STTR Phase I: Development of Flexible Magnets with Induced Anisotropy by Thermal Spray

这个小型企业技术转移第一阶段项目旨在利用热喷涂技术开发柔性、磁性聚合物复合涂层和具有诱导磁晶各向异性能量的独立形式。需要一种成本效益高的方法来有效地制造厚度小于1 mm的各向异性磁结构以及复杂的几何形状，这不能通过挤压工艺来实现。此外，需要在传感器应用中不使用粘合剂的情况下在表面上沉积柔性磁性涂层。Poly Therm建议使用机械熔融工艺开发磁性聚合物粉末。粉末将通过燃烧火焰喷射，粘结剂熔化，复合材料撞击基材以产生涂层或释放表面以产生独立形式。在沉积过程中，磁相也将分散在溶液中并从外部注入火焰中，以获得最大的磁相含量。磁场将在沉积过程中使磁性颗粒定向，以产生定向的磁性结构。柔性磁性薄膜和复杂的3D结构的发展将为柔性磁体打开新的市场。涂层将用于磁性传感器和专有紧固件。汽车部件、航空航天部件、机电设备、电机、执行器、磁性紧固件和磁记录设备将从此类磁性材料的发展中受益。

This Small Business Technology Transfer Phase I project aims to develop flexible, magnetic polymer composite coatings and free-standing forms having induced magnetocrystalline anisotropy energy using thermal spray technology. There exists a need for a cost-effective method for efficiently making anisotropic magnetic structures less than 1mm in thickness as well as complex, geometric shapes, which cannot be achieved by an extrusion process. Furthermore, there is a need to deposit flexible magnetic coatings onto a surface without the use of adhesives for sensor applications. Poly Therm proposes to develop magnetic polymer powders using a mechanofusion process. The powders will be injected through a combustion flame whereby the binder melts and the composite impacts a substrate to produce coatings or a release surface to produce free-standing forms. The magnetic phase will also be dispersed in solution and injected externally into the flame during deposition for maximum magnetic phase content. A magnetic field will orient the magnetic particles during deposition to create oriented magnetic structures. The development of flexible magnetic thin films and complex 3D structures will open new markets for flexible magnets. Coatings will be used for magnetic sensors and proprietary fasteners. Automotive components, aerospace components, electromechanical devices, motors, actuators, magnetic fasteners, and magnetic recording devices will benefit from the development of such magnetic materials.