WO2017105346A1 - Procédé de fabrication d'une structure magnétique et structure magnétique - Google Patents

Procédé de fabrication d'une structure magnétique et structure magnétique Download PDF

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Publication number
WO2017105346A1
WO2017105346A1 PCT/SG2016/050598 SG2016050598W WO2017105346A1 WO 2017105346 A1 WO2017105346 A1 WO 2017105346A1 SG 2016050598 W SG2016050598 W SG 2016050598W WO 2017105346 A1 WO2017105346 A1 WO 2017105346A1
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WO
WIPO (PCT)
Prior art keywords
magnetic material
fragments
magnetic
container
pluralities
Prior art date
Application number
PCT/SG2016/050598
Other languages
English (en)
Inventor
Loh You Chua
Original Assignee
Esmo Technologies Pte. Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Esmo Technologies Pte. Ltd. filed Critical Esmo Technologies Pte. Ltd.
Publication of WO2017105346A1 publication Critical patent/WO2017105346A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14631—Coating reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14819—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being completely encapsulated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2202/00—Physical properties
    • C22C2202/02—Magnetic

Definitions

  • the present invention relates broadly to a method of fabrication of a magnetic structure and to a magnetic structure.
  • Embodiments of the present invention provide a method of fabrication of a magnetic structure and a magnetic structure that seek to address that need.
  • a method of fabricating 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 with respect to each other during the breaking of the magnetic material; forming an intermediate structure comprising the fragments of the magnetic material, wherein lateral movement of the plurality of fragments with respect to each other is substantially inhibited in the formed intermediate structure; placing the intermediate structure and a 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 being disposed in the container to form the magnetic material structure.
  • a magnetic material structure comprising an intermediate structure comprising fragments of at least one single piece of magnetic material, wherein lateral movement of the plurality of fragments with respect to each other is inhibited; and a cured curable material encapsulating the intermediate structure; wherein the intermediate structure conforms to a support surface of the magnetic material structure.
  • Figures 1(a) to (c) illustrate a stage 1 fabrication process according to an example embodiment.
  • FIGS 2(a) to (d) illustrate an alternative stage 1 fabrication process according to an example embodiment.
  • Figures 3(a) and (b) illustrate a stage 2 fabrication process according to an example embodiment.
  • FIGS 4(a) and (b) illustrate an alternative stage 2 fabrication process according to an example embodiment.
  • Figure 5 shows a flowchart illustrating a method of fabricating a magnetic material structure according to an example embodiment.
  • Embodiments of the present invention relate to a method of fabrication of a magnetic structure and to a magnetic structure providing improvements in the fabrication of magnetic structures with desired properties, e.g. in terms of one or more of the magnetic strength, the size, the thickness, the mechanical properties etc.
  • Figures 1 to 4 show schematic drawings illustrating methods of fabricating a magnetic structure and magnetic structures according to example embodiments, for use in devices and methods for magnetic treatment.
  • Figures 1(a) to (c) illustrate a stage 1 fabrication process according to an example embodiment.
  • a fixture element in the form of two adhesive sheet portions 101 is attached onto a single piece 100 of magnetic material.
  • the piece 100 of magnetic material is disposed between the two adhesive sheet portions 101, as shown in Figure 1(a).
  • the adhesive sheet portions 101 are attached along opposing surfaces of the magnetic material.
  • the magnetic material is in an un- magnetized state during the stage 1 process steps.
  • the adhesive sheet portions 101 comprise two separate strips/pieces of elastic adhesive that are each stretched in this embodiment, thereby binding the magnetic material. As a result a compressive force is exerted on the magnetic material.
  • fixture elements and other methods of applying the fixture elements can be used, as long as lateral movement of the magnetic material fragments 104 ( Figure 1(c)) with respect to each other is inhibited.
  • a single elastic adhesive may be stretched and may be wound around the opposing surfaces of the magnetic material.
  • a pair of co-operating punches 102a, b is used in this embodiment to physically break the piece of magnetic material into a plurality of adjoining magnet fragments, as shown in Figure 1(b).
  • the punches 102a, b each comprise a plurality of protrusions (not resolved in Figure 1(b)) on respective leading surfaces 105a, b.
  • the punches 102a, b are advanced relative to each other so as to move towards the magnetic material and to apply a force onto the magnetic material to break the magnetic material.
  • the punches 102a, b are retracted relative to each other after the piece of magnetic material is broken, forming a plurality 103 of adjoining magnet fragments 104, as shown in Figure 1(c).
  • the relative lateral movement of the punches 102a, b may be effected by lateral movement of only one of the punches, e.g. the upper punch 102a.
  • the bottom punch 102b and/or both punches 102a, b may be moved to effect the relative lateral movement to apply a force onto the magnetic material to break the magnetic material into the plurality 103 of adjoining magnet fragments 104.
  • both punches 102a, b have protrusions formed on the respective leading surfaces 105a, b in this example, only one of the punches 102a, b may have protrusions formed thereon, the other having a substantially flat counter or support surface.
  • the punch 102a and/or the punch 102b can have other geometries and configurations, as long as the punch can break the magnetic material into the plurality 103 of magnet fragments 104. Also, other techniques for applying horizontal, lateral and/or bending stresses to fragment the magnetic material may be applied in different embodiments.
  • a first intermediate magnetic structure 106 comprising the plurality 103 of adjoining magnet fragments 104 is obtained. Lateral movement of the magnet fragments 104 with respect to each other during the breaking of the magnetic material and in the first intermediate magnetic structure is inhibited by the adhesive sheet portions 101.
  • FIGS 2(a) to (d) illustrate an alternative stage 1 fabrication process according to an example embodiment.
  • a fixture element in the form of two adhesive sheet portions 201 is attached onto two or more pieces 203 a,b of magnetic material.
  • the piece 203a, b of magnetic material are disposed between the two adhesive sheet portions 201, as shown in Figure 2(a).
  • the adhesive sheet portions 201 are attached along opposing respective surfaces of the pieces 203a, b of magnetic material.
  • the magnetic material is in an un-magnetized state during the stage 1 process steps.
  • the adhesive sheet portions 201 comprise two separate strips/pieces of elastic adhesive that are each stretched in this embodiment, thereby binding the respective pieces 203a, b of magnetic material. As a result a compressive force is exerted on the respective pieces 203a, b of magnetic material.
  • a single elastic adhesive may be stretched and may be wound around the opposing surfaces of the magnetic material.
  • a pair of co-operating punches 202a, b is used in this embodiment to physically break the pieces 203a, b of magnetic material into respective pluralities of adjoining magnet fragments, as shown in Figure 2(b).
  • the punches 202a, b each comprise a plurality of protrusions (not resolved in Figure 2(b)) on respective leading surfaces 207a, b.
  • the punches 202a, b are advanced relative to each other so as to move towards the respective pieces 203a, b of magnetic material and to apply a force onto the pieces 203a, b of magnetic material to break each piece 203a, b of magnetic material.
  • the punches 202a, b are retracted relative to each other after the pieces 203a, b of magnetic material are broken, forming respective broken pieces 205a, b of adjoining magnet fragments 204a, b, as shown in Figure 2(c).
  • the fixture element here in the form of the two adhesive sheet portions 201 inhibits the lateral movement of fragments within each broken piece 205a, b of adjoining magnet fragments 204a, b, and inhibits lateral movement of the broken pieces 205a, b relative to each other.
  • the relative lateral movement of the punches 202a, b may be effected by lateral movement of only one of the punches, e.g. the upper punch 202a.
  • the bottom punch 202b and/or both punches 202a, b may be moved to effect the relative lateral movement to apply a force onto the pieces 203a, b of magnetic material to break the pieces 203a, b of magnetic material into the broken pieces 205a, b.
  • both punches 202a, b have protrusions formed on the respective leading surfaces 207a, b in this example, only one of the punches 202a, b may have protrusions formed thereon, the other having a substantially flat counter or support surface.
  • the punch 202a and/or the punch 202b can have other geometries and configurations, as long as the punch can break the pieces 203a, b of magnetic material into the broken pieces 205a, b.
  • other techniques for applying horizontal, lateral and/or bending stresses to fragment the magnetic material may be applied in different embodiments.
  • a second intermediate magnetic structure 206 comprising the broken pieces 205a, b connected by the fixture element inhibiting lateral movement of the fragments, here in the form of the adhesive sheet portions 201.
  • the second intermediate magnetic structure 206 advantageously exhibits an inherent mechanical flexibility due to the interconnecting fixture element portions e.g. 209 between the broken pieces 205a, b of magnetic material.
  • a mechanically flexible design can be provided with substantially the same or similar amount of magnetic material, i.e. with substantially the same or similar magnetic interference strength (after magnetization).
  • wearable device such as wrist bands or straps, knee bands or straps, shoulder bands or straps, leg bands or straps, and ankle bands or straps, where mechanical flexibility may be desired for avoiding breakage, and/or for conforming to the user's body, which may improve comfort and/or effectiveness of the device.
  • 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 the group of separated broken pieces 205a, b of magnetic material, with lateral movement of fragments in each separated broken piece 205a, b continued to be inhibited.
  • the third intermediate magnetic structure 210 can be used for fabrication of magnetic structures with high mechanical flexibility and high flexibility of overall shape and dimensions.
  • wearable device such as wrist bands or straps, knee bands or straps, shoulder bands or straps, leg bands or straps, and ankle bands or straps, where mechanical flexibility and flexibility in overall shape and dimensions may be desired for avoiding breakage, and/or for conforming to the user's body, which may improve comfort and/or effectiveness of the device.
  • the pieces 203a, b are shown to be rectangular in this example. It will be appreciated that the pieces 203a, b can be of other shapes, e.g. square, circular, disk-shaped etc., depending on design requirements.
  • the fixture element here in the form of the adhesive sheet portions 101, 201, serves to inhibit lateral movement of the magnet fragments by exerting a compressive force to hold the magnet fragments 104, 204a, b in place with respect to each other.
  • the magnetic material is in an un- magnetized state during the stage 1 processes described above, which advantageously avoids any magnetic repulsive forces between the magnet fragments 104, 204a, b.
  • the magnet fragments 104, 204a, b are in practice spaced adjacent to each other with a small separation gap defining a boundary between adjoining magnet fragments 104, 204a, b to produce a magnetic field created by magnetic interference.
  • the adhesive sheet portions 101, 201 are preferably sufficiently deformable such that the adhesive sheet portions 101, 201 are not or not substantially broken when force is applied to break the pieces of magnetic material.
  • the adhesive sheet portions 101, 201 can be, for example, cellophane tape or polyethylene tape.
  • adhesive sheet portions 101, 201 are provided on the bottom and top of the pieces of magnetic material, however, it will be appreciated that a single adhesive sheet can be attached along at least one surface of the piece of magnetic material, as long as the plurality of magnet fragments 104, 204a, b can be held securely such that relative lateral movement of the magnet fragments 104, 204a, b is inhibited, thereby maintaining small gaps between the adjoining magnet fragments 104, 204a, b.
  • the magnetic interference created by the adjoining magnet fragments 104, 204a, b is intensified.
  • the magnetic material may comprise, for example, a magnetic plate or may be provided as a magnetic material film coated on a solid substrate.
  • a coated magnetic film on the surface of a solid substrate such as plastics or nonmagnetic metals may be used.
  • the magnetic material can be made of materials comprising, for example, one or more of a group consisting of ferrite, ceramics, samarium cobalt, or neodymium.
  • the intensity of magnetic interference created between the magnet fragments 104, 204a, b depends on several factors and can be generally represented by the following equation:
  • Bi is the average magnetic flux density of the magnet fragments 104, 204a, b
  • L is the total length of the boundary between the magnet fragments 104, 204a, b [m];
  • g is the average gap distance between the magnet fragments 104, 204a, b [m], where g ⁇ 0;
  • D is the perpendicular distance from a surface plane of the magnet fragments 104, 204a, b [m], ⁇ 0. From the above equation (1), it is observed that at a given perpendicular distance (D) from a surface plane of the magnet fragments 104, 204a, b, the intensity of magnetic interference is proportional to the length of the boundary between the magnet fragments 104, 204a, b (L) and the square of the average magnetic flux density (B i) of the magnet fragments 104, 204a, b. However, the intensity of magnetic interference is inversely proportional to the square of the average gap distance (g) between the magnet fragments 104, 204a, b.
  • the gap distance between adjoining magnet fragments 104, 204a, b is decreased, the intensity of the magnetic interference is increased as the magnetic interference intensity is inversely proportional to the square of the gap distance (g). Therefore, the gap distance between adjoining magnet fragments 104, 204a, b is preferably maintained as small as possible to achieve magnetic interference of a greater intensity.
  • the separation gaps between the magnet fragments 104, 204a, b can, for example, be in the range of about 0.01mm to about 1.00mm. This advantageously creates a substantially intensified magnetic interference.
  • the size and/or the number of magnets required to achieve a desired magnetic field strength is reduced. This in turn can preferably reduce the total weight and cost of the device.
  • Figures 3(a) and (b) illustrate a stage 2 fabrication process according to an example embodiment.
  • the stage 2 process is illustrated in Figures 3(a) and (b) with the first intermediate magnetic structure 106 being used.
  • the stage 2 fabrication process can be equally applied using the second intermediate magnetic structure 206, or the third intermediate structure 210.
  • the first intermediate magnetic structure 106 is placed into a mould container 300 and sealed with epoxy resin(s) or other suitable plastic material(s) 302 and allowed to cure, forming a magnetic structure 304 comprising the intermediate magnetic structure 106, the cured epoxy resin(s) or other suitable plastic material(s) 302, and the container 300.
  • the container is preferably made of plastic, e.g. from Polystyrene (PS), Polycarbonates (PC), Polypropylene (PP) or Polyethylene (PE).
  • PS Polystyrene
  • PC Polycarbonates
  • PP Polypropylene
  • PE Polyethylene
  • the curing time can take between about 20 mins to 4 hours.
  • the first intermediate magnetic structure 106 is placed into the mould container 300 such that the first intermediate structure 106 is supported by a bottom surface 305 of the container 300 and sealed with the epoxy resin(s) or other suitable plastic material(s) 302.
  • the bottom surface 305 is substantially flat, it will be appreciated that the bottom surface can have a different shape including, but not limited to, an arc shape or a dome shape.
  • the first intermediate structure 106 due to a degree of flexibility preferably provided by the fixture element, e.g. in the form of two adhesive sheet portions 101 ( Figure 1), advantageously conforms to the shape of the bottom surface 305 under gravitational force and/or under the weight of the epoxy resin(s) or other suitable plastic material(s) 302 during the sealing. This advantageously enables that the intermediate structure being used can be incorporated in the formed magnetic structure 304 in a desired shape (e.g. flat, arc shape, or dome shape), which can achieve a desired magnetic strength and/or shape of the magnetic interference field generated by the magnetic structure 304.
  • a desired shape e.g. flat, arc shape, or dome shape
  • the stage 2 process can be equally applied using the second intermediate magnetic structure 206, or the third intermediate structure 210 thus forming a magnetic structure comprising the second intermediate magnetic structure 206, the cured epoxy resin(s) other suitable plastic material(s) 302, and the container 300, or comprising the third intermediate magnetic structures 210, the cured epoxy resin(s) other suitable plastic material(s) 302, and the container 300.
  • the third intermediate structure 210 is used, the separated broken pieces 205a, b are preferably placed at a lateral distance from each other chosen to achieve a desired magnetic strength and/or mechanical property of the formed magnetic material structure 304.
  • the container 300 is shown to be cylindrical in this example. It will be appreciated that the container can be of other shapes, e.g. cubic or cuboid, depending on design requirements.
  • FIGs 4(a) and (b) illustrate an alternative stage 2 fabrication process according to an example embodiment.
  • the stage 2 process is illustrated in Figures 4(a) and (b) with the first intermediate magnetic structure 106 being used.
  • the stage 2 fabrication process can be equally applied using the second intermediate magnetic structure 206, or the third intermediate structure 210.
  • the first intermediate magnetic structure 106 is placed into a mould container 400 and sealed with an injection molding plastic material(s) 402 and allowed to cure.
  • the mould container material and the injection molding plastic material(s) are chosen such that the cured material 402 can be removed from the mould container, forming a magnetic structure 404 comprising the intermediate magnetic structure 106 and the cured injection molding plastic material(s) 402.
  • the container is preferably made from a solid material for easy removal of the magnetic structure after curing of the injection molding plastic material(s) 402, e.g. from a metal such as steel.
  • the injection molding plastic material(s) may be Polystyrene (PS), Polycarbonates (PC), Polypropylene (PP) or Polyethylene (PE).
  • PS Polystyrene
  • PC Polycarbonates
  • PP Polypropylene
  • PE Polyethylene
  • the first intermediate magnetic structure 106 is placed into the mould container 400 such that the first intermediate structure 106 is supported by a bottom surface 405 of the container 400 and sealed with the injection molding plastic material(s) 402. While in the embodiment shown in Figures 4(a) and (b) the bottom surface 405 is substantially flat, it will be appreciated that the bottom surface can have a different shape including, but not limited to, an arc shape or a dome shape.
  • the first intermediate structure 106 due to a degree of flexibility preferably provided by the fixture element, e.g. in the form of two adhesive sheet portions 101 ( Figure 1), advantageously conforms to the shape of the bottom surface 405, under gravitational force and/or under the weight of the injection molding plastic material(s) 402 during the sealing.
  • the intermediate structure being used can be incorporated in the formed magnetic structure 404 in a desired shape (e.g. flat, arc shape, or dome shape), which can achieve a desired magnetic strength and/or shape of the magnetic interference field generated by the magnetic structure 404.
  • a desired shape e.g. flat, arc shape, or dome shape
  • the stage 2 process can be equally applied using the second intermediate magnetic structure 206, or the third intermediate structure 210, thus forming a magnetic structure comprising the second intermediate magnetic structure 206 and the cured injection molding plastic material(s) 402, or comprising the third intermediate magnetic structure 210, and the cured injection molding plastic material(s) 402.
  • the separated broken pieces 205a, b are preferably placed at a lateral distance from each other chosen to achieve a desired magnetic strength and/or mechanical property of the formed magnetic material structure 404.
  • the container 400 is shown to be cylindrical in this example. It will be appreciated that the container can be of other shapes, e.g. cubic or cuboid, depending on design requirements.
  • the magnetic material may be magnetized before, during or after the stage 2 process. If the third intermediate structure 210 is used, the magnetic material may be magnetized during or preferably after the stage 2 process.
  • the magnetic South polarity is used for sports & physical enhancement, e.g. to increase muscle strength as well as for pain relief, and food preservation.
  • the magnetic North polarity is preferably used for wine & beverage enhancement.
  • the magnetic poles can be differentiated by marking or color differences in the fabricated magnetic structures 304, 404.
  • the magnetic structures 304, 404 thus fabricated advantageously exhibit preferred mechanical properties governed by the choice of epoxy resin(s),/other suitable plastic material(s), or injection molding plastic material(s).
  • the magnetic structures may be made of a chosen mechanical strength and/or flexibility as desired for a particular application.
  • the mechanical strength and/or flexibility is additionally governed by the material of the mould container 300, which further increases design options by providing additional one or more design parameters.
  • the container material may be chosen to have higher stiffness than the epoxy resin(s) or other plastic material(s) in the cured state, which can advantageously provide a magnetic structure with a relative harder shell and a softer core, which may improve breakage avoidance, shape conforming and/or wearer comfort.
  • the shaping and the encapsulating of the intermediate magnetic structure is advantageously performed simultaneously, instead of performing one step for pre-shaping the intermediate magnetic structure into a desired shape, followed by a separate encapsulation step applied to the pre-shaped intermediate magnetic structure.
  • magnetic structures 304, 404 can be used as single piece structures, or two or more of the magnetic structures 304, and/or 404 may be stacked together to form a combined magnetic structure with increased net magnetic interference strength accordingly.
  • the thickness of the intermediate magnetic structures 106, 206, 210 may differ in different embodiments, and may be in a range from about 0,01mm to about 2mm, for example about 0,05mm in one embodiment.
  • the thickness of the magnetic structure 304, 404 can e.g. be in a range from about 0,05 to about 3mm. As mentioned above, two or more magnetic structures 304 and/or 404 may be stacked together to form a combined magnetic structure with increased net magnetic interference strength, and with increased total thickness accordingly.
  • Figure 5 shows a flowchart 500 illustrating a method of fabricating a magnetic material structure according to an example embodiment.
  • step 502 at least one single piece of magnetic material is broken into a plurality of fragments.
  • step 504 lateral movement of the plurality of fragments with respect to each other is inhibited during the breaking of the magnetic material.
  • step 506 an intermediate structure comprising the fragments of the magnetic material is formed, wherein lateral movement of the plurality of fragments with respect to each other is inhibited in the formed intermediate structure.
  • the intermediate structure and a curable material are placed into a container such that the intermediate structure is supported by, and conforms to, a support surface of the container.
  • the curable material is cured while being disposed in the container to form the magnetic material structure.
  • the breaking may comprise breaking two or more interconnected single pieces of magnetic material into interconnected respective pluralities of fragments, and inhibiting the lateral movement comprises inhibiting lateral movement of fragments within each broken piece and inhibiting lateral movement of the pluralities of fragments relative to each other.
  • the intermediate structure may comprise the interconnected pluralities of fragments.
  • the method may further comprise separating the interconnected pluralities of fragments into a group of separated pluralities of fragments, and wherein the intermediate structure comprises the group of the separated pluralities of fragments.
  • the placing of the intermediate structure may comprise disposing the separated pluralities of fragments at a lateral distance from each other on the support surface of the container, the lateral distance being chosen to achieve a desired magnetic strength and/or mechanical property of the formed magnetic material structure.
  • the formed magnetic material structure may comprise the container, the intermediate structure and the cured curable material.
  • the curable material and a material of the container may be chosen to achieve a desired mechanical property of the formed magnetic material structure.
  • the method may further comprise removing the intermediate structure and the cured curable material from the container, and wherein the formed magnetic material structure comprises the intermediate structure and the cured curable material.
  • the fragments of the magnetic material may be magnetically polarized after the magnetic material structure is formed.
  • Inhibiting relative movement of the fragments of magnetic material may comprise providing a fixture element on the pieces of magnetic material prior to the breaking of the pieces of magnetic material.
  • the fixture element may comprise at least one adhesive sheet portion attached along at least one surface of the respective pieces of magnetic material.
  • the fixture element may comprise two adhesive sheet portions attached along opposing surfaces of the 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 flat, arc shaped, or dome shaped.
  • the support surface may be a bottom surface of the container.
  • a magnetic material structure comprises an intermediate structure comprising fragments of at least one single piece of magnetic material, wherein lateral movement of the plurality of fragments with respect to each other is inhibited; and a cured curable material encapsulating the intermediate structure; wherein the intermediate structure conforms to a support surface of the magnetic material structure.
  • the intermediate structure may comprise interconnected respective pluralities of fragments from two or more interconnected pieces of magnetic material, wherein lateral movement of the fragments in each plurality of fragments and lateral movement of the pluralities of fragments relative to each other is inhibited.
  • the intermediate structure may comprise the interconnected pluralities of fragments.
  • the intermediate structure may comprises separated respective pluralities of fragments from two or more pieces of magnetic material, wherein lateral movement of the fragments in each plurality of fragments and lateral movement of the pluralities of fragments relative to each other is inhibited.
  • the separated pluralities of fragments may be disposed at a lateral distance from each other, the lateral distance being chosen to achieve a desired magnetic strength and/or mechanical property 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.
  • a surface of the container may form the support surface.
  • the curable material and a material of the container may be chosen to achieve a desired mechanical property of the formed magnetic material structure.
  • the fragments of the magnetic material may be magnetically polarized.
  • Inhibiting lateral movement of the fragments of magnetic material may be by means of a fixture element.
  • the fixture element may comprise at least one adhesive sheet portion attached along at least one surface of the respective pluralities of fragments.
  • the fixture element may comprise two adhesive sheet portions attached along opposing surfaces of the respective pluralities of fragments.
  • the adhesive sheet may be an elastic plastic sheet.
  • the shape of the support surface may be flat, arc shaped, or dome shaped.
  • a surface of the intermediate structure may form at least part of the support surface.
  • the methods of fabrication of a magnetic structure and magnetic structures described above have applications in various devices and methods for magnetic treatment for enhancing sports and physical performance & increase muscle strength as well as for relief from ailments such as chronic aches and pain or injuries or post-surgery recovery or illnesses, and also for food preservation, wine & beverage enhancement.
  • a non-limiting list includes wearable devices such as wrist bands or straps, knee bands or straps, shoulder bands or straps, leg bands or straps, and ankle bands or straps, and their use for magnetic treatment for relief from ailments such as chronic aches and pain or injuries or post-surgery recovery or illnesses.
  • Other applications include shoe insoles or build-in devices in shoes & sandals, wearable clothing, or hand grip straps for sports rackets.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une structure de matériau magnétique et une structure magnétique. Le procédé comprend les étapes consistant à rompre au moins une pièce unique d'un matériau magnétique en une pluralité de fragments ; à inhiber le mouvement latéral de la pluralité de fragments les uns par rapport aux autres lors de la rupture du matériau magnétique ; à former une structure intermédiaire comprenant les fragments du matériau magnétique, le mouvement latéral de la pluralité de fragments les uns par rapport aux autres étant sensiblement inhibé dans la structure intermédiaire formée ; à placer la structure intermédiaire et un matériau durcissable dans un contenant de manière telle que la structure intermédiaire est supportée par une surface de support du contenant et se conforme à celle-ci ; et à durcir le matériau durcissable pendant qu'il est disposé dans le contenant pour former la structure de matériau magnétique.
PCT/SG2016/050598 2015-12-15 2016-12-09 Procédé de fabrication d'une structure magnétique et structure magnétique WO2017105346A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SG10201510294WA SG10201510294WA (en) 2015-12-15 2015-12-15 Method of fabrication of a magnetic structure and magnetic structure
SG10201510294W 2015-12-15

Publications (1)

Publication Number Publication Date
WO2017105346A1 true WO2017105346A1 (fr) 2017-06-22

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SG (1) SG10201510294WA (fr)
WO (1) WO2017105346A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH048311A (ja) * 1990-04-27 1992-01-13 Asahi Kogyo Kk 発泡樹脂シートへの磁石片結合方法
WO2008030191A1 (fr) * 2006-09-08 2008-03-13 Esmo Technologies Pte. Ltd. Dispositif destiné à traiter des objets ou des liquides périssables et procédé de fabrication du dispositif
US20100244608A1 (en) * 2007-12-06 2010-09-30 Toyota Jidosha Kabushiki Kaisha Permanent magnet, manufacturing method thereof, and rotor and ipm motor
US20120274165A1 (en) * 2011-02-14 2012-11-01 Toyota Jidosha Kabushiki Kaisha Rotor magnet, rotor, and rotor manufacturing method
CN105489338A (zh) * 2015-12-15 2016-04-13 杨平 磁性结构的制造方法以及磁性结构
CN205428619U (zh) * 2015-12-15 2016-08-03 杨平 磁性材料结构

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH048311A (ja) * 1990-04-27 1992-01-13 Asahi Kogyo Kk 発泡樹脂シートへの磁石片結合方法
WO2008030191A1 (fr) * 2006-09-08 2008-03-13 Esmo Technologies Pte. Ltd. Dispositif destiné à traiter des objets ou des liquides périssables et procédé de fabrication du dispositif
US20100244608A1 (en) * 2007-12-06 2010-09-30 Toyota Jidosha Kabushiki Kaisha Permanent magnet, manufacturing method thereof, and rotor and ipm motor
US20120274165A1 (en) * 2011-02-14 2012-11-01 Toyota Jidosha Kabushiki Kaisha Rotor magnet, rotor, and rotor manufacturing method
CN105489338A (zh) * 2015-12-15 2016-04-13 杨平 磁性结构的制造方法以及磁性结构
CN205428619U (zh) * 2015-12-15 2016-08-03 杨平 磁性材料结构

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