US2005258403A1PendingUtilityA1

Method of preparing polymer composite using unidirectionally solidified giant magnetostrictive material

25
Individually held — no corporate assignee on recordPriority: Oct 12, 2001Filed: Sep 13, 2002Published: Nov 24, 2005
Est. expiryOct 12, 2021(expired)· nominal 20-yr term from priority
Inventors:Won ParkZin Lee
Y10S428/90Y10S428/928H01F 1/0306Y10T428/24997Y10T428/249967H01F 1/00H10N 35/85H10N 50/01
25
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Claims

Abstract

Disclosed is a preparation method of a polymer composite using a giant magnetostrictive material, which is advantageous in that electric resistivity and magnetostrictive strain are increased while the unidirectionally solidified texture in the material is maintained as it is. The method consists of removing the rare earth or the eutectic phase from a unidirectionally solidifed rare earth giant magnetostrictive material; and infiltrating a polymer resin to the rare earth or cutectic phase-removed void, followed by curing the infiltrated resin. Thereby, there can be provided the polymer composite, which is advantageous in that eddy current loss is decreased due to increased electric resistivity, and magnetostrictive strain is improved as well as fracture resistance is higher due to the soft and tough properties of polymer.

Claims

exact text as granted — not AI-modified
1 . A method of preparing a polymer composite the method comprising: 
 a) removing a eutectic phase from a unidirectionally solidified giant magnetostrictive material to create a rare earth metal phase with voids; and    (b) infiltrating a polymer resin into the voids; and    (c) curing the polymer resin.    
   
   
       2 . The method as set forth in  claim 1 , wherein the removing in (a) is performed by thermally annealing the magnetostrictive material at a higher temperature than a eutectic temperature.  
   
   
       3 . The method as set forth in  claim 1 , further comprising: before the infiltrating step, removing all gases present in the magnetostrictive material under any of an inert gas and a vacuum.  
   
   
       4 . The method as set forth in  claim 1 , further comprising applying pressure to the polymer resin to prevent formation of pores in the polymer resin upon curing.  
   
   
       5 . The method as set forth in  claim 1 , wherein the giant magnetostrictive material comprises a rare earth-iron magnetostrictive alloy.  
   
   
       6 . The method as set forth in  claim 5 , wherein the rare earth-iron magnetostrictive alloy is selected from the group consisting of:  
       Tb x Dy 1-x Fe 2-w (0.27≦x≦0.35, 0≦w≦0.20);  Tb x Ho 1-x Fe 2-w (0.10≦x≦1.00, 0≦w≦0.20);  Sm x Dy 1-x Fe 2-w (0.80≦x≦1.00, 0≦w≦0.20);  Sm x Ho 1-x Fe 2-w (0.60≦x≦1.00, 0≦w≦0.20);  Tb x Ho y Fe 2-w (0.10≦x≦1.00, 0≦y≦0.9, 0≦z≦0.8, 0≦w≦0.20, x+y+z=1); and  Sm x Ho y Dy z Fe 2-w (0.60≦x<1.00, 0≦y≦0.4, 0≦z≦0.4, 0≦w≦0.20, x+y+z=1).  
   
   
       7 . A polymer composite prepared by the method of  claim 1 .  
   
   
       8 . The method of  claim 1 , wherein the removing step is performed by thermally annealing the magnetostrictive material at about 1000° C. for approximately 6 hours.  
   
   
       9 . The method of  claim 1 , wherein the curing step is performed by heating the polymer resin at about 80° C. for approximately 2 hours.  
   
   
       10 . The method of  claim 1 , wherein the polymer resin is selected from the group consisting of epoxy resin, phenol resin, polyimide and polystyrene.  
   
   
       11 . The method of  claim 1 , wherein the polymer composite includes a rare earth metal phase, and wherein the polymer resin has a lower Young's modulus than the rare earth metal phase.  
   
   
       12 . The method of  claim 1 , wherein the unidirectionally solidified giant magnetostrictive material includes about 90% by volume of Laves phase and about 10% by volume of eutectic phase.  
   
   
       13 . The method of  claim 1 , wherein the infiltrated resin is a YD-114 epoxy resin.  
   
   
       14 . A method of preparing a polymer composite, the method comprising: 
 (a) replacing a eutectic phase with a polymer resin, in a giant magnetostrictive material that comprises a rare earth metal phase and the eutectic phase; and    (b) curing the polymer resin.    
   
   
       15 . The method of  claim 14 , further including thermally annealing the magnetostrictive material at a higher temperature than a eutectic temperature to remove the eutectic phase from the magnetostrictive material.  
   
   
       16 . The method of  claim 14 , further comprising, before the replacing, removing all gases present in the magnetostrictive material under any of an inert gas and a vacuum.  
   
   
       17 . The method of  claim 14 , further comprising applying pressure to the polymer resin to prevent formation of pores in the polymer resin upon curing.  
   
   
       18 . The method of  claim 14 , wherein the giant magnetostrictive material comprises a rare earth-iron magnetostrictive alloy.  
   
   
       19 . The method of  claim 18 , wherein the rare earth-iron magnetostrictive alloy is selected from the group consisting of:  
       Tb x Dy 1-x Fe 2-w (0.27≦x≦0.35, 0≦w≦0.20),  Tb x Ho 1-x Fe 2-w (0.10≦x≦1.00, 0≦w≦0.20),  Sm x Dy 1-w Fe 2-w (0.80≦x≦1.00, 0≦w≦0.20),  Sm x Ho 1-x Fe 2-w (0.60≦x≦1.00, 0≦w≦0.20),  Tb x Ho y Dy z Fe 2-w (0.10≦x≦1.00, 0≦y≦0.9, 0≦z≦0.8, 0≦w≦0.20, x+y+z=1), and  Sm x Ho y Dy z Fe 2-w (0.60≦x<1.00, 0≦y≦0.4, 0≦z≦0.4, 0≦w≦0.20, x+y+z=1).  
   
   
       20 . The method of  claim 14 , wherein the polymer resin is a YD-114 epoxy resin.  
   
   
       21 . The method of  claim 14 , wherein the removing step is performed by thermally annealing the magnetostrictive material at about 1000° C. for approximately 6 hours.  
   
   
       22 . The method of  claim 14 , wherein the curing step is performed by heating the polymer resin at about 80° C. for approximately 2 hours.  
   
   
       23 . The method of  claim 14 , wherein the polymer resin is selected from the group consisting of epoxy resin, phenol resin, polyimide and polystyrene.  
   
   
       24 . The method of  claim 14 , wherein the polymer resin has a lower Young's modulus than the rare earth metal phase.  
   
   
       25 . The method of  claim 14 , wherein the giant magnetostrictive material includes about 90% by volume of Laves phase and about 10% by volume of eutectic phase.  
   
   
       26 . A polymer composite prepared by the method of  claim 14 .  
   
   
       27 . A polymer composite material comprising: 
 a Laves phase of a rare earth metal in unidirectionally solidified dendrite form and having a giant magnetostrictive material; and    a polymer resin filling void between the dendrites of the Laves phase.    
   
   
       28 . The polymer composite of  claim 27 , wherein the Laves phase is selected from the group consisting of:  
       Tb x Dy 1-x Fe 2-w (0.27≦x≦0.35, 0≦w≦0.20),  Tb x Ho 1-x Fe 2-w (0.10≦x≦1.00, 0≦w≦0.20),  Sm x Dy 1-x Fe 2-w (0.80≦x≦1.00, 0≦w≦0.20),  Sm x Ho 1-x Fe 2-w (0.60≦x≦1.00, 0≦w≦0.20),  Tb x Ho y Dy z Fe 2-w (0.10≦x≦1.00, 0≦y≦0.9, 0≦z≦0.8, 0≦w≦0.20, x+y+z=1), and  Sm x Ho y Dy z Fe 2-w (0.60≦x≦1.00, 0≦y≦0.4, 0≦z<0.4, 0≦w≦0.20, x+y+z=1).  
   
   
       29 . The polymer composite of  claim 27 , wherein the polymer resin is selected from the group consisting of epoxy resin, phenol resin, polyimide and polystyrene.  
   
   
       30 . The polymer composite of  claim 27 , wherein the polymer resin has a lower Young's modulus than the rare earth metal phase.  
   
   
       31 . The polymer composite of  claim 27 , wherein the giant magnetostrictive material includes about 90% by volume of the Laves phase and about 10% by volume of the polymer resin.  
   
   
       32 . The polymer composite of  claim 27 , wherein the Laves phase comprises a rare earth-iron magnetostrictive alloy.

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