Notes on US Patent 2019/0084194 A1 - Structure Formation Using Electromagnetic Fields

Patent Information

  • Patent Application Publication Number: US 2019/0084194 A1
  • Publication Date: March 21, 2019
  • Applicant: John P. Keady, Fairfax Station, VA, USA

Abstract

  • The invention pertains to a method for forming structures using curable fluids or pastes in conjunction with electromagnetic fields.

Background of the Invention

  • Traditional methods of forming structures include:
    • Heat and cure molding
    • 3D printing
    • Removal of material
    • Riveting and welding
    • Curing epoxies
  • Limitations of traditional methods:
    • Difficulty in forming complex shapes with large undercuts
    • Need for drafts in molded structures
  • Proposed method allows for easier formation of complex shapes.

Definitions of Fluids Involved

  • Ferrofluids:
    • Composed of nanoscale particles (≤ 10 nanometers) of iron compounds.
    • Properties: Colloidal suspensions that maintain stability under strong magnetic fields.
    • Applications: Seals, lubricants, and nanoelectromechanical systems.
  • Magnetorheological Fluids (MRF):
    • Similar to ferrofluids but with larger micrometer-scale magnetic particles.
    • These fluids solidify in the presence of a magnetic field.
  • Electrorheological Fluids (ER):
    • Suspensions of non-conducting particles in an insulating fluid.
    • Exhibit a reversible change in viscosity when subjected to an electric field, acting like a Bingham plastic.

Methods for Structure Formation

  1. Application of Fields:
    • Utilizing magnetic fields, electric coils, or electrodes to create fields in which curable fluids are applied.
  2. Layering Process:
    • Structures can be built layer by layer, allowing for complex construction.
  3. Use of Curable Materials:
    • Fluids can include acrylic paints mixed with magnetic powders, rubber, plastics, or molten metal.

Exemplary Applications and Figures

  • Figure 1: Illustration of structure formation using a magnetic field with applicator inserting curable fluid into a magnetic field, resulting in a shapable fluid.
  • Figures 2-5: Show various formed structures indicating the effectiveness of the technology in producing precise shapes.
    • Example: Features formed by a magnetic field beneath the canvas when acrylic paint is cured.

Curable Mediums

  • Can vary widely including liquids, mixtures, colloidal suspensions, foams, gels, and particle suspensions.
  • Example: Use of High Strength Rubber mixed with magnetic responsive particles or alumilite casting rubber.

Detailed Description of Exemplary Embodiments

  • The methods allow for innovative production techniques for both small and large structures.
  • Enables the movement and molding of materials to fill complex shapes effectively.

Claims

  1. Method of forming a structure:
    • Apply electric/magnetic field.
    • Insert curable fluid that deforms under the field.
    • Remove field post-curing to retain shape.
  2. A structure that retains >90% of its shape after field removal.
  3. Cured magnetoresponsive fluid as a form of structure manipulated by fields.