CN105489338A - Manufacturing method of magnetic structure and magnetic structure - Google Patents
Manufacturing method of magnetic structure and magnetic structure Download PDFInfo
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- CN105489338A CN105489338A CN201510933761.7A CN201510933761A CN105489338A CN 105489338 A CN105489338 A CN 105489338A CN 201510933761 A CN201510933761 A CN 201510933761A CN 105489338 A CN105489338 A CN 105489338A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 26
- 239000000696 magnetic material Substances 0.000 claims abstract description 101
- 239000012634 fragment Substances 0.000 claims abstract description 77
- 239000000463 material Substances 0.000 claims abstract description 48
- 238000000034 method Methods 0.000 claims abstract description 36
- 230000002401 inhibitory effect Effects 0.000 claims abstract description 13
- 238000013467 fragmentation Methods 0.000 claims description 2
- 238000006062 fragmentation reaction Methods 0.000 claims description 2
- 239000000853 adhesive Substances 0.000 description 27
- 230000001070 adhesive effect Effects 0.000 description 27
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- 238000002347 injection Methods 0.000 description 10
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- 239000004033 plastic Substances 0.000 description 10
- 229920003023 plastic Polymers 0.000 description 10
- 239000004593 Epoxy Substances 0.000 description 8
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- 239000004698 Polyethylene Substances 0.000 description 5
- 210000003127 knee Anatomy 0.000 description 5
- 238000012986 modification Methods 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 229920000573 polyethylene Polymers 0.000 description 5
- 208000002193 Pain Diseases 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 4
- 238000009920 food preservation Methods 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 238000011282 treatment Methods 0.000 description 4
- 235000014101 wine Nutrition 0.000 description 4
- 208000000094 Chronic Pain Diseases 0.000 description 3
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- 229910052751 metal Inorganic materials 0.000 description 2
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- 229920000515 polycarbonate Polymers 0.000 description 2
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- 229920000298 Cellophane Polymers 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
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- KPLQYGBQNPPQGA-UHFFFAOYSA-N cobalt samarium Chemical compound [Co].[Sm] KPLQYGBQNPPQGA-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/02—Permanent magnets [PM]
- H01F7/0205—Magnetic circuits with PM in general
- H01F7/021—Construction of PM
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/02—Permanent magnets [PM]
- H01F7/0205—Magnetic circuits with PM in general
- H01F7/0221—Mounting means for PM, supporting, coating, encapsulating PM
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Manufacturing & Machinery (AREA)
- Magnetic Treatment Devices (AREA)
- Laminated Bodies (AREA)
Abstract
The invention provides a manufacturing method of a magnetic structure and the magnetic structure. The method comprises the following steps: crushing at least one single sheet of a magnetic material into a plurality of fragments; inhibiting transverse movement of the plurality of fragments relative to each other in the process of crushing the magnetic material; forming an intermediate structure comprising the plurality of fragments of the magnetic material, and essentially inhibiting transverse movement of the plurality of fragments relative to each other in the formed intermediate structure; placing the intermediate structure and a curable material into a container, and enabling the intermediate structure to be supported by the support surface of the container and consistent with the support surface; and curing the curable material when keeping the curable material in the container to form the magnetic material structure.
Description
Technical Field
The present invention generally relates to a method of manufacturing a magnetic structure and a magnetic structure.
Background
There is a continuing need to provide apparatus and methods for magnetic treatment (magnetotherapy) for enhancing exercise and physical performance, increasing muscle strength, and for alleviating ailments such as chronic pain and discomfort or injury or post-operative recovery or illness, and in a manner that is non-invasive, comfortable and does not inhibit human activity, and for magnetic treatment of perishable items such as food or beverage products, for example for food preservation, wine and beverage modification.
Although some apparatus and methods have been proposed, improvements in the manufacture of magnetic structures are still needed in order to provide magnetic structures with desired characteristics, such as one or more of magnetic field strength, size, thickness, mechanical properties, etc.
Embodiments of the present invention provide a method of manufacturing a magnetic structure and a magnetic structure that seeks to meet the above needs.
Disclosure of Invention
According to a first aspect of the present invention, there is provided a method of manufacturing a magnetic structure, comprising the steps of: breaking at least one single piece of magnetic material into a plurality of fragments; inhibiting lateral movement of the plurality of fragments relative to each other during fragmentation of the magnetic material; forming an intermediate structure comprising fragments of the magnetic material, wherein lateral movement of the plurality of fragments relative to each other is substantially inhibited in the formed intermediate structure; placing the intermediate structure and curable material into a container such that the intermediate structure is supported by and conforms to a support surface of the container; and curing the curable material while placed in the container to form the magnetic material structure.
According to a second aspect of the present invention there is provided a magnetic material structure comprising an intermediate structure and a cured, curable material, the intermediate structure comprising at least one monolithic plurality of fragments of magnetic material, wherein lateral movement of the plurality of fragments relative to each other is inhibited; the cured curable material encapsulates the intermediate structure; wherein the intermediate structure conforms to a support surface of the magnetic material structure.
Drawings
Various embodiments of the present invention will be better understood and readily apparent to those skilled in the art from the following description, taken by way of example only, taken in conjunction with the accompanying drawings, in which:
fig. 1(a) to 1(c) illustrate stage 1 of a manufacturing process according to an exemplary embodiment.
Fig. 2(a) to 2(d) illustrate an alternative stage 1 of the manufacturing process according to an exemplary embodiment.
Fig. 3(a) through 3(b) illustrate stage 2 of a manufacturing process according to an exemplary embodiment.
Fig. 4(a) through 4(b) illustrate an alternative stage 2 of the manufacturing process according to an exemplary embodiment.
Fig. 5 shows a flow chart illustrating a method of manufacturing a magnetic material structure according to an example embodiment.
Detailed Description
Various embodiments of the present invention relate to a method of manufacturing a magnetic structure and a magnetic structure that provides improvements in the manufacture of magnetic structures having desired characteristics, such as one or more of magnetic field strength, size, thickness, mechanical properties, and the like.
Fig. 1-4 show schematic diagrams illustrating a method of fabricating a magnetic structure and a magnetic structure for use in an apparatus and method for performing magnetic processing, according to various exemplary embodiments.
Fig. 1(a) to 1(c) illustrate stage 1 of a manufacturing process according to an exemplary embodiment. As shown in fig. 1(a), a fixing element in the form of two adhesive sheet portions 101 is attached to a single sheet 100 of magnetic material. As shown in fig. 1(a), the single sheet 100 of magnetic material is placed between two adhesive sheet portions 101. The adhesive sheet portion 101 is attached along the opposite surface of the magnetic material. Preferably, during the stage 1 processing step, the magnetic material is in an unmagnetized state.
The adhesive sheet portion 101 comprises two separate/elastic adherends, each of which is stretched in this embodiment, thereby constraining the magnetic material. As a result, a compressive force is applied to the magnetic material. However, it should be appreciated that other types of fixation elements and other methods of applying fixation elements may be used, so long as lateral movement of the pieces of magnetic material 104 (fig. 1(c)) relative to each other is inhibited. For example, a single piece of elastic adhesive may be stretched and wrapped around opposing surfaces of a magnetic material.
In this embodiment, a pair of cooperating punches 102a, 102b is used to physically break up a piece of magnetic material into a plurality of contiguous magnet fragments, as shown in fig. 1 (b). The punches 102a and 102b each include a plurality of protrusions (not shown in fig. 1 (b)) on respective front surfaces 105a, 105 b. The punches 102a, 102b are advanced relative to each other so as to move them towards the magnetic material and exert a force on the magnetic material to break it. As shown in fig. 1(c), after the magnetic material pieces are broken, the punches 102a, 102b are retracted relative to each other, forming a plurality 103 of adjoining magnet fragments 104(apluralityofadjoining magnets).
It should be noted that the relative lateral movement of the punches 102a, 102b can be achieved by lateral movement of only one of the punches, for example the upper punch 102 a. However, it should be appreciated that in different embodiments, the bottom punch 102b and/or both punches 102a, 102b may be movable to effect relative lateral movement to exert a force on the magnetic material to fragment it into a plurality 103 of contiguous magnet fragments 104. Moreover, although in this example both punches 102a, 102b have protrusions formed on their respective front surfaces 105a and 105b, only one of the punches 102a, 102b may have protrusions formed thereon while the other has a substantially flat opposing or support surface. Further, it should be appreciated that instead of having a protrusion on the front surface, the punch 102a and/or the punch 102b may have other shapes and configurations as long as the punch is capable of breaking the magnetic material into a plurality 103 of magnet fragments 104. Likewise, other techniques for applying horizontal, lateral, and/or bending stresses may be used in different embodiments to fracture the magnetic material.
Thus, a first intermediate magnetic structure 106 is obtained comprising a plurality 103 of adjoining magnet fragments 104. During the breaking of the magnetic material and in the first intermediate magnetic structure, lateral movement of the magnet fragments 104 relative to each other is inhibited by the adhesive sheet portion 101.
In this embodiment, the magnetic material sheet is shown as being disc-shaped. It should be appreciated that the sheet of magnet material may be other shapes, e.g., square, circular, rectangular, etc., depending on the needs of the design.
Fig. 2(a) to 2(d) illustrate an alternative stage 1 of the manufacturing process according to an exemplary embodiment. As shown in fig. 2(a), a fixing element in the form of two adhesive sheet portions 201 is attached to two or more pieces 203a, 203b of magnetic material. As shown in fig. 2(a), pieces of magnetic material 203a and 203b are placed between two adhesive sheet portions 201. Adhesive sheet portions 201 are attached along opposing surfaces of the pieces of magnetic material 203a and 203 b. Preferably, during the stage 1 processing step, the magnetic material is in an unmagnetized state.
The adhesive sheet portion 201 comprises two separate pieces/elastic of adhesive, each of which is stretched in this embodiment, thereby constraining the respective pieces of magnetic material 203a and 203 b. As a result, a compressive force is applied to the respective pieces 203a and 203b of magnetic material. However, it should be appreciated that other types of securing elements and other methods of applying the securing elements may be used, so long as lateral movement of the pieces of magnetic material 204a, 204b (fig. 2(c)) relative to one another can be inhibited. For example, a single piece of elastic adhesive may be stretched and wrapped around opposing surfaces of a magnetic material.
In this embodiment, a pair of cooperating punches 202a, 202b is used to physically break the pieces of magnetic material 203a, 203b into respective pluralities of contiguous magnet fragments, as shown in fig. 2 (b). The punches 202a and 202b each include a plurality of protrusions (not shown in fig. 2 (b)) on the respective front surfaces 207a, 207 b. The punches 202a, 202b are advanced relative to each other so as to move them towards the respective sheets 203a, 203b of magnetic material and exert a force on the sheets 203a, 203b to break each sheet 203a, 203b of magnetic material. As shown in fig. 2(c), after the pieces 203a, 203b of magnetic material are broken, the punches 202a, 202b are retracted relative to each other to form respective broken pieces 205a, 205b of adjacent magnet pieces 204a, 204 b.
Preferably, the securing element, here in the form of two adhesive wafer portions 201, inhibits lateral movement of the fragments in each of the fragmented pieces 205a, 205b made up of adjoining magnet fragments 204a, 204b, and inhibits lateral movement of the fragmented pieces 205a, 205b relative to each other.
It should be noted that the relative lateral movement of the punches 202a, 202b may be achieved by lateral movement of only one of the punches, such as the upper punch 202 a. However, it should be appreciated that in different embodiments, the bottom punch 202b and/or both punches 202a, 202b may be movable to effect relative lateral movement to exert a force on the sheet of magnetic material 203a, 203b to break the sheet of magnetic material 203a, 203b into broken pieces 205a, 205 b. Moreover, although in this example both punches 202a, 202b have protrusions formed on their respective front surfaces 207a and 207b, only one of the punches 202a, 202b may have protrusions formed thereon while the other has a substantially flat opposing or support surface. Further, it should be appreciated that instead of having a protrusion on the front surface, the punch 202a and/or the punch 202b may have other shapes and configurations as long as the punch is capable of breaking the pieces of magnetic material 203a, 203b into broken pieces 205a, 205 b. Likewise, other techniques for applying horizontal, lateral, and/or bending stresses may be used in different embodiments to fracture the magnetic material.
Thus, a second intermediate magnetic structure 206 is obtained comprising fragmented pieces 205a, 205b, which fragmented pieces 205a, 205b are connected by fixing elements that inhibit lateral movement of the fragments. The second intermediate magnetic structure 206 advantageously exhibits an inherent mechanical flexibility due to the interconnected fixation element portions, e.g. 209, between the fragmented pieces of magnetic material 205a, 205 b. In other words, for the same or similar overall size/shape of the second intermediate magnetic structure 206 (fig. 1(c)) and the first intermediate magnetic structure 106, a mechanically flexible design can be provided by substantially the same or similar amount of magnetic material, i.e., having substantially the same or similar magnetic interference strength (after magnetization). This can advantageously improve incorporation into various magnetic devices where mechanical flexibility is desired to avoid breaking and/or to conform to the body of the user, such as wearable devices, e.g., wrist/wrist bands/wristbands, knee/kneepads, shoulder/shoulder straps, leg/leg bands, and ankle/ankle braces, which can improve the comfort and/or effectiveness of the device.
Optionally, a cutting blade 208 (or other suitable cutting device) is used to cut the second intermediate magnetic structure 206 into a third intermediate magnetic structure 210 comprising a group of separate fragmented magnetic material pieces 205a, 205b, lateral movement of the shards in each of the separate fragmented pieces 205a, 205b continuing to be inhibited. The third intermediate magnetic structure 210 may be used to fabricate a magnetic structure with high mechanical flexibility and high overall shape and dimensional flexibility. This can advantageously improve the incorporation into various magnetic devices where mechanical flexibility and overall shape and size flexibility are desired to avoid breakage and/or to conform to the user's body, such as wearable devices, e.g., wristbands/wristbands, knee/knee braces, shoulder straps/shoulders, leg straps/leg guards, and ankle straps/ankles, which can improve the comfort and/or effectiveness of the device.
In this example, the patches 203a, 203b are shown as rectangular. It should be appreciated that the tabs 203a, 203b may also be other shapes, such as square, circular, disc-shaped, etc., depending on design needs.
During stage 1 described above, the fixing element, here in the form of an adhesive sheet portion 101, 201, acts to inhibit lateral movement of the magnet fragments 104, 204a, 204b by applying a compressive force to hold them in position relative to one another. Preferably, during stage 1 described above, the magnetic material is in an unmagnetized state, which advantageously avoids any magnetic repulsion between the magnet fragments 104, 204a, 204 b. The magnet fragments 104, 204a, 204b are actually spaced apart adjacent to each other with a small separation gap defining a dividing line between adjacent magnet fragments 104, 204a, 204b to produce a magnetic field formed by magnetic interference. Further, the adhesive sheet portions 101 and 201 are preferably sufficiently deformable so that the adhesive sheet portions 101 and 201 do not or substantially do not break when a force is applied to break the magnetic material sheet. The adhesive sheet portions 101 and 201 may be, for example, cellophane tape or polyethylene tape. In the above description, the adhesive sheet portions 101 and 201 are provided at the bottom and top of the magnetic material sheet, however, it should be appreciated that a single adhesive sheet may be attached along at least one surface of the magnetic material sheet as long as the plurality of magnet fragments 104, 204a, 204b can be securely held so that relative lateral movement of the magnet fragments 104, 204a, 204b can be suppressed, thereby maintaining a small gap between the adjoining magnet fragments 104, 204a, 204 b.
The magnetic interference formed by the adjoining magnet pieces 104, 204a, 204b is enhanced by having the plurality of magnet pieces 104, 204a, 204b adjacent to each other and maintaining a small gap between the adjoining magnet pieces 104, 204a, 204 b.
The magnetic material may comprise, for example, a magnetic plate, or may be provided as a film of magnetic material coated on a solid substrate. For example, a coated magnetic film on the surface of a solid substrate such as plastic or non-magnetic metal may be used.
The magnetic material may be made of a material including, for example, one or more of the group consisting of ferrite, ceramic, samarium cobalt, or neodymium. The strength of the magnetic interference formed between the magnet fragments 104, 204a, 204b depends on several factors and can be generally represented by the following formula:
intensity of magnetic interference ═ f (B)1 2,L,g-2,D-2)(1)
Wherein,
B1is the average magnetic flux density of the magnet pieces 104, 204a, 204b gauss]；
L is the total length [ m ] of the dividing line between the magnet fragments 104, 204a, 204 b;
g is the average spacing [ m ] between magnet fragments 104, 204a, 204b, where g ≠ 0; and is
D is the perpendicular distance [ m ] to the surface plane of the magnet fragment 104, 204a, 204b, D ≠ 0.
From the above equation (1), it can be seen that, for a given perpendicular distance (D) to the surface plane of the magnet pieces 104, 204a, 204B, the strength of the magnetic interference and the length (L) of the boundary line between the magnet pieces 104, 204a, 204B and the average magnetic flux density (B)1) Is proportional to the square of. However, the strength of the magnetic interference is inversely proportional to the square of the average spacing (g) between the magnet fragments 104, 204a, 204 b.
Refer to equation (1) (and assume all other coefficients B1L and D remain the same), it can be seen that as the spacing between adjacent magnet fragments 104, 204a, 204b decreases, the strength of the magnetic interference increases because the strength of the magnetic interference is inversely proportional to the square of the spacing (g). Therefore, the spacing between adjacent magnet fragments 104, 204a, 204b is preferably kept as small as possible to obtain a greater strength of magnetic interference.
The separation gap between the magnet fragments 104, 204a, 204b may be, for example, in the range of about 0.01mm to about 1.00 mm. This advantageously results in substantially enhanced magnetic interference.
Since increasing the strength of the magnetic interference can increase the strength of the magnetic field, the size and/or number of magnets required to achieve the desired magnetic field strength is reduced. This in turn can preferably reduce the overall weight and cost of the apparatus.
Fig. 3(a) and 3(b) illustrate stage 2 of a manufacturing process according to an exemplary embodiment. The phase 2 process is illustrated in fig. 3(a) and 3(b) using the first intermediate magnetic structure 106. However, the stage 2 fabrication process can also be implemented with the second intermediate magnetic structure 206 or the third intermediate structure 210.
The first intermediate magnetic structure 106 is placed into a mold container 300, sealed with an epoxy or other suitable plastic material 302, and allowed to cure, forming a magnetic structure 304 that includes the first intermediate magnetic structure 106, the cured epoxy or other suitable plastic material 302, and the container 300. The container is preferably made of plastic, such as Polystyrene (PS), Polycarbonate (PC), polypropylene (PP) or Polyethylene (PE). The curing time may be selected from between about 20 minutes and 4 hours. In particular, the first intermediate magnetic structure 106 is placed in the mold container 300 such that the first intermediate magnetic structure 106 is supported by the bottom surface 305 of the container 300 and sealed with an epoxy or other suitable plastic material 302.
Although the bottom surface 305 is substantially planar in the embodiment shown in fig. 3(a) and 3(b), it should be appreciated that the bottom surface may have different shapes, including, but not limited to, an arc or a dome. Due to the flexibility preferably provided by the securing element, e.g., in the form of two adhesive sheet portions 101 (fig. 1), the first intermediate magnetic structure 106 advantageously conforms to the shape of the bottom surface 305 under the influence of gravity and/or the weight of the epoxy or other suitable plastic material 302 during sealing. This advantageously enables the intermediate structure being used to be incorporated into the formed magnetic structure 304 in a desired shape (e.g., planar, arcuate, or dome-shaped), which enables a desired magnetic field strength and/or shape of the magnetic interference field generated by the magnetic structure 304 to be obtained.
As described above, the stage 2 process can be similarly implemented using either the second intermediate magnetic structure 206 or the third intermediate magnetic structure 210, thus forming a magnetic structure comprising the second intermediate magnetic structure 206, the cured epoxy or other suitable plastic material 302, and the container 300, or a magnetic structure comprising the third intermediate magnetic structure 210, the cured epoxy or other suitable plastic material 302, and the container 300. When the third intermediate structure 210 is used, the separated broken pieces 205a, 205b are preferably placed at a lateral distance from each other, the lateral distance being selected to achieve a desired magnetic field strength and/or mechanical properties of the formed magnetic material structure 304.
In this example, the container 300 is shown as being cylindrical. It should be appreciated that the container may be other shapes, such as a cube or cuboid, depending on design requirements.
Fig. 4(a) through 4(b) illustrate an alternative stage 2 of the manufacturing process according to an exemplary embodiment. The stage 2 process is illustrated in fig. 4(a) and 4(b) using the first intermediate magnetic structure 106. However, the stage 2 fabrication process can also be implemented using either the second intermediate magnetic structure 206 or the third intermediate structure 210.
The first intermediate magnetic structure 106 is placed into the mold container 400 and sealed with injection molded plastic material 402 and allowed to cure. In this example, the mold container material and injection molded plastic material are selected such that the cured material 402 can be removed from the mold container, forming a magnetic structure 404 comprising the intermediate magnetic structure 106 and the cured injection molded plastic material 402. The container is preferably made of a solid material that is easy to remove the magnetic structure after the injection molded plastic material 402 is cured, for example, made of metal, such as steel. The injection molded plastic material may be Polystyrene (PS), Polycarbonate (PC), polypropylene (PP) or Polyethylene (PE). The curing time may be within several seconds. In particular, the first intermediate magnetic structure 106 is placed in the mold container 400 such that the first intermediate magnetic structure 106 is supported by the bottom surface 405 of the container 400 and sealed with the injection molded plastic material 402.
Although the bottom surface 405 is substantially flat in the embodiment shown in fig. 4(a) and 4(b), it should be appreciated that the bottom surface may have different shapes, including, but not limited to, an arc or a dome. Due to the flexibility preferably provided by the securing element, e.g., in the form of two adhesive sheet portions 101 (fig. 1), the first intermediate magnetic structure 106 advantageously conforms to the shape of the bottom surface 405 under the influence of gravity and/or the weight of the injection molded plastic material 402 during sealing. This advantageously enables the intermediate structure being used to be incorporated into the formed magnetic structure 404 in a desired shape (e.g., planar, arcuate, or dome-shaped), enabling a desired magnetic field strength and/or shape of the magnetic interference field generated by the magnetic structure 404 to be obtained.
As described above, the stage 2 process can be similarly implemented with either the second intermediate magnetic structure 206 or the third intermediate magnetic structure 210, thus forming a magnetic structure comprising the second intermediate magnetic structure 206 and the cured injection molded plastic material 402, or a magnetic structure comprising the third intermediate magnetic structure 210 and the cured injection molded plastic material 402. When the third intermediate structure 210 is used, the separated broken pieces 205a, 205b are preferably placed at a lateral distance from each other, the lateral distance being selected to achieve a desired magnetic field strength and/or mechanical properties of the formed magnetic material structure 404.
In this example, the container 400 is shown as being cylindrical. It should be appreciated that the container may be other shapes, such as a cube or cuboid, depending on design requirements.
The magnetization of the magnetic material may be performed before, during or after the phase 2 process. If the third intermediate structure 210 is used, the magnetic material may be magnetized during the phase 2 process or preferably after the phase 2 process. As will be appreciated by those skilled in the art, there are two polarities and directions in the magnetic field. One direction is from the north magnet and the other is from the south pole. Based on scientific convention, the "north" needle of a compass points in the direction of the magnetic flux, i.e., outward from the north pole end of the magnet and inward from the south pole end of the magnet. Preferably, the magnetic south pole is used for exercise and physical enhancement, such as increasing muscle strength and for pain relief, and for food preservation. Magnetic north poles are preferred for the modification of wines and beverages. The magnetic poles can be separated by marking or using color differences in the fabricated magnetic structures 304, 404.
The magnetic structures 304, 404 thus fabricated advantageously exhibit preferred mechanical properties controlled by selection of epoxy/other suitable plastic materials or injection molded plastic materials. For example, the magnetic structure may be made to have a selected mechanical strength and/or flexibility as desired for a particular application. In the magnetic structure 304, the mechanical strength and/or flexibility is additionally controlled by the material of the model container 300, which further increases the design options by providing additional one or more design parameters. For example, the container material may be selected to have a higher hardness in the cured state than epoxy or other plastic materials, which can advantageously provide a magnetic structure having a relatively harder outer shell and a softer inner core, which may be improved in terms of avoiding breakage, shape consistency, and/or wearer comfort. The shaping and packaging of the intermediate magnetic structure is advantageously performed simultaneously during the fabrication of the magnetic structures 304, 404, rather than performing a step of pre-shaping the intermediate magnetic structure to a desired shape, followed by a separate packaging step performed on the pre-shaped intermediate magnetic structure.
It should be noted that the magnetic structures 304, 404 may be used as a monolithic structure, or two or more magnetic structures 304, and/or 404, may be stacked to form a combined magnetic structure with a corresponding increase in the strength of the static magnetic field interference.
In various embodiments, the thickness of the intermediate magnetic structure 106, 206, 210 may vary, and may range from about 0.01mm to about 2mm, such as about 0.05mm in one embodiment.
The thickness of the magnetic structures 304, 404 may be, for example, in the range of about 0.05mm to about 3 mm. As described above, two or more magnetic structures 304 and/or 404 may be stacked together to form a combined magnetic structure having increased magnetostatic interference strength and a corresponding increased overall thickness.
Fig. 5 shows a flow chart illustrating a method of manufacturing a magnetic material structure according to an example embodiment. At step 502, at least one single piece of magnetic material is broken into a plurality of fragments. In step 504, lateral movement of the plurality of pieces relative to each other is inhibited during the breaking of the magnetic material. At step 506, an intermediate structure comprising fragments of magnetic material is formed, wherein lateral movement of the plurality of fragments relative to each other is inhibited in the formed intermediate structure. At step 508, the intermediate structure and curable material are placed into the container such that the intermediate structure is supported by and conforms to (i.e., conforms to) the support surface of the container. At step 510, the curable material is cured while disposed in the container to form a magnetic material structure.
The fragmenting may comprise fragmenting two or more interconnected individual pieces of magnetic material into respective, interconnected sets of multiple fragments (fragments), the inhibiting of lateral movement comprising inhibiting lateral movement of the fragments in each fragmented piece and inhibiting lateral movement of the sets of multiple fragments relative to each other. The intermediate structure may comprise a plurality of sets of multiple fragments connected to each other. The method may further comprise separating the plurality of interconnected sets of the plurality of fragments into a group of separated sets of the plurality of fragments (the intermediate structure comprises the group of separated sets of the plurality of fragments). The placement of the intermediate structure may include arranging the separated sets of the plurality of fragments on a support surface of the container at a lateral distance from each other, the lateral distance being selected to achieve a desired magnetic strength and/or mechanical properties of the formed magnetic material structure.
The formed magnetic material structure may include a container, an intermediate structure, and a cured curable material. The curable material and the material of the container may be selected to achieve desired mechanical properties of the formed magnetic material structure.
The method also includes removing the intermediate structure and the cured curable material from the container, wherein the formed magnetic material structure includes the intermediate structure and the cured curable material.
The fragments of magnetic material may be magnetically polarized after the magnetic material structure is formed.
Inhibiting relative movement of fragments of magnetic material may include providing a securing element on the pieces of magnetic material prior to breaking the individual pieces of magnetic material. The fixing element may comprise at least one adhesive sheet portion attached along at least one surface of the respective sheet of magnetic material. The fixing element may comprise two adhesive sheet portions attached along opposite surfaces of respective pieces of magnetic material. The adhesive sheet may be an elastic plastic sheet.
The shape of the support surface of the container may be planar, arcuate or dome-shaped.
The support surface may be a bottom surface of the container.
In an exemplary embodiment, the magnetic material structure comprises an intermediate structure comprising at least one monolithic plurality of fragments of magnetic material, wherein lateral movement of the plurality of fragments relative to each other is inhibited; further comprising a cured curable material encapsulating the intermediate structure; wherein the intermediate structure conforms to the support surface of the magnetic material structure.
The intermediate structure may comprise respective interconnected sets of the plurality of fragments from two or more interconnected pieces of magnetic material, wherein lateral movement of the fragments in each set of the plurality of fragments and lateral movement of the sets of the plurality of fragments relative to each other is inhibited. The intermediate structure may comprise a plurality of sets of the interconnected fragments.
The intermediate structure may comprise respective separate sets of the plurality of fragments from two or more pieces of magnetic material, wherein lateral movement of fragments in each set of the plurality of fragments and lateral movement of the sets of the plurality of fragments relative to each other is inhibited. The separate sets of multiple fragments may be placed at a lateral distance from each other, the lateral distance being selected to achieve a desired magnetic field strength and/or mechanical properties of the formed magnetic material structure.
The formed magnetic material structure may further comprise a container surrounding the intermediate structure and the cured curable material. The surface of the container may form a support surface. The curable material and the material of the container may be selected to achieve desired mechanical properties of the formed magnetic material structure.
The fragments of magnetic material may be magnetically polarized.
Inhibiting lateral movement of fragments of magnetic material may be achieved using a fixed element. The fixation element may comprise at least one adhesive patch portion attached along at least one surface of a respective plurality of sets of the plurality of fragments. The fixation element may comprise two adhesive wafer portions attached along opposing surfaces of respective sets of the plurality of fragments. The adhesive sheet may be an elastic plastic sheet.
The shape of the support surface may be planar, arcuate or dome-shaped.
The surface of the intermediate structure may form at least a part of the support surface.
The various methods of manufacturing the magnetic structures described above, as well as the various magnetic structures, find application in various devices and methods for performing magnetic treatments for enhancing exercise and physical performance, increasing muscle strength, and for alleviating ailments such as chronic pain and discomfort or injury or post-operative recovery or illness, as well as for food preservation, wine and beverage modification. A non-limiting list, by way of example only, includes wearable devices (such as wristbands/wristbands, knee/knee pads, shoulder straps/shoulders, leg straps/leg pads, and ankle straps/ankles) and their use in magnetic treatment for the relief of ailments (such as chronic pain and discomfort or injury or post-operative recovery or illness). Other applications include insoles or built-in devices in shoes and slippers, wearable garments, or handle straps for sports racquets. Further examples of apparatus and methods are described, for example, in WO/2015/002615 and WO/2015/084263. The various methods of manufacturing the magnetic structures described above, as well as the various magnetic structures, find application in various apparatus and methods for magnetically treating perishable items, such as food or beverage items, for example, for food preservation, wine and beverage modification. Examples of such apparatus and methods are described, for example, in WO/2006/083232 and WO/2008/030191.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Likewise, the invention encompasses any combination of features, in particular of features in the patent claims, even if this feature or this combination of features is not explicitly specified in the patent claims or in the individual embodiments herein.
Claims (10)
1. A method of manufacturing a magnetic material structure, comprising the steps of:
breaking at least one single piece of magnetic material into a plurality of fragments;
inhibiting lateral movement of the plurality of fragments relative to each other during fragmentation of the magnetic material;
forming an intermediate structure comprising a plurality of fragments of the magnetic material, wherein lateral movement of the plurality of fragments relative to each other is substantially inhibited in the formed intermediate structure;
placing the intermediate structure and curable material into a container such that the intermediate structure is supported by and conforms to a support surface of the container; and
curing the curable material while maintaining the curable material disposed in a container to form the magnetic material structure.
2. The method of claim 1, wherein fragmenting comprises fragmenting two or more interconnected individual pieces of magnetic material into respective, interconnected sets of multiple fragments, and wherein inhibiting the lateral movement comprises inhibiting lateral movement of fragments in each fragmented piece and inhibiting lateral movement of the sets of multiple fragments relative to each other.
3. The method of claim 2, wherein the intermediate structure comprises the interconnected plurality of sets of multiple fragments.
4. The method of claim 2, further comprising separating the interconnected plurality of sets of plurality of shards into a group of separated plurality of sets of plurality of shards, wherein the intermediate structure includes the group of separated plurality of sets of plurality of shards.
5. The method of claim 4, wherein the placing of the intermediate structure comprises arranging the separated sets of the plurality of fragments on the support surface of the container at a lateral distance from each other, the lateral distance being selected to achieve a desired magnetic strength and/or mechanical properties of the formed magnetic material structure.
6. A method according to any preceding claim, wherein the formed magnetic material structure comprises the container, the intermediate structure and the cured curable material.
7. The method of claim 6, wherein the curable material and the material of the container are selected to achieve desired mechanical properties of the formed magnetic material structure.
8. The method of any of claims 1 to 6, further comprising: removing the intermediate structure and the cured curable material from the container, wherein the formed magnetic material structure comprises the intermediate structure and the cured curable material.
9. A method according to any preceding claim, wherein the fragments of magnetic material are magnetically polarised after the magnetic material structure is formed.
10. The method of any one of the preceding claims, wherein inhibiting lateral movement of the fragments of magnetic material comprises: the sheet of magnetic material is provided with a fixing element prior to breaking the sheet of magnetic material.
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| WO2017105346A1 (en) * | 2015-12-15 | 2017-06-22 | Esmo Technologies Pte. Ltd. | Method of fabrication of a magnetic structure and magnetic structure |
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