Magnetic Plastic Induction

Abstract

A plastic product having magnetic properties and a method for making the same is provided. The method comprises creating a mixture of a nylon and a metal, melting the mixture to create a melted mixture of the metal suspended in the nylon, injecting the melted mixture into a mold to harden the melted mixture and shape the melted mixture into the product's shape, applying an electrical current to the mold while the mixture is in a viscous state to align the poles of the metal suspended in the nylon in the mixture in a single direction before the mixture has hardened, and applying a magnetic field to the hardened mixture to provide the product with magnetic properties.

Claims

1. A method for making a plastic product having magnetic properties, comprising: creating a mixture of a nylon and a metal; melting the mixture to create a melted mixture of the metal suspended in the nylon; injecting the melted mixture into a mold to harden the melted mixture and shape the melted mixture; applying an electrical current to the mold while the mixture is in a viscous state to align the poles of the metal suspended in the nylon in the mixture in a single direction before the mixture has hardened; and applying a magnetic field to the hardened mixture to provide the product with magnetic properties.

2. The method according to claim 1, wherein the nylon in the mixture is in the form of nylon pellets.

3. The method according to claim 2, wherein the metal in the mixture is in the form of barium ferrite particles.

4. The method according to claim 2, wherein the metal in the mixture is in the form of strontium ferrite particles.

5. The method according to claim 2, wherein the metal in the mixture is in the form of barium ferrite particles or strontium ferrite particles.

6. The method according to claim 5, wherein approximately 67-70% by weight of the mixture is the nylon and approximately 30-33% by weight of the mixture is the metal.

7. The method according to claim 6, wherein the electrical current applied to the mold is direct current.

8. The method according to claim 7, wherein approximately thirty-one volts of direct electrical current is applied to the mold for between three and six seconds

9. The method according to claim 5, wherein the mixture is heated at a temperature between 500 and 525 degrees Fahrenheit.

10. The method according to claim 5, wherein the melted mixture is injected into the mold using co-rotating screws.

11. The method according to claim 5, wherein at least one magnet is affixed to an exterior surface of the mold to assist in aligning the poles of the metal suspended in the nylon in the mixture.

12. The method according to claim 5, wherein the method is performed at least in part using an apparatus comprising: a hopper configured to receive the mixture of the nylon and the metal; a screw configured to inject the melted mixture into the mold; the mold; and a direct current transformer configured to provide the electrical current applied to the mold.

13. The method according to claim 1, wherein applying the magnetic field to the hardened mixture comprises removing the hardened mixture from the mold and applying the magnetic field to the hardened mixture using a pulse charger.

14. The method according to claim 1, wherein applying the magnetic field to the hardened mixture comprises removing the hardened mixture from the mold and applying the magnetic field to the hardened mixture using a plurality of N52 magnets.

15. A plastic product having magnetic properties, comprising a mixture comprising a nylon and a metal; wherein the mixture is melted to form a melted mixture of the metal suspended in the nylon and injected into a mold configured to harden the melted mixture and shape the melted mixture; wherein an electrical current is applied to the mold while the mixture is in a viscous state to align the poles of the metal suspended in the nylon in the mixture in a single direction before the mixture has hardened; and wherein a magnetic field is applied to the hardened mixture to provide the product with magnetic properties.

16. The plastic product according to claim 15, wherein the mixture comprises 67-70% by weight the nylon and 30-33% by weight the metal.

17. The plastic product according to claim 16, wherein the metal is barium ferrite or strontium ferrite.

18. The plastic product according to claim 17, wherein the nylon is nylon 6, nylon 66 or nylon 610.

19. The plastic product according to claim 15, wherein the electrical current applied to the mold is direct current.

20. The plastic product according to claim 15, wherein the magnetic field is applied to the hardened mixture by a pulse charger, a magnetic resonance imaging machine or a plurality of magnets after the hardened mixture has been removed from the mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 shows a material created in accordance with the prior art.

[0035] FIG. 2 shows a comprehensive diagram of a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0036] FIG. 3 shows an internal side view of an embodiment of an industrial plastic injection molding machine, used in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0037] FIG. 4 shows a further embodiment of an industrial plastic injection molding machine, used in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0038] FIG. 5 shows a further embodiment of an industrial plastic injection molding machine, used in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0039] FIGS. 6A-6C show various embodiments of injection nozzles utilized in an industrial plastic injection molding machines used in various embodiments of the present invention.

[0040] FIGS. 7A and 7B show various embodiments of an injection mold having magnets attached to the exterior of the mold, to assist in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0041] FIG. 8A shows a pulse charger used in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0042] FIG. 8B shows a series of magnets in a process for making a magnetic plastic material in accordance with an embodiment of the present invention.

[0043] FIG. 9 shows an example of the magnetic plastic material created in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0044] The present invention will now be described with reference made to FIGS. 2-9. Measuring the magnetic strength of something is quantified as a Gauss number. This determines the magnetic grade. A higher number indicates a stronger magnet. The magnetic material inside something qualifies as maximum energy product and is expressed in MGOe (megagauss oersteds) and represents the strongest point which is defined as BH.sub.max. Another measurement is described as “pull” force which is how much force is exerted to pull a magnet away from something. The pull force is valued with the specific grade labeled as “N” followed by a number.

[0045] There is even another measurement to determine the magnetic field of something and where exactly the strongest point is. It is expressed as a Tesla (1 Tesla=10,000 Gauss). The Tesla measurement is for larger magnetic field measurements and Gauss for smaller measurements. This application making guitar picks and other products, particularly small products, would fall into Gauss range of measurement.

[0046] However, the Gauss number can be applied to two different measurements. The first is the residual flux density or B.sub.r, which is the magnetic induction remaining in a saturated magnetic material after the magnetic field has been removed. So once the material magnetized according to the present invention, it can also be demagnetized to see what residual induction is remaining to define its magnetic properties even more. The second measurement is the “surface field” strength, which is right at the surface of the magnet.

[0047] FIG. 2 illustrates an example of the magnetic plastic induction process 200 according to an embodiment of the invention, which includes: pre-mixed granulated BaFe plastic pellets 201, feed hopper 202, heating barrel 203, ram/screw 204, steel machine tool 205, variable DC transformer 206, anode 207, cathode 208, mold 209, electromagnetic current 210, plastic 211, BaFe particle poles aligned 212, and ground wire 213.

[0048] According to one embodiment, the pre-mixed BaFe and plastic pellets 201 used in the invention include extruded nylon plastic pellets and BaFe particles having a size of three microns and tumbled. The plastic pellets and BaFe are combined in a ratio of approximately 67-70% plastic and 30-33% BaFe, by weight. In alternative embodiments, alloys other than BaFe can be utilized, including for example SrFe. Additionally, the alloys used may also include oxygen atoms, such as barium hexaferrite (BaFe.sub.12O.sub.19) or strontium hexaferrite (SrFe.sub.12O.sub.19). Further metal compounds may be used in the present invention that are not expressly listed herein without deviating from the scope of the present invention.

[0049] The premixed pellets 201 are provided to a feed hopper 202. The mixture 201 is then provided from the feed hopper 202 to a heating barrel 203, which melts the mixture 201 of nylon pellets and BaFe particles. In one embodiment, the heating barrel 203 may have an internal temperature between 500-525° F. The mixture 201 is liquefied in the heating barrel 203 and transferred to the machine tool 205 by way of a ram/screw 204. In particular, the viscous or semi-viscous mixture is inserted into the mold 209.

[0050] A variable or adjustable DC voltage transformer 206 can be utilized, with which one can intermittently or constantly control the amount of electromagnetic current 210 or voltage through the mold 209 inside the machine tool 204 of the injection machine. Alternating current would not work in the method because it alternates directions, as described previously herein. For the present process, direct current is provided flowing in one direction. In one embodiment of the invention, the DC voltage transformer 206 can be a UniSource PS-303D or PS-305D single output DC power supply.

[0051] An anode 207 and a cathode 208 are attached to the machine tool 205, and connected to the low voltage transformer 206. An electric current 210 is transferred through the machine tool 205, using the low voltage transformer 206. For example, the low voltage transformer 206 may have a variable range, a range including 31 volts (e.g., a range of 15-40 volts), such that 31 volts, for example, are simultaneously being transferred through the entire machine tool, including the semi-viscous but slowly cooling and hardening plastic 211. While the plastic 211 is hardening within the mold 209, the poles 212 of the BaFe are locked in place and suspended within the plastic 211. Once locked in place, there is enough magnetic continuity to allow a magnetic arc to occur.

[0052] Upon completion of the molding process, the molded product can be removed from the machine and can be magnetized. The material can be magnetized using a number of different devices, including for example a pulse charger, an Mill machine or a series of magnets, such as N52 magnets. The device used for magnetizing the material is placed in physical approximation to the material and preferably generates a strong magnetic field, such as a field of approximately one Tesla.

[0053] FIG. 3 shows an internal side view of an industrial plastic injection molding machine 300 for use in the present invention, including the low voltage variable (or current limiting) AC to adjustable DC transformer 310, along with where it attaches to the mold 308 clamped within the hydraulic press of the newly retrofitted machine. There is also a ground wire 313 attaching to the machine 300 itself that limits the current from travelling to other components of the machine 300. Additionally, rubber insulation clamping plates 312 may optionally be provided to further protect the machine 300. The injection molding machine 300 can be further protected from an electrical surge using such non-conductive rubber pads 312.

[0054] The injection molding machine 300 includes: a mixture 301 of plastic granules and BaFe/SrFe particles in a hopper 302, reciprocating screw 303, barrel 304, heater 305, nozzle 306, mold cavity 307, mold 308, moveable platen 309, low voltage current limiting AC to adjustable DC transformer 310, connecting wires 311, rubber insulation clamping plate 312, ground wire 313, and AC plug-in 314. An injection section 315 of the injection molding machine 300 comprises the hopper 302, reciprocating screw 303, barrel 304, heater 305 and nozzle 306. A clamping section 316 of the injection molding machine 300 comprises the mold cavity 307, mold 308, moveable platen 309 and rubber insulation clamping plate 312. The low voltage DC current limiting AC to adjustable DC transformer section of the injection molding machine 300 comprises the DC transformer 310, connecting wires 311 and ground wire 313.

[0055] FIG. 4 illustrates an additional example of an injection molding machine 400 that can be used in the process of making magnetic plastic materials in an embodiment of the present invention. The machine 400 includes a DC transformer 401, hydraulic platen 402, digital control panel 403, screw 404, hopper 405, heating barrel 406, a control panel interface 407 flush with the inserted variable DC transformer 401, a cable 408 connecting to injection mold 409 and additional wiring 410.

[0056] FIG. 5 illustrates a further additional example of a plastic injection molding machine 500 that can be used in the process of making magnetic plastic materials in an embodiment of the present invention. The machine 500 includes a hopper 501, screw 502, a mold 503, an inserted variable DC transformer 504, a cable 505 connecting the transformer 504 to the mold 503 and a cable 506 connecting the transformer 504 to a power supply. No ground wire may be needed in this embodiment of the machine 500, as the machine 500 grounds to self. The transformer 504 may be flush to a control panel interface.

[0057] The size of the ferrous particles inside the nylon or other polymer can vary from 1.5 to 30 microns. It is important to factor in the potential danger and damage to the operator running the machine, the injectors and the injector machine as a whole. The clogging from residual buildup and/or the abrasion of the injectors are serious concerns. If the particles are too big to be forced through a small tip on an injection nozzle, then molten plastic at high pressure would or could be misdirected, creating serious and dangerous consequences to the operator and/or the injection machine. The solution is to fit the injection machine with the suitable nozzle size for the specific project. Nozzle tips are interchangeable on all injection machines, and there are many different types and orifice sizes to the nozzle tips. Tips having wider openings would be used if larger plastic particles are used.

[0058] Examples of several injection nozzle tips are illustrated in FIGS. 6A, 6B and 6C. FIG. 6A illustrates a full taper injection nozzle 600a. FIG. 6B illustrates a nylon injection nozzle 600b. FIG. 6C illustrates a general purpose injection nozzle 600c. The injection nozzles 600a, 600b, 600c may have varying orifice sizes depending on the size of the particles being injected. The radii 601a, 601b, 601c of the injection nozzles 600a, 600b, 600c may be between ½″ and ¾″. The injection nozzles 600a, 600b, 600c may have lengths 602a, 602b, 602c of 1.5 inches and rear openings 603a, 603b, 603c of ½″. The injection nozzles 600a, 600b, 600c preferably including threading 604a, 604b, 604c to permit easy attachment and detachment.

[0059] In certain embodiments of the invention, illustrated in FIGS. 7A and 7B for example, the injection molds 700a, 700b, can be outfitted with magnets 701a, 701b on the exterior surface of the injection molds 700a, 700b. The magnets 701a, 701b can include, for example, N52 magnets. If needed, adding N52 magnets 701a, 701b to the outside or edges of the mold 700a, 700b increases the magnetic “load” assisting a larger magnetic field that is created during electromagnetic induction process of the present invention. N52 magnets are some of the most powerful magnets on the Earth. The N stands for neodymium and 52 is numerical reference to its strength. Approximately one Tesla of magnetic load may be required to charge or magnetize the finished plastic product. A pulse charger or magnetic coil, for example, can generate approximately one Tesla.

[0060] Molds can be quite complex on the inside, but are generally very flat on the outside so they can fit in between the platen and hydraulic pistons of the injection molding machine forcing them together. This is done for stability. If the ferrous particles, or magnetic filler material inside the polymer being used are too big, and/or the mold itself is relatively large, powerful N52 magnets can be placed on the flat side or edges of the mold to assist in the electromagnetic induction process. This will help the DC current steer the ferrous particles in one direction. The N52 magnets 701a, 701b are placed on the flat side or edges of the molds 700a, 700b so as not to get in the way of the platen and are positioned accordingly, as each mold has a different shape.

[0061] Upon completion of the molding process, the molded product can be removed from the machine and can be magnetized. The material can be magnetized using a number of different devices, including for example a pulse charger, an Mill machine, a series of magnets, such as N52 magnets, and any other devices with a magnetic load. FIG. 8A illustrates an example of a pulse charger 800 that can be used in the present invention to magnetize the molded product. FIG. 8B illustrates an example of an arrangement of magnets 810a and 810b that can alternatively be used to magnetize a molded product 820 in accordance with an alternative embodiment of the present invention. The magnets 810a and 810b may be powerful magnets, such as N52 magnets, and each magnet 810a and 810b may comprise several magnets, including for example six magnets, attached together. Each of the magnets 810a and 810b may have an attached handle (not shown) to aid in manipulating the magnets 810a and 810b. The product 820 removed from the mold, or a plurality of such products, can be placed in between the two magnets 810a and 810b, which are separated by a short distance. Within a short period of time, such as one second or less, the product 820 is magnetized by the magnetic field generated by the magnets 810a, 810b, and can be removed.

[0062] FIG. 9 illustrates a sample of a guitar pick made using the process of magnetic plastic induction according to the present invention. In FIG. 9, the guitar pick 900 is magnetically attracted to a metallic object 920, which in the example illustration is the metallic portion 920 of a set of pliers 910. The prior art sample shown in FIG. 1 is clunky, heavy, dense, and brittle. In contrast, the material 900 shown in FIG. 9 is lightweight. Also, the sample 900 in FIG. 9 shows the difference between a fully magnetic product and partially magnetic material, as in FIG. 1. The sample in FIG. 1 includes an inner coupling cylinder with a groove notched on one end. If you place the other end on the permanent rare earth magnet also included, you will notice there is no magnetic repulsion, only attraction. If one takes the sample of the guitar pick 900 of FIG. 9 and place both sides on the magnet, you will see both attraction and repulsion. This proves the BH Curve is constant through the whole sample, not just one end.

[0063] For guitar picks in accordance with the present invention, the mixture of nylon and BaFe can melt in the heating barrel within several minutes. The material is injected for 0.5 seconds at 700 psi with a 2.0 second “hold time” at 400 psi and another 8 seconds of “cooling time.” The product is ejected from the mold by being forced or pushed out of the mold by an internal pin that runs through the mold. The entire time from injection to ejection can be a cycle of approximately 15 seconds, including 3-6 seconds for the induction and the cooling time to harden properly before ejection. As the plastic might be solid at the end of the 6 seconds, it is still somewhat pliable, and the ejector pin could scar or indent the product.

[0064] Table 1 shows nine samples of manufacturing a material as described previously, starting with the highest voltage and longest duration that the machinery used allows. For each sample, a Gauss number was determined in relation to the length and voltage of a DC current through an injection mold. The plastic samples were then placed next to a magnetic coil to increase its Gauss number from the DC transformer. A ground wire was connected to the injection machine and the machine was separately grounded.

TABLE-US-00001 TABLE 1 Plastic Injection Molding with Barium Ferrite Electromagnetic Induction Tests Duration of Induction Sample (in seconds) Voltage/Current 1 6.00 31 V/0.28 amps 2 3.00 31 V/0.28 amps 3 2.50 31 V/0.28 amps 4 2.00 15 V/0.13 amps 5 1.75 15 V/0.28 amps 6 1.50 15 V/0.28 amps 7 1.00 31 V/0.28 amps 8 0.50 31 V/0.28 amps 9 0.25 31 V/0.28 amps

[0065] On the first sample, 31 volts and 0.28 amps were run through the machine mold in the injection machine for a period of 6 seconds, which is the entire time that the plastic is purged through the screw into the mold and then hardened. On the second sample, 31 volts and 0.28 amps were run through the machine mold in the injection machine for a period of 3 seconds. The resulting Gauss number for the material after application of 31 volts to the mold for a period of 3-6 seconds may typically be between N8 and N12, although this number may vary based on other factors such as the type and amount of filler.

[0066] Tests were continued to see where the current becomes too weak to align the poles of the BaFe particles. When the voltage was cut in half to 15 volts, it resulted in serious effects of no magnetic arc. There was some very slight magnetic pull, but not to defy gravity. The Gauss number would be less than the Gauss number from the first test at 31 volts. Tests were continued, cutting the duration to shorter time periods, until no magnetic arc was found and MGOe had reduced to zero. A test sample was also run with no current running through the tool. To dispel any doubt that a sample could be magnetized without the induction process, the sample was then placed next to the magnetic coil and it did not maintain an arc.

[0067] There are many applications in which “magnetic plastic” could be used, examples of which are described herein.

[0068] Mag-Lev trains will be the way people travel globally upon the Earth in the future. In fact, we already do, but it will become a global phenomenon. As this technology advances and becomes quicker and lighter, “magnetic plastic” can be used in the construction of Mag-Lev trains. If automobiles had bumpers that were magnetized with the same poles, they would not be immune from accidents, but they could repel themselves and minimize severe impacts. The same principle could be applied to football helmets in reducing severe head injury.

[0069] Attracting plastic to itself and metal has endless benefits, from sorting recycled plastic to lightweight space tools that could attach themselves without tethers to a spacecraft. Components in machine design and mechanical engineering using “magnetic plastic” would revolutionize the industry. Production would be faster, easier and more cost efficient. Creating an endless energy supply would not just require the forces of nature anymore. Wind, solar and hydro-energy all require certain and specific conditions. Giant “magnetic plastic” turbines could lay flat on the Earth, or even under, it, and protected from the elements. Two giant “magnetic plastic” propellers clamped together, and with the same magnetic flux, would repel around and around indefinitely, generating endless energy. The gravity inflicted on metal components would create friction and drag and not power a turbine. “Magnetic plastic” would have the same magnetic arc as metal but not the same weight or resistance, meaning it would be much faster, generating much more energy.

[0070] “Magnetic plastic” could also be used in attaching lids to bottles, thereby eliminating threads so things don't need to be screwed together, or bottles could attach to holders in cars. Toys made from “magnetic plastic” would make them interactive and interchangeable. Poker chips can be made from the material, which would stick together and be easily stacked and easily pulled apart. Prosthetic limbs could have magnetic attraction helping secure themselves to the body. There would be additional advancements in the medical field, as pins, bolts and sutures inside the body that had an electromagnetic current through them would not only be lightweight and stay in place, but would also assist in circulation in the body and minimize clotting. Airplanes are most vulnerable when they take off and when they land. Switching from rubber tires to “magnetic plastic” coupling and repulsion tracks on runways would make flying exponentially more safe. Objects that are attached, screwed, nailed, glued, clipped or wedged together would now simply be attracted to themselves. Cooking utensils in high volume restaurants could be stuck to the wall and not in drawers. Baby high chairs could be made of “magnetic plastic” reducing fumbles and spills of plates, cups and spoons. Sippy cups can be stuck to the refrigerator when the child is done and too small to place it in the sink.

[0071] Magnetizing plastic materials such as nylon could also have benefits in recycling, simply in the collection and the sorting process. Most nylons reach the garbage dumps, decaying very slowly. Nylons are robust polymers and lend well to recycling. Nylons are generally added directly in a closed loop at the injection machine, where grinding sprues and runners are then added to the virgin pellets. Yet, at certain plants they are extruded all over again to find new life. Discarded plastic products would attract to themselves in the wild and in the oceans, magnetic plastic products would group themselves together, aiding in its recycling.

[0072] While there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods described may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice.