Title: Magnetic feed material and its use in producing bonded permanent magnets by additive manufacturing

Abstract

A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

Inventors:

Paranthaman, Mariappan Parans; Li, Ling; Kunc, Vlastimil; Post, Brian K.; Rios, Orlando; Fredette, Robert H.; Ormerod, John

Issue Date:

Tue Sep 08 00:00:00 EDT 2020

Research Org.:

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1735221

Patent Number(s):

10766181

Application Number:

15/796,110

Assignee:

UT-Battelle, LLC (Oak Ridge, TN)

Patent Classifications (CPCs):

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS 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

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B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B29C2948/92209 - Temperature
B29C2948/92704 - Temperature
B29C2948/92895 - Barrel or housing
B29C48/0022 - {combined with cutting}
B29C48/022 - {characterised by the choice of material}
B29C48/04 - Particle-shaped
B29C48/83 - {Heating or cooling the cylinders}
B29C48/875 - for achieving a non-uniform temperature distribution, e.g. using barrels having both cooling and heating zones
B29C48/92 - Measuring, controlling or regulating
B29C64/106 - using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
B29C64/314 - Preparation

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS 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

B29K2077/00 - Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material
B29K2103/06 - Metal powders, metal carbides or the like
B29K2505/12 - Iron
B29K2995/0008 - Magnetic or paramagnetic

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

B33Y10/00 - Processes of additive manufacturing
B33Y70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

C - CHEMISTRY C08 - ORGANIC MACROMOLECULAR COMPOUNDS C08K - Use of inorganic or non-macromolecular organic substances as compounding ingredients

C08K2003/0856 - {Iron}
C08K2201/01 - Magnetic additives
C08K3/08 - Metals

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01F - MAGNETS

H01F1/0572 - {with a protective layer}
H01F1/0578 - {bonded together}
H01F41/0253 - {for manufacturing permanent magnets}

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DOE Contract Number:  

AC05-00OR22725

Resource Type:

Patent

Resource Relation:

Patent File Date: 10/27/2017

Country of Publication:

United States

Language:

English

Subject:

36 MATERIALS SCIENCE