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.

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.