Patent ID: 12249457

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a system comprising electromagnets to generate a magnetic field for manufacturing. More specifically, the present invention relates to a programmatically controlled and coordinated drive for one or more electromagnets. The electromagnets may generate a field having dynamic magnetic flux densities to achieve touchless transporting, heating, melting, and shaping of a conductive material.

The system may comprise a high-speed, high-power electrical switch, a programmatic control drive, and a flux former comprising an electromagnet and/or electromagnetic coil. The flux former may also comprise a plurality of electromagnets and/or electromagnetic coils. The system may produce a dynamic magnetic field. The dynamic magnetic field may produce a controlled flux density distribution. The controlled flux density may manipulate and/or heat a target material without mechanical contact. The manipulation may include, but is not limited to, levitation, transport, confinement, and forming of materials into a desired physical shape and/or profile.

As used herein, a “surface” is defined in the specification, drawings, and claims as a subset of a mathematical surface, is always finite, exists in three-dimensional space, and has two faces having opposite normals at every point of the surface.

As used herein, the term “working volume” is defined in the specification, drawings, and claims as a three-dimensional volume in free space in which a programmatically defined flux density may be provided by the electromagnets for the manipulation and heating of material. The electromagnets of the present invention are disposed entirely outside of the working volume and produce the programmatically defined flux density that reaches into the working volume. A working volume may be subject to other influences, too, e.g., acceleration (including gravitational acceleration), convection, thermal radiation, etc. The working volume may be any shape and/or dimension including, but not limited to, a trough, a channel, a sphere, a cylinder, a cube, a polygon, or a combination thereof.

As used herein, the term “target” and/or “target material” is defined in the specification, drawings, and claims as a compound, mixture, or substance comprising a metal atom. The term “metal” or “metals” includes, but is not limited to, metal hydroxides, metal oxides, metal salts, elemental metals, metal ions, non-ionic metals, minerals, or a combination thereof.

The target may comprise, but is not limited to, neodymium (“Nd”), praseodymium (“Pr”), dysprosium (“Dy), copper (“Cu”), lithium (“Li”), sodium (“Na”), magnesium (“Mg”), potassium (K”), calcium (“Ca”), titanium (“Ti”), vanadium (“V”), chromium (“Cr”), manganese (“Mn”), iron (“Fe”), cobalt (“Co”), nickel (“Ni”), cadmium (“Cd”), zinc (“Zn”), aluminum (“Al”), silicon (“Si”), silver (“Ag”), tin (“Sn”), platinum (“Pt”), gold (“Au”), bismuth (“Bi”), lanthanum (“La”), europium (“Eu”), gallium (“Ga”), scandium (“Sc”), strontium (“Sr”), yttrium (“Y”), zirconium (“Zr”), niobium (“Nb”), molybdenum (“Mo”), ruthenium (“Ru”), rhodium (“Rh”), palladium (“Pd”), indium (“In”), hafnium (“Hf”), tantalum (“Ta”), tungsten (“W′), rhenium (“Re”), osmium (“Os”), iridium (Ir”), mercury (“Hg”), lead (“Pb”), polonium (“Po”), cerium (“Ce”), samarium (“Sm”), erbium (“Er”), ytterbium (“Yb”), thorium (“Th”), uranium (“U”), plutonium (“Pu”), terbium (“Tb”), promethium (“Pm”), tellurium (“Te”), or a combination thereof.

As used herein, the term “flux density” is defined in the specification, drawings, and claims as the amount of magnetic flux in an area taken perpendicular to the magnetic flux's direction. The Système International d'Unités (SI) unit of flux density is the Tesla (T).

As used herein, the term “drive density” is defined in the specification, drawings, and claims as the time-varying power output from a controller.

As used herein, the term “time-varying power density” is defined in the specification, drawings, and claims as a current or voltage that resembles a sine wave, square wave, triangular wave, and combinations thereof which may include positive or negative biases.

As used herein, the term “stable equilibrium” is defined in the specification, drawings, and claims as volumes of space where electromagnetic forces on conductive materials balance and result in little to no motion. System equilibria may be categorized as either “stable” which attract and “unstable” which repel. Stable equilibria are analogous to a valley, where a ball will roll back to the bottom of the valley if disturbed. Unstable equilibria are analogous to a hilltop, where a ball can balance on top but will roll away if disturbed.

As used herein, the term “pose control” is defined in the specification, drawings, and claims as the ability of a system to control all geometric degrees of freedom of the target material including translation and rotation as well as derivatives thereof, such as velocity and acceleration.

As used herein, the term “flux pocket” is defined in the specification, drawings, and claims as a region of stability in the electromagnetic field, where small spatial deviations beyond this region result in forces and torques restoring an object to this region.

As used herein, the term “amplitude modulation” is defined in the specification, drawings, and claims as increasing or decreasing the amplitude of the time-varying power input to a plurality of electromagnetic coils to programmatically generate regions of high flux density.

As used herein, the term “phase modulation” is defined in the specification, drawings, and claims as coordinating the power amplitude peak time of multiple coils and correspondingly the peak time of magnetic flux density. This may also be referred to as “commutation”, “magnetic river”, or “traveling wave magnetic field”. Phase modulation generates a force in the direction of the modulation.

As used herein, the term “frequency modulation” is defined in the specification, drawings, and claims as increasing or decreasing frequency of amperage to the electromagnet which results in an increase or decrease in the rate of change of the corresponding flux density. Frequency modulation allows for the independent control of heat input to the target and force exerted on the target.

The system may comprise an array of independently-controlled induction coils that create a magnetic flux density to move, melt, and reshape a target material including, but not limited to, an aerospace metal. The system may recycle standard aerospace metals in space. The array of independently controlled induction coils may create an arbitrary eddy current and a Lorentz force to move, melt, and shape metal, e.g., “free-cast” a target material. This present invention may be an inductive foundry and may have applications including but not limited to: recycling, material handling, docking, welding, large-scale additive manufacturing, metal coating, and formation of large scale structures.

The system may use an array of programmable electromagnets to form arbitrary magnetic equilibria that can transport, hold, heat, melt, and form conductive materials like aluminum. The system may be touchless and have no moving parts, but may be adaptable. Identical or similar system components may be used to heat a target material to different temperatures or manipulate a target material into different physical profiles or positions with software updates alone.

The system may be programmed and/or configured to produce an unlimited number of manufactured shapes from a target material without reconfiguring the components of the system. The system may require less maintenance compared to other metal processing systems because it is touchless and has no moving parts.

The system may comprise a working volume diameter. Smaller diameters (10-20 mm) may increase efficiency, and may be able to concentrate power on less material and lose less material from radiative heat transfer. The working volume diameter may be at least about 5 mm, about 5 mm to about 25 mm, about 10 mm to about 20 mm, or about 25 mm. A small working volume diameter (e.g., <25) may concentrate energy and limit losses. A smaller diameter may also enable greater recycling throughput than larger diameters. The system may comprise and/or operate at a higher voltage and lower current to have greater efficiency and throughput. The system may achieve around at least about 5%, about 5% to about 25%, about 10% to about 20%, or about 25% electrical-to-thermal power efficiency. The system may achieve a recycling throughput of at least about 0.5 kg/hr, about 0.5 kg/hr to about 5.0 kg/hr, about 1.0 kg/hr to about 4.5 kg/hr, about 1.5 kg/hr to about 4.0 kg/hr, about 2.0 kg/hr to about 3.5 kg/hr, about 2.5 kg/hr toa bout 3.0 kg/hr, or about 5.0 kg/hr.

The present invention has applications in two distinct environments, i.e., terrestrial applications and space applications. There are many applications on earth where precise programmatic control of electromagnetic fields can be used for improved physical control of conductive materials and heat generated in those materials. For example, this technology can improve E-waste material separation, where programmatically tailored forces can be generated for each target to separate waste streams at a more fine granularity than is possible with today's technologies. There are many applications in recycling and beneficiation for next generation precious metals, including but not limited to lithium, rare earth metals including but not limited to neodymium, precious metals including but not limited to silver and gold, as well as base metals including but not limited to nickel, copper, and cobalt, as well as any other valuable materials that are conductive. By offering more precise and capable recycling processes the need for conflict materials such as tin and tungsten are reduced. The present invention also has applications in metal processing such as aggressive mixing of molten alloys, dross and slag reclamation, molten metal pumping and transportation, as well as shielding of sensitive components such as electrodes or sensors. The present invention can also be used on earth for crack repair and joining. By heating a crack until wetted and using inductive forces to aggressively mix the wetted area it is possible to reform and heal the material. By following a precise thermal profile when cooling, it is possible to then return the material to similar material properties of strength and ductility. Applications for this include railroad crack repair, crack repair of aerospace applications including but not limited to airplanes and reusable rockets, boat hull repair, as well as affixing or repairing aluminum components for food stuffs, which are typically made from difficult to weld alloys and demand a very high level of cleanliness.

Using the present invention in a space environment has many advantages and applications as a recycling and additive manufacturing process. The majority of man-made objects in low earth orbit are made from conductive materials, so the present invention can be used for on-orbit soft docking that is touchless, has no moving parts, and can generate programmatically controlled forces on non-standard geometries objects in zero gravity. In the same way, the present invention can also be used as a material intake for asteroid and lunar mining. Material mass is more easily suspended in a low gravity environment which greatly reduces the power required to move and form materials. Using the invention in a vacuum mitigates conductive and convective heat losses while also maintaining material purity by reducing oxidation, opening the door to new materials and alloys. As the cislunar economy grows, closed-loop recycling processes are key to turning end-of-life materials into something useful. The system of the present invention can generate numerous forms of basic feedstocks for processes including but not limited to welding. Additionally, the present invention can be used as a metal additive manufacturing process where metal is transported, heated to melting, formed, and allowed to cool into more complex part shapes that are useful for construction, including but not limited to rods, spars, scaffolding, and various other structural elements. This manufacturing process of the present invention has a potentially unlimited build volume in space, where conductive metal goes in one side and useful cross-sectional structures are extruded out the other side. In this way, structures that would be impossible to launch into orbit because of their shape and scale can now be made in space from materials that would typically be burned up in the atmosphere. This manufacturing process is the ideal tool for in-space recycling and manufacturing. Finally, the present invention can be used in space as a combined “vacuum cleaner” and “cutting torch” using electromagnetic induction for safely collecting debris at small and large scales as the cornerstone of debris remediation services. For small-scale debris, the system draws in particles and chips generated during cutting, drilling or other manufacturing operations. This is analogous to using a vacuum cleaner alongside a drill to suck up debris as it is created. For large-scale debris, this system melts a targeted area of a satellite or rocket body, draws in the molten material, and traverses to the next area. This is analogous to a cutting torch. This multipurpose system can serve as a small satellite payload, robot end effector, or as a handheld or mountable tool for astronauts. Other applications include but are not limited to induction brazing or welding, and plugging holes from debris impact. The system of the present invention addresses the growing problem and opportunity of active debris remediation and in-space assembly and manufacturing.

Turning now to the figures,FIG.1shows one electromagnet and controller. As illustrated inFIG.1, flux control module100comprises an electromagnet120driven by power controller110that may programmatically power the coil122which is disposed around a body124. Body124comprises a material having high magnetic permeability. Electromagnet120generates a magnetic dipole through body124when current is provided by power controller110to coil122. The orientation of this dipole is denoted by positive charge126for the positive pole and by negative charge128for the negative pole. The orientation relates to the direction of the magnetic flux when a positive current flows from power controller110into coil122through positive lead112and returns to power controller through negative lead114. For a time-varying current, such as an alternating circuit, the magnetic dipole also changes with time and maintains a consistent phase relationship to the current.

The + and −notation, as exemplified by positive charge126and negative charge128inFIG.1but used herein throughout, represents a momentary status of the dipoles through the respective coil122and body124as controller110drives a positive current into coil122through lead112. The + and −notation indicate a relative timing or phase relationship between the poles and any depictions are representative of a specific snapshot in time.

FIG.2shows an array of five electromagnets200distributed about a flat surface. Five electromagnets are arrayed against working surface250, which is planar. Three electromagnets are aligned to form column210, which is parallel to axis252of working surface250. Three electromagnets align to form row220which is parallel to axis254. The electromagnets each have a pole contacting surface250on the magnet face of the surface. Such a distribution of electromagnets allows control over a target (not shown) in a working volume disposed on the working face side the surface, i.e., the side opposite the magnet face. Not shown is the controller which is configured to independently drive each of the electromagnets but is able to modulate magnetic flux on the working face side of surface250to manipulate conductive materials located there. Array of five electromagnets200generates a flux pocket which creates a stable equilibrium for the target material by coordinating the time-varying power to each of the five electromagnets.

FIG.3shows an array of five electromagnets300disposed around one side of curved working surface350. Array of five electromagnets300comprises five electromagnets distributed about the magnet face side of curved working surface350comprising straight longitudinal axis354and orthogonal azimuthal axis352. Each electromagnet comprises a pole meeting curved working surface350from the magnet face. Three magnets forming row320are disposed parallel to surface axis354. The magnets forming arc310are disposed parallel to surface axis352. A controller (not shown) is configured to independently drive each of the electromagnets and is able to modulate magnetic flux on the working face side of the surface350to manipulate conductive materials located there.

FIG.4shows flux former400comprising an array of electromagnets, configured for touchless manipulation of a target material by amplitude modulation. Flux former400is oriented according to three-dimensional Cartesian coordinate system462. Flux former400comprises an array of electromagnets configured for touchless manipulation of a target material by amplitude modulation. Flux former400shown comprises twelve electromagnets distributed about a trough-shaped surface450on the magnet face side of the surface. The electromagnets are arranged in four rows410,420,430, and440each comprising three magnets (e.g.,410a,410b, and410c), each electromagnet being independently connected to a controller (not shown) which selectably supplies a modulated current to each electromagnet. Channel460exists on the working face side of surface450and represents the region selected for usable manipulation of target480.

Flux former400may operate in a terrestrial environment wherein gravitational force acts on target480in a negative Y axis, downward direction that is countered by forces induced by the functioning of flux former400. Thus, the gravitational force pulls target480toward the bottom of surface450. This gravitational bias is an asymmetry that explains the asymmetrical form (i.e., having an open top) of this embodiment of the invention.

Channel (e.g., working volume)460is prescribed to be on the working side of surface450, but some of a working volume's extents are not dependent (or not solely dependent) on the shape of the surface.

The trough of surface450may have no top, but channel460is bounded. One basis for limiting the extent of a working volume is to ensure, by design, that the system of a particular embodiment is able to exert adequate control over a target. In this case, “adequate control” is being able to induce adequate force in an appropriate direction so as to enable manipulation of the target with whatever level of performance is specified as being required.

While surface450, from the working side, represents a maximum allowed extent for channel460, flux former400shows that channel460is inset from surface450.

The appropriate inset, which may comprise a physical barrier of channel460from a surface450) may depend on specific conditions and may change overtime. For example, while target480is solid, the inset may be determined to be zero, since there may be no reason to prevent contact between target480and the components of flux former400. The inset may be non-zero, i.e. have a defined physical width, to prevent target480exiting channel460and contacting the components of flux former400. A non-zero inset may be provided to prevent contact in the event of loss of power in flux former400. These components include, but are not limited to, a pole of an electromagnet; a structure that may support the electromagnets; a containment wall that physically isolates the electromagnets; and/or associated circuitry. If target480comprises molten metal, contact with an electromagnet pole or other physical structure may cause damage, including melting, scarring (e.g., pitting), thermal stresses. Additionally molten material may solidify on the surface of flux former400, which may cause a buildup a target480material and necessitate cleaning or repair. Flux former400may be configured to prevent target480from contacting flux former400components while being manipulated and/or heated.

Additional factors may influence the dimensions of a working volume. For example, if the environment is subject to vibration, or modulations in power, the amplitude of such variations and the effect they have on the performance of the flux former400may be adjusted. The ability to tune controller and the electromagnets may provide margin for error or a safety margin, thus providing confidence that a target will remain under control in all expected circumstances.

Properties of target480or its constituent material(s) may affect the dimensions of a working volume. For example, the viscosity of a material may depend on temperature. Similarly, the surface tension of a liquid material may depend on temperature. A highly viscous material may behave significantly like a solid, but materials having a low viscosity, or a low surface tension, may be more difficult to control finely and can thus warrant a tighter working volume (e.g., one where the inset from the working surface is increased).

While a working volume such as channel460may remain fixed to encompass a minimum volume that is usable under all expected conditions, the working volume may also be dynamically determined, e.g., becoming smaller (as would be the case with an increased inset from the surface450) as a target melts into a liquid form, or larger (a decreased inset) as a target becomes solid (i.e., solidifies).

The criteria for determining an appropriate working volume are by way of example and not limitation. Many parameters that will become apparent to those skilled in the art that may influence the optimal and/or desires dimensions working volume including, but not limited to, frequency of cleaning and/or maintenance; tolerance system reliability, operating parameters including, but not limited to, speed of operation; or a combination thereof.

FIGS.5and6show flux formers500and600, respectively, illustrating the instantaneous magnetic flux in a right-to-left direction and left-to-right direction, respectively.FIGS.5and6show a section of flux former400(seeFIG.4), but at different phases of an amplitude modulation process, to illustrate how a controller varies the current to four electromagnets410a,420a,430a, and440a. Varying the current arranges the poles and strengths of electromagnets to generate particular distributions of magnetic flux580,680, which have greatest density near the bottom of the working volume460.

Three-dimensional Cartesian coordinate system562is used to describe channel460, which is shown in cross-section inFIGS.5and6, wherein “the bottom” is the least Y direction, according to the three-dimensional Cartesian coordinate axes562, showing the Y and X axes and for which the Z axis is coming out of the page inFIGS.5and6and thus is not shown there. A cross section of the trough-shaped surface450is shown inFIG.5, but not shown inFIG.6.

Modulation of electromagnets410a,420a,430a,440aprovide the greatest density of magnetic flux lines580and680as the magnetic field from the negative poles are attracted across the channel460to the positive poles on the other side.

The controller (not shown) is able to change the direction and path of the magnetic field lines580,680by rapidly switching the currents to the electromagnets410a,420a,430a,440a. Alternating between the flux formers500and600generates a controlled changing of flux density in the channel460to induce currents in the conductive material of the target (not shown inFIGS.5and6, for clarity) and thus impart force on the target. The imparted force is a component of the flux pocket, and represents a portion of the keeping force on the target wherein one function of the keeping force is to prevent the target (not shown) from approaching too closely the bottom portion (least Y-ward) of channel460. In some embodiments, the negative Y-ward axis can be aligned to the downward direction in a gravity field (not shown) such as on the surface of a planet, in which case this keeping force is opposed to the gravitational attraction acting on the target (not shown inFIGS.5and6).

FIG.7shows flux former700, illustrating instantaneous magnetic flux wherein two flux densities are formed between two pairs of electromagnets. Flux former700shows a different portion of flux former400, and illustrates the controller (not shown) applying a different pattern of time-varying currents to produce a different distribution of magnetic flux in working volume460to exert a different set of forces on a target, again shown in cross section. Two regions of high flux density in a trough shape are created by changing the configuration of the poles so pole420bis attracted to pole410b, and pole430bis attracted to440b. This creates lifting force in the Y direction for levitation of the target, according to the three-dimensional Cartesian coordinate axes462, keeping force in the X direction as well as limited control of the flux pocket in the X direction. Varying the current arranges the poles and strengths of electromagnets to generate particular distributions of magnetic flux780.

When the controller combines these drives of the electromagnets in flux former400, a stable flux pocket is generated and is able to hold a target, e.g., an aluminum ball, in place. The controller may adjust its amplitude modulation of the electromagnets to exert precise position control within channel460in any of the X, Y, and Z directions, thereby moving the flux pocket of stable equilibrium.

FIG.8shows flux former400illustrating the effect of a controller applying a pattern of amplitude modulation generating keeping forces. Flux former400illustrates the effect of the controller applying a pattern of amplitude modulation generating keeping forces. The flux former400is shown again inFIG.8, in which the controller is driving the electromagnets using amplitude modulation. Electromagnets410a,420a,430a, and440aas well as410c,420c,430c, and440cgenerate flux densities which product keeping forces892and894acting on target480. Electromagnets410b,420b,430b,440cgenerating lifting forces (not shown) to counteract the force of gravity in the Y direction and keeping forces in the X-axes.

When operating in microgravity conditions (i.e., wherein the target is not substantially affected by an external downward force in the direction of the negative Y-axis), two additional rows of three coils each (not shown) would mirror the bottom two rows420and430. Trough-shaped working surface450may be replaced by a cylindrical surface (not shown) for which the angular axis may be closed. Channel460may be replaced by a more symmetric volume, e.g., a bounded cylindrical working volume, instead of the flat-topped working volume due to the increased symmetry of the conditions, i.e., zero or near-zero gravitational force in all directions and a radially symmetric surface.

FIG.9shows a top down view flux former900, illustrating the effect of the controller applying a pattern of phase modulation to generate directional force on a target. Flux former900illustrates the effect of the controller applying a pattern of phase modulation to generate directional and rotational force on the target. The controller may employ phase modulation to differently manipulate the target. In one example, shown inFIG.9, electromagnets410a,410b, and410c; and440a,440b, and440, of flux former900are driven by the controller (not shown) using phase modulation. In this mode, the controller selects the drive for each consecutive electromagnet in a row (e.g.,410,440) to be a current that is progressively 120 degrees out of phase relative to the electromagnet before it in the row. Together, as each coil successively reaches maximum power, one after the other, they create a spatially-moving wave of high flux density that moves across the target, causing a force in the direction of the phase modulation shown by arrows982and984.

If the direction of the phase modulation is reversed, e.g., if the currents are instead selected by the controller to be −120 degrees out of phase, then the direction of force generated is reversed.

FIG.10shows a top down view of flux former1000, illustrating the effect of the controller applying a pattern of phase modulation to generate a rotational force on a target. Flux former1000illustrates the effect of the controller applying a pattern of phase modulation to generate directional and rotational force on the target.FIG.10shows a configuration wherein the controller selects directions of phase modulation that are in opposition, shown by1082and984. The phase modulation of row410is opposite to that in row440. In this configuration, the flux dynamics cause a torque1092or force couple on the target material480. The controller is able to control the rotational orientation of the target material about the Y-axis. Similarly, by using phase modulation with the electromagnet rows, it is possible to control rotation of the target480on the X-axis.

FIG.11shows a side view of flux former1100, illustrating the effect of the controller applying a pattern of phase modulation to generate a rotational force on a target. Flux former1100illustrates the effect of the controller applying a pattern of phase modulation to generating a rotational force on the target. In this configuration, the flux dynamics cause a torque1192or force couple on the target material480. The controller may be configured to use phase modulation across many combinations of electromagnets (whether by row or arc, or other collections of magnets and phasing). For example, the controller may select to drive the four electromagnets410b,420b,430b, and440bwith currents that are 90 degrees out of phase to each other, in order to rotate the target material about the Z-axis.

FIG.12shows showing how phase modulation1200may be used to generate keeping forces. Phase modulation may be used as a keeping force, as shown inFIG.12. With multiple electromagnets disposed to either end of an axis of a working volume, a controller can select an inward sweeping phase modulation.FIG.12shows the controller's drive of the current for three electromagnets on one side1210phased 120 degrees from each other and sweeping inward. Also shown are three coils on the other side1220phased 120 degrees from each other sweeping inward. The phasing of the coils will keep the target480in the center of the device by inducing forces1212and1222respectively.

FIG.13shows how phase modulation may be used to sort and purify the target material. System1300comprises two arrays of electromagnets that form a working surface with triangular cross section where the controller selects an appropriate phase modulation so as to generate a rotational force1322to spin the target such that the resulting centripetal acceleration separates material by density as it the target material melts, shown as an oval profile1332.

FIG.13shows material separation via temperature and centripetal sorting. Separating different material may be accomplished using centripetal acceleration. The target, which may comprise a plurality of conductive materials, may be heated to the highest melt temperature and spun to create one or more homogenous layers. The target may then be cooled to the lowest melt temperature and spun faster to physically separate the molten layer from the solid sphere in to a homogenous ring. Separation of the plurality of conductive materials can be accomplished using precise temperature control and centripetal acceleration. The plurality of conductive materials may be inductively heated to the highest material melting temperature. Without a gravitational field, the plurality of conductive materials will not separate, however, spinning the plurality of conductive materials with Lorentz forces creates a centrifugal force that separates the materials by density. If spun sufficiently fast, the plurality of conductive materials forms an oblate spheroid exposing each material layer. The plurality of conductive materials then cools to the lowest material melting temperature so there exists a dense solid ring around a molten core which can be separated out. The process is repeated to separate each layer. The separation process will preserve material alloying for typical aerospace materials. Oxidation (i.e. dross) is not a concern in vacuum and eddy current mixing ensures homogeneous distribution of alloying elements. Contaminants, such as paint, grease, and threadlocker, may gasify or become slag, but may still be purified centrifugally.

FIG.14shows inductive manipulation of molten metal without any physical contact, e.g., free-casting. System1400may free-cast an unlimited number of forms from feedstock and comprises electromagnetic array1402. Electromagnetic array1402comprises a plurality of electromagnets1404. Lorentz forces may push and pull section of target material1406to form a desired shape. In essence, this creates a reprogrammable electromagnetic mold. Target material1408is disposed in proximity to the working volume of electromagnetic array1402which heats and draws section of target material1406into the working volume of electromagnetic array1402via Lorentz forces. Section of target material1406may be heated and/or melted and separated from target material1408. Section of target material1406is manipulated by electromagnetic array1402to form product1412, which is ejected from system1400. Alternatively, section of target material1406is manipulated while remaining attached to target material1408. Target material1408is gradually drawn into the working volume of electromagnetic array1402along path1410. The process may create basic shapes including, but not limited to, ingots, bars, rods, plates, sheets, filament wire, brackets, extrusions, shells, tanks, or a combination thereof. System1400has an infinite build volume in microgravity environments may incrementally add sections of material1406to the large workpieces while maintaining hold of cooled sections with Lorentz forces. Parts produced by system1400will have rounded edges and may require post processing (machining, grinding, tapping, etc.) for higher precision as needed. Production speed may be comparable to traditional casting and may have significantly faster additive manufacturing than traditional methods.

FIG.15shows an embodiment of the system free-casting a target material. System1500comprises electromagnetic arrays1502. Target material1504is disposed between electromagnetic arrays1502and within working volume1506.

FIGS.16A and16Bshow an embodiment of an electromagnet array with associated controllers, and an electromagnet array, respectively. System1600comprises controlled electromagnet array1602comprising electromagnet array1604and controller array1606. Electromagnet array1604and controller array1606comprise a plurality of electromagnets and controllers, respectively.

FIGS.17A and17Bshows an embodiment of the system of the present invention comprising 24 independently-controlled electromagnet coils, and an array of 24 independently-controlled electromagnet coils, respectively. System1700comprises electromagnet array1702comprising and an array of 24 independently-controlled electromagnet coils. The 24 independently-controlled electromagnet coils are disposed according to electromagnet tors1702A,1702B,1702C, and1702D. System1700further comprises controllers1704in communication with electromagnet array1702. Electromagnet array1702and controllers1704are disposed within housing1706.

FIG.18shows module electronics assembly1800comprising amplifier board1802. Module electronics assembly1800comprises a plurality of amplifier board1802, each of which may deliver 840 W of power.

FIG.19and show cold plate model1900comprising electromagnet array1902, controller plate1906, processor1912, and amplifier plate1910. Electromagnet array1902comprises a plurality of electromagnet coil1904. Controller plate1906comprises a plurality of microcontrollers1908. Amplifier plate1910comprises a plurality of amplifier boards1914.

FIG.20shows cold plate model2000comprising bottom plate2002, seal2004, top plate2006, electromagnet array2008, amplifier plate2010, fluid port2012, and channel2014. Cooling fluid enters fluid port2012and passes through channel2014to cool amplifier2010and electromagnet array2008.

FIGS.21A,21B,21C,21D,21E, and21Fshow flux former1702comprising channel2102. Target material2104is manipulated by flux former1702to position it at any point along and/or within channel2102of flux former1702.

FIG.22shows flux former2200comprising electromagnet array2202, induction heat ring2204, and compression roller2206. Unformed target material2208passes through induction heat ring2204, which causes unformed target material2208to melt and become extrudable target material2210. Extrudable target material2210is manipulated, e.g., extruded by electromagnet array2202as it passes through flux former2200. Extrudable target material2210is then formed by compression roller2206into a wire shape.

The target material, e.g., conductive materials, are repelled from a region of high-density flux and motivated to travel from a higher flux density to a lower flux density. The system may create a stable, three-dimensional volume where conductive material will be held without need for mechanical contact, i.e., without touching the target, by using a plurality of programmatically controlled electromagnets generating higher flux density surrounding a pocket of lower flux density. The shape and position of this flux pocket, which forms the working volume, may be programmatically controlled in three-dimensional space.

Flux pockets may be created with or without feedback from sensors. In the field of control system engineering, systems without feedback sensors are termed “open loop” and with feedback sensors are termed “closed loop”. Closed loop systems may be more precise and robust.

The system may recycle or process materials of varying shape and composition using a plurality of programmably controlled electromagnets to form stable electromagnetic equilibria by dynamically changing the magnetic flux density based on sensor feedback of the target material to transport, hold, heat, melt, and form these materials. The system may also operate without the need for contact and without the need for moving parts.

In mathematics, a surface is a two-dimensional manifold, which means that it resembles a two-dimensional Euclidean space near each point. Locally, that gives a surface two opposed faces, having opposite normals at each point in the region. For surfaces of interest here, these opposed faces cover the full extent of the surface.

A surface can have zero or more edges. One example of a surface is the entirety of a two-dimensional sphere, has no edge, and is continuous everywhere. A surface may have a single edge, such as a surface that is a circular region of a planar surface, and is bounded by a circular edge; or a surface that is one portion of a two-dimensional sphere after the sphere is divided by a plane, e.g., a two-dimensional hemisphere comprising no points having positive azimuth, the edge of which is the circle that is the intersection of the sphere with the plane. A surface may be a portion of an infinite two-dimensional cylinder bounded (sliced) at two different positions along the longitudinal axis has two edges, one at each end. A cylindrical surface bounding a finite solid cylinder may have no edges, as the ends of the solid cylinder can be capped by planar portions of the bounding surface. A surface may have an arbitrary number of holes, each hole bounded by an edge, and thus, a surface can have an arbitrary number of edges.

The system may comprise one or more electromagnets disposed to each have at least a first pole meeting a working surface comprising a first and a second face. The electromagnets may be disposed at the first face (the “magnet side”) of the working surface, with each of the electromagnets having the first pole directed through and/or at the surface. The opposite second face of the working surface is the “working side” of the surface. On the working side, the surface represents a maximum bound of an allowable working volume. The electromagnet may comprise two poles and each pole may have a negative or positive charge.

The system may comprise a flux former, comprising one or more electromagnets and/or electromagnet coils configured to generate an electromagnetic flux. The electromagnetic flux may have defined dimensions.

The system may comprise a controller that may select the frequency of the current driving one or more of the electromagnets. The controller may be a modulating controller. The frequency modulation may increase or decrease the amount of heat being induced in the target material while not significantly changing the force applied by the magnetic field. The frequency of the time-varying current input may be increased while the amplitude is decreased to increase heat while maintaining constant force. The value of frequency modulation is the ability to control the target material with an adequate amount of force, while allowing the target material to transition from liquid to solid while retaining a prescribed shape.

The system may further comprise a sensor in communication with the controller. The sensor may be configured to provide information regarding the position of a target. The controller may receive feedback from the sensor and operate a closed control loop to better control position, velocity, and acceleration of the target.

The target material may be solid, and the controller may drive the electromagnets to heat the conductive material of the target and/or target material. Heating may cause some or all of the materials of the target to melt. At least a portion of the material of the target may be provided in liquid form and the target may cool to the point that some or all of the liquid materials solidify.

The target material may be melted to become liquid metal and the controller may select phase modulation to generate forces on the liquid metal. The controller may collect the liquid metal in a reservoir and draw off the liquid material to flow into a desired shape generated by a programmatically defined flux density and phase modulation. If the material is allowed to cool and solidify, the target can retain this shape.

Modulation of the electromagnets may act differently on a solid target, a liquid target, and a semi-solid/semi-liquid target. Solid and liquid metals may react differently with respect to flux density. Target materials of differing conductivity may react differently, and these differences may be used to manipulate the target material including but not limited to, by separating or mixing the target material.

The change in behavior between solid and liquid metal may be advantageously used for sorting or drawing materials with dissimilar melting temperatures. The target material may also be aggressively mixed particularly as the mixture is solidifying. Aggressive mixing occurs when the system applies an amplitudal modulation on a liquid metal target material. The keeping forces of amplitudal modulation may generate reduced repulsive forces in metals after melting because the target material will internally mix. However, the reduced repulsive force in combination with phase modulation generates a force as great as the normal repulsive force.

A number of factors may affect aggressive mixing. For example, the penetration depth of the magnetic flux into a material, which is based on frequency, may affect aggressive mixing. As a target material solidifies in zero gravity the frequency of the sin wave is increased to reduce the penetration depth. The reduction in penetration depth allows a force to be applied to the liquid metal without heating it as much compared to not increasing the frequency of the sin wave. Another factor is closed loop control where the target is contacted with magnetic flux when it leaves the desired shape in order to push it back into place. These factors contribute to generating keeping forces while not adding heat to the liquid metal, which is quickly cooling from radiative thermal losses until it solidifies in the desired shape.

The system may be used to address different material properties and environments. For example, in microgravity environments or at small scales, the target material surface tension may be a significant force component. Modulation of the electromagnets can be adapted for these changes.

Different forces and heat may be induced on a target by the controller. The controller may select one or more patterns of time-varying currents. Different pattern of currents may be imposed by time-domain multiplexing, wherein a first pattern is selected and applied by the controller for a first interval, then a second pattern is selected and apply by the controller for a subsequent interval, with the interleaving of the patterns occurring at a rate sufficient to achieve the desired manipulation of the target. The principle of superposition may be used, wherein the controller sums the currents from the first and second patterns and with the superposition of forces being induced on the target being likewise summed, provided that current and magnetic saturation limits are not exceeded. These combined patterns may induce a combination of forces, torques, and or heat in the target material.

The target material may be programmatically flattened, stretched, drawn, or formed while being kept within the working volume. The heat may be programmatically controlling to allow solidification of the target while still exerting keeping and shaping forces.

A conductive material may be delivered to the system and the system may actively ingest the conductive material to become a target by the controller selecting specific current modulations to draw the material into the working volume once the material is at least partially disposed within working volume. The electromagnetic of the system may apply a force to eject the target material from the working volume of a system.

The system may be a plurality of systems arranged in series or in parallel. In systems arranged in series, the controller may select current modulations appropriate to moving a target out of the working volume to eject the target from a first system. The ejected target may be delivered to a second system, and a target exiting a working volume of the first system may be a target material incoming to the working volume of the second system.

The system may comprise a sensor. The sensor may be in communication with a controller and/or modulating controller. The sensor may be configured to provide information and/or send a signal to the controller and/or modulating controller. The information and/or signal may relate to characteristic of a target material including, but not limited to, the shape, temperature, position, rotation, velocity, composition, or a combination thereof. The controller and/or modulating controller may control a flux that transports, holds, heats, melts, and/or form a target material after receiving and/or in response to the information and/or signal received from the sensor.

The system may comprise and/or operate at a defined wattage. The wattage may be at least about 6 W, about 6 W to about 1 MW, about 50 W to about 0.75 MW, about 100 W to about 0.5 MW, about 500 W to about 0.25 MW, about 1 KW to about 200 KW, about 50 KW to about 150 KW, or about 1 MW.

Embodiments of the present invention provide a technology-based solution that overcomes existing problems with the current state of the art in a technical way to satisfy an existing problem for contactless and/or microgravity metal formation. Embodiments of the present invention achieve important benefits over the current state of the art, such as contactless metal forming, metal manipulation in microgravity environments, and precision metalworking. Some of the unconventional steps of embodiments of the present invention include one or more electromagnets generating a magnetic flux to manipulate conductive metal.

INDUSTRIAL APPLICABILITY

The invention is further illustrated by the following non-limiting examples.

Example 1

Melted gallium was manipulated in a system, e.g., the inductive foundry, of the present invention. Melted gallium was used an as an analog for aluminum. Both gallium and aluminum are non-ferrous, with aluminum having higher electrical and thermal conductivity, and lower density (all advantageous for this process) but a higher melting temperature than gallium.

Melted gallium was disposed into a trough. Without the effect of gravity, the material would float free, and its movement would be more apparent. For a terrestrial demonstration, the effects were more subtle but could be seen by comparing the liquid metal to the top edge of a crucible containing the melted gallium.

The melted gallium was collected in the center of the trough. The inductive foundry phased the coils to create forces that pushed the gallium to the center of the trough. In space, melted scrap would need to be collected and contained, ideally without contact to avoid material contamination, heat transfer, and contamination buildup on the equipment. Induced torques caused the metal to rotate, which may be used later for refinement or other purposes.

The melted gallium was moved to the right, back to center, and to the left. This sequence demonstrated stable, intentional control of the metal for handling, continuous flow, or moldless-casting. Control was accomplished without a feedback sensor for simplicity (i.e. open loop) or with a feedback sensor (e.g., LIDAR) for greater accuracy.

The melted gallium was divided in two portions. Once the inductive foundry melted the scrap, it naturally collected into a single unit due to surface tension or electromagnetic forces. The inductive foundry processes controlled the melted gallium's physical shape. The inductive foundry was able to split a single blob of material and dispense a finite amount without touching it.

The preceding example can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.

Note that in the specification and claims, “about” or “approximately” means within twenty percent (20%) of the numerical amount cited.

Although the invention has been described in detail with particular reference to these embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.