Bonded permanent magnets produced by additive manufacturing

Patent metadata

Field	Value
Publication number	US-2018215854-A1
Application number	US-201815887490-A
Country	US
Kind code	A1
Filing date	Feb 2, 2018
Priority date	Feb 2, 2017
Publication date	Aug 2, 2018
Grant date	—

Abstract

A method for producing a bonded permanent magnet by additive manufacturing, the method comprising: (i) incorporating components of a reactive precursor material into an additive manufacturing device, the reactive precursor material comprising an amine component, an isocyanate component, and particles having a permanent magnetic composition; and (ii) mixing and extruding the crosslinkable reactive precursor material through a nozzle of the additive manufacturing device and depositing the extrudate onto a substrate under conditions where the extrudate is permitted to cure, to produce a bonded permanent magnet of desired shape. The resulting bonded permanent magnet and articles made thereof are also described.

First claim

What is claimed is:

1 . A method for producing a bonded permanent magnet by additive manufacturing, the method comprising:
(i) incorporating components of a reactive precursor material into an additive manufacturing device, the reactive precursor material comprising an amine component, an isocyanate component, and particles having a permanent magnetic composition; and (ii) mixing and extruding said reactive precursor material through a nozzle of said additive manufacturing device and depositing the extrudate onto a substrate under conditions where the extrudate is permitted to cure, to produce a bonded permanent magnet of desired shape; wherein said amine component comprises an amine-containing molecule selected from at least one of the following structures:

wherein:
L 1 is a straight-chained or branched alkyl linker containing at least four and up to twelve carbon atoms;
R 1 , R 2 , R 3 , and R 4 are selected from straight-chained or branched alkyl or alkenyl groups containing one to three carbon atoms, and saturated or unsaturated cyclic hydrocarbon groups;
L 2 is a linker containing at least one saturated carbocyclic ring; and
R 5 and R 6 are selected from straight-chained or branched alkyl or alkenyl groups containing three to eight carbon atoms, and saturated or unsaturated cyclic hydrocarbon groups.

2 . The method of claim 1 , wherein said amine component comprises an amine-containing molecule according to Formula (1).

3 . The method of claim 2 , wherein said amine-containing molecule according to Formula (1) has the following structure:

4 . The method of claim 1 , wherein said amine component comprises an amine-containing molecule according to Formula (2).

5 . The method of claim 4 , wherein said amine-containing molecule according to Formula (2) has the following structure:

6 . The method of claim 1 , wherein, as the extrudate exits from the nozzle and is deposited on a substrate, the extrudate is exposed to a directional magnetic field of sufficient strength to align the particles having a permanent magnetic composition.

7 . The method of claim 1 , wherein, after depositing said extrudate onto said substrate, the extrudate continues to undergo amine-isocyanate crosslinking over at least thirty minutes.

8 . The method of claim 1 , wherein said permanent magnetic composition comprises at least one element selected from iron, cobalt, nickel, copper, gallium, and rare earth elements.

9 . The method of claim 1 , wherein said permanent magnetic composition has a rare earth composition.

10 . The method of claim 9 , wherein said permanent magnetic composition has a samarium-containing, neodymium-containing, or praseodymium-containing composition.

11 . The method of claim 1 , wherein said reactive precursor material further comprises a non-magnetic solid filler material that increases the viscosity of the reactive precursor material.

12 . The method of claim 11 , wherein said non-magnetic solid filler material comprises carbon particles.

13 . The method of claim 12 , wherein said carbon particles are carbon nanotubes.

14 . The method of claim 11 , wherein said non-magnetic solid filler material comprises metal oxide particles.

15 . The method of claim 14 , wherein said metal oxide particles are selected from clay and silica particles.

16 . The method of claim 1 , wherein said isocyanate component is an aliphatic isocyanate.

17 . The method of claim 16 , wherein said aliphatic isocyanate is HDI or IPDI.

18 . The method of claim 1 , wherein said isocyanate component is an aromatic isocyanate.

19 . The method of claim 18 , wherein said aromatic isocyanate is TDI or MDI.

20 . The method of claim 1 , wherein said isocyanate component comprises at least one isocyanate-containing molecule containing an isocyanurate ring.

21 . The method of claim 20 , wherein said isocyanate-containing molecule has the following structure:

wherein L 3 , L 4 , and L 5 are selected from straight-chained, branched, and cyclic alkyl linkers containing at least four and up to twelve carbon atoms.

22 . The method of claim 1 , wherein said particles having a permanent magnetic composition are included in an amount of at least 50 wt. % in said reactive precursor material.

23 . The method of claim 1 , wherein said particles having a permanent magnetic composition are included in an amount of at least 60 wt. % in said reactive precursor material.

Assignees

• Ut Battelle Llc
• Univ Iowa State Res Found Inc
• Ppg Industries Inc

Inventors

• Paranthaman M Parans
• Rios Orlando
• Carter William G
• Fenn David
• Nlebedim Cajetan Ikenna

Classifications

• C08G18/7893

  having three nitrogen atoms in the ring · CPC title

• H01F1/0578

  bonded together · CPC title

• C08G2140/00

  Compositions for moulding powders · CPC title

• C08K3/346

  Clay · CPC title

• C08K3/041

  Carbon nanotubes · CPC title