least partially in a fluid medium phase, such that the magnetic
material is held in suspension within the fluid medium phase of the
first structural material in a largely encapsulated form. In turn,
once the composite of the first structural material and the
magnetic material reach a gel phase, the second structural material
is added to adhere or bond to the first structural material and the
magnetic material. The second structural material essentially
encapsulates the first structural material and the magnetic
material or may adhere or bond to one or more selected surfaces
thereof. In some embodiments of the present invention, the weight
ratio of magnetic material to structural material in the resulting
magnetic material composite is between about 80:20 and about
98:2.
[0033] In some embodiments of the present invention, a first
structural material and a magnetic material are admixed and one or
more magnetic fields are applied to the admixed materials to cause
the magnetic particles or compound(s) of the magnetic material
migrate and aggregate in a desired manner in one or more portions
of the magnetic material composite before the structural material
cures. Then, prior to the curing of the first structural material,
for example, at or near the beginning of a gel phase or at anytime
prior to the gel phase entering a solid phase or state, a second
structural material of the same or like type is adhered to or
bonded to the magnetic material composite in whole or in part to
form an article. The a second structural material has a molecular
structure compatible with the first structural material
[0034] To facilitate explanation of the present invention, the term
"magnetic material" as used herein includes a magnetic particle or
particles, a magnetizable particle or particles, a magnetic
compound, a magnetizable compound, a magnetic or magnetizable
nano-particle or nano-particles, and combinations thereof. The term
"magnetic material" is not meant to be limited to a material that
exhibits a magnetic moment in the absence of an external magnetic
field and includes materials that exhibit a magnetic moment in the
presence of an external magnetic field.
[0035] As used herein, a "magnetic material composite" and
"magnetic material composition" refers to a composite material
comprising at least a magnetic component and another component.
[0036] As used herein, a "structural magnetic composite" refers to
a composite material comprising at least a magnetic component and a
structural component.
[0037] As used herein, the terms "structural magnet", "structural
magnets" and the like refer to a monolithic article of manufacture
having a composition and structure to support and resist one or
more loads (i.e., forces applied to the article of manufacture),
having a magnetic moment in one or more portions thereof, and
having one or more portions free of or substantially free of
magnetic material admixed with a structural component or material
during formation of the monolithic article of manufacture.
[0038] As used herein, the term "magnetic particle" or "magnetic
compound" refers to a ferromagnetic material or compound that
exhibits a magnetic moment in the absence of an external magnetic
field. Examples of a magnetic material include, but are not limited
to iron, cobalt, nickel and the like iron oxide, ferrites of
cobalt, zinc and similar known metals frequently used in
powder.
[0039] As used herein, the term "magnetizable particle" or
"magnetizable compound" refers to a metallic particle or a compound
that becomes magnetized in the presence of an external magnetic
field.
[0040] As used herein, the term "magnetic nano-particle" refers to
a particle having a size in any dimension from about 1 nm to about
100 nm.
[0041] As used herein, the term "structural material" refers to a
material having a composition and structure to support and resist
one or more loads (i.e., forces applied thereto).
[0042] As used herein, the term "stratify" refers to the formation
or arrangement of a material, such as a magnetic material, into one
or more layers or spatial distributions.
[0043] To form a magnetic material composite in accordance with an
illustrative embodiment of the present invention, the magnetic
material may be uniformly distributed and admixed throughout a
material, such as a first structural material. Preferably, the
first structural material is in a fluid, for example, liquid,
medium phase when mixed with the magnetic material. The magnetic
material is then stratified to form a layer or layers of magnetic
material in or on the first structural material or to form
different spatial distributions of the magnetic material in or on
the first structural material. Then, once the first structural
material and the magnetic material have sufficiently gelled, but
not fully cured, a second structural material of the same or like
type is adhered to or bonded to the composite of first structural
material and magnetic material.
[0044] In some embodiments, a catalyst may be introduced to the
then-fluid first structural material to facilitate hardening. In
some embodiments, a catalyst may be introduced to the then-fluid
second structural material added to the gel phase of the composite
first structural material and magnetic material to facilitate
hardening. Additionally, during the fluid phase of the first
structural material or the second structural material, the material
may be used in a molding or other formation process to form an
article of manufacture. Such molding or formation processes may
include injection, rotary or other molding process, application as
a resin in a fiberglassing process, roll formation, sheet
formation, and other such methods known in the art. An electric
current or magnetic field may then be introduced through the mold
or form such as to cause the magnetic material mixed with the
structural material to migrate and aggregate in a desired manner in
one or more portions of the magnetic material composite before the
structural material cures.
[0045] In turn, the composite of the first structural material and
magnetic material may be removed from the mold during the gel phase
of the cure process and placed in a second mold or form. The second
structural material of the same or like type as of the first
structural material is added to the second mold or form and allowed
to bond or adhere to the article formed from the first mold to form
the structural material of the present invention.
[0046] Once the structural material has cured, one or more portions
of the magnetic material composite is thus free or substantially
free of the magnetic material admixed to the first structural
material component of the formed article. Further, once the
magnetic material has migrated, aggregated and aligned, an electric
current or magnetic field may then be introduced to the material to
magnetize the magnetic material, if not yet magnetized, thereby
creating a magnet or structural magnet that overcomes conventional
structural limitations.
[0047] Alternatively, the fluid medium phase of the magnetic
material composite, comprising the first structural material and
the magnetic material, may be combined with a hardening catalyst
(if needed) and applied to a surface, such as in a fiberglassing
process, a coating process and other processes known in the art.
Once applied to the surface, an electric current or magnetic field
may then be introduced to the surface to cause the magnetic
material to migrate and aggregate in a desired manner in one or
more portions of the structural-magnetic material composite before
the material cures. Once the structural-magnetic material composite
has cured, one or more portions of the material is free or
substantially free of the magnetic material admixed to the
structural material component on the coated surface. Further, once
the magnetic material has migrated, aggregated and aligned, an
electric current or magnetic field may then be introduced to the
material to magnetize the magnetic material, if not yet magnetized
or to align the molecular orientation of the structural
material.
[0048] By controlling the application of the electric current, the
magnetic field, or both to the composite, it is possible to align
the magnetic moments of the magnetic material to stratify
disposition of the magnetic material during the fluid medium phase
of the structural material to form different layers or spatial
distribution in the magnetic material composite with different
magnetic properties and to align the molecular orientation of the
structural material. Thus, the magnetic material may be aligned in
a desired direction, in a desired portion or portions of the
article, on the surface of an article or combinations thereof.
[0049] The above processes can be used for a structural material
that comprises an epoxy, polymer, or similar material known in the
art, and with a hardening process that may include the use of an
introduced hardener catalyst. The above processes can be used with
a variety of curing processes, such as, but not limited to,
electrical induction curing, temperature curing, and other
processes known in the art.
[0050] The resulting articles of manufacture, when removed from the
form or mold, have a structural shape and size as (by way of
example) rotor arrays, stator arrays, rotor/impeller arrays, and
other like structural components. Likewise, the resulting coated
surfaces once cured require little or no finishing and may act as a
structural element or a protective layer. In addition, the forming
processes may be combined with other fabrication processes, such as
the embedding of other components in or around the structural
composite material to create parts with additional components such
as winding coils, and the like.
[0051] FIGS. 1A and 1B illustrate an illustrative magnetic material
composite 10 taught by the present invention. The magnetic material
composite 10 comprises a first structural material 12A, a magnetic
material 14 and a second structural material 12B. The first
structural material 12A and the magnetic material 14 may be admixed
to first form a preform magnetic material composite 10A. In turn
the second structural material 12B is adhered to or bonded to the
preform magnetic material composite 10A to form the magnetic
material composite 10. The structural materials may comprise any
suitable polymeric material having a composition to support and
resist one or more loads (i.e., forces applied thereto). Short
chain polymers are preferred for use in the structural material 12A
of the illustrative embodiment of the invention, although long
chain polymers may also be used in the structural material 12A.
Short chain polymers are preferred for use in the structural
material 12B of the illustrative embodiment of the invention,
although long chain polymers may also be used in the structural
material 12B. The magnetic material 14 may include particles,
materials and/or compounds that exhibit a magnetic moment in the
absence of an external magnet field and/or particles, materials,
and/or compounds that exhibit a magnetic moment in the presence of
an external magnetic field.
[0052] The illustrative preform magnetic material composite 10A and
magnetic material composite 10 may be formable into a number of
shapes, dimensions and sizes. The illustrative magnetic material
composite 10 is well suited for use as one or more elements in a
pump, a motor, a turbine or any other article or manufacture that
may include one or more magnets. The illustrative magnetic material
composite 10 facilitates formation of monolithic mechanical members
having structural support monolithically integrated therein to
allow the magnetic material composite 10 to resist one or more
loads without an additional substructure and having one or more
magnetic properties. Beneficially, the illustrative magnetic
material composite 10 may have a number of desired structural
properties and magnetic properties tailored to a particular
application. The illustrative magnetic material composite 10 avoids
the drawbacks of mechanically fastening magnets to a substructure
for structural support. Additionally, the illustrative magnetic
material composite 10 avoids the drawbacks of conventionally bonded
magnets, as the magnetic material composite 10 has one or more
portions free or substantially free of the magnetic material 14 and
one or more portions in which the magnetic material 14 is
aggregated and aligned in a desired fashion.
[0053] To obtain a desired magnetic property of the magnetic
material composite 10, a magnetic field, an electric field, or a
combination of both a magnetic field and an electric field are
applied to the magnetic material composite 10 in a state that
allows the magnetic material 14 to migrate and aggregate in the
first structural material 12A, thereby achieving a desired magnetic
property and, to, when desired, align the molecular orientation of
the structural material. For example, a magnetic field, an electric
field or a combination of both may be applied to the magnetic
material composite 10 to stratify the magnetic material 14 into one
or more layers or one or more spatial distributions. In another
example, a magnetic field, an electric field or a combination of
both may be applied to the preform magnetic material composite 10A
before it cures to cause the magnetic material to migrate and
aggregate near a surface of, for example, a cavity in a mole or the
surface of an object coated with the magnetic material 14 and the
first structural material 12A. The magnetic material composite 10
is well suited for use in a lamination process, such as with
fiberglass, carbon fiber and the like. Additionally, the magnetic
material composite 10 may be used to form an object or article of
manufacture with a vacuum bagging process. A vacuum bagging process
provides both pressure and vacuum to facilitate cure of the
magnetic material composite 10 by compacting the material
composite, providing good consolidation and interlaminar bond and
drawing out trapped air and other gases to result in a low void
content.
[0054] The magnetic material composite 10 may maintain a liquid
form or a partially liquid form or gel until cured, at which time a
phase transition is complete and the magnetic material composite 10
becomes a solid.
[0055] A catalyst 16 may be added with the first structural
material 12A and/or the magnetic material 14 of the magnetic
material composite to accelerate a chemical reaction of the
compounds or materials forming the first structural material
12A.
[0056] The first structural material 12A may take the form of a
powder, a liquid or a combination of a powder and a liquid.
Likewise, the magnetic material 14 may take the form of a powder, a
liquid, a powder suspended in a liquid and combinations
thereof.
[0057] In some embodiments of the present invention, the first
structural material 12A and the magnetic material 14 initially
forms a colloidal dispersion. That is, the particles or droplets of
the magnetic material 14 are distributed evenly throughout the
first structural material 12A before an electric or magnetic field
is applied to cause the magnetic material 14 to migrate and
aggregate in one or more portions of the perform magnetic material
composite 10A. In some embodiments the size of dispersed particle
are between 1 nm and 1000 nm in at least one dimension. Once the
particles or compounds of the magnetic material 14 are sufficiently
dispersed in the first structural material 12A a magnetic field, an
electric field or a combination of both is applied to the perform
magnetic material composite 10A to cause the magnetic material 14
to migrate and aggregate in a desired area, position, layer and the
like of the preform magnetic material composite 10A prior to cure
thereof.
[0058] The preform magnetic material composite 10A may have a
viscosity that allows the preform magnetic material composite 10A
to be applied to a surface of an object similar in manner to paint
or a coating such that the preform magnetic material composite 10A
bonds to a surface of the object. Once the preform magnetic
material composite 10A is applied to a surface of an object as a
coating or a paint, a magnetic field, an electric field or a
combination thereof may be applied to cause the magnetic material
14 to migrate and aggregate into a desired shape or pattern before
the preform magnetic material composite 10A sufficiently bonds to a
surface of the object. That is, the magnetic material 14 may be
caused to migrate and aggregate to from a protective surface for
the object. In turn, the preform magnetic material 10A may be
coated or bonded to a layer of the second structural material
12B.
[0059] FIG. 1B illustrates the second structural material 12B is
adhered or bonded to a portion of the first structural material
12A. The second structural material 12B may essentially encapsulate
the first structural material 12A and in turn the magnetic material
14 or may adhere or bond to a limited surface area of the first
structural material 12A. The second structural material 12B is
molecularly compatible with the first structural material 12A. The
second structural material 12B may comprise any suitable polymeric
material having a composition to support and resist one or more
loads (i.e., forces applied thereto). Short chain polymers are
preferred for use in the structural material 12B of the
illustrative embodiment of the invention, although long chain
polymers may also be used in the structural material 12B.
[0060] FIG. 2 illustrate steps taken to form a magnetic material
composite 10 according to illustrative embodiments of the
invention. FIG. 2 is discussed in relation to FIGS. 1, 3A, 3B, 3C,
3D, 3E and 3F.
[0061] Referring to FIG. 2, in step 200, a magnetic material 14 is
selected. As discussed above the magnetic material 14 may be in the
form of a powder, a flake, a solid of any sort, a liquid, a solid
suspended in a liquid and other forms known in the art.
[0062] In step 202, a first structural material 12A is selected. As
discussed above in relation to FIG. 1, the first structural
material 12A may be a composite material, a polymeric material
and/or other materials known in the art. The first structural
material 12A may take a number physical forms including, but not
limited to, a powder, a flake, and other solids, along with a
liquid and particles suspended in a liquid and other materials
known in the art. The first structural material 12A is preferably
in a fluid phase form in an initial stage.
[0063] In step 204, the selected magnetic material 14 and the
selected first structural material 12A are admixed to form the
preform magnetic material composite 10A. FIG. 3A illustrates an
exemplary admixed preform magnetic material composite 10A with the
magnetic material 14 admixed in and substantially dispersed
throughout the first structural material 12A, though one skill in
the art will recognize that the magnetic material may be dispersed
in any suitable manner.
[0064] In step 205, the admixed preform magnetic material composite
10A may be injected into one more cavities of a mold. In some
embodiments, in step 205, the first structural material 12A and the
magnetic material 14 are injected separately in a simultaneous
fashion or nearly simultaneous fashion or in a sequential fashion
or any combination thereof. In turn, in step 206 a magnetic field
is applied to the one or more cavities of the mold to cause the
magnetic material 14 to migrate and aggregate in a desired fashion
according to the supplied magnetic field. FIGS. 4 and 5 depict
exemplary systems and molds suitable for use in accordance with the
teachings of the present invention.
[0065] In some embodiments, the admixing of the first structural
material 12A and the magnetic material 14 occurs in one or more
cavities of the mold. In some embodiments, the first structural
material 12A and the magnetic material 14 are added or co-injected
into one or more cavities of the mold. In some embodiments, the
first structural material 12A and the magnetic material 14 are
added or injected into one or more cavities of the mold in a
sequential manner.
[0066] In step 206, a field is applied to the preform magnetic
material composite 10A to cause the magnetic material 14 to migrate
and aggregate in a desired manner in one or more portions of the
preform magnetic material composite 10A. As a result, the first
structural material 12A may essentially encapsulate or otherwise
form a carrier material for the magnetic material 14.
[0067] FIG. 3B illustrates an exemplary application of a magnetic
field to the preform magnetic material composite 10A to cause the
magnetic material 14 to migrate and aggregate in a desired pattern
in one or more portions of the preform magnetic material composite
10A. FIG. 3B illustrates six magnets 18A-18F. Each magnet 18A-18F
has a north pole and a south pole. The magnets 18A-18F are placed
in close proximity to the preform magnetic material composite 10A
while still in a state that allows migration and aggregation of the
magnetic material 14.
[0068] The magnets 18A-18F generate magnetic fields 20. The
magnetic fields 20 developed between opposing magnets, i.e., 18A
and 18B, 18B and 18E, and 18C and 18F to cause the magnetic
material to migrate and aggregate in a desired manner in one or
more portions of the preform magnetic material composite 10A. In
this illustrative example, the magnetic material 14 is stratified
to form three layers of magnetic material within the preform
magnetic material composite 10A, though one skilled in the art will
recognize that the magnetic material composite may have more or
fewer than three layers of magnetic material therein. As a result,
the layers of structural material between the layers of the
magnetic material 14 may be free of or substantially free of the
magnetic material 14. The number of magnets illustrated is merely
exemplary and any number of magnets may be used to achieve a
desired distribution and alignment of the magnetic material 14 in
the preform magnetic material composite 10A.
[0069] Additionally, the magnets 18A-18F may be used to align the
magnetic material 14 to form an anisotropic magnet in the magnetic
material composite 10.
[0070] FIG. 3C illustrates another embodiment of the present
invention. In some embodiments, two magnets 18G and 18H are placed
in close proximity to the preform magnetic material composite 10A
while the preform magnetic material composite 10A is in a state
suitable to allow the magnetic material 14 to migrate and aggregate
therein. The magnetic field or fields generated by the magnets 18G
and 18H cause the migration and aggregation of the magnetic
material 14 relative to the first structural material 12A.
Additionally, the magnets 18G and 18H may be used to align the
magnetic material 14 to form an anisotropic magnet in the preform
magnetic material composite 10A.
[0071] FIG. 3D illustrates another exemplary embodiment of the
present invention. In some embodiments, one magnet 18J may be used
to cause the magnetic material 14 to migrate and aggregate in a
desired manner in one or more portions of the magnetic material
composite 10. For example, the magnet 18J may cause the magnetic
material 14 to migrate and aggregate along a surface and/or end
portion of the preform magnetic material composite 10A while the
preform magnetic material composite 10A is in a state that allows
the magnetic material 14 to migrate and aggregate.
[0072] The number of magnets depicted in FIG. 3B, 3C, 3D and 3E are
merely illustrative. Additional, magnets may be used as necessary
to cause the magnetic material 14 to migrate and aggregate in a
desired fashion in one or portions of the preform magnetic material
composite 10A.
[0073] As will be discussed in more detail in relation to FIG. 4,
the magnets 18A-18J may be associated with one or more cavities of
a mold to cause migration aggregation alignment of the magnetic
material 14 in the preform magnetic material composite 10A prior to
cure thereof.
[0074] In some embodiments, additional steps may be taken once the
magnetic field or electric field is applied to the preform material
composite 10A in step 206 of FIG. 2. For example, the preform
magnetic material composite 10A once cured or at any time after the
magnetic material 14 has migrated, aggregated and aligned in a
desired fashion, may be again subjected to a magnetic field to
magnetize the magnetic material 14.
[0075] In step 208, an article formed by steps 200 through 206 is
removed from the mold while in a gel state or phase. In step 210,
the article may be placed in a cavity of a second mold. In step
212A, a second structural material 12B is selected and injected
into the cavity of the second mold. In turn, the injected second
structural material 12B bonds to the surface of the preform
material composite 10A, preferably without additional preparation
of the article. In some embodiments, the second structural material
12B is molecularly compatible with the first structural material
12A. Once the injected second structural material 12B cures
sufficiently, the article may be removed from the second mold.
[0076] FIGS. 3E and 3F illustrate exemplary embodiments of a
magnetic material composite formed in accordance with the teachings
of the invention, where the magnetic material 14 becomes magnetized
in the presence of an external magnetic field after mixture and/or
encapsulation with the first structural material 12A.
Electromagnets 22A-22F may be used to magnetize the magnetic
material 14 after magnets 18A-18F have caused the magnetic material
14 to migrate and aggregate in a desired fashion in one or more
portions of the preform magnetic material composite 10A. FIG. 3F
depicts the magnetic field 24 and the magnetic field 14 of the
preform magnetic material composite 10A once magnetized by the
electromagnets 22A-22F. Those skilled in the art will appreciate
the number of electromagnets 22A-22F depicted in FIG. 3E and the
magnetic fields 24 depicted in FIG. 3F is merely illustrative. The
number of electromagnetic used to magnetize the magnetic material
14 of the preform magnetic material composite 10A may be less than
six or more than six and the strength of the magnetic field 24 may
vary depending on the magnetic properties of the magnetic material
14 admixed with the first structural material 12A.
[0077] Additionally, in some embodiments, the magnetic material may
be magnetized prior to admixing with the first structural material
12A.
[0078] FIG. 4 illustrates an exemplary system 400 suitable for
practicing the present invention. The illustrated system is a
co-injection molding system 400 that is configured to inject at
least two materials into a mold cavity. Working materials suitable
for use with the present invention include the magnetic material 14
and the first structural material 12A, such as polymer based
materials. The illustrative co-injection molding system 400
includes a first working material source 410, a second working
material source 412A, and a distribution means 414. The
illustrative co-injection molding system 400 further includes
nozzle assemblies 416A-416D and mold 418. Mold 418 includes gates
420A-420D and cavities 422A-422H. The cavities 422A-422H have any
suitable shape suitable for forming a structural magnet having a
desired shape.
[0079] The illustrative co-injection molding system 400 includes a
control mechanism 440 and magnets 450A-450J. The magnets 450A-450J
may be permanent magnets, electromagnets or a combination of
permanent magnets and electromagnets. The magnets 450A-450J have an
operation and a function similar to the magnets depicted in FIGS.
3B-3D. That is, the magnets 450A-450J are used to apply a magnetic
field to the preform magnetic material composite 10A while in the
cavities 422A-422H to cause the magnetic material 14 to migrate and
aggregate in a desired fashion in one or more portions of the
preform magnetic material composite 10A. Additionally, the magnets
450A-450J may be used to align the magnetic material 14 to form one
or more anisotropic magnets or to magnetize the magnetic material
14 or both. The magnets may have any suitable size, shape, number,
arrangement and/or orientation suitable for the uses described
above and are not limited to the illustrative embodiment.
[0080] The control mechanism 440 is preferably programmable and may
include electronic and optical components and may include a central
processing unit (CPU), memory, storage such a hard drive or optical
drive, an input control, a modem, a network interface, a display
and the like. The CPU is able to execute instructions and control
the duration and the strength of the magnetic fields supplied by
the magnets 450A-450J. The CPU is able to execute instructions to
also control field strength of a magnetic field supplied by the
magnets 450A-450J. Additionally, the CPU may control each component
of the control mechanism 440 and may read or write to a memory such
as instructions or data so that the control mechanism 440 can
control the magnets 450A-450J.
[0081] FIG. 4 illustrates a combination of magnets located within
the mold 418 (i.e., magnets 450B-4501) and magnets affixed to or
adjacent to an exterior portion of the mold 450 (i.e., magnets 450A
and 450J). In some embodiments of the present invention the mold
418 has only interior magnets, for example any of magnets
450B-450I, placed in close proximity to each cavity in a mold. In
some embodiments, the mold 418 may only have magnets located on an
exterior surface or in close proximity to an exterior surface, for
example, magnets 450A and 450J. In other embodiments, the mold 418
may have a combination of magnets located internally to the mold
and magnets affixed to an external surface of the mold.
[0082] The number of magnets depicted both internal to the mold 418
and external to the mold 418 are merely illustrative and are meant
to illustrate the principal that a magnetic field may be applied to
the material injected into any of the cavities 422A-422J to cause
the magnetic material 14 to migrate, and aggregate in a desired
fashion in one or more portions of the preform magnetic material
composite 10A while in the mold 418. Additionally, any of the
magnets 450A-450J may be used to align the magnetic material 14 to
form an anisotropic magnet in the preform magnetic material
composite 10A and, if desired, to magnetize the magnetic material
14. The principals of migration, aggregation, alignment and
magnetization are discussed above in relation to FIG. 2 and FIGS.
3A-3D.
[0083] For the purposes of the discussion herein, the use of the
term "distribution means" refers to a plurality of interconnected
fluid carrying passages for distributing at least one fluid flow
received from an inlet to one or more egresses. A distribution
means can include a number of sets of manifold blocks or a number
of sets of fluid carrying passages. Known terms of art, such as hot
runner and manifold, are examples of a suitable distribution
means.
[0084] The first working material source 410, second working
material source 412A, and distribution network 414 cooperatively
operate to deliver at least two working material streams to nozzle
assemblies 416A-416D upstream of gates 420A-420D. Nozzle assemblies
416A-416D combine the working material streams and feed gates
420A-420D with a combined material stream for delivery to cavities
422A-422H. In one embodiment, the first working material source 410
is the source of the first structural material 12A and the second
working material source 412A is the source of the magnetic material
14.
[0085] In one embodiment of the present invention, first and second
working material sources 410 and 412A are reciprocating screw
injection units and distribution means 414 is a hot runner having
separate flow channels for each working material and being arranged
such that the material flow through each flow channel is balanced
and equal.
[0086] FIG. 5 illustrates an exemplary system suitable for
practicing the present invention. Injection molding system 540 is
configured to inject one working material into a mold cavity. In
some embodiments the magnetic material composite 10 is admixed
prior to use in an injection molding system. In such embodiments,
the injection molding system may include a single material source.
Injection molding system 540 includes a working material source 510
and a distribution network 514. Injection molding system 540
further includes nozzle assemblies 524A, 524B, and mold 518. Mold
518 includes gate 520A, gate 520D, cavity 522A, cavity 522B and
magnets 550A-550F. The working material source 510 is the source
for the preform magnetic material composite 10A.
[0087] The injection molding system 540 includes a control
mechanism 540 and magnets 550A-550F. The magnets 550A-550F may be
permanent magnets, electromagnets or a combination of permanent
magnets and electromagnets. The magnets 550A-550F have an operation
and a function similar to the magnets depicted in FIGS. 3B-3D. That
is, the magnets 550A-550F are used to apply a magnetic field to the
preform magnetic material composite 10A while in the cavities
522A-522D to cause the magnetic material 14 to migrate and
aggregate in a desired fashion in one or more portions of the
preform magnetic material composite 10A. Additionally, the magnets
550A-550F may be used to align the magnetic material 14 to form one
or more anisotropic magnets or to magnetize the magnetic material
14 or both.
[0088] The control mechanism 540 is programmable and may include
electronic and optical components and may include a central
processing unit (CPU), memory, storage such a hard drive or optical
drive, an input control, a modem, a network interface, a display
and the like. The CPU is able to execute instructions and control
the duration and the strength of the magnetic fields supplied by
the magnets 550A-550F. The CPU is able to execute instructions to
also control field strength of a magnetic field supplied by the
magnets 550A-550F. Additionally, the CPU may control each component
of the control mechanism 540 and may read or write to a memory such
as instructions or data so that the control mechanism 540 can
control the magnets 550A-550F.
[0089] FIG. 5 illustrates a combination of magnets located within
the mold 518A (i.e., magnets 550B-550E) and magnets affixed to or
adjacent to an exterior portion of the mold 518A (i.e., magnets
550A and 550F). In some embodiments of the present invention the
mold 518A has only interior magnets, for example, magnets
550B-550E, which may be placed in close proximity to each cavity in
a mold. In some embodiments the mold 518A may only have magnets
located on an exterior surface or in close proximity to an exterior
surface, for example, magnets 550A and 550F. In other embodiments,
the mold 518A may have a combination of magnets located internally
to the mold and magnets affixed to an external surface of the
mold.
[0090] The number of magnets depicted both internal to the mold
518A and external to the mold 518A are merely illustrative and are
meant to illustrate the principal that a magnetic field may be
applied to the material injected into any of the cavities 522A-522D
to cause the magnetic material 14 to migrate and aggregate in a
desired fashion in one or more portions of the preform magnetic
material composite 10A while in the mold 518A. Additionally, any of
the magnets 550A-550F may be used to align the magnetic material 14
to form an anisotropic magnet in the preform magnetic material
composite 10A and, if desired, to magnetize the magnetic material
14. The principals of migration, aggregation, alignment and
magnetization are discussed above in relation to FIG. 2 and FIGS.
3A-3D.
[0091] The working material source 510 and distribution means 514
cooperatively operate to deliver a working material stream to
nozzle assemblies 524A and 524B upstream of gates 520A and 520B.
Nozzle assemblies 524A and 524B feed gates 520A and 520B with a
working material stream for delivery to cavities 522A, 522B and
522C, 522D, respectively.
[0092] The injection systems depicted in FIGS. 5 and 6 are well
suited for use to inject the second structural material 12B. That
is, the injection systems depicted in FIGS. 5 and 6 are
configurable to include additional material sources or the cavities
of the mold may include removable inserts that allow the preform of
magnetic material 10A to be removed and then reinserted into the
cavity for bonding to the second structural material 12B to form
the composite magnetic material 10.
[0093] FIG. 6 illustrates an end view of an exemplary fluid
movement apparatus 610 according to the teachings of the present
invention. The fluid movement apparatus 610 may be a pump, a
turbine, a fan, a motor having one or more elements, parts or
components formed from the magnetic material composite 10.
[0094] The fluid movement apparatus 610 includes a stator assembly
612A and a rotatable element such as an impeller assembly 614. The
impeller assembly 614 includes a number of impeller blades
616A-616D that extend radially from a center point 618. The center
point 618 represents the point about which the impeller assembly
614 rotates. The center point 618 may also be an axle or shaft
having either mechanical bearings or magnetic bearings about which
the impeller assembly 614 rotates. Those skilled in the art will
appreciate the impeller assembly 614 is illustrated with four
impeller blades merely for illustrative purposes and can include
fewer than four impeller blades or more than four impeller blades
depending on the application and use of the fluid movement
apparatus 610. Further, those skilled in the art will appreciate
the impeller blades of the impeller assembly 614 can have a curved
shape and be twisted depending upon the fluid material being
handled and the application in which the fluid movement apparatus
610 operates.
[0095] In some embodiments, the impeller blades 616A-616D are
formed from the magnetic material composite 10. In some
embodiments, the stator assembly 612A is formed from the magnetic
material composite 10. In some embodiments, the impeller blades
616A-616D and the stator assembly 612A are formed from the magnetic
material composite 10. Additionally, in some embodiments the
impeller blades 616A-616D form a rotor assembly having magnetic
properties. An operational, functional and structural relationship
of the fluid movement apparatus 610 is discussed in more detail in
U.S. application Ser. No. 11/293,982, the content of which is
incorporated herein by reference.
[0096] The various embodiments of the above described magnetic
material composite are well suited for use in various industries
such as boating, air handling, petroleum, chemical, pharmaceutical,
medical, automotive, aeronautic, magnetic levitation,
hydroelectricity and other commercial, residential and industrial
applications.
[0097] While the present invention has been described with
reference to illustrative embodiments thereof, one skilled in the
art will appreciate that there are changes in form and detail that
may be made without departing from the intended scope of the
present invention as defined in the pending claims. For example,
the magnetic material composite 10 may have a varying thickness, or
may include additional materials such as adhesives to facilitate
bonding of the material to a surface of an object.
* * * * *