Device including material originating from magnetic particles providing structural and magnetic capabilities

Abstract

A device or part thereof, comprising specifically located concentrations of material originating from magnetic particles, thereby integrating magnetic field interactive capabilities, combined or integrated in specific configurations with a different primarily metallic material, corresponding to suitable structurally analyzed criteria, thereby creating a structural load bearing device or part thereof, with magnetic field interactive capabilities.

Claims

1. A part of a device, with structural load bearing capabilities, comprising specifically located concentrations of material originating from magnetic particles with magnetic field interactive capabilities, non homogeneously distributed and amalgamated with a matrix of a different material to said material originating from magnetic particles, comprising one or more of; a matrix of a different metal, a structural matrix of a different metal, a matrix of a different magnetic particle material to said material originating from magnetic particles, distributed and amalgamated with said matrix, thereby creating an amalgamated non homogeneous material with distinct regions of material originating from magnetic particles amalgamated with said matrix or structural matrix, said amalgamated non homogeneous material forming a part of a device, configuring materials to resist loads associated with said device, conforming to a suitable structurally analyzed design, possessing magnetic field interactive capabilities combined with structural load bearing capabilities.

2. The part of a device of claim 1, comprising part of one or more of; a mechanical device, an electrical device, a magnetic device, a magnetic field interactive device, with material originating from magnetic particles, specifically located, configured and amalgamated with a suitable matrix or structural matrix of a different material to the material originating from magnetic particles, creating a device with a non homogeneous matrix designed to resist imposed loads associated with said device thereby comprising structural load bearing capabilities combined with magnetic field interactive capabilities.

3. The part of a device of claim 1 comprising a magnetic component of a magnetic field interactive mechanism such that the magnetic component exhibits a specifically located and aligned primary magnetic field force which is interacted upon by a secondary magnetic field force which reinforces the primary magnetic field force thereby increasing said magnetic components capacity to generate one or more of; torque, power, or energy while minimizing demagnetization potential at the increased capacity of the magnetic component while also allowing flux weakening of the magnetic component by reducing the reinforcing effects of the secondary magnetic field force, wherein said secondary magnetic field force is created by one or more of; a co-axial coil winding, a remote acting magnetic flux imposing co-axial flux on the primary magnetic field force, thereby creating a magnetic flux variable mechanism with demagnetizing protection and flux weakening ability.

4. The part of a device of claim 1 wherein said part of a device is formed into a primarily V shaped formation in cross section, therein providing a core on which a magnetic coil array is formed, said coil array comprising one of; a stator drive coil, a rotor drive coil, a linear drive coil, a reinforcing coil associated with a magnetic material, wherein said primarily V shaped formation creates an array of V coil wound cores, whereby a magnetic flux and associated magnetic poles are created within said cores by; permanently magnetic particles, electrical current flow within co-axially acting coils associated with a soft magnetic particle core, electrical current flow within coils associated with non magnetic core material, induced in electrically conductive particles by a changing interactive magnetic field, wherein said primarily V shaped formation of V coil wound cores are arranged so that a wide section of a V shape faces an air gap and like poles are in proximity to like poles and adjacent to an air gap creating reinforcing fields while a base of a V shape forms a non like pole region of a back flux return path.

5. The part of a device of claim 1 comprising material originating from magnetic particles wherein said magnetic particle material gives rise to magnetic field forces specifically aligned, located and concentrated within one of; a matrix of different material to that of the magnetic particle material, a structural matrix of different material to that of the magnetic particle material, forming a non homogeneous amalgamation of magnetic particle material with said matrix or structural matrix which create specific magnetic field arrays forming integrated magnetic multi-pole arrays comprising one of; a Diagonal V array, having a primarily V shaped array wherein a wide section of the V faces an air gap and like poles are in proximity to like poles and adjacent to the air gap with pairs of like poles facing the air gap therein creating a reinforcing magnetic field with non like poles joining at a base point of the V forming back face flux return paths which eliminate any necessity for back iron within the part of a device matrix material into which the V base is amalgamated, a Halbach array utilizing said integrated magnetic multi-pole array wherein the Halbach array concentrates magnetic flux on an air gap face, a like pole to like pole array created utilizing a magnetic flux at like pole interfaces creating flux concentrations, an alternating north-south pole array creating alternating north-south flux concentrations, forming integrated magnetic particle concentrations specifically located within matrix or structural matrix material different to that of the magnetic particle material, conforming to a suitable structurally and magnetically analyzed design forming an integrated magnetic field interactive part of a device with structural load bearing capabilities.

6. The part of a device of claim 5 wherein said part of a device forms a magnetic field interactive component with an integrated magnetic multi-pole array comprising one of; a Diagonal V array having a primarily V shape, a Halbach array, wherein said integrated magnetic multi-pole array is incorporated into a specific component and provides a primary source of passive magnetic field flux for one or more of; magnetic components of a magnetic levitation vehicle, a magnetic bearing, a permanent magnet rotor of an electric machine, a multiple disk rotor of a motor and/or generator, thereby enabling said component with an additional motor and/or generator capability, a steering rack, therein performing a function of a tubular linear motor providing servo assistance to a steering rack, a wheel rim comprising magnetic field interactive material incorporated into said wheel rim, therein creating a structurally integrated in-wheel motor and/or generator, a magnetic field interactive disk utilized in place of a conventional disk brake, to allow formation of a combined motor and/or generator and friction disk brake, said magnetic field interactive component possessing structural load bearing capabilities associated with a specific component while also sustaining magnetic field interactive capabilities.

7. The part of a device of claim 1 utilized in magnetic field interactive device and mechanisms which comprise a permanent magnet rotor of a synchronous electric motor and/or generator with coil wound stator poles which interact with said rotor having a peripheral region comprised of a magnetic field interactive material which utilizes said rotor of alternating magnetic poles, along said rotor peripheral surface comprising magnetic particle material, with adjoining back flux return paths eliminating a need for back iron, incorporated into a non homogeneous amalgamation within a metal matrix or metal structural matrix of a different material to that of the magnetic particle material wherein an integrated magnetic multi-pole rotor is formed which possesses magnetic flux which interacts with electronically controlled coil wound stator core poles disposed within a motor casing with an air gap separating said stator core poles from the rotor periphery wherein stator cores are formed from soft magnetic particle material and are integrated into the motor casing with magnetic particles blending into the motor casing matrix and forming a continuity of back flux paths between the stator core poles therein eliminating a need for back iron, wherein said motor and/or generator utilize particle material in the rotor and in a combined stator and motor casing.

8. The part of a device of claim 1, forming part of a magnetic field interactive component associated with passive controlled magnetically levitated vehicles wherein said magnetically levitated vehicles utilize a matrix material with non homogeneously integrated magnetic particle material to form an integrated magnetic multi-pole array of permanently magnetic, particles incorporated into a metal matrix or metal structural matrix of a different metal to that of the magnetic particles wherein said integrated magnetic multi-pole array is arranged in; a Diagonal V array comprising a primarily V shaped array, a Halbach array, a suitable alternative array, whereby a method of levitation is utilized comprising; a passive system of moving magnetic field arrays which interact with a track of transposed conductors comprising one or more of; shorted coils, stacks of insulated conductive laminates, a suitable alternative inductive material, to create opposing inductive forces in said track which levitate the vehicle, thereby maintaining a stable air gap width and allowing stable levitation of said vehicle.

9. The part of a device of claim 1 comprising magnetic particles, which give rise to magnetic field forces, incorporated with a matrix or structural matrix of a passive magnetic bearing which forms part of an axial support shaft of a rotor of a combined motor and/or generator mechanism, said axial support shaft comprising one or more of; an integrated part of the passive magnetic bearing, a support for a separate attachment of an integrated multi-pole array forming an inner section of a passive magnetic bearing, wherein an opposing magnetic field results from one or more of; a cylinder shaped track of transposed conductors rigidly mounted around a periphery of said passive magnetic bearing of the axial support shaft, comprising one or more of; shorted conductive coils, insulated conductive laminates, in which an opposing interactive magnetic field is induced by axially aligned flux poles of said passive magnetic bearing associated with the axial support shaft or an attachment to said axial support shaft, an integrated magnetic multi-pole array rigidly contained in proximity to said axial support shaft comprising a magnetic array wherein the passive magnetic bearing associated with the axial support shaft has like poles of a magnetic array opposing a rigidly contained integrated magnetic multi-pole array aligned across an air gap so that like poles of magnetic arrays are opposite one another in a repulsion mode, wherein said magnetic array is one of; a Diagonal V array, a Halbach array, a suitable alternative array with a capacity to provide radial and axial support to a shaft, which applies magnetic flux forces with axial and radial components and results in axial and radial shaft support which is enhanced in terms of shaft stability by combining induced, repulsion effects with those of purely magnetic repulsion effects.

10. A part of a device, with magnetic field interactive capabilities comprising one or more of; magnetic particles, fused magnetic particles, which give rise to magnetic field forces, wherein said magnetic particles and/or fused magnetic particles comprise an amalgamated part in combination with one or more of; a metal matrix or metal structural matrix of a different material to that of the magnetic particles, a metal matrix or structural matrix material combined with reinforcing fibers, filaments or particles, a magnetic particle matrix or structural matrix of another type of magnetic particle, a suitable non metal matrix or structural matrix comprising one of; a ceramic material, a ceramic composite material, wherein amalgamation and/or incorporation of said magnetic particles and/or fused magnetic particles with said matrix or structural matrix forms a non homogeneous distribution of magnetic particles and/or fused magnetic particles with said matrix or structural matrix creating an amalgamated part of a device comprising specifically located concentrations of said magnetic particles and/or fused magnetic particles amalgamated and/or incorporated with said matrix or structural matrix which conforms to a suitable analyzed design, configuring materials to resist loads associated with said device, to form an integrated load bearing part of a device possessing magnetic field interactive capabilities, forming part of said device.

11. The part of a device, with magnetic field interactive capabilities of claim 10 comprising magnetic particles which give rise to magnetic field forces amalgamated and/or incorporated in specifically located concentrations with the matrix or structural matrix of a disk of a different material to that of the magnetic particles, said part of a device comprising axially supported rotational disks which comprise one or more disks, wherein multiple disks comprise one of; a tightly packed series of disks forming a disk or cylinder, a series of disks which include a space between disks which locates suitable disk shaped drive coils, with air gaps between disk faces or cylinder periphery and drive coils, wherein said disk faces or cylinder periphery incorporate integrated magnetic multi-pole arrays, wherein magnetic flux fields are created on disk or cylinder surfaces adjacent to drive coils creating an interaction between drive coil flux and disk or cylinder magnetic flux which give rise to rotational torque forces, therein comprising a part of a device with structural load bearing capabilities and magnetic field interactive capabilities as determined necessary for said part of a device.

12. The part of a device, with magnetic field interactive capabilities of claim 10 comprising a material incorporating one or more of; concentrations of non homogeneously distributed magnetic particles, clusters of homogeneous concentrations of magnetic particles creating a non homogeneous composite, wherein magnetic particle concentrations are utilized in distributions comprising one or more of; varying in an axial direction, varying in a radial direction, varying in a circumferential direction, particles being incorporated and/or amalgamated with a matrix material or structural matrix material so as to form a structurally integrated component with a peripheral surface of concentrations of magnetic particles which forms an integrated magnetic multi-pole array over said rotors surface region, conforming to a magnetically analyzed design which places magnetic particles where they are beneficial to magnetic field flux.

13. The part of a device, with magnetic field interactive capabilities of claim 10 comprising magnetic particles forming magnetic particle arrays which give rise to magnetic field forces, wherein said magnetic particles are incorporated in specifically located concentrations within an electric motor and/or generator casing matrix or structural matrix, said magnetic particles comprising one or more of; permanently magnetic particles, soft magnetic particles, electrically conductive particles, a combination thereof, incorporated within said casing matrix or structural matrix of a different material to the magnetic particle material, comprising one or more of; metal non magnetic material, suitable non metal material, magnetic metal material, particles of a different type of magnetic particle, a material additionally reinforced with incorporated fibers, wherein said magnetic particles form a magnetic particle array of one of; a Diagonal V array having a primarily V shaped array, a Halbach array, a like pole to like pole array, an alternating north and south pole array, forming a non homogeneous amalgamation of magnetic particles amalgamated and/or incorporated with another type of material matrix or structural matrix to form an integrated structural load bearing casing of, the electric motor and/or generator.

14. The part of a device with magnetic field interactive capabilities of claim 10 comprising magnetic particles which give rise to magnetic field forces incorporated in specifically located concentrations with a matrix or structural matrix of a different material to that of the magnetic particles wherein said matrix or structural matrix comprises one or more of; a matrix or structural matrix of a metal material, a matrix or structural matrix of suitable non metal material, creating part of a vehicle associated device, utilizing integrated magnetic multi-pole arrays comprising one of; a Diagonal V array, a Halbach array, a like pole to like pole array, an alternating north and south pole array, wherein magnetic fields are created in a surface of the part of said vehicle associated device which is adjacent to a drive coil wherein an interaction between the drive coil flux and the integrated magnetic multi-pole arrays give rise to rotational torque forces acting on the vehicle associated device creating a combined motor and generator capability with structural load bearing capabilities consistent with loading characteristics of said device while integrating specific magnetic flux arrays thereby creating a combined motor and generator with regenerative braking capabilities and structural load bearing capacity.

15. The part of a device with magnetic field interactive capabilities of claim 10 comprising magnetic particles which give rise to magnetic field forces, incorporated in specifically located concentrations with a matrix or structural matrix of one or more of; a steering rack gear rod, part of a steering rack gear rod, a part of a steering actuation mechanism, of a different material to that of the magnetic particles creating a steering servo-assistance device utilizing integrated magnetic multi-pole arrays, wherein magnetic fields are created within the steering servo-assistance device incorporating said integrated magnetic multi-pole arrays in proximity to a drive coil incorporated within a casing enveloping said steering servo-assistance device, wherein an interaction between drive coil flux and the integrated magnetic multi-pole arrays of the steering servo-assistance device give rise to one or more of; a linear drive force, axially oriented, acting on said steering rack gear rod, or a part of said steering rack gear rod, a rotational force acting on a rotational part of a steering actuation mechanism, wherein said steering servo-assistance device provides functions associated with a steering system while comprising magnetic particles in integrated magnetic multi-pole arrays within said steering servo-assistance device matrix or structural matrix to provide servo-assistance to a steering system.

16. The part of a device with magnetic field interactive capabilities of claim 10 comprising magnetic particles, fused magnetic particles including material originating from magnetic particles wherein said part of a device comprises fused and amalgamated magnetic particle material and a matrix or structural matrix material of a different material to that of the magnetic particle material to form a specific configuration of concentrations of magnetic particle material with said matrix of a different material, conforming to suitable structurally and magnetically analyzed design criteria, with regard to load bearing requirements and magnetic field interactive requirements of said part of a device thereby creating an integrated non homogeneous amalgamation of material originating from magnetic particles with said matrix of a different material forming said part of a device possessing structural load bearing capabilities combined with magnetic field interactive capabilities.

17. The part of a device with magnetic field interactive capabilities of claim 16 with a matrix or structural matrix material forming a load bearing co-axial support member combined in unit with a rotor of a device with different material to said matrix material originating from magnetic particles amalgamated with said co-axial support member combined with said rotor, with magnetic particles and matrix material forming a non homogeneous periphery to said co-axial support member combined with said rotor, said periphery comprising concentrations of magnetic particle material in specific, isolated concentration, around said periphery amalgamated with said matrix of a different material thereby forming an integrated, amalgamated rotor with a co-axial support member integrated and amalgamated with a region of material originating from magnetic particles with a different matrix material creating an integrated, unitary, magnetic field interactive rotor and combined support member.

18. The part of a device of claim 10 with magnetic particle material amalgamated and fused with particles of a metal of a different material to that of the magnetic particle material said magnetic particle material comprising a non homogeneous configuration incorporated with said particles of a metal of a different material with clusters of magnetic particle material concentrated primarily adjacent to an air gap separating static and moving parts of the device comprising a magnetic field interactive device with structural load bearing capabilities consistent with structural and magnetic requirements of said device conforming to suitable structurally analyzed criteria.

Description

DESCRIPTION OF THE DRAWINGS

[0184] FIG. 1A Shows a prior art drawing by Mallinson which depicts differing pole alignments within a permanently magnetic material which result in a concentration of magnetic flux primarily on one side of the material. From this origin the Halbach magnet array of FIG. 1B. resulted.

[0185] FIG. 1C Applies the first embodiment of the present invention to a Halbach magnetic field array wherein magnetic particles are specifically located in concentrations within the matrix of another material being either a metal matrix material or in some specific cases a non-metallic matrix. Said magnetic particles being specifically located, aligned and magnetized to form a non homogeneous integration of magnetic particles and matrix material which exhibits a primarily one sided flux array of Halbach design. Item 1 depicts a permanent magnetic segment and shows the direction of pole alignment with North pole of the magnet at the head of the arrow.

[0186] Item 2 depicts a similar pole alignment resulting from an integrated, specifically located concentration of magnetic particles within a component the matrix of which differs from that of the magnetic particles.

[0187] Item 3 represents a region of the component comprised predominantly of matrix material.

[0188] FIG. 1D shows a more efficient Halbach array of magnetic segments, item 4 giving rise to magnetic flux which in this example interact with a track of transposed conductors, item 5 forming the basis of an inductive levitating Maglev transport vehicle.

[0189] FIG. 1E utilizes the first embodiment of the present invention to create a similar Halbach array which for example can be a non homogeneous amalgamation of specifically located concentrations of magnetic particles within a metal matrix forming a structurally integrated component which is easily formed to a specific shape and can be for example simply bolted or otherwise fastened into position on a vehicle or machine. This has application to Maglev vehicles which function in a purely passive repulsion mode due to induction in track item 6, or in an attraction mode in combination with control coils. Such an integrated Distributed Magnetic Metal Matrix Composite material has numerous uses some of which are described to show the principle associated with the present invention, which range from linear drive systems, material accelerators, motor drive systems to particle and light focusing systems.

[0190] FIG. 2A depicts an alternative magnetic array to that of the Halbach array, and constitutes the forth embodiment of the present invention, which is described as a Diaonal or V array or Diagonal V array. This array is less complex than the Halbach array and is easier to assemble and easier to magnetize. It offers a similar one sided reinforcing flux while the array also acts as a back flux or return flux path negating the necessity for back iron. Additionally the reinforcing face places like poles, North-North, South-South, in close proximity thereby creating regions of highly concentrated flux which can be highly beneficial to interaction with a conductive material passing through such field, for example a motor coil winding or an inductive track of transposed conductors as described in a Maglev passive system. The more rapid rise and fall of magnetic flux, when compared with the Halbach array which has flux spread over a greater pole area, can be beneficial in having greater effect on moving particle systems including light and particle systems and having particular usage in permanent magnet motor drive, and magnetic power transfer systems which have significant potential usage in Hybrid and Electric Vehicles.

[0191] FIG. 2B Shows a similar Diagonal V array utilizing the first embodiment of the present invention wherein magnetic particles, being in this instance permanently magnetic particles, are amalgamated and integrated into the matrix or structural matrix of an item being a material or component such that particle concentrations are specifically located to form a non-homogeneous composition of magnetic particles and matrix material with consideration being given to magnetic field requirements and array formation along with the structural requirements and structural integrity of the component so formed.

[0192] Item 2 represents magnetic particles bound within a matrix material, while item defines primarily matrix material. The Distributed Magnetic Metal Matrix Composite material so formed can form part of a component, for example, a ring or band around the circumference of a cylindrical rotor, or an attachment to a wheel rim, or alternatively it can form part of the matrix or structural matrix of the component, for example, the rotor or wheel rim can integrate magnetic particles into specifically located distributions within said component.

[0193] FIG. 2C and FIG. 2D Depict rare earth magnet rod arrays forming both a Halbach array and a Diagonal V array performed as a test described in the later section of the Preferred Embodiments of the Present Invention utilizing equal amounts of magnetic material in arrays of identical magnetic rods, 5 for each array. The easily performed test which was highly repeatable in terms of results showed the Diagonal V array to be significantly stronger on the reinforcing side than was the case with this particular Halbach array. It should be noted that in the case of both arrays the use of separate magnet segments creates far from perfect continuity of back face or return flux on the non reinforcing flux side. None the less the use of magnet segments is common practise in industry, thus making such a test quite relevant. Usage of fully integrated magnetic particle system as disclosed in the first embodiment of the present invention can be highly beneficial to both the described arrays and most other commonly utilized magnet arrays as inter-magnetic particle connection can be complete with no air gaps what ever on the internal flux path, the only open flux being on the working or interactive flux air gap reinforcing face.

[0194] FIG. 2E Depicts a prior art Halbach coil array which in the case of the referenced US patent claiming said array is formed by an array of separate coils with pole alignments mirroring those of a Halbach magnet segment array, therein possessing similar advantageous characteristics typified by the Halbach array.

[0195] FIG. 2F Depicts a V coil array characteristic of the third embodiment of the present invention. Said V coil array can be formed from separate coils with like poles in proximity on the reinforcing side and non like poles in proximity on the non reinforcing side. Alternatively there can be a continuity of the conductor wire between coils forming legs of the V while power to the combined V coils can be supplied in a wide range of sequences depending on the type of drive system being fabricated. It is important that pole alignment be kept in mind as the reinforcing effect comes from the proximity of like poles while continuity of back face flux, elimination of back iron, and minimizing loses results from non like poles in proximity and a flux flow path being created at the base or point of the V, a situation clearly depicted in FIG. 2H.

[0196] FIG. 2G Depicts a co-axial reinforcing coil arrangement for a permanent magnet array specifically utilized to reduce the chance of permanent magnet demagnetization, which can occur when said magnet is exposed to an external opposing magnetic field as can be the case in numerous motor drive systems.

[0197] In this example a Halbach permanently magnetic particle array is formed utilizing embodiments of the present invention, to create an integrated system. However separate magnet segments could also serve the purpose albeit with some loss of efficiency. In this case the primary North-South pole arrays which form the reinforcing poles are approximately perpendicular to a working air gap and are wound with co-axial coils or have remotely acting coils with field connection to the magnet arrays such that the coil poles reinforce the permanent magnet poles therein allowing the motor or mechanism to for example apply higher load or torque under, as example, low speed or stall conditions while maintaining the magnetic core above magnet coercive strength and therein avoiding demagnetization when under an opposing magnetic field which would otherwise create demagnetizing problems. Additional benefit can come for example in a rotational permanent magnet rotor motor with coil wound rotor poles provided with electronically controlled power via slip rings for example, wherein as motor speed increases reinforcing effect of the co-axially interacting coils can be diminished and even moderately reversed, with care, thereby allowing rotor magnetic flux reduction as required thus reducing back emf in the stator drive coils and improving motor efficiency therein creating an electronically controlled system which improves motor torque while also reducing the risk of demagnetization and allows field weakening with speed. Slip rings are a minor inefficiency when compared with the gains achieved. Additionally a remote supply of magnetic flux to the rotor is a possible method of avoiding slip ring usage.

[0198] The reinforcing co-axial coils can also be designed to improve magnetization of magnetic material after motor assembly or to re-magnetize an accidentally partially demagnetized magnetic material.

[0199] FIG. 2H Can be considered representative of a number of embodiments of the present invention. The first embodiment incorporates specifically located magnetic particles within a matrix or structural matrix of a material forming a non-homogeneous amalgamation of magnetic particles which for example can be permanently magnetic particles, soft magnetic particles, electrically conductive particles or a combination there of.

[0200] If we consider the particles in FIG. 2H item 7 to be permanently magnetic particles then this drawing could for example represent a section of a permanent magnet machine rotor with Diagonal V arrays of magnetic particles co-axially reinforced by V coil arrays to achieve a high torque machine with demagnetizing protection and field weakening capabilities with a highly efficient rotor configuration with a maximized one sided (air gap side) flux concentrations, highly concentrated flux at the poles and no requirement for back iron, thus allowing freedom in the material choice for the rotor and particle matrix which is integrated with the rotor matrix.

[0201] Alternatively if we consider the magnetic particles to be soft magnetic particles integrated into a matrix of for example a highly structural material such as aluminium alloy suitable alternatives and alloys there of, which can be fiber reinforced composite, item 3 in this example, can form a combined stator and machine casing while the stator is an amalgamated and integrated soft magnetic particle array formed into a V core with V coil winding in a formation where the air gap region has like poles of the V in close proximity and in proximity to the air gap and rotor while the base or point of the V is integrated into the matrix or structural matrix of the casing material and forms the Non Like Pole region of the flux return path thus eliminating the need for back iron and also creating a very short flux return path which improves motor efficiency while the V coil, V core formation maximizes one sided flux on the air gap side in the same way as does the Diagonal V magnet array. V coils adjacent to the air gap have like poles in proximity in order to maximize flux efficiency.

[0202] Note, FIGS. 1C, 1E, 2G, and 2H depict magnetic particles integrated into a matrix material to form a component which can be described as an integrated magnetic multi-pole array.

[0203] FIG. 3A Shows a prior art permanent magnet rotor motor with magnet segments item 9 which could in the prior art be replaced by a formed to shape homogenous blend of magnetic particles and binder which would have specifically located magnetized poles in place of the magnet segments. Said rotor interacts with magnetic field forces created by the stator 8 which in the prior art could be formed from multiple sheets of soft magnetic laminate material within a machine casing or housing, said laminates forming stators and/or rotors can comprise integrated and amalgamated clusters of magnetic particle material, or alternatively the casing and stator item 8 could be formed from a homogeneous blend of soft magnetic particles and binder material thereby forming both the machine casing and an integral stator.

[0204] FIG. 3B Incorporates embodiments of the present invention wherein the casing and stator are an amalgamated integration of soft magnetic particles forming as example salient stator poles and a back flux path while the structural matrix material acts as, a binder for the magnetic particles and a structural machine casing component in one item, potentially improving structural integrity and also magnetic flux as each specific material concentration is placed where it is required for maximum benefit unlike the prior art homogeneous distribution which tends to be a compromise, neither optimizing structural integrity nor magnetic field producing capacity. The rotor of FIG. 3B shows an array of permanently magnetic particles, with magnetic field item 12 amalgamated into a rotor matrix core of another material type, item 11 which could for example be an aluminum alloy, suitable alternative or alloy there of.

[0205] A back iron flux path is no longer necessary as the magnetic particle array also form an efficient back flux return path. Said rotor forms an integrated unitary structural component comprised of non homogeneous specifically located concentrations of magnetic particles incorporated and amalgamated into a structural matrix forming material, which can have vastly greater structural integrity to that of the prior art while also creating a more efficient magnetic field interactive mechanism than that offered by the prior art. This embodiment and principles there of can be utilized in numerous mechanisms, one of which is Hybrid and Electric Vehicle motor/generator systems and accessory drive motors.

[0206] FIG. 3C Incorporates soft magnetic particles, item 10 to form V cores for the V coil arrays all of which are an integrated part of the structural matrix which forms the motor case design with permanently magnetic particle arrays shown as item 12, a rotor with spokes which may be fiber reinforced and matrix material which may be any suitable material, as example aluminium or suitable alternatives, wherein the void regions, apart from lightening the structure also assist manufacture and magnetizing of the permanently magnetic particles. Said particles could also be soft magnetic particles which form unseen salient rotor projections within a non magnetic matrix therein allowing the motor so formed to function as a reluctance type synchronous motor, as apposed to the permanent magnet synchronous motor configuration utilizing the permanently magnetic particle array.

[0207] Note that all stator assemblies shown in FIGS. 3A, 3B, 3C have coil wound salient stator cores, for simplicity the coils are not shown however the direction of coil flux applied to adjacent V coils is shown on the particle cores of FIG. 3C.

[0208] FIG. 4A Shows an axial flux rotor utilizing specifically located concentrations of permanently magnetic particles, forming a one sided reinforcing array of the Diagonal V formation of the forth embodiment of the present invention, therein forming what will be described as a Distributed Magnetic Metal Matrix Composite Disk wherein as example said disk matrix is an aluminium alloy or suitable alternative.

[0209] FIG. 4B Shows a process for manufacture of the disk wherein former plates 16 and 17 comprising specifically located and pole aligned magnetic field forces create a mold which is filled with a blend of, in this example aluminium particles which may be specially coated to assist the process, and specially multi-coated permanently magnetic particles which are preferably anisotropic particles in this example, optionally specially coated short fibers of for example carbon can be added to improve structural integrity. The total particle mass being subjected to high frequency vibration and if necessary gaseous intrusion to create a fluidized particle bed wherein specific magnetic particles primarily separate from the non magnetic matrix material or differing magnetic matrix material leaving only a small amount of matrix particle within the specific magnetic particle concentration which due to the application of specifically located and aligned magnetic field forces associated with the former plates causes the specific permanently magnetic particles of this example to assume the desired magnetic array formation while also aligning the anisotropic particles in the preferred magnetic pole alignment. The finished disk comprises a dense a dense fused, non homogeneous amalgamation of magnetic particle material integrated with matrix material, said amalgamation combining magnetic field interactive capabilities with structural load bearing capabilities in conformance with the loads associated with said disk, therein representing a structurally analyzed design.

[0210] Utilizing Powder Metal and Metal Matrix Manufacturing Technology the Powder Metal Disk is exposed to heat and pressure to form a structurally integrated disk which may be further processed to further densify and finish the component as necessary. If necessary the finished product may be further magnetized. Further advances in powder metal technology allow direct deposition and fusing of several different types of metal powder particles and/or ceramic particles without the need for a mold, such additive manufacturing is known as 3D printing of multiple metal types and ceramics often using a laser for sintering.

[0211] Where additive manufacture is employed, creation of an anisotropic magnetic material can be assisted by appropriate choice and pretreatment of magnetic particles and/or subjecting a partially completed device to premagnetizing of specific magnetic field arrays such that further deposited magnetic particles, overlaying the premagnetized part of the device, will align in preferred orientation with the flux of the premagnetized part creating anisotropic magnetic particle regions.

[0212] An alternative to blending a matrix powder with magnetic particles or using additive manufacture is to form magnetic particle preforms which can be pre-magnetized into the desired arrays the particles of which are bound together by a final particle coating for example which is exposed to moderate heat and molding pressure. These magnetic particle preforms would then be assembled in the mold between the former plates 16 and 17 and held in place by a magnetic field applied by the former plates or alternative adhesion means said preforms being the inverted V formations of particles, items 13 and 14 which would form a series of separated slightly porous preforms assembled into the mold between the former plates. The mold would be closed and injected from above and below as example with high pressure molten aluminium alloy, or suitable alternative, which may be a fine metal powder which assumes the flow characteristics of a liquid or molten metal, the temperature of the molten metal or alternative heat and pressure treatment, would decay the preliminary bonding coating applied to the magnetic particles exposing a secondary matrix compatible coating which fuses and partially sinters the particles while also allowing some infiltration of matrix material into voids between magnetic particles. Since this can be a relatively high temperature process it is desirable to apply magnetic field forces to the magnetic particle arrays as the component cools to achieve the desired magnetic flux characteristics of the component. References given within this disclosure explain in depth the metallurgical technology and associated techniques.

[0213] Magnetic particles referenced in relation to FIG. 4B could also be soft magnetic particles or specially treated electrically conductive particles wherein said particles are attracted to an applied magnetic field and specifically located particle concentrations form within a matrix of a different material.

[0214] FIG. 4C Depicts a mechanism utilizing components manufactured by the prior mentioned process. Matrix material Item 24 can if desired form the primary structure of the disks shown in section in this drawing and the axial support structure or alternatively the disks can be attached to the axial support structure. There is no specific limit to the number of disks that can be mounted coaxially, these can be tightly packed, however in this example a pair of disks is shown as example. An appropriate disk shaped drive coil Item 23 is positioned in a gap between the disks. The drive coil may be installed in sections. The reinforcing field faces of the disks shown in this example face toward the drive coils, as would be the case if Halbach or other arrays were chosen in preference to the Diagonal V array of magnetic particles of this example. Reinforcing arrays Item 22 on the section and also shown in FIG. 4A, as north pole arrays Item 13 and south pole arrays Item 14 should preferably be arranged so that the north pole array on one disk faces the south pole array on the adjacent disk with the drive coils and an air gap separating the disk faces. A small radial misalignment of north-south arrays can create flux lines which are skewed from axial alignment and may benefit motor/generator characteristics in some circumstances.

[0215] The disks are supported on an axial support shaft which as example can be aluminium alloy and is itself supported by passive magnetic bearings acting in the repulsion mode. These are shown as having Diagonal V arrays; though alternative arrays are equally suited; of permanently magnetic particles integrated into the matrix of axial support shaft Item 30 and as a separate attachment of a Distributed Magnetic Metal Matrix Composite attached to the axial support shaft Item 21. These are conical in shape as are the outer repelling arrays attached to supports Items 20 and 27 or being an integrated part of the supports Items 28 and 29, which may be single or multiple components. In all instances reinforcing arrays face the air gap and like poles are opposite one another across the air gap. Like poles repel and the conical formation acts both axially and perpendicular to the axis thus restraining the shaft in all directions. Further axial restraint can be achieved mechanically Item 31 or by utilizing an addition magnetic flux in repulsion mode Item 19. Item 31 could be replaced with a drive take off for direct mechanical connection. Further stability of the magnetic bearing and magnetic disk assembly can be achieved by allowing magnetic flux to interact with transposed/disposed conductors as referenced in FIG. 1D and FIG. 1E adding stability due to induced repulsive fields in the conductors which tend to self stabilize.

[0216] The passive magnetic bearing mounted disk motor/generator assembly could with the attachment of a wheel rim and tire assembly to the outer circumference of one of the disks provide a self contained magnetic bearing supported wheel drive assembly for a light weight vehicle with the bearings providing frictionless support.

[0217] The passive magnetic bearings may be replaced by ball or roller bearings of a conventional form.

[0218] Power take off may be from either or both ends items 19 and 31 or the mechanism may function as an energy storage device wherein generator mode returns power to the system.

[0219] Such disk motor/generators have a wide array of uses and the reduced complexity, efficiency and structural integrity achieved utilizing embodiments of the present invention further expands the realms of usage.

[0220] As regards Hybrid and electric vehicles said disk motor/generator have a multitude of uses. The compact nature of the disk motor/generator lends itself to usage in all form of accessory items from fan motors to water/oil pumps to air conditioning pump drives. A significant amount of primary drive and motor/generator functions can be achieved using such a Distributed Magnetic Metal Matrix disk motor/generator.

[0221] As example such a system can be attached to one or both ends of the crankshaft of a hybrid I.C. engine replacing the flywheel and dampener therein acting as an additional power source to the I.C. engine, acting as a generator and also assisting engine braking under deceleration therein regenerating braking energy, and also taking the place of the stator motor. Such disks can be built into transmission casings, added to drive shafts in for example a multiple series of such disks to provide an extremely compact yet powerful motor/generator or, as a following figure shows, mounted within a wheel in the region of the conventional brake disk. The same principles can be applied to drum shaped rotor/stator components.

[0222] FIG. 5A Depicts a wound rotor D.C. brushed motor utilizing commutators and brushes or a slip ring, brushes and electronic control unit, to transfer power to the rotor windings. The rotor can as example be a conventional prior art core generally made up of soft magnetic laminate stacks or as a homogeneous soft magnetic particle core.

[0223] However in this present invention embodiment example the rotor is formed from non magnetic material for example aluminium, magnesium, titanium or stainless steel with distributed concentrations of integrated soft magnetic particles amalgamated into regions which form salient rotor cores item 32 utilizing embodiments of the present invention which are then wound with insulated conductive wire to form drive coils, or alternatively said drive coils can be housed within the magnetic particles of the rotor core or placed within co-axial cavities formed in the particle core. The inner coil region is then filled with magnetic particle material thereby further strengthening flux.

[0224] The casing would in the prior art either support permanent magnet segments or have wound field coils as in FIG. 3A item 8.

[0225] However utilizing aspects of the present invention the casing matrix or structural matrix in this example contains specifically located concentrations of permanently magnetic particles item 34 which form poles within the non magnetic motor casing matrix, item 33. The casing structural matrix can be formed from aluminium, magnesium, titanium, stainless steel, or suitable alternative and can also be fiber reinforced utilizing, carbon, boron, glass, or other suitable fiber. The casing can also be of a non-metallic material such as plastic which is formed from a blend of magnetic particles, plastic particles or suitable non metal and optional reinforcing fiber wherein said casing is a structural integrated component providing magnetic field producing capabilities while also performing the role of a machine casing. An example of the machine type would be an electric drill, an angle grinder, an electric tooth brush, a house hold electric machine, a fan, and numerous other mechanisms. Most of the accessory drive motors used on Hybrid and electric vehicles can utilize this type of motor as it is low cost, small, robust and easily mass produced. The casing can be as example, metal, composite, plastic, reinforced plastic or any suitable alternative.

[0226] FIG. 5B Depicts a permanent magnet rotor and utilizes a machine casing similar to that explained in relation to FIG. 3C and requires no further explanation as said machine casing utilizes several embodiments of the present invention, however the rotor differs significantly from that of FIG. 3C although it also utilizes distributed concentrations of specifically located and pole aligned permanently magnetic particles these particles are now concentrated in salient rotor poles item 35 while the rotor matrix or structural matrix is primarily a non magnetic material such as aluminium or suitable alternative as was the case with the rotor of FIG. 3C although both rotors could also be formed of a suitable plastic material or non metal. The salient rotor poles of FIG. 5B utilize aspects of the first and second embodiments of the present invention the principles of which were described in relation to FIGS. 2G and 2H wherein a permanent magnetic particle array distributed within a different material matrix in specifically located concentrations forming magnetic arrays with specific pole alignment and had a co-axially imposed electro-magnetic field imposed upon the permanently magnetic field to reinforce said permanently magnetic field and thus improve motor torque characteristics while also reducing the chance of demagnetization of the permanently magnetic material and additionally allowing field weakening of the rotor flux at higher speeds thus further improving motor efficiency and speed capabilities.

[0227] A motor/generator of the type shown in FIG. 5B could also function as a reluctance type motor with salient rotor cores utilizing soft magnetic particles in place of the permanently magnetic particles and without the coaxial rotor windings or remotely applied coaxial flux to the rotor. Maintaining a certain amount of permanently magnetic particle material specifically located along with salient soft magnetic particle material can create a motor which has both magnetic and reluctance drive characteristics.

[0228] It should be noted that the motor/generators depicted are representative of the principles associated with the present invention and numerous motor types and designs can utilize principles of embodiments associated with the present invention.

[0229] FIG. 6A Shows several methods of incorporating a Distributed Magnetic Metal Matrix Composite material into, as example an in wheel drive system for a Hybrid and or electric vehicle and extends the principles of a prior US. patent by the inventor of this present invention. The disk drive and regenerative braking system items 22,23,24 show at least two disks designed in a similar fashion to those shown in FIG. 4. The mode of operation will be evident upon referral to the description of FIG. 4. It should also be noted that depending on the motor drive type, permanently magnetic synchronous AC/DC as the example or reluctance type or induction type, said magnetic particles may also utilize soft magnetic or electrically conductive particles specifically distributed in non homogeneous amalgamations.

[0230] From an operational point of view such a disk system could replace the original friction disk brake.

[0231] The trend toward larger diameter wheels and lower profile tires allow quite a large diameter drive surface as represented by particle concentrations 22 and 24 and flat disk shaped drive coil item 23 which can result in quite high torque and good regenerative braking characteristics. Also since the disks would be made of as example, aluminium, ceramic composite, carbon composite or suitable alternative and the total system including the friction disk brake and caliper items 39 and 38 respectively; which act at a large radius and are smaller than original due to the braking assistance provided by the regenerative braking system which also acts as a motor drive and generator as required; probably weighs a similar amount and possibly less than the larger diameter cast iron original brake disc and associated caliper found on many high performance vehicles. The disk item 39 can be an extension of the main drive disk and be suitably surface treated in the region of friction contact with the brake pad or can be a separate floating disk utilizing the inner main drive disk as a hub for attachment utilizing easily available fasteners in location 40.

[0232] FIG. 6A also shows an embodiment utilizing permanently magnetic particles item 2; which in an alternative motor type could be either soft magnetic particles or electrically conductive particles; specifically located within the matrix or in this example the structural matrix item 3 of an inner wheel rim item 36. The magnetic particles are laid out as per FIG. 4B items 13 and 14 however in this instance the X-X Section would be taken through the centre of the magnetic array around the circumference of the inner wheel rim. The drive coils 23 in this instance would be of a cylindrical orientation maintained at a constant air gap distance from the inner rim. Suitable structural resins being available for binding and protecting the drive coils. The wheel rim can be formed from any suitable material as example, aluminium alloy, magnesium alloy, titanium, carbon composite or a standard magnetic or non magnetic rim to which an inner distributed magnetic particle array in the form of a hoop is attached.

[0233] It should be noted that although this embodiment utilizes Diagonal V permanent magnet arrays as example any suitable array such as Halbach or alternatives can be used utilizing the principles of embodiments of the present invention. Utilizing powder metallurgical techniques and technology of metal particle additive manufacturing, fused and sintered magnetic particles can be non homogeneously amalgamated in concentrations and/or clusters around the inner rim periphery of said rim forming a structural load bearing part with the magnetic particles combined with the rim matrix material creating a composite rim matrix being both structural load bearing and magnetic field interactive, said composite rim matrix can be described as a structural matrix.

[0234] The described disk drive, regenerative brake, and friction brake combination can be easily installed in new Hybrid and electric vehicle as can the wheel rim drive/generator and regenerative braking system.

[0235] The systems as shown because of the nature of incorporation of most of the drive system within a pre-existing or in place of a pre-existing component add minimal weight. Also when utilized on large diameter wheel rims these systems when applied to potentially all four wheels are capable of generating significant torque and regenerative braking capabilities.

[0236] Such systems are very easily retrofitted to existing vehicles, and can be especially useful to a company wishing to down size the motor in a particular model range to achieve the necessary economy/pollution criteria while maintaining suitable performance and drivability characteristics without the necessity to redesign the basic vehicle or drive train structure, as with the exception of suitable mounting structure for the drive coils, these systems are purely a bolt on option, and the electronics to allow integration into a vehicle are easily available in the market place. Additionally these systems apply their torque directly to the road and do not create any greater stress on the suspension system than those applied by the original braking system thus requiring no major mechanical redesign of the vehicle to which they are fitted.

[0237] FIG. 6B Details an almost frictionless servo-assistance steering rack mechanism which overcomes the friction or stiction effect often associated with electric steering servo-systems which rely on a directly gear connected electric motor for their servo-assistance. The electric motor is often directly geared to the steering column, is generally electronically and or micro-processor controlled and often mimics road feel by feed back weighting while not giving the driver any true idea of the actual tire to road slip condition. This is acceptable to a large number of drivers and unacceptable to a significant number of drivers many of whom consider driving a pleasurable activity rather than a means of purely getting from one place to another.

[0238] Since electric servo-assisted steering can be expected to dominate the Hybrid and electric vehicle sector the present invention and the embodiment of magnetic particles in specifically located concentrations within another material matrix or structural matrix allows the creation of a novel, non contact steering rack servo-system. FIG. 6B shows a steering rack item 41, its casing item 42 and the rack pinion gear item 43.

[0239] The rack can be manufactured from a non-magnetic material for example stainless steel. The rack and its incorporation of specifically located distributions of, for example permanently magnetic particles, can be manufactured to precise tolerances by powder metallurgical techniques or other suitable techniques. The magnet arrays can for example be those of the Diagonal V array as shown and described for a disk item in FIG. 4B and in particular the passive bearings of FIG. 4C. However the form of the array will follow that of the X-X section of FIG. 4B axially along the rack with rings of like poles running around the circumference of the steering rack rod section item 45 as was the case with the passive magnetic bearings item 30. Thus forming separated magnetic North-gap-South rings of magnetic particles integrated into the structural matrix of the steering rack. Drive coils 44 are built into the circumference of the rack casing, creating a vehicle which employs a maximum efficiency magnetically interactive mechanism thus the rack and casing provide the servo-action avoiding usage of a second motor servo.

[0240] The use of such a system is considered unique and novel however for this specific usage the use of rings of permanently magnetic material forms a new use for a prior art tubular linear motor/actuator which confines rings of rare earth magnetic material within a sheathed thrust rod. These linear servo-motors utilize electronically controlled magnetic drive coils around the circumference of a non magnetic thrust rod with alternating North-South rings of rare earth magnet segments along the working length of the thrust rod. These are known as tubular or encased linear actuators and the incorporation of such a servo-motor into a vehicle steering rack assembly represents a new use for such a system in the case of utilizing conventional magnet ring segments.

[0241] However the use of the first embodiment of the present invention to replace the magnet segments with a Distributed Magnetic Metal Matrix composite system further adds to the Novelty.

[0242] The use of embodiments of the present invention in such linear actuators and linear servo-motors should also be considered novel as the replacement of magnet rings which then require sheathing in a stainless steel jacket is time consuming and costly. The present invention can allow easier production of said thrust rods associated with linear actuators/motors, while also allowing placement of magnetic particles and matrix material to avoid the use of sheaths or jacketing since a thin layer of matrix material can be retained outside the magnetic particle arrays, all being within an integrated component. Additionally the structural portion of the rod is increased resulting in a significantly stronger rod section, which in the prior art is turned down to a smaller diameter to accept the coaxial magnet rings.

PREFERRED EMBODIMENTS

[0243] The primary objective of the present invention is to create a vastly more efficient, structurally integrated electro-magnetic field and magnetic field interactive machine or mechanism, wherein interactive relates to the mode of operation of the mechanism as a result of at least one magnetic field producing component having an effect on another element or component in a predetermined manner. Said effect could for example be the induction of an electric current or an opposing magnetic field or a transfer of torque or energy from one component to another, via magnetic or electro-magnet field interaction.

[0244] Machine or mechanism types which can primarily benefit from the present invention are those which involve the usage of permanently magnetic material, and electro-magnetic and magnetic mechanisms. Hybrid and Electric Vehicles and the overall efficiency and integrity of the vehicle is dependant upon all such mechanisms working to utmost efficiency in terms of energy usage, long term reliability, structural integrity, weight and size management, cost and ease of manufacture. Most hybrid vehicles and a major proportion of all electric vehicle primary drive systems and secondary accessory motor drives utilize Permanent Magnet Motors and virtually all of these use attached or embedded permanent magnet segments or formed to shape magnets wherein these magnets are generally a relatively homogeneous blend of magnetic particles or particles with an amount of binder material distributed around the particles forming a homogeneous blend.

[0245] The present invention differs totally from the prior art by taking a component and incorporating into the matrix or structural matrix of the component specifically located concentrations of magnetic field producing elements in predetermined distributions.

[0246] This present invention allows the creation of a new generation of magnetic and electro-magnetic field interactive machines which are smaller, lighter, more robust, potentially more energy efficient with a higher power to weight/size ratio. Characteristics that are critical to the efficiency and development of Hybrid and Electric Vehicles and most other similarly interactively motivated mechanisms and machines.

[0247] These new and novel interactive elements allow the creation of new and unique machines and drive mechanisms a number of which relate to vehicles.

[0248] Inspection of the provisional specification which is claimed as a priority document to be read in association with the present invention describes and portrays a number of drive mechanisms for vehicles or machines.

[0249] A number of drive mechanisms are shown ranging from multiple disks, flywheels and similar structures attached to drivelines, transmission housings or wheel assemblies, wheel rims and hubs all of which can incorporate magnetic field producing elements, as can secondary rings or disks attached to the primary items and manufactured utilizing principles of the present invention. Although these are secondary attached components, they are also composite structural items with specifically located concentrations of magnetic field creating elements integrated into a matrix which differs totally from attached magnets or formed to shape ring magnets of the prior art.

[0250] A number of potential drive mechanisms follows as example and should not be construed as being complete as those skilled in the art will understand that the principles of the present invention can be applied to a large proportion of magnetic field and electro-magnetic field interactive mechanisms/machines.

[0251] Mechanisms and drive modes explained in the provisional specification which is included in totality as a priority document are listed below without elaborate explanation as the principles involved will be understood by those skilled in the art. Incorporation of magnetic particles into appropriate static or rotational components of a drive system and incorporation of said magnetic particles into metallic components such as Aluminium, magnesium, titanium or non metallic components such as carbon composite or ceramic, said components being, stator or rotor discs, hubs, wheel rims, housings, wherein generally the magnetic particles are incorporated or amalgamated into the matrix, however since incorporating magnetic field producing medium into the matrix of many of the described components is novel the usage of embedded magnetic segments, coils, conductive material or magnetically soft material, will also be novel as will be the case with specifically located concentrations of magnetic particles amalgamated within the component matrix of rotor disks and stacks of rotor disks and static components interleaved within said rotor disks, flywheels and or drive components. Magnet arrays may be a Halbach or alternative array, formed by magnetic particles in the component matrix or surface matrix or alternatively entrapped permanent magnet material in specific arrays may be utilized.

[0252] Component material can be ceramic composite, carbon composite, carbon ceramic, metal matrix composite, metal matrix, steel, stainless steel, cast iron, aluminium, magnesium, resin composite, or any suitable material in association with suitable magnetic material.

[0253] Magnetic particles varying in size from nano-particles to large particles several millimeters or more in size can be utilized to achieve a composite matrix or alternatively a composite, surface matrix wherein magnetic particles are oriented and or concentrated in predetermined locations and field orientations and alignment.

[0254] Magnetic Particles can be distributed throughout the matrix in mechanisms or machine components wherein this would represent a new and novel solution, or concentrated and or aligned in specific location with specifically aligned poles in relation to the gap surface as a result of the manufacturing process and also as a result of imposed magnetic fields during manufacture, especially relevant to anisotropic permanently magnetic particles.

[0255] It will be realized by those skilled in the art that procedures and technological developments referenced in the prior art patent documents listed can easily be utilized to produce embodiments of the present invention. For example magnetic particles can be incorporated into Powder Metallurgical Components and those of metal matrix composites and non metallic matrix type composites, the magnetic particles can be surface treated or coated for compatibility with the matrix material of the component. Magnetic particle concentration, location, and alignment being the result of formed preforms or particles held in position by magnetic field forces or deposited and fused in specific locations utilizing powder metal additive manufacturing, as example.

[0256] There are numerous means and methods of achieving the desired component form and only a few examples are given to facilitate understanding of the principles by those skilled in the art.

[0257] There are also numerous electric motor drive systems, motor/generator types, electronic control units, microprocessors and an array of equipment easily available in the market to those skilled in the art which can provide the requirements of the present invention and only a few examples are listed to facilitate understanding of the principles associated with the present invention.

[0258] Application of magnetic fields during component manufacture can align and magnetize permanently magnetic particles to achieve better concentration of particles and localized magnetic field forces while aligning anisotropic particles in optimum direction. Magnetic particles, soft magnetic particles and electro statically charged particles including piezoelectric particles, as example can be similarly distributed and concentrated throughout a matrix of differing particles or particles of differing magnetic field. The process of localization, concentration and alignment of particles can be further assisted by creating a fluidized bed of particles resulting as example from vibration, being mechanical, acoustic, or electromagnetic variations. A work piece comprising additive manufacturing can benefit in terms of particle alignment, anisotropy, by partial magnetizing of specific regions of magnetic particle deposition at an early stage of deposition thus assisting alignment of subsequent particles deposited and fused.

[0259] Following manufacture final magnetizing of the magnet particles in their predetermined patterns and field alignments can be carried out resulting in components with concentrations of North/South magnetic poles distributed in specific locations of the component face, said component can be for example a friction rotor of a disk brake, an attachment to said brake disk, part of a wheel hub, wheel rim or attachment to said wheel rim, a flywheel, disk or drum type attachment to a rotational component of a motor drive component, drive shaft, gear box or transmission component or numerous other components creating a new and novel drive system.

[0260] In addition to providing magnetic field effects the magnetic particles can reinforce the structural matrix of the component in much the same way as aggregate and sand reinforce a cement matrix to form concrete, specific sizing and variation of particle size as well as particle concentration in specific regions of a component can provide structural integrity characteristics suited to specific regions of a component while also providing regions of highly concentrated magnetic flux.

[0261] Rigidity and a high modulus of elasticity in compression is associated with a high concentration of magnetic particles in a binder matrix while a region of diminished magnetic particle concentration takes on the characteristics of the matrix material which may be a ductile, high tensile, low or high modulus material allowing a composite material with highly beneficial variable structural characteristics which can be tailored to suit the region of usage.

[0262] Since magnetic particles can be of much higher hardness than the component matrix these particles can greatly improve wear resistance and increase the coefficient of friction of a surface.

[0263] Clusters of particles can be incorporated into the matrix and surface matrix of both metallic and primarily non-metallic components, for example, disks during the manufacture of the disk by using a pair of former disks which provide a mold for the new disk. These former disks can have specifically located and aligned magnetic fields across their surfaces in predetermined patterns forming specific arrays, clusters of anisotropic or isotropic permanently magnetic particles are attracted to the fields and aligned (anisotropic). Infilling void regions within particle concentrations and the general matrix using, resins, or molten metal can utilize procedures well known in the art and referenced in this disclosure can result in a formed disk with arrays of specifically located concentrations of magnetic particles impregnated and amalgamated within the disk matrix, whether that be aluminium alloy, or other metals which penetrate the voids around particles during disk formation or impregnates the boundaries of the particle clusters while heat and or pressure fuses or sinters the particles. Said particles may be pre-coated with a material similar to or compatible with the matrix material, thereby creating an integrated structure of high structural integrity. Former plates can also be associated with additively manufactured disks or other device shapes, achieving improved surface finish and additionally applying a magnetizing flux if required.

[0264] U.S. Pat. No. 5,594,186 Krause et al. filed Jul. 12, 1995 and U.S. Pat. No. 6,502,423 Schmitt filed Aug. 30, 2000 Describe technology utilized in the field of Metal Matrix Composites aspects of which can be utilized in the manufacture of the present invention.

[0265] A metal matrix composite, carbon ceramic or carbon composite or resin composite matrix material amalgamated with magnetic particle clusters in specific locations and concentrations can form for instance a wheel rim with a high proportion of magnetic particles in appropriate regions while maintaining impact resistance and structural integrity in regions designed for primary strength has great advantages over a uniform blend of particles throughout said wheel rim which creates a brittle inefficient structure with inefficient material usage as would be the case with a uniform highly concentrated costly blend of magnetic particles throughout the component as used in prior art. Metal Particles or molten metal are easily formed into complex shapes and as with the prior mentioned matrix materials can impregnate a magnetic particle array. Said magnetic particles could also be specifically shaped and aligned preforms of bonded or sintered particles held into specific locations within a mold by for example, magnetic fields associated with the mold which would have a secondary benefit of pre-aligning anistropic particles during the manufacturing process resulting in stronger more concentrated fields. As example US. Patent Application 20090311541 Anderson et. al. which could be utilized for forming some components associated with the preset invention.

[0266] Magnetic particles 5 to 10 microns or larger particles or as small as nano particles are presently commercially available in the field of magnet manufacture. The particles may be coated or etched to assist bond, mixing, and amalgamating with the matrix material.

[0267] Carbon/Resin composite automotive and bicycle wheel rims are presently marketed and these same materials can easily be manufactured using similar techniques to those presently involved but including specifically located concentrations of magnetic particles thereby creating wheel rims with magnetic field creating capacity. However specifically located and distributed concentrations of magnetic particles integrated and amalgamated into a metal matrix or structural matrix to form a Distributed Magnetic Metal Matrix Composite is even greater significance to the principles of the present invention.

[0268] Such a wheel rim can be formed in a mould or former, Vacuum forming is often employed with resin/plastic matrix binder materials. The mold would generally be fitted with specific magnetic field arrays which mirror those arrays required in the finished magnetic rim section. Resin/Plastic components are generally heat cured in an autoclave after which permanently magnetic particles; anisotropic or isotropic, though anisotropic will yield a higher flux density, will be finally magnetized if the in mould magnetizing is insufficient. A wide array of components can be similarly formed, these can for example be wheel hubs to which a brake disk is attached, various discs, such as flywheels and rotational components attached to a vehicle drive line, which when associated with electro-magnetic drive coils can provide motor/generator capabilities, U.S. Pat. No. 4,995,675 Tsai filed Jul. 12, 1989 describes a method of manufacturing carbon composite wheel for a bicycle. Combining these rims with an adjacent electro-magnetic coil array can create a wheel structure capable of drive and regenerative braking using prior art motor/generator theory and electronics, which differs totally from prior art wheel drive systems which attach magnetic field creating elements to a wheel structure, often in the form of magnet segments, and is unlike the present invention which integrate arrays of magnetic particles within the matrix or structural matrix of in this example, a wheel rim, with due consideration to both magnetic field creation and maintenance of structural integrity in a simple amalgamated component. A distributed magnetic metal matrix composite component can be formed by combining Particle Metallurgical Technology, Metal Matrix Technology and Metal Matrix Permanent Magnet Technology, examples of which are referenced.

[0269] Using Metal Matrix Composite experience, powder metallurgical techniques, squeeze casting, rotary forging, Metal Injection Molding, Additive Manufacturing, and a variety of methods associated with manufacturing metal bonded magnets, suitable methods of manufacture are available which can integrate a wide array of metallic materials and magnetic particle distributions to form a structurally sound component.

[0270] Since most permanent magnetic particles and the majority of soft magnetic particles proposed for usage are attracted to magnetic fields the use of such fields in moulds and formers is a good solution for placement of particles and arrangement of particle arrays and holding the particles or preforms of said particles in position while infilling the mould with powdered metal alloys, plastic or molten metal phases. WIPO Patent WO/2004/062838 Powder Metallurgical Production of a component having Porous and Non Porous Parts, describes a procedure for producing a component with specific regions of different material such methods can be utilized by the present invention to form a component containing specific concentrations of magnetic particles.

[0271] As example, a metal alloy for instance aluminium alloy, wheel rim can be formed from aluminium in the plastic or semi-molten state. Magnetic particles or preforms of magnetic particles can be held firmly in a mold by strong magnetic fields. U.S. Pat. No. 5,894,644 Mravic filed Apr. 20, 1999 describes a method of infiltrating a porous preform with liquid metal in the case of the present invention the preform can be of magnetic particles, the liquid metal, any suitable metal which can also form regions of component outside the preform region, forming a, cast or formed wheel rim. Magnetic fields can align anistropic particles and also magnetize the arrays, which can for example be restricted to the portion of the rim which may for example be maintained relatively flat in section and thus easily associated with an electro-magnetic drive coil array. An alternative method of fabrication would be to use powder metallurgical techniques to form an initially flat strip of aluminium with integrated magnetic particles integrated within the central region of the strip of aluminium thus making forming and magnetizing relatively straight forward, while the outer edges of the strip of aluminium are free of magnetic particles and remain ductile and suited to normal rolling and forming processes.

[0272] The usage of the phrase as example or for example as utilized in the present disclosure is intended to describe one of potentially many options and in no way should an example be considered as a sole or exclusive reference thereby binding the limits of the disclosure since those skilled in the art will realize there are numerous alternatives.

[0273] A more complex rim shape could be an inner section of a bolted three piece wheel rim which can then be rolled into a ring shape; butt welded and have the ductile edges which do not contain magnetic particles rolled using standard forming procedures for such items to form the desired rim shape while containing within the central region of the rim section a magnetic particle array integrated into the structural matrix of the component. A far lighter, more robust magnetic field producing wheel section than that of the prior art which attaches or embeds magnetic segments onto or into a rim section.

[0274] A wide array of mechanisms and machine components can be like-wise manufactured utilizing magnetic particle systems of the present invention and prior art metallurgy or fabrication technology combining the mechanisms so produced with permanent magnetic arrays of the forth embodiment, and coil arrays of the second and third embodiments of the present invention to create highly efficient machines or mechanisms. A number of patent are referenced which precisely explain detailed methods associated with the manufacture of components, procedures and methods which can be related to manufacture of the present invention.

[0275] Use with Hybrid vehicles is an important aspect of the present invention. Electric motors, wheels, flywheels, disk and drum shaped components associated with drive components can all utilize embodiments of the present invention. However both internal combustion engines and electric motors can benefit from some form of gear reduction system to transfer torque.

[0276] The present invention is ideally suited to the manufacture of magnetic drive and torque transfer systems. Magnomatics systems were previously referenced. These systems evolve very little heat, as there is no direct contact involved and minimal losses thus such magnetic gear boxes and power transfer systems do not necessarily have to be built of metal, composites and reinforced plastics can also be utilized in the manufacture, thus integrating specifically located concentrations of magnetic particles, as described in embodiments of the present invention, into components of these mechanisms can create small, light weight, efficient, easily mass produced magnetic gearboxes which are ideally suited to Hybrid and electric vehicles and numerous other power and torque transfer mechanisms.

[0277] As another example of the wide array of uses for the present invention, consider electric hand tools, drills, angle grinders, saws and numerous house-hold appliances.

[0278] Most of these machines have a significant portion of the casing formed in plastic. Within this casing is generally housed a stator of steel laminates or soft magnetic core material and field windings. Some of the latest electronically controlled machines utilize permanent magnet segments attached to the rotor while most utilize commutators and brushes powering a coil wound rotor. The segmented commutators and associated brush sparking causes brush and commutator wear.

[0279] The stator core and field windings take up a lot of space, add weight, and are a significant source of overall machine efficiency losses.

[0280] Some of the most recent machine developments aim to replace the coil wound/commutator rotor with either attached magnet segments or a formed to shape magnetic material can be suitably replaced with embodiments of the present invention there are several other alternatives which can result in a smaller, lighter, more efficient yet equivalently powerful machine. An example is to incorporate within the casing of the machine, which in this example is plastic, arrays of permanently magnetic particles amalgamated into the plastic casing in specifically located and flux aligned concentrations to form suitable magnetic arrays which do not require. back iron as a flux return path and concentrate most flux on the rotor gap face. One such array would be the so named Diagonal or V array of the forth embodiment of the present invention. This magnetic stator would react with a wound rotor similar to the original rotor which can use the original commutator rotor or slip rings in place of commutators and electronic control of power supply as the more suitable solution as brush wear and sparking would be greatly reduced. The original commutator system is also usable though this may also require electronic control of power supply. The machine effectively functioning as a synchronous AC or DC machine depending on overall design and electronic control chosen.

[0281] The advantages of the first and primary embodiment of the present invention are clear from this example.

[0282] A large, cumbersome, inefficient, somewhat difficult to manufacture coil wound stator is replaced by a much smaller, lighter, more efficient, robust and virtually fail safe array of permanently magnetic particles amalgamated, and integrated into the structural matrix of the machine casing in specific, precisely controlled locations and concentrations creating a machine that is potentially significantly smaller and lighter than electronically controlled machines using permanent magnet rotors and large cumbersome coil wound stator cores.

[0283] A potential improvement of the above noted cumbersome coil wound stator core of the prior art would be to utilize the first and third embodiments of the present invention to amalgamate magnetic particles into the machine casing however in this case the magnetic particles would be soft magnetic particles forming cores amalgamated into the casing and being coil wound. Said cores could be set out in a V coil array thereby avoiding long return flux paths which are normally created in the back iron of the stator. Such a design would allow a smaller lighter machine than that of the prior art, and can utilize an array of rotor type. The housing or case of the machine would be primarily matrix material of the desired structural integrity blending and integrating into the V coil cores which are primarily magnetic particles with surface treatment to allow compatibility with the structural matrix of the machine casing.

[0284] Thus several different machine designs are described one using a brushed rotor and permanently magnetic particles integrated into the machine case and others using a permanently magnetic rotor (PM), a reluctance type rotor, an induction type rotor or a combined reluctance/PM rotor, formed according to embodiments of the present invention and a coil wound stator utilizing the machine casing into which stator core material is integrated again utilizing embodiments of the present invention and offering significant advantages over the prior art.

[0285] The above examples highlight typical modes of usage of embodiments of the present invention which can be applied to the vast majority of machines and mechanisms which operate as a result of magnetic field and or electro-magnetic field interaction.

[0286] Another example of a magnetic/electro-magnetic field interactive mechanism which can utilize embodiments of the present invention is a pseudo-magnetic-gear-motor/generator of a type similar to that of Magnomatics incorporating embodiments of the present invention can create a Hybrid and or electric power, drive and transmission system in one integrated unit which is both highly efficient and unlike the prior art which predominantly utilizes magnetic segments, the present invention utilizing specifically located and distributed concentrations of magnetic particles lends itself to mass production and thus cost savings which is very difficult utilizing the prior art, while creating a more robust, structurally integrated machine than can be created utilizing magnetic segments of the prior art.

[0287] Several Engineering companies have announced a range extender purpose built I.C. engine directly connected to a generator to maintain a power charge in an electrically motivated vehicles battery thereby potentially reducing battery weight and size and improving convenience. The I.C. engine/generator, used to charge batteries and or to potentially directly power electric motors the I.C. engine optimized to operate efficiently in a range suited to the electric generator and potentially not optimized to additionally drive the vehicle wheels through a conventional transmission system.

[0288] The generator can utilize aspects of embodiments of the present invention to further improve efficiency while reducing size and weight however a key issue mentioned earlier in this present disclosure is to maximize both efficiency and utilization of all power sources to motivate a vehicle, therein maximizing performance of the vehicle in relation to total energy/drive producing items onboard said vehicle. Clearly using every available drive source to power/drive the vehicle during relatively short bursts of acceleration will maximize vehicle performance assuming that achieving this goal does not incure large weight/size/cost penalties due to for example cumbersome gear drives or up grading motors to both charge batteries via, alternators/generators and also drive wheels via a conventional transmission. Clearly there are conflicting issues involved and thus compromises must be made.

[0289] Minimizing the compromises especially in relation to drive/power/torque transfer systems is now possible as a result of a prior mentioned magnetic gear/torque transfer/motor/generator combined system known as Pseudo-Direct Drive Electric Machines as previously referenced, and also referenced along with other types of electric motor/generator systems which can benefit from embodiments of the present invention Refer to The University of Sheffield Electrical Machines and Drives Research Group.

[0290] A magnetic gearbox is much less restrictive in terms of engine drive, the magnetic gearbox possessing almost infinite drive variability thereby allowing said I.C. engine to operate in its optimum while the magnetic gearbox transfers torque to the wheels. For example a purpose built I.C. engine placed transversely in a vehicle chassis, as is common front wheel drive practise with a pair of pseudo direct drive motor/generator/magnetic gear box attached directly to each end of the I.C. motor crank shaft can drive a pair of wheels via the magnetic gear box systems, which generally would be micro-processor controlled/monitored, thereby doing away with conventional gearboxes and differentials. During maximum performance the I.C. motor would drive the wheels via the magnetic gear boxes, additionally the motor/generator section of the pseudo-direct drive system would also power the wheels utilizing stored battery/capacitor energy, thus maximizing usage of all drive systems available.

[0291] The pseudo direct drive can be electronically controlled and micro-processor monitored to totally or partially switch out the I.C. engine effectively declutching the engine during regenerative braking or during electrical drive of the wheels, the wheels can be fully driven by the I.C. motor, while the generator, section of the pseudo direct drive utilizes part of the I.C. engine energy to also charge the batteries, at standstill the I.C. engine can provide charge energy only thus an almost infinite array of drive/recharge/regenerative energy usage is possible by electronic control of such a system, this would also easily incorporate A.B.S. antilock braking, anti-slip, stability control and all other manner of electronically controlled safety aspects of the vehicle dynamics.

[0292] Clearly the highest efficiency, maximum performance vehicle will utilize as many drive mechanisms carried by the vehicle for more than just one purpose with minimum compromise. As exampled the pseudo direct drive system allows a purpose built I.C. engine to function efficiently as both a highly efficient drive for an alternator/generator and also to assist in driving the vehicle wheels directly when higher performance is desired. This system is highly efficient when used with Hybrid and electric vehicles and especially suited to using embodiments of the present invention.

[0293] Utilizing as many drive items as possible can at minimal cost allow maximizing vehicle capabilities for instance air conditioning pumps are found on most automobiles produced, and are generally directly belt driven from an I.C. engine via an electrically actuated clutch mechanism. Cooling a vehicle interior consumes a large amount of energy, electric vehicles often utilize a combined electric motor to drive the air-conditioner pump while hybrid electric vehicles can utilize either an electric motor drive or direct drive from the I.C. engine. Assume for example that a combined air conditioner pump electric motor/generator is also directly driven by the I.C. engine via the normal clutch/belt system. It is very easy to adapt a system, for example utilizing one or more unidirectional clutch mechanisms whereby under maximum performance requirements the air conditioner pump draws no power and the electric motor which normally powers the pump transfers power directly to the I.C. engine to boost performance additionally electronic control allows optimization of efficiency whereby under other circumstance the I.C. engine of the hybrid drives the air conditioner pump plus the motor/generator to recharge batteries and or capacitors, thereby boosting charge and drive capability of the vehicle beyond that of using only the primary electric motor/generator of the hybrid vehicle. The compromise in this example is the maintaining of a clutch and belt drive connection to the motor however the power to drive an air conditioner pump is significant, around 4 kW (5 horse power) is drawn thus a significant amount of power which can assist during performance requirements. Reduction in mass and reduced package size allows increased vehicle integration flexibility thus full and total usage of all primary power usage mechanisms will result in a more efficient vehicle wherein motor/generators utilize embodiments of the present invention integration of the pseudo direct drive system in place of a conventional transmission system also reduces the compromises.

[0294] However a further improvement can be made in the basic design by exchanging aspects of the prior art for example attached or embedded permanent magnet segments for an integrated system offered by embodiments of the present invention which can further improve efficiency, reduce size and weight, greatly improve structural integrity and robustness while also greatly easing production difficulties and allowing ease of mass production and inherent cost reductions.

[0295] The following patent references disclose aspects of the prior art which can be utilized in the manufacture of components incorporating embodiments of the present inventions.

[0296] U.S. Pat. No. 5,123,373 Iyer et. al filed Nov. 5, 1992 Discloses a method for coating fibres used in composites by fluidizing particles with high frequency vibrations allowing even particle coating of said fibers.

[0297] As example external forces can be provided by, vibration forces, a magnetic forces an acoustic force a rotational force or combination there-of. Magnetic separators use permanent magnets or electro-magnets and can benefit from a high vibration fluidized bed to assist particle separation, fluidization of particles can be assisted by gas distribution within the particle container. Selective heating of specific particles is possible by use of microwave/millimeter wave technology, whereby, for example, magnetic particles can be specifically heated to melt a pre-coating which creates bond of particles within a specific magnetic field/pole/array as determined by an applied external magnetic field array associated with the molding container. WIPO Patent WO/2003/072835 Method and Apparatus for separating Metal Values discloses technology which may be applied to the present invention.

[0298] Thus by adopting technology of the prior art and the knowhow of those skilled in specific aspects of the art all elements of the present invention can be realized.

[0299] Utilizing methods of the prior art a component or mechanism, for example a rotor disk of a motor, a flywheel disk, a brake rotor disk, a cylinder such as a wheel rim or surround of a transmission component can be formed of matrix material in particle form or liquid/semi liquid or gel form blended with magnetic particles which are confined within a suitable mould or forms. Said former having suitably placed magnetic field arrays or electro-magnetic field arrays which differentially attract the magnetic particles. Application of a fluidizing force such as high frequency vibration which can be externally applied to the former mold or associated with the mold by rapid variation of the magnetic fields applied to the former and or the addition of a gaseous medium can result in fluidization of the mass within the former moulds and separation and attraction of specific magnetic particles in arrays which align pole wise, and cling together to correspond with the chosen array applied to the former molds. Premolds of magnetic particles can be held in place by magnetic field force, adhesive or suitable alternatives. The magnetic particles can be pre-coated with several coating layers, the first of which can bond the particles under the influence of microwave/millimeter wave application to allow easy handling of the preformed component after which final heating, sintering and or pressure application can break down the bond coating, exposing the matrix compatible particle coating which allows fusing the component which is a non-homogeneous amalgamation of specifically located concentrations of magnetic particles integrated into a matrix material to form a homogenous structural mass with specifically located, oriented and concentrated magnetic particle arrays. Said component may undergo further densification by gaseous or liquid impregnation techniques or further forming procedures.

[0300] U.S. patents further referenced which provide disclosures of the prior art which can be utilized in some part to realize embodiments of the present invention are supplied as example.

[0301] U.S. Patent Application 20090026026 Martino. Vehicular Brake Rotor formed by powder metallurgy. The technology disclosed can be utilized to incorporate magnetic particles into an array of components.

[0302] U.S. Pat. No. 4,838,936 Akechi et al. filed May 23, 1988 Forged Aluminium Alloy Spiral parts and Fabrication There-of, discloses high strength high precision components formed by forging aluminum alloy powder.

[0303] U.S. Pat. No. 4,915,605 Chan et al. filed May 11, 1989 Method of Consolidation of powder aluminium and aluminium alloys and aluminium metal matrix composites, discloses a powder preform component consolidated under heat and pressure by a bed of flowable particles which transmit pressure and heat.

[0304] U.S. Pat. No. 7,553,561 Sakamoto et al. filed Jul. 19, 2005 Rare Earth Magnet, discloses a permanent magnet formed from multicoated magnetic particles to achieve excellent corrosion resistance.

[0305] U.S. Patent Application 20080304974 Marshall et al. First Stage Dual-Alloy Turbine Wheel, discloses a first alloy powdered metal Astroloy disk to which is joined a second alloy by hot isostatic pressing.

[0306] U.S. Pat. No. 4,581,300 Hoppin et al. Sep. 21, 1982 Dual Alloy Turbine Wheel, discloses a dual alloy turbine wheel wherein a direct metallurgical bond is created between the differing alloy component parts. This disclosure could be utilized to metallurgically integrate a component part with another component part which in the case of the present invention could be a part incorporating an array of magnetic particles in specifically located concentrations within said part.

[0307] WIPO Patent WO/2004/062838 Powder Metallurgical Production of a Component Having Porous and Non Porous Parts, discloses a component produced by powder metallurgy, methods of achieving metallurgical bonds, between differing materials by pre-coating a metal powder with a coating compatible or of similar composition to the material to which a bond is to be made during sintering.

[0308] The structurally integrated component contains a porous region which in the case of the present invention can be magnetic particles which is of varying concentration and varies in density and or porosity and is then interspersed or infiltrated by another metal phase during sintering said phase forming what would be the matrix of the present invention if such technology was utilized to incorporate magnetic particles into a component.

[0309] In the case of the present invention magnetic particles are suitably treated, which may include etching and or multiple surface coatings to achieve ultimate magnetic capabilities while having excellent compatibility with the matrix material within which said particles are amalgamated.

[0310] U.S. Pat. No. 6,136,265 Gay filed Aug. 9, 1999 Powder Metallurgy method and articles formed thereby, generally relates to a process of coating metal particles with solid polymer binders, lubricants and other materials prior to compaction.

[0311] A number of the above reference patent example disclose methods associated with Powder Metallurgy and Metal Matrix Composites, there are numerous other methods which can be equally well employed to incorporate embodiments of the present invention. It has also been mentioned in prior sections of this disclosure that regions of a component which contain a high concentration of magnetic particles will often become brittle and suffer a lack of ductility, tensile strength and impact resistance. Therefore improved tensile capacity and impact resistance can prove to be a limiting factor in some mechanisms especially those exposed to high stresses for example, high speed flywheels. Additional reinforcement of such components can be achieved by incorporating into the structure of the component flexible high tensile fibre filaments as example carbon, boron, aromatic polymide, ceramic and other fibers which may be specifically distributed along lines of stress or randomly distributed through the particle binding matrix and or the component matrix.

[0312] U.S. Pat. No. 4,676,722 Koenig filed Jun. 30, 1987 High Peripheral Speed wheel for a Centrifugal Compressor.

[0313] The disclosure explains the use of fibers and filaments of carbon, boron glass or aromatic polymide utilizing a resin bonding agent of epoxy, polyimide or phenolic resin. Such a component formation can easily accommodate specifically located concentrations of magnetic particles to provide a component of high structural integrity which performs its primary function while additionally integrating magnetic field producing medium within said components matrix or structural matrix.

[0314] Developments in metallurgy also allow the integration of such reinforcing fibers within the matrix of a metal matrix component, which for the purposes of the present invention can also integrate magnetic particles in specifically located concentrations thereby creating a fully integrated structural material or component.

[0315] Methods and principles of the present invention can be utilized to manufacture large or small magnetic components. These can, for example, be a unitary magnetic system with a North-South Pole or a multi-pole system wherein the magnetic material is concentrated in a required specific region and integrated and amalgamated into a matrix material which can be strong and ductile and can be used to attach; via. Bolts, Rivets, welds or alternatives; said unitary magnetic system. A far superior system to the prior art which is comprised purely of a homogeneous blend of magnetic particles and metal matrix binder which is generally too brittle to bolt or rivet and not easily welded or brazed. The new unitary magnetic systems can be large or small and differs totally from the homogenous blend of particles and binder which form the prior art permanent magnet. The present invention utilizing specifically located concentrations of magnetic particles where they are most beneficial, altering the concentrations within the integrated material in varying concentrations to suit requirements of the location and utilizing a gradation of particles blending into the matrix material forming a non homogenous blend of particles within a matrix material such that the characteristics of the matrix material are utilized in regions requiring such characteristics for example a ductile non brittle matrix material required for bolting to a primary component.

[0316] For the purposes of the present invention a Distributed Magnetic Metal Matrix Composite shall describe a material conforming to a generally non-homogeneous distribution of magnetic particles within a material of another metal or different magnetic particles wherein magnetic particle concentrations are specifically located so as to achieve the design requirements of both the magnetic material and the structural load bearing material, therein conforming to suitable magnetically and structurally analyzed design criteria.

[0317] As with plastic/resin matrix composites Metal Matrix Composites can have large strength and modulus gains as a result of incorporation of reinforcing fibers such as carbon, boron, glass fibers, Kevlar (polyaramid), or other suitable fibers. Short randomly oriented fibers can be mixed into the matrix, while in particle or liquid (molten) form or mixed with the magnetic particles or both, thereby significantly improving structural characteristics and particularly, rigidity, tensile and bending strength, impact and fatigue resistance thereby allowing a thinner, lighter weight load bearing section. Additionally longer or continuous strands of reinforcing fibers can be specifically located within the Distributed Magnetic Metal Matrix Composite to provide additional strength, for example improved tensile and compressive strength and improved modules of elasticity and thus rigidity of a component, for example, carbon fibers integrated and firmly bonded in specific locations within an aluminium matrix can greatly improve structural characteristics. The same carbon fiber strands passing around or through regions containing high proportions of magnetic particles can likewise greatly improve structural integrity, for instance tensile, bending strength, and fatigue loading and greatly improve safety factors against component failure said fibers are often suitably coated for compatibility with the chosen matrix material.

[0318] Present technology allows easy access to such materials and the technology to include these reinforcing fibers in metal matrix materials. The following references describe a small portion of the available technology.

[0319] U.S. Pat. No. 4,731,298 Shindo et. al. filed Dec. 9, 1985, Carbon fiber-reinforced light metal composites, discloses carbon fibers bound with aluminium or aluminium alloy or magnesium/magnesium alloy to form a metal fiber composite. Methods of component manufacture include molten metal impregnation, and stir casting as example. Titanium boron coatings are also mentioned and titanium is potentially a matrix material used with distributed magnetic particles to form a light weight high strength magnetic field generating component with both a structural components use such as a wheel rim or motor/generator high speed rotor and a magnetic field generating capability as defined by a Synthetic Multifunctional Material which was defined and claimed by the Inventor of the present invention in U.S. Pat. No. 7,703,717.

[0320] U.S. Pat. No. 5,733,390 Kingston, filed Dec. 7, 1995. Carbon Titanium composites discloses methods for coating carbon fibers to achieve compatibility with a titanium matrix, however in this case the fiber is surface bonded to the metal. This patent also clearly states a few deficiencies associated with resin/plastic bound composites which include damage sensitivity, low bearing strength and fastening difficulties.

[0321] Surface bonding of high strength fiber reinforcement can be considered an option with some specialized components and has an advantage of being able to easily vary the amount and orientation of the carbon fibre or alternative fibre in order to put the required strength where it is needed.

[0322] Nickel and other coatings can be applied to reinforcing fibers to act as wetting agents and to assist compatibility with the matrix material.

[0323] U.S. Pat. No. 5,468,358 Ohkawa et. al. filed Jul. 6, 1993 Fabrication of fiber-reinforced composites which include those of carbon, ceramic, or metal matrix composites using electro-phoretic infiltration of an array or preform which is a quite complex procedure suited to high end usage.

[0324] U.S. Pat. No. 5,162,159 Tenhover et al. filed Nov. 14, 1991 Metal alloy coated reinforcements for use in metal matrix composites, utilize carbon fiber, silicon carbide fiber or other suitable fibers and provides a coating which allows compatibility with the matrix metal and resists high temperature degradation of the fibers.

[0325] U.S. Pat. No. 6,033,622 Maruyama filed Sep. 21, 1998. Method for Making Metal Matrix Composites which discloses a composite material comprising a metal matrix reinforced with particles of silicon carbide for example, using powder metallurgy wherein a metal alloy powder and a particulate powder are mixed then consolidated at elevated temperature is an example of prior art and could easily include short reinforcing fibers of carbon, boron, silicon carbide or suitable alternatives plus magnetic particles which as with the other particulate materials should also be suitably coated for compatibility with the matrix. Particles can be coated with a material compatible with the metal matrix material to ease wetting and amalgamation wherein a non homogeneous particle blend forms an integrated structural material.

[0326] Magnetizing the particles prior to mixing with the matrix, then utilizing a magnetizing array of magnetic fields to hold magnetic particles in specific locations within a mold containing said magnetic particles, or preforms of magnetic particles, and if desired reinforcing fibers along with either matrix particles or molten matrix material. A magnetizing field can be applied during consolidation of the component body within the mold and or can be applied to the final solid body to set magnetic fields, arrays and pole alignments.

[0327] U.S. Pat. No. 6,154,352 Kais filed Mar. 27, 1997 Method of Magnetizing a Cylindrical Body discloses interesting technology which can be applied to components utilizing embodiments of the present invention.

[0328] Also of interest is Talat Lecture 1402 Aluminium Matrix Composites Materials Advanced Level 1L. Froyen, University of Leuven, Belgium, referencing methods of manufacture of Aluminium Matrix Composites which is relevant to a number of other metal matrix materials, continuous and discontinuous short fibre composites, particle composites, manufacturing techniques, and application examples, automotive, aerospace, electronics (due to good heat dissipation) sports and leisure. This paper clearly shows the viability and ease of manufacture of the present invention by utilizing technology associated with Metal Matrix Composites, Sintered and Metal Bonded Magnets, and a range of Metallurgical Techniques available to those skilled in the art. Ref. Conventional Powered Metal Components bear similarity to metal matrix components and provide very important technology for the manufacture of embodiments of the present invention.

[0329] Another interesting Reference that highlights potential beneficial uses of the present invention is; Ref:Proceeding of the Federal Transit Administrations Urban Maglev Workshop Washington D.C. Sep. 8-9, 2005. Several Maglev transport levitation systems make usage of Halbach arrays above and or below a track of transposed conductors the Diagonal V array can be used in place of a Halbach array with potential benefits in magnetic field strength and more highly concentrated flux peaks for a set quantity of magnetic material usage. Embodiments of the present invention using either normal magnet segments or magnetic particle embodiments, in a Diagonal or V array or Halbach array using magnetic particles in a structural metal matrix can provide benefits over that of the prior art.

[0330] It should be noted that the Diagonal or V Magnet Array which is relevant to magnet segments or magnetic particle formed arrays is analogous to the electrically induced field equivalent V coil array thus said V coil array can offer significant advantages especially when combined with the Diagonal or V magnetic array, as example a rotor incorporating and integrating magnetic particles in a Diagonal or V array interacting with a V coil array in a stator field coil arrangement with no requirement for magnetic flux back iron. The matrix material which integrates the magnetic material of the V coil core can form for example an integrated motor case which can be of a variety of materials for example, aluminium, magnesium, plastic or suitable alternative since there is no requirement for back iron as the V coil forms a continuous flux path. Embodiments of the present invention can be beneficial and find usage in Maglev Vehicles referenced.

[0331] To verify the viability of the Diagonal or V magnet array and analogous V coil array a very simple experiment was performed comparing the Diagonal or V magnet array with the Halbach magnet array using a primary criteria with each array of equivalent amount of magnetic material. (Important for cost and weight considerations) Each of the two arrays used 5 identical 10 mm. long by 5 mm. diameter (Nd Fe B) round bar or rod magnets.

[0332] The arrays were mounted in a 10 mm. by 10 mm. by approximately 50 mm. long section of soft wood. One section for each array. Holes just smaller than the diameter of the magnet segments (rods) were drilled to correspond with Halbach and Diagonal or V arrays. In the case of the Halbach array 3 vertical rods North-South-North were placed in vertical, (relative to horizontal work table), drill holes. The lower sections between vertical magnets was recessed to allows placement of 2 horizontal magnets acting as the back face flux path of the Halbach arrays. Refer to drawings. The Diagonal or V array was formed by drilling holes in V formation at a drill angle of approximately 45 degrees off vertical and 5 rod magnets were pushed into the holes with the upper face being the reinforcing field face and magnets installed south touching south, gap, north touching north, gap, south, while the lower face has north touching south and acts as the return or back flux path which is very short and therein advantageous while the upper reinforcing face creates highly concentrated north and south flux densities which will improve induced fields as a result of interaction with a moving conductor passing through such an array which is an added benefit to the total field strength produced by the 5 magnet rods.

[0333] The total field strength for particular magnet arrays using the same amount of magnetic material is representative of the attraction force or repulsion force of a particular array, important in, for example a magnetic bearing or levitating device, while a levitating device that functions as a result of induced fields benefit greatly as is also the case with most electric motor drives which rely on both magnetic field strength and a rapid rise and decay of a high density flux.

[0334] In this experiment we are checking only the levitating or lifting ability of the two arrays by measuring the distance between the reinforcing magnet array surface placed horizontal to the work table and a standard weight (magnetic steel piece) being levitated (lifted) vertically upward. (Air Gap)

[0335] The distance at which levitation occurred was measured by a vernier gauge attached to the arrays mounted on the rigid non magnetic material and touching the work table surface to measure the distance at which levitation or lifting of the weight occurred by both the reinforcing faces and the return flux back face fields for Halbach and Diagonal or V arrays.

[0336] The average results are listed below and were highly repeatable with a variation of no more than 0.05 mm. It should also be noted that this experiment gives only comparative results of the overall field strengths and back face strengths, of a Halbach array compared with a Diagonal or V, magnetic field array.

[0337] Array air gaps were aligned parallel to the magnetic steel piece being lifted. The average height of the array above the standard weight at which levitation occurred for both the reinforcing front face of the array and the back flux return path were Halbach array reinforcing 8.50 mm. back face 5.75 mm. Diagonal or V array reinforcing 10.25 mm. back face 5.85 mm.

[0338] Conclusion; the total magnetic field strength of a fixed amount of magnetic material for the reinforcing side of the array is significantly greater for the Diagonal or V array than the Halbach array, and since magnetic field strength decreases in an approximately exponential function relative to distance the Diagonal or V array appears to offer approximately a 20% increase in field strength to that of the Halbach array plus potentially sharper flux peaks.

[0339] Another very significant advantage of the Diagonal or V especially where complex component shapes are involved is the ease of magnetizing the V array.

[0340] For the purposes of the present invention magnetic particles shall define; permanently magnetic particles, soft magnetic particles which become magnetic under the influence of a magnetic field, an assembly of electrically conductive particles which become magnetic under the influence of a changing magnetic field, or material particles which under the influence of mechanical forces generate magnetic field forces.

[0341] For the purposes of the present invention magnetic field and electro-magnetic field interactive materials/components/devices can be defined as magnetic field interactive as per a prior definition. As example a machine, a mechanism, a mechanical appliance, a component of a machine, shall define a magnetic field interactive item wherein said item possesses magnetic field forces and the capacity to impose the influence of said magnetic field forces on other items, wherein said other items would also be defined as magnetic field interactive items since these items exhibit a capability of being influenced by magnetic field forces. As example virtually all electric machines are motivated as a result of an electrical current giving rise to magnetic field forces which then interact with other items which are directly influenced by the interaction with said magnetic field forces. A permanent magnetic motor/generator is also a magnetic field interactive machine as is a magnetic power transfer system, as is an eddy current braking system, as are for the purposes of the present disclosure all items which function or operate as a result of the influence or interaction of a magnetic field force wherein all such items being mechanisms, machines, components or materials there of shall be defined as being magnetic field interactive.

[0342] With respect to the above description the optimum dimensional relationships for the components of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art and all equivalent relationships to those in the drawings and described in the specification are intended to be encompassed by the present invention.

[0343] Therefore the foregoing is considered as illustrative only of the principles of the invention. It is not desired to limit the invention to the exact construction, operation and usage shown and described, thus all suitable modifications and equivalents may be considered to fall within the scope of the invention.

Summarising and Defining Important Aspects of the Invention

[0344] A primary criteria of the present invention is the creation of a material, component or device which is structural load bearing, conforming to suitable structurally analyzed design criteria combined with magnetic field interactive capabilities in primarily a unitary, or series of unitary, amalgamated body or part thereof.

[0345] The present invention discloses in one form, a device with magnetic field interactive capabilities, thereby possessing the capacity/capability to interact with another magnetic field force/flux, said device in one form incorporating and amalgamating with said device matrix material another material originating from magnetic particles possessing as example, permanently magnetic flux, reluctance flux, and/or inductive/induced flux. A composite magnet is representative of said device FIG. 1C, 1E, 2B. The magnet could as example comprise a soft magnetic core, or a conductive/inductive core with a periphery or extremities of permanently magnetic particles or vice/versa a permanently magnetic core with a periphery of soft magnetic material, or inductive material. (Refer to Drawings) A permanently magnetic material can benefit in terms of flux concentration, distribution, flux alignment and material properties by incorporating for example a soft magnetic core/inductive core with a periphery of permanently magnetic particles or numerous other configurations; additionally, as characterized by references and drawings, such as FIG. 3B and FIG. 3C said magnetic component or device, can be enhanced structurally by specifically placing or configuring a particular type of structural load bearing material in a region of high load, representing examples of structural integrity resulting from suitable structurally analyzed design since material strength is located precisely as required and magnetic flux is also located exactly as required each with design consideration for the other; said device being, as in this example, a composite magnet/composite magnetic device integrating/incorporating permanently magnetic particles and/or magnetic particles with a different material matrix (primarily metal) with consideration to the flux characteristic of a certain quantity of permanently magnetic material and/or magnetic material while the metal matrix combined with the magnetic particle material provides structural integrity imparting said composite magnet or magnetic device, multipurpose/multifunctional characteristics

[0346] In order to reduce the necessity for extensive explanation of prior art technology which can be utilized in creating embodiments of the present invention, an array of references are cited and included in their entirety by reference and should be considered to represent the present state of the art and that which is known and understood by those skilled in the art. The present invention holds great economy for the efficient usage of in particular rare earth magnetic material by combining it with other magnetic material, as example soft magnetic particles to create a distributed magnetic metal matrix composite, with particular attention to structural integrity.

[0347] Note; The dash (/) between, for example, Motor/Generator in this disclosure and claims carries the meaning of; a motor or a generator or a combined motor and generator.

[0348] Note; As is made clear throughout this disclosure, magnetic particles are defined as particles or pieces of material which are either permanently magnetic or become magnetic and or magnetic field interactive under the influence of an applied magnetic or electro-magnetic field or electric current. Magnetic particles are incorporated within a material/component matrix creating a non homogeneous composite. A cluster of magnetic particles may be homogeneous and may form a highly concentrated fused mass however the combined matrix plus magnetic particles is a non homogeneous composite.

[0349] This disclosure cites and references many patents and Trade Marks/Names such as Kevlar, Magnomatics, Pseudo Direct Drive, Maglev, Inductrack, along with other Company/Brand Name which are the property of other parties and should not be interpreted as a comprehensive or partial grant of assignment to or by the writer of this disclosure or any third party, patent/utility model, trademark, trade name, copyright, design or any other intellectual property right by this writer/inventor or any other third parties, nor does it infer any agreement between said writer and other third party owners of patents, trade marks and other property nor that the present invention can be freely used in association with said third parties property or vice versa.

[0350] The foregoing disclosure while describing several preferred methods for manufacture of Distributed Magnetic Metal Matrix Composite Materials should not be restricted to the exact methods described as many methods for metal forming, particle manufacture, distribution and consolidation, are known to those skilled in the art and are listed on commonly used web sites such as Wikepedia, and as per diagrams and descriptions associated with the priority document all such methods which result in the formation of Distributed Magnetic Metal Matrix Composite Materials are intended to be encompassed by the present invention.

[0351] Additionally it is the nature of what is formed, namely a Distributed Magnetic Metal Matrix Composite Material; which can contain, individual magnetic particles, fused and integrated magnetic particles, totally fused clusters of magnetic particles which are indistinguishable from a mass of magnetic alloy or any combination thereof bound and integrated with a matrix material of one or more elements or alloys wherein said matrix material is configured to perform functions essential to the operation of said component/device, said functions are highlighted in the Drawing reference section with particular reference to drawing FIGS. 3B and 3C wherein different materials are specifically placed where they are most beneficial. Structural, matrix materials are placed Specifically with regard to regions of high stress, as shown in the drawing FIG. 3C, radial members radiate from the central axis to the periphery of the rotor, these members are primary structural load bearing members and are specifically designed and located with consideration to structural integrity and the requirements of magnetic flux. The magnetic particle material is placed so as not to interfere with structural integrity while maximizing magnetic flux and maintaining or improving structural integrity functions, which is an important criteria of the disclosure wherein a material/component/device comprises specific regions of magnetic material and structural, matrix material forming a non homogeneous composite structural material thus creating a magnetic field interactive material/component/device, with multifunctional capabilities due to combining structural load bearing capabilities with magnetic field interactive capabilities.

[0352] The prior mentioned composite magnet FIG. 1C, 1E, 2B is one example, however FIGS. 3B and 3C show as an example a structurally enhanced rotor with specific placement of structural matrix material. It is additionally stated that specific regions requiring enhanced structural integrity can further incorporate reinforcing fibers of boron, carbon or equivalent therein allowing the creation of, for example, a high speed rotational device otherwise known as an Energy Storage Flywheel FIG. 4, due to specific alignment of structural, matrix material, optional reinforcement, and magnetic particle material. FIG. 4A shows the structural, matrix material radiating like radial members from the central axis to support the weaker magnetic material so as to achieve the multipurpose/multifunctional requirements of a magnetic field interactive rotational device and that of a heavily loaded structural member.

[0353] The important concept of structural integrity with a magnetic particle material integrated with the structural matrix of a load bearing shaft is clearly shown in FIG. 4C wherein said load bearing shaft incorporates with said components structural matrix magnetic particles so arranged to create magnetic bearings while maintaining structural integrity of said shaft. Another example of a Multipurpose/Multifunctional Device with significant structural integrity while additionally locating magnetic particles so as to provide an axial drive force while maintaining the structural integrity essential to such a device is shown in FIG. 6B showing a combined steering rack rod, gear and axial drive magnetic flux combined within the one device.

[0354] The examples are representative of primary principles associated with the present invention and clearly show the inter-related nature of structurally sound design and analysis with particular attention related to maximizing both structural integrity and magnetic flux location so as to enhance said structural integrity, additionally enhanced by integrating said magnetic particles in a manner that does not create a weakness between matrix material and magnetic particle material, clearly shown in the drawings as matrix material and magnetic particles amalgamated together so that the separate constituents integrate, creating a multipurpose device capable of load bearing structural integrity while also possessing magnetic field interactive capabilities.

[0355] Attention is drawn to the significance of the word structural and how for the purposes of this disclosure it defines a primary aspect, indicative of a quality, associated with the design, location and method of integration of magnetic particles and reinforcing fibers if used, with the matrix/structural matrix of a device or component so as to achieve a specific degree of structural integrity; attention being drawn to references relating to FIG. 3B, FIG. 3C and FIG. 4A. Wherein matrix material and magnetic particle material are located, distributed and configured so as to provide optimum characteristics of structural integrity and magnetic flux interaction/generation. FIG. 3C depicts a rotor wherein structural load stresses radiate from the central axis, via radial members to support the peripheral rotor region incorporating magnetic particles. FIG. 4A shows a section of solid rotor wherein matrix material Item 3 is specifically configured and designed so as to provide structural support to the lower strength magnetic particle regions, said matrix material plus magnetic particles thereby being classified as creating a structural matrix material. Specifically designed, configured, and analyzed structurally for the stresses and loads associated, said rotor is capable of functioning as an energy storage device with motor/generator capabilities associated with suitably distributed regions of magnetic particles, therein performing a multifunctional role as a heavily loaded mechanical device, and that of a motor/generator device.

[0356] FIG. 4C shows a section of magnetic bearings supporting multiple disks, magnetic particles item 30 are incorporated within the structural matrix of the support shaft, said support shaft thereby providing multifunctional attributes of a structurally loaded shaft while also functioning as part of a magnetic bearing, said magnetic particles being configured, distributed, and structurally analyzed so as to allow suitable structural integrity to the shaft while also providing the desired magnetic flux.

[0357] Unlike many conventional components/devices which are designed exclusively for one purpose the present invention discloses components/devices which are multifunctional comprising, at least, structural load bearing devices which additionally comprise magnetic field interactive capabilities.

[0358] All rotational components may, for the purpose of this disclosure, be defined as rotors and should not be restricted to the classical description used to describe that which has an exclusive and unitary purpose of a motor/generator.

[0359] The present invention comprises primarily a multifunctional/multipurpose, structural load bearing medium while additionally possessing magnetic field interactive capabilities.

[0360] The intended scope of the invention is as defined in the independents claims which claim a metal or suitable non metal, matrix or structural matrix material, any prior disclosure, methods or configurations relating to plastic or resinous matrix materials can in suitable applications utilize appropriate metallic or suitable non metallic material matrix/structural matrix material in place of plastics.

Definitions and Meanings Relevant to this Specification and Claims

Additive Manufacture

[0361] A process comprising for the purpose of this disclosure, magnetic particles, metal particles or ceramic particles which can utilize direct deposition and fusing with other different particles or solid support medium described as the matrix with which said particles are fused and amalgamated. 3D metal printing is an example.

Alloy/Alloyed

[0362] A homogeneous mixture or solid solution of two or more metals.

Amalgamate/Amalgamation

[0363] A process of binding together into a solid unbroken mass. To combine into a unified or integrated whole, combining or uniting multiple materials into one form or entity.

Architectural Attributes or Characteristics

[0364] Associated with a device relate to form and function of said device, for example, a wheel rim looks and functions as one would expect of a wheel rim, while supporting loads for which it was designed.

Body

[0365] A mass making up a component or device.

Device

[0366] Is a mechanism or something made for a particular purpose, especially a piece of mechanical equipment, apparatus, or machine and should be considered inter-changeable and used as appropriate.

Distributed Magnetic Metal Matrix Composite Material

[0367] Describes, for the purposes of this disclosure a metal matrix material which incorporates and integrates specifically located concentrations of particles of material comprising magnetic field interactive capabilities which are bound, fused, alloyed or otherwise amalgamated into specific regions with the metal matrix material therein enabling the combined matrix material plus magnetic particle material, which thereby forms a non homogeneous composite material, with magnetic field interactive capabilities. There are many possible methods of manufacturing said composite material, one method described in the preferred embodiment involves the incorporation of magnetic particles with said metal matrix material which in regions of high magnetic particle concentration create a dense material which can take the form, in the case of metal particles, of a region of near pure metal alloy wherein the original particles form a fused/integrated mass which is likewise fused/integrated into the matrix and is no longer distinguishable as particles. The key point of this disclosure is to create said Distributed Magnetic Metal Matrix Composite Material and the Magnetic Field Interactive Devices produced from it and should be interpreted as comprising specific regions which originate from magnetic particles within a composite material formed by combining magnetic particles and matrix material wherein the composite material comprises magnetic particles in specific beneficial locations integrated into a matrix material which is predominantly metallic in origin said matrix comprising characteristics which are beneficial to the structural integrity of said device.

Fused/Fused Mass

[0368] To bind together, melted together, or flow together generally as a result of Heat and Pressure, a mass of particles or pieces which join and flow together to form a solid unbroken mass.

Homogeneous

[0369] For the purposes of this disclosure a homogeneous material matrix is a material having uniform composition and properties throughout said materials matrix, uniform nature, constant physical properties. As example a metal alloy is a homogeneous mixture of two or more metals, or two or more elements in which a major component is a metal, eg. Brass which is zinc plus copper, or steel which is iron plus carbon or a neodymium magnet which comprises a homogeneous distribution of neodymium, iron and boron.

Integrated

[0370] To make into a whole by bringing all parts together, becoming part of the component/device body, thereby acting in unison with said component/device and within the general alignment/shape/size of said body.

Integrated Magnetic Multipole Array

[0371] Comprises magnetized magnetic particles integrated into a matrix material thereby creating a magnetic material with 2 or more poles. FIGS. 1C, 1E, 2G and 2H magnetic particle material integrated with a matrix material to form a component which can be described as an integrated magnetic multipole array.

Incorporated

[0372] Shall for the purposes of this disclosure infer the same meaning as integrated.

Inductive Material

[0373] Material in which magnetic fields are induced, by a primary magnetic field or by electrically conductive elements which give rise to magnetic field forces resulting from an imposed electrical current.

Material Sustaining a Magnetic Field

[0374] For the purposes of this disclosure said material shall possess Magnetic Field Interactive capabilities due to comprising one or more of permanently magnetic material, inductive material, electrically conductive material, soft magnetic material.

Magnetic Material

[0375] Material which interacts with a magnetic field or a changing magnetic field, for example permanently magnetic material, and soft magnetic material, and electrically conductive material.

Magnetic field Interactive Material/Component/Device

[0376] A Material/Component/Device that interacts with a magnetic field in proximity. For example, Material sustaining a magnetic field, comprising material which interacts with a magnetic field due to pre-existing magnetic fields within said material, or a material exhibiting characteristics of being attracted to a magnetic field such as soft magnetic material or material in which a magnetic field is induced by a primary magnetic field such as inductive materials and electrically conductive materials, thereby possessing the capacity to interact with said magnetic field.

Magnetic Particles

[0377] Particles or pieces of material ranging from Nano Particle size to several millimeter whereby said particles comprise magnetic field interactive material and are bound within a matrix material, said particles comprising, permanently magnetic particles, soft magnetic particles, electrically conductive and/or inductive particles, piezo-electric particles.

Metal Matrix

[0378] For the purposes of this disclosure shall be represented by Metal Matrix and/or suitable non metal matrix.

Matrix

[0379] Matrix of a component or device shall be defined as a continuous uniform solid phase body in or with which particles and or fibers are incorporated, amalgamated and integrated. Particles amalgamated, incorporated, integrated with this Matrix become a structural part of the component and are not simply attached to or embedded into said component. Matrix can assist in supporting magnetic particles which are amalgamated and fused with said matrix. Matrix can be of; particle origin, molten liquid form, semi plastic form, or solid form.

Multifunctional

[0380] Components/Devices possessing multifunctional/multipurpose characteristics shall be defined as comprising at least structural load bearing capacity suitable for the particular component/device as well as magnetic field interactive capabilities, for example, a wheel rim supporting a vehicle load incorporating specifically located clusters of magnetic particles allowing usage as a motor/generator rotor plus acting as a wheel rim mounting a tire and supporting vehicle loads FIG. 6A Item 2.

Non-Homogeneous

[0381] In the context utilized for this disclosure relates to a non-uniform distribution of material with another type of material, thereby forming a non homogeneous substance, element, component or device. In particular a non uniform distribution of magnetic particles with a matrix of a different material for the purpose of providing specific required characteristics. Such characteristic result in part from said non-uniform distribution of magnetic particles with matrix material and can extend to a wide array of characteristics, as example but not restricted to; magnetic flux characteristics, structural integrity and load bearing characteristics. Possessing, as depicted in the drawings, specification, and priority documents, an ability to vary magnetic particle location and/or configuration and/or concentration within a matrix/structural matrix in the X, Y, Z axis simultaneously eg. (radial, axial, circumferential) within a unitary material/component/device and is not restricted to uniform concentration or configuration of magnetic particles, which may include reinforcing fibers, in one or more axis thus allowing structural and magnetic flux diversity while improving integrity since particles and matrix materials can be specifically placed, configured and concentrated for optimal performance, structurally and magnetically. Differing from non-uniformity due to manufacturing tolerances wherein some divergence from total uniformity is expected and provides no significant specific required/desired characteristics.

Structure

[0382] In this disclosure referring to the engineering application of providing an ability to withstand a certain loading to the component/device or withstanding an external force, performing as a load bearing element, and not the commonly used terminology of something built, an assembly of items or something constructed.

Structural Matrix

[0383] Is a non homogeneous integrated, amalgamated combination of matrix material and magnetic particle material which forms the body of a material/component/device which for the purposes of this disclosure is primarily metallic, though suitable non metal material devoid of plastic or resinous materials and other non plastic load bearing materials should also be considered suitable for use in the present invention, said structural matrix of a component relates to formation of a structural load bearing material with a suitable combination of matrix and magnetic particle material and involves some amount of structural analysis or intuitive understanding to determine the effects of said material on the load bearing strength and integrity characteristics of the combined (composite) material/component/device. For the purposes of this disclosure incorporating materials, or particles which may include reinforcing fibers with the matrix of a different material/component/device forms a structural matrix and imparts unique properties to the thus formed composite material/component/device, said particles and or fibers being located with specific attention to suitable alignment/location/configuration to have desirable correspondence with loading (stresses) within the material/component/device.

Suitable Non Metals

[0384] Devoid of plastic or resinous material; as example, ceramics, ceramic composites, fibers of carbon or boron are stated in the Specification while those skilled in the art will know of a number of suitable non metallic materials.

Suitable Structurally Analyzed Design

[0385] Essential for the creation of a Structural Load Bearing material/component/device wherein a set of loading requirements are arrived at and correspond with requirements of for example a particular device or part thereof. Loadings sustained or imposed must be resisted in a fashion that does not exceed safe limits of the materials comprising said device thus creation of a reliable structural device involves some degree of structurally analyzed design. This can be achieved using mathematical and or computer based structural analysis, for example finite element analysis, or by intuitive analysis by someone highly skilled in the art, or by testing a sample under working load conditions and possibly to destruction, all represent forms of suitable structurally analyzed design.

V Coil, V Core or Diagonal V Array

[0386] Represent approximately or substantially V shaped combinations of coils, core material, and/or magnetic particle arrays wherein each combination possesses a North and South magnetic pole at least some time during operation.

[0387] Generally the point of the V will join in a non like magnetic pole eg. North South flux path which to a large extent eliminates free magnetic flux on this side, forming a back flux path, while the North and South opposite ends of the V are active flux regions generally in proximity to an air gap.

Examples of Material/Devices Associated with the Claims

[0388] Fused Magnetic Particles may form regions comprising clusters of magnetic particles which are dense homogeneous masses of fused magnetic particle material in which individual magnetic particles are no longer distinct (since distinct magnetic particles may not be apparent in a fused mass) none the less the combined material will comprise a region of fused magnetic particle material amalgamated with a different material matrix wherein said combined material, is non homogeneous due to the specific location of concentrations of fused magnetic material which originates from magnetic particles. It is the non homogeneous distribution of magnetic material, originating from magnetic particle materials, within said combined structural material (composite) which is a primary criteria in this disclosure.

[0389] Following are several specific examples of materials/devices associated with the claims, said examples can assist in understanding the claims.

[0390] All examples, illustrations, references and methods of manufacture are intended to be illustrative rather than limiting.

Example 1

[0391] A disk or cylinder shaped rotor comprising one or more soft magnetic disk or cylinder. Refer to FIG. 3B, 3C, 4A rotors show possible sections for arrangement of magnetic particles within said disc or cylinder.

[0392] The present invention would in one embodiment incorporate and amalgamate permanently magnetic material with matrix material in specific regions of said soft magnetic disk or cylinder therein forming part of the composite structure of the disk/cylinder. The magnetic material can be varied in location, concentration, and configuration, wherein the magnetic material is bound with the structure of the rotor with particular attention to loading and suitable structural matrix configuration, (corresponding with suitable structurally analyzed design criteria) such that regions of matrix material support the generally more fragile material, additionally placing the concentrated magnetic material where it is most beneficial to magnetic flux, rather than being embedded or pressed into grooves or voids around the periphery as observed in the majority of present state of the art, thereby resulting in a significant improvement in magnetic flux, structural integrity and potential easing manufacture.

Example 2

[0393] The present invention would, in one form, combine permanently magnetic material, primarily in the form of permanently magnetic particles, with for example load bearing soft magnetic material to create a non homogeneous permanent magnet device (composite magnet) comprising permanently magnetic material distributed in concentrations where said magnetic flux is most beneficial eg. in the outer extremities of the composite magnet specially that region which is in proximity to the region of magnetic flux interaction such as the air gap separating a rotor from a stator, while the inner regions of said composite magnet and regions farther from the region of interaction contain lower proportions of permanently magnetic material or act as a back flux path. Refer to FIGS. 1C, 2B and 2G. These regions of soft magnetic material greatly improve the structural integrity of the otherwise brittle permanent magnet material and are structurally designed to provide the composite magnet with regions of structural load bearing capacity, thus creating a multifunctional component comprising magnetic field interactive capabilities with structural load bearing capacity.

Summary of Several Preferred Methods of Forming Claimed Materials/Components/Devices

[0394] A magnetic field interactive material/component/device of this disclosure can be formed utilizing metallurgical techniques and technology wherein magnetic particles are bound, aligned and located in a non homogeneous amalgamation with; a metal matrix of a different metal to that of the magnetic particles, a metal structural matrix of a different metal to that of the magnetic particles, a different magnetic particle forming a matrix, a suitable non metal matrix devoid of plastic or resinous material differing from the magnetic particles, a combination of two or more metal matrix types, wherein said magnetic particles comprise at one or more of specifically located distributions of fused magnetic particles, clusters of homogeneous concentrations of magnetic particles creating a non homogeneous composite, specifically located non homogeneous distributions of magnetic particle concentrations, thereby forming an integrated structural material with magnetic field interactive capabilities.

[0395] Magnetic particles can be initially bound, aligned and located as one or more of; loose unbound magnetic particles, magnetic particles bound into a preform, a blend of more than one type of magnetic particles, a blend of magnetic particles and metal matrix particles of a different metal, a blend of magnetic particles and a flowable fluid form of metal matrix material of a different metal to that of the magnetic particles, a blend of magnetic particles with metal matrix material and reinforcing material, magnetic particles deposited and fused with a matrix of a different material wherein said magnetic particles are specifically distributed, configured and aligned to form concentrations of specifically located magnetic particles which form localized arrays of magnetic particles within at least one of; a fused mass of magnetic particles, localized arrays of magnetic particles with one or more of; a matrix of a different metal, a structural matrix of a different metal, a matrix of different magnetic particles thereby forming a non homogeneous structural load bearing material with magnetic field interactive capabilities.

[0396] The magnetic field interactive material/component/device can utilize a mold which consists of; opposing formers which incorporate specific magnetic flux arrays, associated mold, said mold containing a specific quantity of at least one of; a blend of magnetic particles and non magnetic metallic matrix particles, a blend of magnetic particles and metallic matrix particles of a differing magnetic field interactive capacity to that of the magnetic particles, a blend of magnetic particles and different magnetic particles wherein said different magnetic particles also possess different magnetic field interactive capacity, a blend of magnetic particles and a flowable fluid form of metal matrix material of a different type of metal to that of the magnetic particles and possessing differing magnetic field interactive capacity to that of the magnetic particles, wherein prior to said mold contents sustaining heat and pressure, mold applied magnetic field forces act on the blend of magnetic particles and matrix metal whereby said magnetic field forces, which mirror magnetic arrays required in a finished component, concentrate magnetic particles in specific locations and arrangements and align anisotropic magnetic particles, said magnetic field forces being assisted in separating, concentrating and aligning by one or more of; creation of a fluidized particle bed by; gaseous intrusion, vibration of the mold utilizing, agitation of said mold contents utilizing; mechanical, magnetic, acoustic, suitable alternative means, thereby forming a distributed magnetic metal matrix composite component.

[0397] An alternative method to magnetic field concentration of magnetic particles applicable in magnetic material of differing magnetic field interactive capacity or when magnetic particles and a matrix metal have similar magnetic field interactive capacity; whereby concentrations of specifically located magnetic particles can be achieved by forming magnetic particle preforms, said preforms can be premagnetized in specific magnetic flux arrays prior to installation into a mold, said preforms alternatively being magnetized upon installation into the mold by said mold applied magnetic field forces, wherein mold flux also assists in maintaining said preform in position, said mold containing a specific amount of matrix metal in addition to the preforms, said matrix metal being in one or more of; a particle form, a flowable molten liquid form, a plastic form, a fluidized particle form, wherein contents of said mold are subjected to heat and pressure which fuses and sinters magnetic particles and forces matrix material into porous regions of the preform, which can be assisted by special pre-coating on particles, thereby creating an integrated magnetic multi-pole array within a component.

[0398] A further method for manufacture of a non homogeneous magnetic particle material amalgamation with a matrix material can be achieved utilizing additive manufacturing, especially direct deposition techniques whereby a magnetic particle material is directly deposited to form an amalgamation with a solid matrix support material. Several particle types can be deposited at the same time or one preceding the other, creating distinct regions of fused and amalgamated magnetic particle material with an interspersed region of another type of fused particle material which is primarily of metallic origin which forms a matrix with either or both particle materials further gaining support of a base matrix which can be of a different material to the other materials. For example a support shaft of a rotor of a different material to that of the magnetic particles can provide a support matrix for an axial build up of magnetic particle material which is axially homogeneous within the region of magnetic particles, there being for example 4 or 6 rows of protruding axially aligned rows equally spaced around the circumference of the rotor shaft with an axially oriented gap between each row of magnetic particle material, said gap can remain or can be infilled with progressive deposition of a suitable fused particle differing from that of the magnetic particles, and may be similar or of a different material to that of the rotor shaft. Infill deposition can also be accomplished progressively with the deposition of magnetic particles using a multiple material 3D additive manufacturing device. Direct deposition and fusing of an amalgamation of magnetic particles to a support shaft of a different material can comprise a radial build up of material which is axially homogeneous within the region of magnetic particle material as described or may be a continuous radial build up of magnetic particle material around the support shaft forming rings of material with an axial gap between rings, said gap can be infilled with a support matrix material similar to or different to the support shaft. Thus forming part of the steering rack of FIG. 6B with V shaped rings of fused magnetic particle material item 45, amalgamated with a support shaft item 41.

[0399] The wheel rim of FIG. 6A could have magnetic particle material deposited, fused and amalgamated with the inner rim matrix in specific regions and specific configuration, keeping in mind air gap magnetic flux requirements and the need to create a back flux path. The disk of 6A could likewise comprise a solid matrix support disk with which magnetic particle material is deposited and amalgamated with optional matrix particle infill in regions void of magnetic particle material, thereby further improving overall matrix support.

[0400] Inspection of FIG. 3B, FIG. 3C, FIG. 4B, and FIG. 4C show rotational (rotor) type devices amalgamating material originating from magnetic particles with matrix material. One skilled in the art of additive manufacture will understand that this powder metal manufacturing technology can be utilized to manufacture many examples of the present invention.

[0401] Magnetic particles are deposited in specific configurations which will create magnetic field interactive arrays, said magnetic particles can be primarily induced to deposition in a preferred magnetic orientation creating a primarily anisotropic magnetic particle region by premagnetizing pole regions after an initial magnetic particle deposition which will cause specific magnetic particle alignment with preferred pole orientation in subsequently deposited magnetic particles resulting in regions of primarily anisotropic fused magnetic particle material.