Search Results (19)

Several application possibilities exist in terms of polymer-bonded magnets, such as the sensors or smaller motors, for example, in the window operators of cars. Increasing demand and rising environmental awareness necessitate a higher understanding in terms of the possible recycling strategies for polymer-bonded magnets, especially in the context of a circular economy; post-consumer materials are barely available in terms of polymer-bonded magnets. This paper investigates the focused aging of polymer-bonded magnets based on thermoplastics and ferrite-based fillers via temperature and chemical treatment to reveal the post-industrial products representative of post-consumer products via fast aging. The changes in the dimension and the magnetic properties via these treatments are analyzed. Further, new samples are produced with 50 weight-% of recycled material to investigate the impact of the treatment on the magnetic properties of recycled samples. It was proven that both the dimension and magnetic properties were affected by the treatments. Unexpectedly, the magnetic properties increased with the fast aging based on the temperature treatment due to a so-called “snowball effect”. In addition, only the magnetic properties changed within the recycled material, where they reached about 100 mT and were about the same to 20% less relative to the ideal remanence B_R value. With these investigations, the usability of the recycling strategy of reusing shreds in terms of thermoplastic-based polymer-bonded magnets with ferrite-based fillers was proven in terms of the post-industrial products representative of post-consumer products via fast aging. Full article

Polymer-bonded magnets are increasingly being used in terms of applications in drive technology and, more specifically, in new concepts based on reluctance motors. The increasing demand for polymer-bonded magnets, especially in the context of electromobility, is leading to a shortage of materials, mainly in terms of the finite resource neodymium–iron–boron (NdFeB). So far, the recycling strategy for polymer-bonded magnets based on thermosets is pyrolysis, which leads to either a massive reduction of the magnetic properties or a high energy requirement. Therefore, the paper investigates an alternative recycling strategy for polymer-bonded magnets based on thermosets based on the reusage of shreds. Several influencing factors such as the form of the carrier material and the temperature level were varied in order to find a suitable recycling method. It was found that the magnetic properties were reduced by at least 15% compared to the pure material. The required energy and the CO₂ emission were reduced by 90% compared to the pyrolysis. Thus, the strategy of recycling polymer-bonded magnets based on thermosets by the reusage of shreds leads to improved conditions compared to pyrolysis and is, therefore, a suitable alternative. Full article

Multipolar bonded magnets based on a thermoset matrix provide the opportunity to expand the applications of bonded magnets, especially within the drive technology industry, in terms of the high thermal and chemical resistance, along with a higher utilisation of the magnetic potential. To realize the application of polymer bonded magnets based on thermosets within the drive technology industry, general design parameters in terms of the material, the process parameters, and the tool concept are needed. These allow for a fundamental realization of multipolar bonded magnets with complex geometries in drive technologies, based on thermosets as the matrix material. This paper investigates the impact of the material (matrix material and filler grade), the process conditions (holding pressure (p_h) and heating time (t_h)), and the tool concept (gating position and system, sleeve material, pole division, and sample thickness) on the magnetic properties in terms of the remanence (B_R) and the deviation (Δs) of the pole division, as well as the orientation of the fillers in the middle of the pole and at the pole pitch. For each parameter, an optimised value is derived. In the majority of the cases, this value is equal in terms of the magnetic properties and the orientation. In terms of the sleeve material and the sample thickness, the ideal value differs between the two criteria. Therefore, an optimised value for each criterion, as well as an overall value, is defined. In terms of the material, PF, along with a high filler grade; in terms of the process conditions, a high holding pressure (p_h) and a low heating time (t_h); and in terms of the tool concept, a two-pinpoint gating system, located in the middle of the pole, a Ferro-Titanit-Cromoni sleeve material, a high pole division, as well as small sample thickness, should be selected to improve the properties of polymer bonded magnets based on thermosets. Full article

The applications of polymer-bonded magnets are increasing within drive technology mostly because of new concepts concerning the magnetic excitation of direct current (DC) or synchronous machines. To satisfy this rising demand for hard magnetic filler particles—mainly rare earth materials—in polymer-bonded magnets, a recycling strategy for thermoplastic-based bonded magnets has to be found that can be applied to polymer-bonded magnets. The most important factor for the recycling strategy is the filler material, especially when using rare earth materials, as those particles are associated with limited resources and high costs. However, thermoplastic-based bonded magnets reveal the opportunity to reuse the compound material system without separation of the filler from the matrix. Most known recycling strategies focus on sintered magnets, which leads to highly limited knowledge in terms of strategies for recycling bonded magnets. This paper illustrates the impact of different amounts of recycling material within the material system on material behavior and magnetic properties that can be achieved by taking different flow conditions and varying gating systems into account. The recycled material is generated by the mechanical reuse of shreds. We found that a supporting effect can be achieved with up to 50% recycled material in the material system, which leads to only minimal changes in the material’s behavior. Furthermore, changes in magnetic properties in terms of recycled material are affected by the gating system. To reduce the reduction in magnetic properties, the number of pin points should be as low as possible, and they should located in the middle. The filler orientation of the recycled material is minimally influenced by the outer magnetic field and, therefore, mainly follows the flow conditions. These flow conditions are likely to be affected by elastic flow proportions with increasing amounts of recycled material. Full article

This paper presents sustainable technology for environmentally friendly composite production. Biobased unsaturated polyester resin (b-UPR), synthesized from waste polyethylene terephthalate (PET) glycosylate and renewable origin maleic anhydride (MAnh) and propylene glycol (PG), was reinforced with unmodified and vinyl-modified biosilica nanoparticles obtained from rice husk. The structural and morphological properties of the obtained particles, b-UPR, as well as composites, were characterized by Fourier-transform infrared spectroscopy (FTIR), nuclear magnetic resonance spectroscopy (NMR), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) techniques. The study of the influence of biosilica modification on the mechanical properties of composites was supported by hardness modeling. Improvement of the tensile strength of the b-UPR-based composite at 2.5 wt.% addition of biosilica modified with vinyl silane, named “b-UPR/SiO₂-V” composite, has been achieved with 88% increase. The thermal aging process applied to the b-UPR/SiO₂-V composite, which simulates use over the product’s lifetime, leads to the deterioration of composites that were used as fillers in commercial unsaturated polyester resin (c-UPR). The grinded artificially aged b-UPR composites were used as filler in c-UPR for the production of a table top layer with outstanding mechanical properties, i.e., impact resistance and microhardness, as well as fire resistance rated in the V-0 category according to the UL-94 test. Developing sustainable composites that are chemically synthesized from renewable sources is important from the aspect of preserving the environment and existing resources as well as the extending their life cycle. Full article

Multipolar bonded magnets based on thermosets offer the opportunity to expand the applications of bonded magnets with respect to an increasing chemical and thermal resistance compared to thermoplastics. To utilise this option, the correlation between the material system and the magnetic properties must be explored amongst other influencing factors. This paper investigates the magnetic properties and the orientation of thermoset- (epoxy resin and phenolic resin) based bonded ring magnets with a hard magnetic filler of strontium-ferrite-oxide. The influence of the matrix material and the filler grade on the magnetic properties is correlated with the material characterisation showing a high impact of the embedding of the fillers into the matrix on the orientation and with that the magnetic properties. Based on a network theory, it can be justified that the magnetic properties can be increased due to a phenolic resin and a high filler grade. Further, it was shown that the orientation along the sample depth is highly affected by the strength of the outer magnetic field and limited in terms of the high-tool temperature in a thermoset-based production. With that, the sample depth, which reveals a proper orientation, is restricted so far. Full article

To expand the range of applications of multipolar bonded magnets based on a thermoplastic matrix, the chemical and thermal resistance has to be increased and the reduced orientation in the rapid solidified surface layer has to be overcome. To meet these requirements, the matrix of multipolar bonded magnets can be based on thermosets. This paper investigates in the magnetic properties, especially in the orientation of hard magnetic fillers, the pole accuracy and the mechanical properties of multipolar bonded ring magnets based on the hard magnetic filler strontium-ferrite-oxide and compares the possibilities of thermoplastic (polyamide)- and thermoset (epoxy resin, phenolic resin)-based matrices. It was shown that the magnetic potential of the thermoset-based material can only be fully used with further magnetization. However, the magnetic properties can be increased using thermoset-based compounds compared to thermoplastics in multipolar bonded ring magnets. Further, a model of the orientation and pole accuracy is found in terms of thermoset-based multipolar magnets. In addition, the change of the mechanical properties due to the different matrix systems was shown, with an increase in E-Modulus, E_t, and a reduction in tensile strength, σ_m, and elongation at break, ε_m, in terms of thermosets compared to thermoplastics. Full article

New and soft composites with good mechanical stretchability are constantly addressed in the literature due to their use in various industrial applications such as soft robotics. The stretchable magnetic materials presented in this work show a promising magnetic effect of up to 28% and improved magnetic sensitivity. The composites are soft in nature and possess hardness below 65. These composites were prepared by mixing silicone rubber with fillers such as graphene nanoplatelets (GNP), electrolyte-iron particles (EIP), and their hybrid via solution mixing. The final composites were cured at room temperature for 24 h and their isotropic and anisotropic properties were studied and presented. The mechanical properties under compressive and tensile strain were studied in detail. The results show that the compressive modulus was 1.73 MPa (control) and increased to 3.7 MPa (GNP) at 15 per hundred parts of rubber (phr), 3.2 MPa (EIP), and 4.3 MPa (hybrid) at 80 phr. Similarly, the mechanical stretchability was 112% (control) and increased to 186% (GNP) at 15 phr, 134% (EIP), and 136% (hybrid) at 60 phr. Thus, GNP emerges as a superior reinforcing filler with high stiffness, a high compressive modulus, and high mechanical stretchability. However, the GNP did not show mechanical sensitivity under a magnetic field. Therefore, the hybrids containing GNP and EIP were considered and an improved mechanical performance with magnetic sensitivity was noticed and reported. The mechanism involves the orientation of EIP under a magnetic field causing a magnetic effect, which is 28% for EIP and 5% for hybrid. Full article

Filler additive is used to provide superior bonding in rubber matrix to enhance the storage modulus of magnetorheological elastomer (MRE). However, the magneto-induced modulus is reduced as the initial storage modulus increases. Therefore, this paper aims to increase the magneto-induced modulus and maintain the initial storage modulus by combining filler and plasticizer additives. Both types of additives have different functions, where cobalt ferrite (CoFe₂O₄) is capable of enhancing the maximum storage modulus and silicone oil (SO) reduces the initial storage modulus. Thus, four MRE samples have been fabricated using (a) no additive, (b) CoFe₂O₄, (c) SO, and (d) a combination of CoFe₂O₄ and SO. The sample’s hardness and magnetic properties were investigated via Durometer Shore A and Vibrating Sample Magnetometer (VSM), respectively. Furthermore, the rheological properties of MRE samples in terms of storage modulus were investigated upon the frequency and magnetic field sweep using a rheometer. The results demonstrated that the storage modulus of the MRE samples has increased with increasing the oscillation frequency from 0.1 to 50 Hz. Interestingly, the combination of additives has produced the largest value of magneto-induced modulus of 0.90 MPa as compared to other samples. Furthermore, their initial storage modulus was in between samples with SO (lowest) and without additive (highest). Therefore, fundamental knowledge in adding the combination of additives can offer solutions for a wide range of stiffness in MR device applications such as vibration and noise control devices, sensing devices, and actuators. Full article

Polymer-bonded magnets have increased significantly in the application of drive technology, especially in terms of new concepts for the magnetic excitation of synchronous or direct current (DC) machines. To satisfy the increasing demand of hard magnetic filler particles and especially rare earth materials in polymer-bonded magnets, different strategies are possible. In addition to the reduction in products or the substitution of filler materials, the recycling of polymer-bonded magnets is possible. Different strategies have to be distinguished in terms of the target functions such as the recovery of the matrix material, the filler or both materials. In terms of polymer-bonded magnets, the filler material—especially regarding rare earth materials—is important for the recycling strategy due to the limited resource and high costs. This paper illustrates two different recycling strategies relative to the matrix system of polymer-bonded magnets. For thermoset-based magnets, a thermal strategy is portrayed which leads to similar magnetic properties in terms of the appropriated atmosphere and process management. The mechanical reusage of shreds is analyzed for thermoplastic-based magnets. The magnetic properties are reduced by about 20% and there is a change in the flow conditions and with that, an influence on the pole accuracy. Full article

The article investigates the peculiarities of the effect of ferromagnetic fillers (FMFs) of various natures (Ni, Co, Fe, FeCo, SmCo₅) on the formation of the structure and properties of 2-hydroxyethylmethacrylate (HEMA) with polyvinylpyrrolidone (PVP) copolymers. The composites were characterized using FTIR-spectroscopy, SEM, DMTA, magnetometry of vibrating samples, specific electrical resistivity studies, and mechanical and thermophysical studies. The formation of a grafted spatially crosslinked copolymer (pHEMA-gr-PVP) was confirmed and it was established that the FMF introduction of only 10 wt.% into the copolymer formulation increased the degree of crosslinking of the polymer network by three times. The surface hardness of composites increased by 20–25%. However, the water content decreased by 16–18% and lay within 42–43 wt.%, which is a relatively high number. The heat resistance of dry composites was characterized by Vicat softening temperature, which was 39–42 °C higher compared to the unfilled material. It was established that the obtained composites were characterized by a coercive force of 200 kA × m⁻¹ and induction of a magnetic field at the poles of 4–5 mT and 10–15 mT, respectively. The introduction of FMF particles into pHEMA-gr-PVP copolymers, which, in the dry state, are dielectrics, provides them with electrical conductivity, which was evaluated by the specific volume resistance. Depending on the FMF nature and content, as well as their orientation in the magnetic field, the resistance of filled materials could be regulated within 10²–10⁶ Ohm·m. Therefore, the modification of HEMA with PVP copolymers by ferromagnetic fillers of various natures provides the possibility of obtaining materials with unique predicted properties and expands the fields of their use, for instance as magnetic sorbents for various applications, as well as the possibilities associated with their being electrically conductive materials that can respond by changing of electrical conductivity, depending on various factors. Full article

The applications of bonded magnets in the field of injection-molded samples can be expanded by thermoset-based polymer-bonded magnets, as thermosets provide the opportunity to comply with the demands of, for example, the chemical industry or pump systems in drive applications through to their improved chemical and thermal resistance, viscosity and creep behaviour, especially compared to thermoplastic-based magnets. This paper investigates the influence of the matrix material (epoxy resin, phenolic resin), the filler type (strontium-ferrite-oxide, neodymium-iron-boron) and the filler grade on the reaction kinetics and the viscosity. Based on the determination of the impact, the theory of the network structure is founded. The network and the cross-linked structure are essential to know, as they significantly define not only the material but also the sample behaviour. The correlation between the material system and the mechanical as well as the magnetic properties is portrayed based on the general understanding of the behaviour in terms of the reaction kinetics and the viscosity as well as the theory of the network structure. With that, a basic understanding of the correlation within the material system (matrix, filler, filler grade) and between the reaction kinetics, the network and the cross-linked structure was determined, which gives the opportunity to change the mechanical and the magnetic properties based on the analyzed impact factors and to expand the applications of bonded magnets in the field of thermoset-based ones. Full article

Magnetic composites and self-healing materials have been drawing much attention in their respective fields of application. Magnetic fillers enable changes in the material properties of objects, in the shapes and structures of objects, and ultimately in the motion and actuation of objects in response to the application of an external field. Self-healing materials possess the ability to repair incurred damage and consequently recover the functional properties during healing. The combination of these two unique features results in important advances in both fields. First, the self-healing ability enables the recovery of the magnetic properties of magnetic composites and structures to extend their service lifetimes in applications such as robotics and biomedicine. Second, magnetic (nano)particles offer many opportunities to improve the healing performance of the resulting self-healing magnetic composites. Magnetic fillers are used for the remote activation of thermal healing through inductive heating and for the closure of large damage by applying an alternating or constant external magnetic field, respectively. Furthermore, hard magnetic particles can be used to permanently magnetize self-healing composites to autonomously re-join severed parts. This paper reviews the synthesis, processing and manufacturing of magnetic self-healing composites for applications in health, robotic actuation, flexible electronics, and many more. Full article

Thermal interface materials with high thermal conductivity and low hardness are crucial to the heat dissipation of high-power electronics. In this study, a high magnetic field was used to align the milled carbon fibers (CFs, 150 μm) in silicone rubber matrix to fabricate thermal interface materials with an ordered and discontinuous structure. The relationship among the magnetic field density, the alignment degree of CFs, and the properties of the resulting composites was explored by experimental study and theoretical analysis. The results showed higher alignment degree and enhanced thermal conductivity of composites under increased magnetic flux density within a certain curing time. When the magnetic flux density increased to 9 T, the CFs showed perfect alignment and the composite showed a high thermal conductivity of 11.76 W/(m·K) with only 20 vol% CF loading, owing to the ordered structure. Meanwhile, due to the low filler loading and discontinuous structure, a low hardness of 60~70 (shore 00) was also realized. Their thermal management performance was further confirmed in a test system, revealing promising applications for magnetic aligned CF–rubber composites in thermal interface materials. Full article

Polymer bonded magnets based on thermoplastics are economically produced by the injection molding process for applications in sensor and drive technology. Especially the lack of orientation in the edge layer, as well as the chemical resistance and the creep behavior limit the possible implementations of thermoplastic based polymer bonded magnets. However, thermoset based polymer bonded magnets have the opportunity to expand the applications by complying with the demands of the chemical industry or pump systems through to improved chemical and thermal resistance, viscosity and creep behavior of thermosets. This paper investigates the influence of hard magnetic particles on the flow and curing behavior of highly filled thermoset compounds based on an epoxy resin. The basic understanding of the behavior of those highly filled hard magnetic thermoset systems is essential for the fabrication of polymer bonded magnets based on thermosets in the injection molding process. It is shown that several factors like the crystal structure, the particle shape and size, as well as the thermal conductivity and the adherence between filler and matrix influence the flow and curing behavior of highly filled thermoset compounds based on epoxy resin. However, these influencing factors can be applied to any filler system with respect to a high filler amount in a thermoset compound, as they are based on the material behavior of particles. Further, the impact of the flow and curing behavior on the magnetic properties of polymer bonded magnets based on thermosets is shown. With that, the correlation between material based factors and magnetic properties within thermosets are portrayed. Full article