| |
| United States Patent Application |
20080224806
|
| Kind Code
|
A1
|
|
Ogden; Orval D.
; et al.
|
September 18, 2008
|
MATERIAL MAGNETIZER SYSTEMS
Abstract
A system for improved magnetization of flexible magnetic sheet material,
such as magnetic rubber. More particularly, this invention relates to
providing a system for magnetization of pre-printed flexible magnetic
sheet material.
| Inventors: |
Ogden; Orval D.; (Marietta, OH)
; Stotler; Donald G.; (Marietta, AZ)
; Ball; Bernard F.; (Marietta, AZ)
|
| Correspondence Name and Address:
|
Stoneman Volk Patent Group
3770 NORTH 7TH STREET, Suite 100
PHOENIX
AZ
85014
US
|
| Serial No.:
|
048140 |
| Series Code:
|
12
|
| Filed:
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March 13, 2008 |
| U.S. Current Class: |
335/284 |
| U.S. Class at Publication: |
335/284 |
| Intern'l Class: |
H01F 7/20 20060101 H01F007/20 |
Claims
1) A system related to magnetization of at least one substantially planar
sheet of substantially flexible magnetizable material having at least one
pre-printed face surface, and at least one opposite face surface, said
system comprising:a) at least one first magnetic field source structured
and arranged to produce at least one first magnetic field;b) at least one
second magnetic field source structured and arranged to produce at least
one second magnetic field; andc) at least one geometric positioner
structured and arranged to geometrically position said at least one first
magnetic field source and said at least one second magnetic field source
to generate at least one first high-flux field region resulting from at
least one magnetic-field interaction between said at least one first
magnetic field and said at least one second magnetic field;d) wherein
said at least one first high-flux field region is situate substantially
between said at least one first magnetic field source and said at least
one second magnetic field source;e) wherein said at least one geometric
positioner comprises at least one passage structured and arranged to
allow moving passage of the substantially flexible magnetizable material
through said at least one first high-flux field region;f) wherein said at
least one second magnetic field source is structured and arranged to
physically contact at least one opposite face surface during passage of
the at least one substantially planar sheet of substantially flexible
magnetizable material through said at least one first high-flux field
region; andg) wherein said at least one first magnetic field source is
structured and arranged to avoid physical contact with the at least one
pre-printed face surface during passage of the at least one substantially
planar sheet of substantially flexible magnetizable material through said
at least one first high-flux field region.
2) The system according to claim 1 wherein:a) said at least one second
magnetic field source comprises at least one advancer structured and
arranged to movably advance the at least one substantially planar sheet
of substantially flexible magnetizable material in at least one
sheet-feed direction passing substantially through said at least one
first high-flux field region; andb) such moving advancement of the said
at least one second magnetic field source substantially through said at
least one first high-flux field region results in substantially permanent
magnetization of at least one first region of the substantially flexible
magnetizable material.
3) The system according to claim 1 wherein said at least one geometric
positioner comprises:a) at least one upper support frame structured and
arranged to support said at least one first magnetic field source; andb)
at least one lower support frame structured and arranged to rotationally
support said at least one second magnetic field source.
4) The system according to claim 3 wherein said at least one first
magnetic field source and said at least one second magnetic field source
are each generated by at least one permanent magnet.
5) The system according to claim 4 wherein:a) said at least one first
magnetic field source comprises at least one first magnetizer bar
comprising at least one first longitudinal axis;b) said at least one
first magnetizer bar comprises a first set of discrete field-producing
laminations spaced substantially along said at least one first
longitudinal axis;c) each discrete field-producing lamination of said
first set comprises at least one substantially circular magnetic disk
magnetically coupled with at least one substantially circular
flux-conducting spacer; andd) each said at least one substantially
circular magnetic disk and each said at least one substantially circular
flux-conducting spacer are substantially coaxial with said at least one
first longitudinal axis.
6) The system according to claim 5 wherein:a) said at least one second
magnetic field source comprises at least one second magnetizer bar
comprising at least one second longitudinal axis;b) said at least one
second magnetizer bar comprises a second set of discrete field-producing
laminations spaced substantially along said at least one second
longitudinal axis;c) each discrete field-producing lamination of said
second set comprises at least one substantially circular magnetic disk
magnetically coupled with at least one substantially circular
flux-conducting spacer; andd) each said at least one substantially
circular magnetic disk and each said at least one substantially circular
flux-conducting spacer are substantially coaxial with said at least one
second longitudinal axis.
7) The system according to claim 6 further comprising:a) at least one
powered rotator structured and arranged to rotate said at least one
second magnetizer bar about said at least one second longitudinal axis;b)
wherein rotation of said at least one second magnetizer bar by said at
least one powered rotator movably advances the at least one substantially
planar sheet of substantially flexible magnetizable material through said
at least one first high-flux field region by frictional contact with the
at least one opposite face surface; andc) wherein the at least one
substantially planar sheet of substantially flexible magnetizable
material may be permanently magnetized by such movement through said at
least one first high-flux field region.
8) The system according to claim 7 wherein said at least one upper support
frame and said at least one lower support frame are structured and
arranged to maintain said at least one first longitudinal axis and said
at least one second longitudinal axis in substantially parallel
alignment.
9) The system according to claim 8 wherein said at least one upper support
frame and said at least one lower support frame are structured and
arranged to maintain said at least one first longitudinal axis and said
at least one second longitudinal axis in substantially vertical
alignment.
10) The system according to claim 9 wherein:a) said at least one upper
support frame comprises at least one mount structured and arranged to
removably mount said at least one upper support frame to said at least
one lower support frame;b) said at least one mount is structured and
arranged to maintain said at least one upper support in a fixed position
relative to said at least one lower support frame; andc) said at least
one upper support frame is structured and arranged to provide at least
one freedom of movement of said at least one first magnetizer bar
relative to said at least one second longitudinal axis.
11) The system according to claim 10 further comprising:a) at least one
third magnetic field source structured and arranged to produce at least
one third magnetic field; andb) at least one fourth magnetic field source
structured and arranged to produce at least one fourth magnetic field;c)
wherein said at least one upper support frame is structured and arranged
to support said at least one third magnetic field source;d) wherein said
at least one lower support frame structured and arranged to rotationally
support said at least one fourth magnetic field source;e) wherein said at
least one upper support frame and said at least one lower support frame
are structured and arranged to geometrically position said at least one
third magnetic field source and said at least one fourth magnetic field
source to generate at least one second high-flux field region resulting
from at least one magnetic-field interaction between said at least one
third magnetic field and said at least one fourth magnetic field;f)
wherein said at least one second high-flux field region is situate
substantially between said at least one third magnetic field source and
said at least one forth magnetic field source;g) wherein said at least
one passage is structured and arranged to allow moving passage of the
substantially flexible magnetizable material through said at least one
second high-flux field region;h) wherein said at least one fourth
magnetic field source is structured and arranged to come into physical
contact with the at least one opposite face surface during passage of the
at least one substantially planar sheet of substantially flexible
magnetizable material through said at least one second high-flux field
region; andi) wherein said at least one third magnetic field source is
structured and arranged to avoid physical contact with the at least one
pre-printed face surface during passage of the at least one substantially
planar sheet of substantially flexible magnetizable material through said
at least one second high-flux field region.
12) The system according to claim 11 wherein said at least one third
magnetic field source and said at least one fourth magnetic field source
are each generated by at least one permanent magnet.
13) The system according to claim 12 wherein:a) said at least one third
magnetic field source comprises at least one third magnetizer bar
comprising at least one third longitudinal axis;b) said at least one
third magnetizer bar comprises a third set of discrete field-producing
laminations spaced substantially along said at least one third
longitudinal axis;c) each discrete field-producing lamination of said
third set comprises at least one substantially circular magnetic disk
magnetically coupled with at least one substantially circular
flux-conducting spacer; andd) each said at least one substantially
circular magnetic disk and each said at least one substantially circular
flux-conducting spacer is substantially coaxial with said at least one
third longitudinal axis.
14) The system according to claim 13 wherein:a) said at least one fourth
magnetic field source comprises at least one fourth magnetizer bar
comprising at least one fourth longitudinal axis;b) said at least one
fourth magnetizer bar comprises a fourth set of discrete field-producing
laminations spaced substantially along said at least one fourth
longitudinal axis;c) each discrete field-producing lamination of said
fourth set comprises at least one substantially circular magnetic disk
magnetically coupled with at least one substantially circular
flux-conducting spacer; andd) each said at least one substantially
circular magnetic disk and each said at least one substantially circular
flux-conducting spacer is substantially coaxial with said at least one
forth longitudinal axis.
15) The system according to claim 14 wherein:a) said at least one powered
rotator is structured and arranged to provide powered rotation of said at
least one fourth magnetizer bar about said at least one fourth
longitudinal axis;b) such powered rotation of said at least one fourth
magnetizer bar movably advances the at least one substantially planar
sheet of substantially flexible magnetizable material through said at
least one second high-flux field region by frictional contact with the at
least one opposite face surface; andc) at least one second region of the
at least one substantially planar sheet of substantially flexible
magnetizable material is permanently magnetized by such movement through
said at least one second high-flux field region.
16) The system according to claim 15 wherein:a) said at least one upper
support frame and said at least one lower support frame are structured
and arranged to maintain said at least one first longitudinal axis, said
at least one second longitudinal axis, said at least one third
longitudinal axis, and said at least one fourth longitudinal axis in
substantially parallel alignment; andb) said at least one upper support
frame and said at least one lower support frame are structured and
arranged to maintain said at least one third longitudinal axis and said
at least one fourth longitudinal axis in substantially vertical
alignment.
17) The system according to claim 16 wherein:a) said first set of discrete
field-producing laminations of said at least one first magnetizer bar are
axially offset from said third set of discrete field-producing
laminations of said at least one third magnetizer bar; andb) said second
set of discrete field-producing laminations of said at least one second
magnetizer bar are axially offset from said fourth set of discrete
field-producing laminations of said at least one fourth magnetizer bar.
18) The system according to claim 16 wherein:a) said first set of discrete
field-producing laminations of said at least one first magnetizer bar are
vertically aligned with said second set of discrete field-producing
laminations of said at least one second magnetizer bar; andb) said first
set of discrete field-producing laminations and said second set of
discrete field-producing laminations comprise opposite opposing polar
moments.
19) The system according to claim 16 wherein said third set of discrete
field-producing laminations of said at least one third magnetizer bar are
vertically aligned with said fourth set of discrete field-producing
laminations of said at least one fourth magnetizer bar.
20) The system according to claim 16 further comprising at least one
rotation-rate coordinator structured and arranged to coordinate the
rotation rates of said at least one second magnetizer bar and said at
least one fourth magnetizer bar.
21) The system according to claim 16 wherein said at least one
rotation-rate coordinator comprises at least one arrangement of
intermeshed toothed gears.
22) The system according to claim 21 wherein said at least one powered
rotator comprises:a) at least one electrically driven motor comprising at
least one output shaft structured and arranged to transmit at least one
torque force produced by said at least one electrically driven motor;b)
coupled to said at least one output shaft, at least one first resilient
roller rotationally supported within said at least one lower support
frame;c) at least one second resilient roller rotationally supported
within said at least one lower support frame; andd) at least one third
resilient roller rotationally supported within said at least one lower
support frame;e) wherein said at least one first resilient roller, said
at least one second resilient roller, and said at least one third
resilient roller are rotationally coupled by said at least one
arrangement of intermeshed toothed gears;f) wherein said at least one
first resilient roller and said at least one second resilient roller are
structured and arranged rotate said at least one second magnetizer bar by
frictional contact;g) wherein said at least one second resilient roller
and said at least one third resilient roller are structured and arranged
to rotate said at least one fourth magnetizer bar by frictional contact;
andh) wherein rotation of said at least one first resilient roller
induces rotation in said at least one second resilient roller, said at
least one third resilient roller, said at least one second magnetizer
bar, and said at least one fourth magnetizer bar.
23) A method related to magnetization of at least one sheet of
substantially flexible magnetizable material having at least one first
planar face and at least one second planar face, said method comprising
the steps of:a) providing at least one first magnet structured and
arranged to produce at least one first magnetic field;b) providing at
least one second magnet structured and arranged to produce at least one
second magnetic field;c) producing at least one high-flux field region by
geometrically positioning such at least one first magnet above such at
least one second magnet to produce at least one high-flux gap
therebetween;d) forming at least one frictional surface contact between
such at least one second magnet and the at least one second planar
face;e) manipulating such at least one second magnet to movably advance
the at least one sheet of substantially flexible magnetizable material
through such at least one high-flux gap; andf) at least partially
magnetizing the at least one sheet of substantially flexible magnetizable
material during such advancement through such at least one high-flux gap.
24) The method according to claim 24 wherein the step of manipulating such
at least one second magnet to movably advance the at least one sheet of
substantially flexible magnetizable material through such at least one
high-flux gap comprises the step of rotating such at least one second
magnet to facilitate such advancement.
25) A method related to hand-held magnetization of at least one sheet of
substantially flexible magnetizable material comprising at least one
substantially planar surface, said method comprising the steps of:a)
providing at least one modular end cap structured and arranged to
rotationally engage at least one first end of at least one cylindrical
magnet bar;b) selecting from a set of hand-holdable bodies comprising
differing fixed lengths, at least one fixed-length hand-holdable body
structured and arranged to rotationally engage at least one second end of
the at least one cylindrical magnet bar;c) selecting from a set of
cylindrical magnet bars comprising differing fixed lengths, at least one
cylindrical magnet bar comprising a fixed length compatible with such at
least one fixed-length hand-holdable body;d) engaging such at least one
second end of such at least one cylindrical magnet bar within such at
least one fixed-length hand-holdable body;e) engaging such at least one
first end of such at least one cylindrical magnet bar within such modular
end cap; andf) mounting such modular end cap to such at least one
fixed-length hand-holdable body.
26) The method according to claim 26 further comprising the steps of:a)
hand gripping such at least one fixed-length hand-holdable body;b)
positioning such at least one cylindrical magnet bar to contact the at
least one substantially planar surface; andc) rolling such at least one
cylindrical magnet bar across the at least one substantially planar
surface wherein at least partial magnetization of the at least one
substantially planar sheet of substantially flexible magnetizable
material is achieved.
27) A system related to the retrofitting of at least one friction-type
sheet-handling device to enable magnetization of at least one
substantially planar sheet of substantially flexible magnetizable
material, during movement of such at least one substantially planar sheet
of substantially flexible magnetizable material along at least one
transport path of the at least one friction-type sheet-handling device,
said system comprising:a) at least one magnetic field source structured
and arranged to generated at least one magnetic field usable to magnetize
the at least one substantially planar sheet of substantially flexible
magnetizable material; andb) at least one mount structured and arranged
to mount said at least one magnetic field source to the at least one
friction-type sheet-handling device;c) wherein said at least one mount
comprises at least one positioner structured and arranged to situate said
at least one magnetic field source in at least one position producing at
least one magnetic-field interaction between such at least one
substantially planar sheet of substantially flexible magnetizable
material and the magnetic field as such at least one substantially planar
sheet of substantially flexible magnetizable material moves along the at
least one transport path; andd) wherein such at least one substantially
planar sheet of substantially flexible magnetizable material may be
permanently magnetized by such at least one magnetic-field interaction.
28) The system according to claim 27 wherein said at least one magnetic
field source comprisesa) at least one field-producing roller structured
and arranged to produce the magnetic field;b) wherein said at least one
field-producing roller is rotatably held by said at least one mount.
29) The system according to claim 28 wherein said at least one magnetic
field source further comprises:a) at least one field-conducting roller
structured and arranged to form at least one magnetic circuit with said
at least one magnetic roller; andb) situate between said at least one
field-producing roller and said at least one field-conducting roller, at
least one air gap structured and arranged to enable passage of such at
least one substantially planar sheet of substantially flexible
magnetizable material, therethrough;c) wherein said at least one
field-conducting roller is rotatably held by said at least one mount.
30) The system according to claim 29 wherein:a) said at least one
field-producing roller comprises at least one first rotator structured
and arranged to rotate said at least one field-producing roller, in at
least one first direction, about at least one first rotational axis
oriented substantially perpendicular to the movement of such at least one
substantially planar sheet of substantially flexible magnetizable
material, during passage of such at least one substantially planar sheet
of substantially flexible magnetizable material through said at least one
air gap;b) said at least one field-conducting roller comprises at least
one second rotator structured and arranged to rotate said at least one
field-producing roller, in at least one second direction, about at least
one second rotational axis oriented substantially perpendicular to the
movement of such at least one substantially planar sheet of substantially
flexible magnetizable material, during passage of such at least one
substantially planar sheet of substantially flexible magnetizable
material through said at least one air gap;c) said at least one air gap
is sized to provide substantially contemporaneous frictional contact
between such at least one substantially planar sheet of substantially
flexible magnetizable material and both said at least one field-producing
roller and said at least one field-conducting roller during passage
therethrough; andd) such rotation of said at least one field-producing
roller and said at least one field-conducting roller movably advance the
at least one substantially planar sheet of substantially flexible
magnetizable material through said at least one air gap.
31) The system according to claim 30 wherein said at least one first
rotator comprises at least one first torque transfer member structured
and arranged to transfer at least one first torque force of at least one
first rotating member of the at least one friction-type sheet-handling
device to said at least one field-producing roller.
32) The system according to claim 30 wherein said at least one second
rotator comprises at least one second torque transfer member structured
and arranged to transfer at least one second torque force of at least one
second rotating member of the at least one friction-type sheet-handling
device to said at least one field-conducting roller.
33) The system according to claim 31 wherein said at least one first
torque transfer member comprises at least one substantially flexible
drive belt.
34) The system according to claim 31 wherein said at least one first
torque transfer member comprises at least one chain drive structured and
arranged to engage at least one sprocket gear.
35) The system according to claim 32 wherein said at least one second
torque transfer member comprises at least one substantially flexible
drive belt.
36) The system according to claim 32 wherein said at least one second
torque transfer member comprises at least one chain drive structured and
arranged to engage at least one sprocket gear.
37) The system according to claim 29 wherein such at least one magnetic
field source is generated by at least one permanent magnet.
38) The system according to claim 37 wherein:a) said at least one
field-producing roller comprises a plurality of substantially circular
magnetic disks each one magnetically coupled with at least one
substantially circular flux-conducting spacer; andb) each said at least
one substantially circular magnetic disk and each said at least one
substantially circular flux-conducting spacer are substantially coaxial
with said at least one first longitudinal axis.
39) The system according to claim 38 further comprising at least one
separator member structured and arranged to separate such at least one
substantially planar sheet of substantially flexible magnetizable
material from said at least one field-producing roller after such
permanent magnetization.
40) The system according to claim 39 wherein said at least one mount
comprises:a) at least one first end plate and at least one second end
plate;b) wherein said at least one first end plate and said at least one
second end plate comprisei) at least one paired set of receivers, each
one structured and arranged to rotatably receive a respective end of said
at least one field-producing roller and said at least one
field-conducting roller, andii) at least one mechanical fastener
structured and arranged to mechanically fasten said at least one first
end plate and said at least one second end plate to the at least one
friction-type sheet-handling device;c) wherein each paired set of
receiver comprises at least one friction-reducing bearing structured and
arranged to assist reduced-friction rotation of said at least one
field-producing roller and said at least one field-conducting roller.
41) The system according to claim 39 wherein said at least one
field-conducting roller is situate substantially at the end of the at
least one transport path of the at least one friction-type sheet-handling
device.
42) A method related to the retrofitting of at least one friction-type
sheet-handling device to enable magnetization of at least one
substantially planar sheet of substantially flexible magnetizable
material, during movement of such at least one substantially planar sheet
of substantially flexible magnetizable material along at least one
transport path of the at least one friction-type sheet-handling device,
said method comprising the steps of:a) identifying at least one
friction-type sheet-handling device adapted to move such at least one
substantially planar sheet of substantially flexible magnetizable
material along at least one transport path between at least one initial
position and at least one final position;b) providing at least one
magnetic field source structured and arranged to generated at least one
magnetic field usable to magnetize the at least one substantially planar
sheet of substantially flexible magnetizable material; andc) providing at
least one mount to assist the mounting of such at least one magnetic
field source to the at least one friction-type sheet-handling device,
wherein such at least one mount is structured and arranged to situate
such at least one magnetic field source in at least one position
producing at least one magnetic-field interaction between such at least
one substantially planar sheet of substantially flexible magnetizable
material and the magnetic field as such at least one substantially planar
sheet of substantially flexible magnetizable material moves along the at
least one transport path.
43) The method according to claim 41 further comprising the step of:a)
mounting such at least one magnetic field source to the at least one
friction-type sheet-handling device using such at least one mount;b)
wherein at least one modified friction-type sheet-handling device capable
of permanently magnetizing such at least one substantially planar sheet
of substantially flexible magnetizable material is achieved.
44) The method according to claim 42 further comprising the step of
permanently magnetizing such at least one substantially planar sheet of
substantially flexible magnetizable material using such at least one
modified friction-type sheet-handling device.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001]The present application is related to and claims priority from prior
provisional application Ser. No. 60/895,341, filed Mar. 16, 2007,
entitled "MATERIAL MAGNETIZER SYSTEMS", and is related to and claims
priority from prior provisional application Ser. No. 60/944,077, filed
Jun. 14, 2007, entitled "MATERIAL MAGNETIZER SYSTEMS" the contents of
both of which are incorporated herein by this reference and are not
admitted to be prior art with respect to the present invention by the
mention in this cross-reference section.
BACKGROUND
[0002]This invention relates to providing a system for improved
magnetization of flexible sheet material, such as magnetic rubber. More
particularly, this invention relates to providing a system for
magnetization of pre-printed flexible magnetic sheet material.
[0003]Flexible magnetic sheet material is customarily used in a variety of
useful products ranging from refrigerator magnets to temporary signage
applied to exterior metallic surfaces of transportation vehicles. In many
applications, one surface of the flexible magnetic sheet material is
imprinted with advertising or informational indicia. Most commercial
printing processes prohibit the use of magnetize substrates due to
interference of the printing process by the magnetic field of the sheet.
It is therefore customary to magnetize the flexible magnetic sheet after
printing has been applied.
[0004]The flexible magnetic sheet material customarily used in producing
the above-described products has been relatively thick (often about 30
mil). This thickness has allowed the material to be magnetized to a
usable degree by exposure of the unprinted side of the flexible magnetic
sheet material to a magnetic field. The use of thinner more
cost-effective sheet materials (thicknesses below about 15 mil), has been
limited by the lack of effective post-printing magnetization processes. A
system allowing a thinner (pre-printed) flexible magnetic sheet material
to be magnetized to levels nearing those of conventional flexible
magnetic sheet materials would be of great benefit to many.
OBJECTS AND FEATURES OF THE INVENTION
[0005]A primary object and feature of the present invention is to provide
a system to overcome the above-described problems.
[0006]It is a further object and feature of the present invention to
provide such a system capable of producing useful levels of magnetic
imprintation within thinner (pre-printed) flexible magnetic sheet
materials.
[0007]It is another object and feature of the present invention to provide
such a system capable of producing sufficient magnetic force levels
within pre-printed flexible magnetic sheet materials without physically
contacting the pre-printed surface.
[0008]It is another object and feature of the present invention to provide
such a system related to the retrofitting of at least one friction-type
sheet-handling device to enable magnetization of at least one
substantially planar sheet of substantially flexible magnetizable
material, during movement of such at least one substantially planar sheet
of substantially flexible magnetizable material along at least one
transport path of the at least one friction-type sheet-handling device.
[0009]A further primary object and feature of the present invention is to
provide such a system that is efficient, inexpensive, and handy. Other
objects and features of this invention will become apparent with
reference to the following descriptions.
SUMMARY OF THE INVENTION
[0010]In accordance with a preferred embodiment hereof, this invention
provides a system related to magnetization of at least one substantially
planar sheet of substantially flexible magnetizable material having at
least one pre-printed face surface, and at least one opposite face
surface, such system comprising: at least one first magnetic field source
structured and arranged to produce at least one first magnetic field; at
least one second magnetic field source structured and arranged to produce
at least one second magnetic field; and at least one geometric positioner
structured and arranged to geometrically position such at least one first
magnetic field source and such at least one second magnetic field source
to generate at least one first high-flux field region resulting from at
least one magnetic-field interaction between such at least one first
magnetic field and such at least one second magnetic field; wherein such
at least one first high-flux field region is situate substantially
between such at least one first magnetic field source and such at least
one second magnetic field source; wherein such at least one geometric
positioner comprises at least one passage structured and arranged to
allow moving passage of the substantially flexible magnetizable material
through such at least one first high-flux field region; wherein such at
least one second magnetic field source is structured and arranged to
physically contact at least one opposite face surface during passage of
the at least one substantially planar sheet of substantially flexible
magnetizable material through such at least one first high-flux field
region; and wherein such at least one first magnetic field source is
structured and arranged to avoid physical contact with the at least one
pre-printed face surface during passage of the at least one substantially
planar sheet of substantially flexible magnetizable material through such
at least one first high-flux field region.
[0011]Moreover, it provides such a system wherein: such at least one
second magnetic field source comprises at least one advancer structured
and arranged to movably advance the at least one substantially planar
sheet of substantially flexible magnetizable material in at least one
sheet-feed direction passing substantially through such at least one
first high-flux field region; and such moving advancement of the such at
least one second magnetic field source substantially through such at
least one first high-flux field region results in substantially permanent
magnetization of at least one first region of the substantially flexible
magnetizable material. Additionally, it provides such a system wherein
such at least one geometric positioner comprises: at least one upper
support frame structured and arranged to support such at least one first
magnetic field source; and at least one lower support frame structured
and arranged to rotationally support such at least one second magnetic
field source.
[0012]Also, it provides such a system wherein such at least one first
magnetic field source and such at least one second magnetic field source
are each generated by at least one permanent magnet. In addition, it
provides such a system wherein: such at least one first magnetic field
source comprises at least one first magnetizer bar comprising at least
one first longitudinal axis; such at least one first magnetizer bar
comprises a first set of discrete field-producing laminations spaced
substantially along such at least one first longitudinal axis; each
discrete field-producing lamination of such first set comprises at least
one substantially circular magnetic disk magnetically coupled with at
least one substantially circular flux-conducting spacer; and each such at
least one substantially circular magnetic disk and each such at least one
substantially circular flux-conducting spacer are substantially coaxial
with such at least one first longitudinal axis. And, it provides such a
system wherein: such at least one second magnetic field source comprises
at least one second magnetizer bar comprising at least one second
longitudinal axis; such at least one second magnetizer bar comprises a
second set of discrete field-producing laminations spaced substantially
along such at least one second longitudinal axis; each discrete
field-producing lamination of such second set comprises at least one
substantially circular magnetic disk magnetically coupled with at least
one substantially circular flux-conducting spacer; and each such at least
one substantially circular magnetic disk and each such at least one
substantially circular flux-conducting spacer are substantially coaxial
with such at least one second longitudinal axis.
[0013]Further, it provides such a system further comprising: at least one
powered rotator structured and arranged to rotate such at least one
second magnetizer bar about such at least one second longitudinal axis;
wherein rotation of such at least one second magnetizer bar by such at
least one powered rotator movably advances the at least one substantially
planar sheet of substantially flexible magnetizable material through such
at least one first high-flux field region by frictional contact with the
at least one opposite face surface; and wherein the at least one
substantially planar sheet of substantially flexible magnetizable
material is permanently magnetized by such movement through such at least
one first high-flux field region. Even further, it provides such a system
wherein such at least one upper support frame and such at least one lower
support frame are structured and arranged to maintain such at least one
first longitudinal axis and such at least one second longitudinal axis in
substantially parallel alignment. Moreover, it provides such a system
wherein such at least one upper support frame and such at least one lower
support frame are structured and arranged to maintain such at least one
first longitudinal axis and such at least one second longitudinal axis in
substantially vertical alignment.
[0014]Additionally, it provides such a system wherein: such at least one
upper support frame comprises at least one mount structured and arranged
to removably mount such at least one upper support frame to such at least
one lower support frame; such at least one mount is structured and
arranged to maintain such at least one upper support in a fixed position
relative to such at least one lower support frame; and such at least one
upper support frame is structured and arranged to provide at least one
freedom of movement of such at least one first magnetizer bar relative to
such at least one second longitudinal axis. Also, it provides such a
system further comprising: at least one third magnetic field source
structured and arranged to produce at least one third magnetic field; and
at least one fourth magnetic field source structured and arranged to
produce at least one fourth magnetic field; wherein such at least one
upper support frame is structured and arranged to support such at least
one third magnetic field source; wherein such at least one lower support
frame structured and arranged to rotationally support such at least one
fourth magnetic field source; wherein such at least one upper support
frame and such at least one lower support frame are structured and
arranged to geometrically position such at least one third magnetic field
source and such at least one fourth magnetic field source to generate at
least one second high-flux field region resulting from at least one
magnetic-field interaction between such at least one third magnetic field
and such at least one fourth magnetic field; wherein such at least one
second high-flux field region is situate substantially between such at
least one third magnetic field source and such at least one forth
magnetic field source; wherein such at least one passage is structured
and arranged to allow moving passage of the substantially flexible
magnetizable material through such at least one second high-flux field
region; wherein such at least one fourth magnetic field source is
structured and arranged to come into physical contact with the at least
one opposite face surface during passage of the at least one
substantially planar sheet of substantially flexible magnetizable
material through such at least one second high-flux field region; and
wherein such at least one third magnetic field source is structured and
arranged to avoid physical contact with the at least one pre-printed face
surface during passage of the at least one substantially planar sheet of
substantially flexible magnetizable material through such at least one
second high-flux field region. In addition, it provides such a system
wherein such at least one third magnetic field source and such at least
one fourth magnetic field source are each generated by at least one
permanent magnet.
[0015]And, it provides such a system wherein: such at least one third
magnetic field source comprises at least one third magnetizer bar
comprising at least one third longitudinal axis; such at least one third
magnetizer bar comprises a third set of discrete field-producing
laminations spaced substantially along such at least one third
longitudinal axis; each discrete field-producing lamination of such third
set comprises at least one substantially circular magnetic disk
magnetically coupled with at least one substantially circular
flux-conducting spacer; and each such at least one substantially circular
magnetic disk and each such at least one substantially circular
flux-conducting spacer is substantially coaxial with such at least one
third longitudinal axis. Further, it provides such a system wherein: such
at least one fourth magnetic field source comprises at least one fourth
magnetizer bar comprising at least one fourth longitudinal axis; such at
least one fourth magnetizer bar comprises a fourth set of discrete
field-producing laminations spaced substantially along such at least one
fourth longitudinal axis; each discrete field-producing lamination of
such fourth set comprises at least one substantially circular magnetic
disk magnetically coupled with at least one substantially circular
flux-conducting spacer; and each such at least one substantially circular
magnetic disk and each such at least one substantially circular
flux-conducting spacer is substantially coaxial with such at least one
forth longitudinal axis.
[0016]Even further, it provides such a system wherein: such at least one
powered rotator is structured and arranged to provide powered rotation of
such at least one fourth magnetizer bar about such at least one fourth
longitudinal axis; such powered rotation of such at least one fourth
magnetizer bar movably advances the at least one substantially planar
sheet of substantially flexible magnetizable material through such at
least one second high-flux field region by frictional contact with the at
least one opposite face surface; and at least one second region of the at
least one substantially planar sheet of substantially flexible
magnetizable material is permanently magnetized by such movement through
such at least one second high-flux field region. Moreover, it provides
such a system wherein: such at least one upper support frame and such at
least one lower support frame are structured and arranged to maintain
such at least one first longitudinal axis, such at least one second
longitudinal axis, such at least one third longitudinal axis, and such at
least one fourth longitudinal axis in substantially parallel alignment;
and such at least one upper support frame and such at least one lower
support frame are structured and arranged to maintain such at least one
third longitudinal axis and such at least one fourth longitudinal axis in
substantially vertical alignment.
[0017]Additionally, it provides such a system wherein: such first set of
discrete field-producing laminations of such at least one first
magnetizer bar are axially offset from such third set of discrete
field-producing laminations of such at least one third magnetizer bar;
and such second set of discrete field-producing laminations of such at
least one second magnetizer bar are axially offset from such fourth set
of discrete field-producing laminations of such at least one fourth
magnetizer bar. Also, it provides such a system wherein: such first set
of discrete field-producing laminations of such at least one first
magnetizer bar are vertically aligned with such second set of discrete
field-producing laminations of such at least one second magnetizer bar;
and such first set of discrete field-producing laminations and such
second set of discrete field-producing laminations comprise opposite
opposing polar moments. In addition, it provides such a system wherein
such third set of discrete field-producing laminations of such at least
one third magnetizer bar are vertically aligned with such fourth set of
discrete field-producing laminations of such at least one fourth
magnetizer bar. And, it provides such a system further comprising at
least one rotation-rate coordinator structured and arranged to coordinate
the rotation rates of such at least one second magnetizer bar and such at
least one fourth magnetizer bar. Further, it provides such a system
wherein such at least one rotation-rate coordinator comprises at least
one arrangement of intermeshed toothed gears.
[0018]Even further, it provides such a system wherein such at least one
powered rotator comprises: at least one electrically driven motor
comprising at least one output shaft structured and arranged to transmit
at least one torque force produced by such at least one electrically
driven motor; coupled to such at least one output shaft, at least one
first resilient roller rotationally supported within such at least one
lower support frame; at least one second resilient roller rotationally
supported within such at least one lower support frame; and at least one
third resilient roller rotationally supported within such at least one
lower support frame; wherein such at least one first resilient roller,
such at least one second resilient roller, and such at least one third
resilient roller are rotationally coupled by such at least one
arrangement of intermeshed toothed gears; wherein such at least one first
resilient roller and such at least one second resilient roller are
structured and arranged rotate such at least one second magnetizer bar by
frictional contact; wherein such at least one second resilient roller and
such at least one third resilient roller are structured and arranged to
rotate such at least one fourth magnetizer bar by frictional contact; and
wherein rotation of such at least one first resilient roller induces
rotation in such at least one second resilient roller, such at least one
third resilient roller, such at least one second magnetizer bar, and such
at least one fourth magnetizer bar.
[0019]In accordance with another preferred embodiment hereof, this
invention provides a method related to magnetization of at least one
sheet of substantially flexible magnetizable material having at least one
first planar face and at least one second planar face, such method
comprising the steps of: providing at least one first magnet structured
and arranged to produce at least one first magnetic field; providing at
least one second magnet structured and arranged to produce at least one
second magnetic field; producing at least one high-flux field region by
geometrically positioning such at least one first magnet above such at
least one second magnet to produce at least one high-flux gap
therebetween; forming at least one frictional surface contact between
such at least one second magnet and the at least one second planar face;
manipulating such at least one second magnet to movably advance the at
least one sheet of substantially flexible magnetizable material through
such at least one high-flux gap; and at least partially magnetizing the
at least one sheet of substantially flexible magnetizable material during
such advancement through such at least one high-flux gap.
[0020]Moreover, it provides such a method wherein the step of manipulating
such at least one second magnet to movably advance the at least one sheet
of substantially flexible magnetizable material through such at least one
high-flux gap comprises the step of rotating such at least one second
magnet to facilitate such advancement.
[0021]In accordance with another preferred embodiment hereof, this
invention provides a method related to hand-held magnetization of at
least one sheet of substantially flexible magnetizable material
comprising at least one substantially planar surface, such method
comprising the steps of: providing at least one modular end cap
structured and arranged to rotationally engage at least one first end of
at least one cylindrical magnet bar; selecting from a set of
hand-holdable bodies comprising differing fixed lengths, at least one
fixed-length hand-holdable body structured and arranged to rotationally
engage at least one second end of the at least one cylindrical magnet
bar; selecting from a set of cylindrical magnet bars comprising differing
fixed lengths, at least one cylindrical magnet bar comprising a fixed
length compatible with such at least one fixed-length hand-holdable body;
engaging such at least one second end of such at least one cylindrical
magnet bar within such at least one fixed-length hand-holdable body;
engaging such at least one first end of such at least one cylindrical
magnet bar within such modular end cap; and mounting such modular end cap
to such at least one fixed-length hand-holdable body.
[0022]Additionally, it provides such a method further comprising the steps
of: hand gripping such at least one fixed-length hand-holdable body;
positioning such at least one cylindrical magnet bar to contact the at
least one substantially planar surface; and rolling such at least one
cylindrical magnet bar across the at least one substantially planar
surface to at least partially magnetize the at least one substantially
planar sheet of substantially flexible magnetizable material.
[0023]In accordance with another preferred embodiment hereof, this
invention provides a system related to the retrofitting of at least one
friction-type sheet-handling device to enable magnetization of at least
one substantially planar sheet of substantially flexible magnetizable
material, during movement of such at least one substantially planar sheet
of substantially flexible magnetizable material along at least one
transport path of the at least one friction-type sheet-handling device,
such system comprising: at least one magnetic field source structured and
arranged to generated at least one magnetic field usable to magnetize the
at least one substantially planar sheet of substantially flexible
magnetizable material; and at least one mount structured and arranged to
mount such at least one magnetic field source to the at least one
friction-type sheet-handling device; wherein such at least one mount
comprises at least one positioner structured and arranged to situate such
at least one magnetic field source in at least one position producing at
least one magnetic-field interaction between such at least one
substantially planar sheet of substantially flexible magnetizable
material and the magnetic field as such at least one substantially planar
sheet of substantially flexible magnetizable material moves along the at
least one transport path; and wherein such at least one substantially
planar sheet of substantially flexible magnetizable material is
permanently magnetized by such at least one magnetic-field interaction.
Also, it provides such a system wherein such at least one magnetic field
source comprises at least one field-producing roller structured and
arranged to produce the magnetic field; wherein such at least one
field-producing roller is rotatably held by such at least one mount. In
addition, it provides such a system wherein such at least one magnetic
field source further comprises: at least one field-conducting roller
structured and arranged to form at least one magnetic circuit with such
at least one magnetic roller; and situate between such at least one
field-producing roller and such at least one field-conducting roller, at
least one air gap structured and arranged to enable passage of such at
least one substantially planar sheet of substantially flexible
magnetizable material, therethrough; wherein such at least one
field-conducting roller is rotatably held by such at least one mount.
And, it provides such a system wherein: such at least one field-producing
roller comprises at least one first rotator structured and arranged to
rotate such at least one field-producing roller, in at least one first
direction, about at least one first rotational axis oriented
substantially perpendicular to the movement of such at least one
substantially planar sheet of substantially flexible magnetizable
material, during passage of such at least one substantially planar sheet
of substantially flexible magnetizable material through such at least one
air gap; such at least one field-conducting roller comprises at least one
second rotator structured and arranged to rotate such at least one
field-producing roller, in at least one second direction, about at least
one second rotational axis oriented substantially perpendicular to the
movement of such at least one substantially planar sheet of substantially
flexible magnetizable material, during passage of such at least one
substantially planar sheet of substantially flexible magnetizable
material through such at least one air gap; such at least one air gap is
sized to provide substantially contemporaneous frictional contact between
such at least one substantially planar sheet of substantially flexible
magnetizable material and both such at least one field-producing roller
and such at least one field-conducting roller during passage
therethrough; and such rotation of such at least one field-producing
roller and such at least one field-conducting roller movably advance the
at least one substantially planar sheet of substantially flexible
magnetizable material through such at least one air gap. Further, it
provides such a system wherein such at least one first rotator comprises
at least one first torque transfer member structured and arranged to
transfer at least one first torque force of at least one first rotating
member of the at least one friction-type sheet-handling device to such at
least one field-producing roller. Even further, it provides such a system
wherein such at least one second rotator comprises at least one second
torque transfer member structured and arranged to transfer at least one
second torque force of at least one second rotating member of the at
least one friction-type sheet-handling device to such at least one
field-conducting roller. Moreover, it provides such a system wherein such
at least one first torque transfer member comprises at least one
substantially flexible drive belt.
[0024]Additionally, it provides such a system wherein such at least one
first torque transfer member comprises at least one chain drive
structured and arranged to engage at least one sprocket gear. Also, it
provides such a system wherein such at least one second torque transfer
member comprises at least one substantially flexible drive belt. In
addition, it provides such a system wherein such at least one second
torque transfer member comprises at least one chain drive structured and
arranged to engage at least one sprocket gear. And, it provides such a
system wherein such at least one magnetic field source is generated by at
least one permanent magnet. Further, it provides such a system wherein:
such at least one field-producing roller comprises a plurality of
substantially circular magnetic disks each one magnetically coupled with
at least one substantially circular flux-conducting spacer; and each such
at least one substantially circular magnetic disk and each such at least
one substantially circular flux-conducting spacer are substantially
coaxial with such at least one first longitudinal axis. Even further, it
provides such a system further comprising at least one separator member
structured and arranged to separate such at least one substantially
planar sheet of substantially flexible magnetizable material from such at
least one field-producing roller after such permanent magnetization. Even
further, it provides such a system wherein such at least one mount
comprises: at least one first end plate and at least one second end
plate; wherein such at least one first end plate and such at least one
second end plate comprise at least one paired set of receivers, each one
structured and arranged to rotatably receive a respective end of such at
least one field-producing roller and such at least one field-conducting
roller, and at least one mechanical fastener structured and arranged to
mechanically fasten such at least one first end plate and such at least
one second end plate to the at least one friction-type sheet-handling
device; wherein each paired set of receiver comprises at least one
friction-reducing bearing structured and arranged to assist
reduced-friction rotation of such at least one field-producing roller and
such at least one field-conducting roller. Even further, it provides such
a system wherein such at least one field-conducting roller is situate
substantially at the end of the at least one transport path of the at
least one friction-type sheet-handling device.
[0025]In accordance with another preferred embodiment hereof, this
invention provides a method related to the retrofitting of at least one
friction-type sheet-handling device to enable magnetization of at least
one substantially planar sheet of substantially flexible magnetizable
material, during movement of such at least one substantially planar sheet
of substantially flexible magnetizable material along at least one
transport path of the at least one friction-type sheet-handling device,
such method comprising the steps of: identifying at least one
friction-type sheet-handling device adapted to move such at least one
substantially planar sheet of substantially flexible magnetizable
material along at least one transport path between at least one initial
position and at least one final position; providing at least one magnetic
field source structured and arranged to generated at least one magnetic
field usable to magnetize the at least one substantially planar sheet of
substantially flexible magnetizable material; and providing at least one
mount to assist the mounting of such at least one magnetic field source
to the at least one friction-type sheet-handling device, wherein such at
least one mount is structured and arranged to situate such at least one
magnetic field source in at least one position producing at least one
magnetic-field interaction between such at least one substantially planar
sheet of substantially flexible magnetizable material and the magnetic
field as such at least one substantially planar sheet of substantially
flexible magnetizable material moves along the at least one transport
path.
[0026]Even further, it provides such a method further comprising the step
of: mounting such at least one magnetic field source to the at least one
friction-type sheet-handling device using such at least one mount;
wherein at least one modified friction-type sheet-handling device capable
of permanently magnetizing such at least one substantially planar sheet
of substantially flexible magnetizable material is achieved. Even
further, it provides such a method further comprising the step of
permanently magnetizing such at least one substantially planar sheet of
substantially flexible magnetizable material using such at least one
modified friction-type sheet-handling device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027]FIG. 1 shows a generalized schematic side view illustrating the
principal operational components of a high-energy sheet magnetizer
according to preferred embodiments of the present invention.
[0028]FIG. 2 shows a schematic detail view illustrating the principal
operational components of the high-energy sheet magnetizer according to
preferred embodiments of the present invention.
[0029]FIG. 3 shows a plan view of a pair of high-energy magnetizer bars
according to preferred embodiments of the present invention.
[0030]FIG. 4 shows a side view of a high-energy sheet magnetizer
comprising an upper magnetizer unit mounted to a lower magnetizer base
assembly according to a preferred embodiment of the present invention.
[0031]FIG. 5 shows a top view of the high-energy sheet magnetizer
illustrating a preferred positioning of the upper magnetizer unit over
the lower magnetizer base assembly according to the preferred embodiment
of FIG. 4.
[0032]FIG. 6 shows a top view of the high-energy sheet magnetizer of FIG.
4 with the upper magnetizer unit removed from the lower magnetizer base
assembly.
[0033]FIG. 7 shows a top view of the high-energy sheet magnetizer of FIG.
4 with the apertured cover plate removed to expose the magnetic feed
mechanism of the lower magnetizer base assembly.
[0034]FIG. 8 is a sectional view through the section 8-8 of FIG. 4 showing
preferred internal arrangements of the high-energy sheet magnetizer.
[0035]FIG. 9 shows a top view of the support frame of the upper magnetizer
unit of FIG. 4.
[0036]FIG. 10 shows a side view of the support frame of the upper
magnetizer unit of FIG. 4
[0037]FIG. 11 is a sectional view through the section 11-11 of FIG. 9.
[0038]FIG. 12 shows a top view of a first magnet bar (and also
representative of a second magnet bar) according to the preferred
embodiment of FIG. 4.
[0039]FIG. 13 shows a top view of a third magnet bar (also representative
of a fourth magnet bar) according to the preferred embodiment of FIG. 4.
[0040]FIG. 14 shows a top view of the apertured cover plate according to
the preferred embodiment of FIG. 4.
[0041]FIG. 15 shows a detailed view of a ramped aperture of the apertured
cover plate of FIG. 14.
[0042]FIG. 16 shows a diagrammatic sectional view illustrating two
preferred aperture ramping methods of the apertured cover plate of FIG.
14.
[0043]FIG. 17 shows a side view of the gear assembly of the lower
magnetizer base assembly.
[0044]FIG. 18 shows top view of a resilient roller of the lower magnetizer
base assembly.
[0045]FIG. 19 shows a side view of an end plate of the lower magnetizer
base assembly.
[0046]FIG. 20 shows a flow diagram illustrating a preferred method of
operation according to the present invention.
[0047]FIG. 21 shows a top view of a modular hand-held magnetizer according
to a preferred embodiment of the present invention.
[0048]FIG. 22 shows a side view of the modular hand-held magnetizer of
FIG. 21.
[0049]FIG. 23 shows an end view illustrating the modular hand-held
magnetizer of FIG. 21.
[0050]FIG. 24A shows an exploded view of the modular hand-held magnetizer
of FIG. 21.
[0051]FIG. 24B shows a second exploded view illustrating a set of
alternate modular components usable to generate alternate preferred
embodiments of the modular hand-held magnetizer of FIG. 21.
[0052]FIG. 25 illustrates the preferred use of the modular hand-held
magnetizer of FIG. 21.
[0053]FIG. 26 shows a perspective view of a sheet magnetizer modification,
used to update an existing friction-type sheet feeder to comprise
sheet-magnetization capability, according to an alternate preferred
embodiment of the present invention.
[0054]FIG. 27 shows a perspective view of the sheet magnetizer
modification, mounted to an existing friction-type sheet feeder,
according to the preferred embodiment of FIG. 26.
[0055]FIG. 28 shows a perspective view of the sheet magnetizer
modification of FIG. 26.
[0056]FIG. 29 shows a schematic sectional diagram illustrating the
preferred operation of the sheet magnetizer modification of FIG. 26.
[0057]FIG. 30 shows a second schematic sectional diagram further
illustrating the preferred operation of the sheet magnetizer modification
of FIG. 26.
[0058]FIG. 31 shows a partial exploded view illustrating components of the
sheet magnetizer modification of FIG. 26.
[0059]FIG. 32 shows a partial perspective view of an end plate assembly of
the sheet magnetizer modification of FIG. 26.
[0060]FIG. 33 shows a sectional view through a magnetic roller of the
sheet magnetizer modification of FIG. 26.
[0061]FIG. 34 shows a partial side view of an alternate chain drive
assembly according to a preferred embodiment of the present invention.
[0062]FIG. 35 shows a sectional view through the section 35-35 of FIG. 27.
[0063]FIG. 36 shows a partial top view, of the sheet magnetizer
modification mounted to the existing friction-type sheet feeder,
according to the preferred embodiment of FIG. 26.
[0064]FIG. 37 shows a schematic sectional diagram, illustrating an
alternate sheet magnetizer modification, according to another preferred
embodiment of the present invention.
[0065]FIG. 38 shows a functional block diagram, illustrating a preferred
method related to the deployments of the sheet magnetizer modification of
FIG. 26 and the alternate sheet magnetizer modification of FIG. 37,
according to a preferred method of the present invention.
DETAILED DESCRIPTION OF THE BEST MODES AND PREFERRED EMBODIMENTS OF THE
INVENTION
[0066]FIG. 1 shows a generalized schematic side view illustrating the
principal operational components of a generalized high-energy sheet
magnetizer 101. FIG. 2 shows a schematic detail view illustrating the
principal operational components of high-energy sheet magnetizer 101
according to preferred embodiments of the present invention.
[0067]High-energy sheet magnetizer 101 is illustrative of a preferred
embodiment of the magnetizer system, generally identified herein as sheet
magnetizer system 100. High-energy sheet magnetizer 101 preferably
functions to magnetize magnetically imprintable sheet materials such as
flexible magnetic sheet 104. Preferably, flexible magnetic sheet 104
comprises a substantially planar sheet of substantially flexible
magnetizable material having at least one pre-printed side 106 and at
least one substantially unprinted side 108. Such flexible magnetic sheet
materials generally combine a fine magnetizable material within a
flexible binder. The magnetizable material typically comprises a
pulverized ceramic ferrite in a thermoplastic binder. Exposure of the
resulting material to a magnetic field produces a magnetic "imprint"
within the compound, thus generating a substantially permanent magnet,
preferably exhibiting its own measurable magnetic field.
[0068]As noted above, achieving useful flux densities in thinner flexible
magnetic sheet materials is difficult due to the decreased volume of
magnetic materials within the cross-section. The preferred arrangements
of high-energy sheet magnetizer 101 overcome this limitation by exposing
flexible magnetic sheet 104 to regions of high magnetic field intensity.
This technique is particularly effective in producing thin flexible
magnetic sheet materials exhibiting enhanced magnetic pull strength
(approaching flux densities typically associated thicker sheets). In
addition, the preferred structures and arrangements of high-energy sheet
magnetizer 101 allows flexible magnetic sheet 104 to be magnetized
without physical contact between structures of high-energy sheet
magnetizer 101 and the surface of pre-printed side 106. This highly
preferred aspect of the design greatly reduces cost associated with
product loss due to damage of the printed surface during the
magnetization process.
[0069]High-energy sheet magnetizer 101 preferably comprises upper
magnetizer unit 112 and lower magnetizer base-assembly 110, as shown.
Upper magnetizer unit 112 is preferably positioned above lower magnetizer
base-assembly 110, as shown. Preferably, upper magnetizer unit 112
comprises at least one first magnetic field source preferably comprising
first magnet bar 114, as shown. Preferably, lower magnetizer
base-assembly 110 comprises at least one second magnetic field source
preferably comprising second magnet bar 116, as shown. Preferably, upper
magnetizer unit 112 and lower magnetizer base-assembly 110 are structured
and arranged to geometrically position first magnet bar 114 and second
magnet bar 116 to produce at least one magnetic field interaction.
Preferably, first magnet bar 114 and second magnet bar 116 are
geometrically positioned in a closely adjacent and substantially vertical
alignment, as shown. This preferred magnetic-field interaction between
the magnetic fields of first magnet bar 114 and second magnet bar 116
preferably produces at least one first high-flux field region 118, as
shown. Preferably, first high-flux field region 118 is situate
substantially between first magnet bar 114 and second magnet bar 116, as
shown. Preferably, first high-flux field region is situate substantially
within a first gap 120 formed between first magnet bar 114 and second
magnet bar 116, as shown.
[0070]Preferably, flexible magnetic sheet 104 is movably advanced along a
linear feed path 122, as schematically illustrated by the arrow
depictions of FIG. 1. Preferably, flexible magnetic sheet 104 is exposed
to first high-flux field region 118 as it passes through first gap 120
during the advancement along feed path 122, as shown (at least embodying
herein wherein such at least one geometric positioner comprises at least
one passage structured and arranged to allow moving passage of the
substantially flexible magnetizable material through such at least one
first high-flux field region). Passage of flexible magnetic sheet 104
through first high-flux field region 118 preferably produces the
above-described magnetic imprinting within those portions of the sheet
material exposed to first high-flux field region 118 (the exposed regions
showing significant magnetic hysteresis).
[0071]Preferably, feed path 122 is structured to bring second magnet bar
116 into physical contact with unprinted side 108 during passage of
flexible magnetic sheet 104 through first high-flux field region 118, as
shown. Preferably, the substantially horizontal deck surface 123 of feed
path 122 comprises at least one opening 125 through which second magnet
bar 116 upwardly projects to contact unprinted side 108, as shown. This
is in contrast to the preferred positioning of first magnet bar 114 by
upper magnetizer unit 112, preferably arranged to avoid substantially all
physical contact between the pre-printed side 106 of flexible magnetic
sheet 104 and first magnet bar 114, as shown. Preferably, first magnet
bar 114 and second magnet bar 116 are spaced at the smallest practical
distance that results in consistent avoidance of physical contact between
first magnetic bar 114 and pre-printed side 106 during passage of
flexible magnetic sheet 104 through first high-flux field region 118. A
surface-to-magnet separation A of not more than a few millimeters is
generally preferred. This preferred relationship assists in maintaining
high-gauss flux levels within the magnetic circuit formed across first
gap 120. Upon reading the teachings of this specification, those of
ordinary skill in the art will now understand that, under appropriate
circumstances, considering such issues as intended use, magnitude of the
flux within the magnetic circuit, composition of the sheet material,
etc., other gap arrangements, such as larger or smaller gaps,
active/dynamic gap adjustment assemblies, etc., may suffice.
[0072]Preferably, second magnet bar 116 is structured and arranged to
movably advance flexible magnetic sheet 104, in the depicted sheet-feed
direction along feed path 122, as shown. Preferably, rotation of second
magnet bar 116 movably advances flexible magnetic sheet 104 through first
high-flux field region 118 by frictional contact with unprinted side 108,
as shown.
[0073]Preferably, second magnet bar 116 is rotationally mounted within
magnetizer base-assembly 110. In addition, second magnet bar 116 is
preferably operationally coupled to powered rotator assembly 130 that
preferably transmits at least one rotational force (torque) to second
magnet bar 116 (see FIG. 4). This preferred arrangement results in
powered rotation of second magnet bar 116 and advancement of flexible
magnetic sheet 104 along feed path 122, as shown. Preferably, on passage
through first high flux field region 118, flexible magnetic sheet 104 is
preferably exposed to at least one second high-flux field region 124, as
described below.
[0074]Preferably, upper magnetizer unit 112 further comprises at least one
third magnetic field source, preferably comprising third magnet bar 127,
as shown. Preferably, lower magnetizer base-assembly 110 further
comprises at least one fourth magnetic field source preferably comprising
fourth magnet bar 126, as shown. The preferred relationship between third
magnet bar 127 and fourth magnet bar 126 is substantially similar to the
above description pertaining to first magnet bar 114 and second magnet
bar 116. Briefly stated, the geometric relationship between third magnet
bar 127 and fourth magnet bar 126 preferably produces at least one second
high-flux field region 124 resulting from magnetic-field interactions
between third magnet bar 127 and fourth magnet bar 126. Preferably,
second high-flux field region 124 is situated substantially within second
gap 128 formed between third magnet bar 127 and fourth magnet bar 126, as
shown.
[0075]Preferably, flexible magnetic sheet 104 is exposed to second
high-flux field region 124 during passage through second gap 128 as the
sheet is advanced along feed path 122, as shown. Passage of flexible
magnetic sheet 104 through second high-flux field region 124 preferably
produces a magnetic imprint within portions of the sheet material (more
preferably within regions of that were not exposed to first high-flux
field region 118).
[0076]Preferably, feed path 122 is structured to bring fourth magnet bar
126 into physical contact with unprinted side 108 during passage of
flexible magnetic sheet 104 through second high-flux field region 124, as
shown. Like first magnet bar 114, upper magnetizer unit 112 preferably
positions third magnet bar 127 to avoid substantially all physical
contact between the pre-printed side 106 of flexible magnetic sheet 104
and third magnet bar 127. Upon reading the teachings of this
specification, those of ordinary skill in the art will now understand
that, under appropriate circumstances, considering such issues as
intended use, durability of printing, etc., other magnetic bar
positioning arrangements, such as the positioning of the upper magnetic
bars to make minimal contact with a printed surface, utilizing active
dynamic adjustment mechanisms to maintain ideal positional spacing, etc.,
may suffice.
[0077]Preferably, fourth magnet bar 126 is also structured and arranged to
movably advance flexible magnetic sheet 104 along feed path 122, in the
depicted sheet-feed direction. Like second magnet bar 116, fourth magnet
bar 126 is rotationally mounted within magnetizer base-assembly 110 and
is preferably coupled to powered rotator assembly 130 (as shown in FIG.
4). This preferred arrangement results in powered rotation of fourth
magnet bar 126 and power-assisted advancement of flexible magnetic sheet
104 along feed path 122, as shown.
[0078]FIG. 3 shows a plan view illustrating a preferred arrangement of
magnet bars according to preferred embodiments of the present invention.
The illustration of FIG. 3 is representative of the functional pairing of
first magnet bar 114 and third magnet bar 127 of upper magnetizer unit
112 or second magnet bar 116 and fourth magnet bar 126 of magnetizer
base-assembly 110. For clarity of description, the functional pairing of
first magnet bar 114 and third magnet bar 127 will be discussed with the
understanding that the teachings equally applicable to the functional
pairing of second magnet bar 116 and fourth magnet bar 126. Furthermore,
the magnet bars have been isolated from the overall assembly for clarity.
[0079]Preferably, both first magnet bar 114 and third magnet bar 127
extend substantially across substantially the full width of flexible
magnetic sheet 104, as shown. Preferably, first magnet bar 114 comprises
first longitudinal axis 132 preferably oriented substantially
perpendicular to the linear axis 134 of feed path 122 (as generally
defined by the direction of sheet motion), as shown. Preferably, first
magnet bar 114 comprises a first set of discrete magnetizer banks 136,
preferably spaced substantially along the width of first longitudinal
axis 132, as shown. Preferably, each magnetizer bank 136 comprises an
alternating sequence of magnetic plates and flux-conducting plates (as
best described in FIG. 12 and FIG. 13). Preferably, each magnetic plate
comprises a high-strength permanent magnet and each flux-conducting plate
preferably comprises a material exhibiting high permeability when
saturated. Preferably, both magnetic plates and flux-conducting plates
comprise substantially circular peripheral shapes, as shown in FIG. 2.
Preferably, each substantially circular magnetic plate and each
substantially circular flux-conducting plate are substantially coaxial
with first longitudinal axis 132, as shown. Thus, the sequential
laminations of each magnetizer bank 136 form a substantially cylindrical
peripheral surface.
[0080]Preferably, magnetizer banks 136 of first magnet bar 114 are mounted
coaxially on a central bar 138, as shown. Preferably, magnetizer banks
136 are separated by a set of spacers 140 that are also preferably
mounted coaxially on central bar 138, as shown. Spacers 140 preferably
comprise widths generally matching those of magnetizer banks 136, as
shown.
[0081]The preferred structures and arrangements of second magnet bar 116
are substantially identical to those of first magnet bar 114, as
described above. Preferably, the placement of magnetizer banks 136 along
second longitudinal axis 142 of second magnet bar 116 are substantially
identical to those of first magnet bar 114. This preferably places the
lower magnetizer banks 136 of second magnet bar 116 in vertical alignment
with the upper magnetizer banks 136 of first magnet bar 114, as
illustrated in FIG. 2. Thus, a plurality of first high-flux field regions
118 (six in the depicted embodiment)are preferably generated within first
gap 120 by the preferred vertical stacking of first magnet bar 114 over
second magnet bar 116 and the resulting formation of magnetic flux
circuits between upper and lower magnet bars.
[0082]The preferred structures and arrangements of third magnet bar 127
are substantially similar to those of first magnet bar 114, with the
exception of the preferred positioning of magnetizer banks 136 along
third longitudinal axis 143, as shown. Note that magnetizer banks 136 of
first magnet bar 114 are preferably axially offset from magnetizer banks
136 of third magnet bar 127. More preferably, magnetizer banks 136 of
first magnet bar 114 are axially offset a preferred distance
substantially equal to the width of one magnetizer bank 136, as shown
(similarly, magnetizer banks 136 of second magnet bar 116 are axially
offset from those of fourth magnet bar 126). This preferred arrangement
produces a plurality of second high-flux field regions 124 (seven in the
depicted embodiment) within second gap 128, each second high-flux field
region 124 preferably generated by the preferred vertical stacking of
third magnet bar 127 over fourth magnet bar 126. Note that the plurality
of second high-flux field regions 124 of second gap 128 are preferably
axially offset from the plurality of first high-flux field regions 118 of
first gap 120.
[0083]The preferred axial offsetting of magnetizer banks 136 assures that
the full width of flexible magnetic sheet 104 is exposed to at least one
of the above-described high-flux field regions as it is advanced along
feed path 122, as shown. Thus, magnetization of flexible magnetic sheet
104 preferably occurs in parallel strips 144 defined by alternating
exposure to the magnetic fields of the first/second and third/fourth
magnet bars, as shown. The preferred axial offsetting of the depicted
embodiment has been shown to reduce feed-related problems related to the
adhering and wrapping of flexible magnetic sheet 104 around the
magnetizing bars during operation. Upon reading the teachings of this
specification, those of ordinary skill in the art will now understand
that, under appropriate circumstances, considering such issues as
intended use, physical characteristics of the flexible magnetic sheet,
etc., other magnet arrangements, such as utilizing a continuous array of
magnets extending substantially across the sheet width, etc., may
suffice.
[0084]FIG. 4 shows a side view of high-energy sheet magnetizer 102
comprising upper magnetizer unit 112 mounted to lower magnetizer base
assembly 110 according to a preferred embodiment of the present
invention. FIG. 5 shows a top view of high-energy sheet magnetizer 102
illustrating a preferred positioning of upper magnetizer unit 112 over
lower magnetizer base assembly 110 according to the preferred embodiment
of FIG. 4.
[0085]Preferred commercial embodiments of high-energy sheet magnetizer 102
are produced in two widths, a 13-inch model and a 25-inch model. For
illustrative purposes, the following teachings shall describe preferred
structures and arrangements of the 13-inch embodiment. Those of ordinary
skill in the art will appreciate, upon reading the teachings of this
specification, that without undue experimentation, a number of alternate
embodiment widths may be readily developed, including the previously
described 25-inch model. The teachings of this specification will address
specific alternate preferred arrangements of the 25-inch embodiment, as
applicable.
[0086]Preferably, upper magnetizer unit 112 comprises a rigid support
frame 145 adapted to support and position both first magnet bar 114 and
third magnet bar 127 during operation, as shown. Preferably, support
frame 145 comprises cross support 150 modified to comprise a pair of
linear receiver slots 148 (a preferred configuration of support frame 145
is best illustrated in FIG. 9, FIG. 10, and FIG. 11).
[0087]Preferably, first magnet bar 114 and third magnet bar 127 are each
located in one of the linear receiver slots 148, as shown. Preferably,
the lower portion of each linear receiver slot 148 comprises a linear
slot aperture 152, preferably extending substantially the length of each
linear receiver slot 148, as shown. Slot apertures 152 preferably allow
magnetizer banks 136 to extend downwardly through support frame 145, as
best shown in FIG. 10. Preferably, linear receiver slots 148 are adapted
to support both first magnet bar 114 and third magnet bar 127 in
substantially parallel alignment, as shown.
[0088]Preferably, both first magnet bar 114 and second magnet bar 116 are
loosely supported within linear receiver slots 148, as shown. Preferably,
both first magnet bar 114 and second magnet bar 116 are maintained in the
preferred operable position by gravity positioning, as shown. This
preferred arrangement allows both upper magnet bars to move vertically
relative to the lower magnet bars (at least embodying herein wherein such
at least one upper support frame is structured and arranged to provide at
least one freedom of movement of such at least one first magnet bar
relative to such at least one second longitudinal axis). This preferred
arrangement reduces the potential for damage to pre-printed side 106 in
the event of a jam or other misfeed along the path 122. Upon reading the
teachings of this specification, those of ordinary skill in the art will
now understand that, under appropriate circumstances, considering such
issues as intended use, cost, preference, etc., other mounting
arrangements, such as mounting the upper magnetic bars in fixed the
bearing seats, etc., may suffice.
[0089]Preferably, mount assembly 133, removably fastens upper magnetizer
unit 112 to magnetizer base-assembly 110, as shown. This preferred
arrangement allows upper magnetizer unit 112 to be removed from
magnetizer base-assembly 110 when high-energy magnetization is not
required (at least embodying herein wherein such at least one upper
support frame comprises at least one mount structured and arranged to
removably mount such at least one upper support frame to such at least
one lower support frame). Preferably, mount assembly 133 is structured
and arranged to maintain upper magnetizer unit 112 in a fixed position
relative to magnetizer base-assembly 110 using a plurality of mechanical
fasteners, most preferably threaded fasteners 146, as shown.
[0090]FIG. 6 shows a top view of high-energy sheet magnetizer 102 of FIG.
4 with upper magnetizer unit 112 removed from lower magnetizer base
assembly 110 to expose lower magnetizer banks 136. Visible in FIG. 6 is
the preferred positioning of second magnet bar 116 and fourth magnet bar
126 within magnetizer base-assembly 110. Note that magnetizer
base-assembly 110 maintains second magnet bar 116 and fourth magnet bar
126 in substantially parallel alignment at a preferred axis-to-axis
spacing substantially identical to that of first magnet bar 114 and third
magnet bar 127, as shown.
[0091]Preferably, the substantially horizontal deck surface 123 is defined
by the upper plane of apertured cover plate 139, as shown. Preferably,
apertured cover plate 139 comprises a set of rectangular-shaped openings
125A and a set of rectangular-shaped openings 125B preferably arranged in
an offset configuration, as shown. Preferably, openings 125A allow the
magnetizer banks 136 of second magnet bar 116 to project upwardly through
apertured cover plate 139 to contact flexible magnetic sheet 104, as
shown. Preferably, openings 125B allow the magnetizer banks 136 of fourth
magnet bar 126 to project upwardly through apertured cover plate 139 to
contact flexible magnetic sheet 104, as shown.
[0092]Preferably, entry of flexible magnetic sheet 104 to feed path 122 is
facilitated by a downwardly projecting entry ramp 152, preferably mounted
to the side of magnetizer base-assembly 110, at an elevation preferably
matching deck surface 123 (see also FIG. 8). Exit of the magnetized
flexible magnetic sheet 104 from deck surface 123 is preferably
facilitated by a downwardly projecting exit ramp 154, also preferably
mounted to the opposite side of magnetizer base-assembly 110; at an
elevation preferably matching deck surface 123 (see again FIG. 8).
[0093]FIG. 7 shows a top view of high-energy sheet magnetizer 102 of FIG.
4 with apertured cover plate 139 removed to expose magnetic feed
mechanism 160 of lower magnetizer base assembly 110.
[0094]Magnetic feed mechanism 160 preferably includes second magnet bar
116, fourth magnet bar 126, powered rotator assembly 130, first resilient
roller 162, second resilient roller 164, third resilient roller 166, and
gear assembly 168, as shown.
[0095]It is again helpful to note that second magnet bar 116 and fourth
magnet bar 126 are preferably adapted to advance flexible magnetic sheet
104 along feed path 122. Magnetic feed mechanism 160 is preferably
adapted to enable powered rotation of second magnet bar 116 and fourth
magnet bar 126.
[0096]Preferably, powered rotator assembly 130 comprises
electrically-driven motor 170, motor control 171, and output shaft 172,
as shown. Preferably, output shaft 172 is adapted to transmit rotational
torque forces produced by electrically-driven motor 170 to first
resilient roller 162, as shown. A sleeve-type coupler 176 is preferably
used to join output shaft 172 to an extended input shaft 178 of first
resilient roller 162, as shown.
[0097]Preferably, the powered first resilient roller 162 is rotationally
supported within magnetizer base-assembly 110 by a set of low-friction
bearings 174, as shown. Preferably, the idler rollers, preferably
comprising both second resilient roller 164 and third resilient roller
166 are similarly supported within magnetizer base-assembly 110 by
low-friction bearings 174, as shown. Preferably, the rotational axes of
first resilient roller 162, second resilient roller 164, and third
resilient roller 166 are substantially parallel, as shown. In addition,
first resilient roller 162, second resilient roller 164, and third
resilient roller 166 are preferably positionally fixed relative to
magnetizer base-assembly 110, as shown.
[0098]Preferably, second resilient roller 164 and third resilient roller
166 each comprise shaft extensions 180 that preferably project into gear
housing 182, as shown. Extended input shaft 178 of first resilient roller
162 preferably extends through gear housing 182 as it projects
horizontally to engage sleeve-type coupler 176, as shown.
[0099]Preferably, first resilient roller 162, second resilient roller 164,
and third resilient roller 166 are rotationally coupled by operable
engagements with gear assembly 168, as shown. Preferably, gear assembly
168 comprises an arrangement of intermeshed toothed gears located within
gear housing 182, as shown. Gear assembly 168 preferably functions as a
rotation-rate coordinator, preferably functioning to coordinate the
rotation rates of first resilient roller 162, second resilient roller
164, and third resilient roller 166 during operation. Preferred gearing
arrangements of gear assembly 168 are described in greater detail in FIG.
17.
[0100]Preferably, second magnet bar 116 is rotationally mounted within
magnetizer base-assembly 110 by low-friction bearings 174, as shown.
Second magnet bar 116 preferably comprises a position between first
resilient roller 162 and second resilient roller 164, as shown.
Preferably, second longitudinal axis 142 is substantially parallel to the
longitudinal axis of first resilient roller 162 and second resilient
roller 164, as shown. Furthermore, second magnet bar 116 is preferably
positioned to be in direct contact with the outer circumferential face of
both first resilient roller 162 and second resilient roller 164 (as best
illustrated in the sectional view of FIG. 8). Preferably, first resilient
roller 162 and second resilient roller 164 are structured and arranged to
rotate second magnet bar 116 by frictional contact, as shown.
[0101]Preferably, fourth magnet bar 126 is similarly mounted within
magnetizer base-assembly 110 by low-friction bearings 174, as shown.
Fourth magnet bar 126 preferably comprises a position between second
resilient roller 164 and third resilient roller 166, as shown.
Preferably, fourth longitudinal axis 184 of fourth magnet bar 126 is
substantially parallel to the longitudinal axes of second resilient
roller 164 and third resilient roller 166, as shown. Furthermore, fourth
magnet bar 126 is preferably positioned to be in direct contact with the
outer circumferential faces of both second resilient roller 164 and third
resilient roller 166 (as best illustrated in the sectional view of FIG.
8). Preferably, second resilient roller 164 and third resilient roller
166 are structured and arranged to rotate fourth magnet bar 126 by
frictional contact, as shown. Thus, rotation of first resilient roller
162, by the application of torque on extended input shaft 178, preferably
induces powered rotation in second resilient roller 164, third resilient
roller 166, second magnet bar 116, and fourth magnet bar 126, as shown.
[0102]Electrically-driven motor 170 preferably comprises a direct current
(DC) gearmotor, more preferably, a 140 rpm, 90 V direct current,
right-angle gear motor such as those produced by the Dayton Electric
Corporation of Niles Ill. The rotational output of electrically-driven
motor 170 is preferably controlled by motor control 171, as shown.
Preferably, motor control 171 comprises a solid-state speed controller
adapted to convert an alternating current (AC) line-voltage input to full
wave direct-current power compatible with electrically-driven motor 170.
Preferred motor controllers suitable for use with preferred embodiments
described herein include DC speed controllers produced by the Dayton
Electric Corporation of Niles Illinois.
[0103]Magnetizer base-assembly 110 preferably comprises a rigid and
substantially rectangular support frame 186 comprising first endplate
188, second endplate 190 and two side plates 192 preferably extending
therebetween, as shown. Preferably, first endplate 188 and second
endplate 190 are adapted to support and position second resilient roller
164, third resilient roller 166, second magnet bar 116, and fourth magnet
bar 126, as shown. A preferred configuration of first endplate 188 and
second endplate 190 is shown in FIG. 19.
[0104]Preferably, support frame 186 is rigidly mounted to first base plate
194 and second base plate 196, as shown. The preferred extended
configuration of first base plate 194 provides a rigid mounting point for
electrically-driven motor 170, as shown. Preferably, first base plate 194
and second base plate 196 comprise a set of adjustable feet 200 to
facilitate leveling of the assembly prior to use, as shown.
[0105]FIG. 8 is a sectional view through the section 8-8 of FIG. 4 showing
preferred internal arrangements of high-energy sheet magnetizer 102.
Visible in the sectional view of FIG. 8 is upper magnetizer unit 112
mounted to magnetizer base-assembly 110 by mount assembly 133, first
magnet bar 114 vertically aligned above second magnet bar 116, third
magnet bar 127 vertically aligned above fourth magnet bar 126, magnetizer
banks 136 of first magnet bar 114, spacers 140 of third magnet bar 127,
spacers 140 of fourth magnet bar 126, magnetizer banks 136 of second
magnet bar 116, preferred positioning of apertured cover plate 139, and
cross support 150 of support frame 145. In addition, the sectional view
of FIG. 8 shows the preferred mounting of entry ramp 152 and exit ramp
154 to side plates 192. Also visible in FIG. 8 is the preferred
relationship between first resilient roller 162, second resilient roller
164 and second magnet bar 116. In addition, FIG. 8 shows the preferred
relationship between second resilient roller 164, third resilient roller
166, and fourth magnet bar 126.
[0106]Support frame 186 is preferably constructed from one or more
substantially rigid materials, preferably substantially non-magnetic
materials, more preferably a non-magnetic metallic material, most
preferably aluminum. Support frame 186 is preferably assembled using
mechanical fasteners, as shown.
[0107]High-energy sheet magnetizer 102 is preferably designed to rest on
the surface of a workbench or similar horizontal support surface 198, as
shown. The preferred compact size of high-energy sheet magnetizer 102 is
preferably designed facilitate the "in-house" use of the preferred
embodiments by print shops that would typically outsource magnetization
of flexible magnetic sheet 104 after printing.
[0108]FIG. 9 shows a top view of support frame 145 of upper magnetizer
unit 112 of FIG. 4. FIG. 10 shows a side view of support frame 145. FIG.
11 is a sectional view through the section 11-11 of FIG. 9.
[0109]Support frame 145 preferably comprises a generally H-shaped
configuration, preferably comprising an assembly of cross support 150
extending between two end supports 202, as shown in FIG. 9. For the
13-inch embodiment of high-energy sheet magnetizer 102, support frame 145
accommodates a feed path 122 having a width B of about 13 inches, as
shown. Preferably, each receiver slot 148 comprises a width of about 11/8
inch and a center-to-center spacing C of about 2 inches. Preferably, each
receiver slot 148 is milled to comprise a lower radius to better
accommodate the preferred circular outer conformation of the magnet bars,
as shown. Cross support 150 preferably comprises an overall width D of
about 4 inches, as shown.
[0110]Support frame 145 is preferably constructed from one or more
substantially rigid materials, preferably substantially non-magnetic
materials, more preferably a non-magnetic metallic material, most
preferably aluminum.
[0111]Mount assembly 133 preferably comprises the bolted connections
between end supports 202, first endplate 188, and second endplate 190 (of
lower support frame 186).
[0112]FIG. 12 shows a top view of first magnet bar 114(and also
representative of second magnet bar 116) according to the preferred
embodiment of FIG. 4. FIG. 13 shows a top view of third magnet bar 127
(also representative of fourth magnet bar 126) according to the preferred
embodiment of FIG. 4.
[0113]For the 13-inch embodiment of high-energy sheet magnetizer 102,
first magnet bar 114 comprises six magnetizer banks 136 and seven spacers
140, as shown. Preferably, each field-producing bank 136 of first magnet
bar 114 comprises 15 flux-conducting plates, hereinafter identified as
circular washers 204, each circular washer 204 having a thickness of
about 0.03 inches, and 14 magnetic plates, hereinafter identified as
circular magnets 206, each circular magnet 206 having a thickness of
about 0.04 inches. Preferably, circular magnets 206 and circular washers
204 are laminated in alternating sequence. This produces magnetizer banks
136 comprising a preferred overall width E of about 1 inch, as shown.
[0114]End spacers 140 of first magnet bar 114 preferably comprise a width
F of about 0.75 inches, as shown. Intermediate spacers 140 of first
magnet bar 114 preferably comprise a width G of about 0.98 inch, as
shown.
[0115]Third magnet bar 127 preferably comprises seven magnetizer banks 136
and seven spacers 140, as shown. The magnetizer banks 136 at each end of
third magnet bar 127 preferably comprise 11 circular washers 204 each
having a thickness of about 0.031 inches, and 10 circular magnets 206
each having a thickness of about 0.042 inches. This preferably produces
two field-producing banks 136, at each end of third magnet bar 127, each
one having an overall thickness H of about 0.76 inches, as shown. All
spacers 140 of third magnet bar 127 preferably comprise a width G of
about 0.98 inch, as shown.
[0116]Preferably, circular washers 204 of magnetizer banks 136 comprise an
outer diameter X of about 1 inch. Preferably, circular washers 204 of
magnetizer banks 136 preferably comprise at least one
magnetically-conductive material, most preferably steel.
[0117]Preferably, circular magnets 206 of magnetizer banks 136 also
comprise an outer diameter of about 1 inch. Preferably, circular magnets
206 comprise a permanent magnet, more preferably a neodymium-iron-boron
[Nd--Fe--B] permanent magnet, alternately preferably, a samarium-cobalt
[Sm--Co] permanent magnet, alternately preferably, an alnico permanent
magnet, alternately preferably, a hard ferrite [ceramic] permanent
magnet.
[0118]Permanent magnets suitable for use in the preferred embodiments
described herein include commercially available products produced by
Dexter Magnetic Technologies of Fremont Calif. Upon reading the teachings
of this specification, those of ordinary skill in the art will now
understand that, under appropriate circumstances, considering such issues
as intended use, cost, advances in magnet technology, etc., other
magnetic field generation arrangements, such as electromagnets, magnetic
composites, etc., may suffice.
[0119]Magnetizer banks 136 are preferably constructed to have an overall
preferred width as close to 1 inch as possible. Shim washers are
preferably used, on the outside of magnetizer banks 136, to provide minor
width adjustments needed to achieve the preferred widths. Magnetizer
banks 136 are preferably assembled such that the magnet poles of circular
magnets 206 are oriented North/South (relative to each other), as if each
magnetizer bank 136 comprised a single magnetic element.
[0120]Preferably, spacers 140, circular magnets 206, and circular washers
204 are coaxially engaged on central bar 138, as shown. Preferably,
central bar 138 comprises a cylindrical rod, more preferably a "316"
stainless steel, 1/4-inch diameter rod, as shown. Preferably, spacers 140
comprise hollow cylindrical members having an outer diameter of about 0.8
inches. Spacers 140 preferably comprise steel.
[0121]FIG. 14 shows a top view of apertured cover plate 139 according to
the preferred embodiment of FIG. 4. Appertured cover plate 139 is
preferably constructed from a substantially rigid sheet of non-metallic
material, most preferably a brass sheet. Preferably, apertured cover
plate 139 comprises a uniform thickness J of about 0.6 inches, as shown.
Preferably, apertured cover plate 139 comprises a set of
rectangular-shaped openings 125A and a set of rectangular-shaped openings
125B preferably arranged in an offset configuration, as shown.
Preferably, openings 125A allow the magnetizer banks 136 of second magnet
bar 116 to project upwardly through apertured cover plate 139 to contact
flexible magnetic sheet 104, as shown. The preferred spacing of openings
125A preferably match the spacing of magnetizer banks 136 of second
magnet bar 116. Preferably, openings 125B allow the magnetizer banks 136
of fourth magnet bar 126 to project upwardly through apertured cover
plate 139 to contact flexible magnetic sheet 104, as shown. The preferred
spacing of openings 125B preferably match the spacing of magnetizer banks
136 of fourth magnet bar 126.
[0122]Openings 125A preferably comprise an effective open width K of about
1 inch and an effective open length L of about 1.25 inches, as shown.
Openings 125B also preferably comprise an effective open width K of about
1 inch and an effective open length L of about 1.25 inches, with the
exception of the end apertures. Recall that the magnetizer banks 136 at
each end of fourth magnet bar 126 preferably comprise a narrow width, as
shown. For this reason, the two end apertures of openings 125B preferably
comprise a length M of about 1.12 inches, as shown.
[0123]Preferably, the trailing edge of each opening 125A and opening 125B
preferably comprises an angled ramp 208, as shown. Preferably, angled
ramp 208 assists in maintaining smooth and consistent feed performance by
reducing the tendency of flexible magnetic sheet 104 to contact the
trailing edge of the apertures due to magnetic adherence to the
magnetizer banks 136. Preferably, angled ramp 208 comprises a tapered cut
having a length N of about 5/16 inch. Alternately preferably, angled ramp
208 is formed by modifying a section of apertured cover plate 139 two
allow bending of the section downward a distance P of about 1/16 inch, as
shown in FIG. 15 and FIG. 16.
[0124]FIG. 15 shows a detailed view of the alternate "bent" aperture of
the apertured cover plate of FIG. 14. FIG. 16 shows a diagrammatic
sectional view illustrating the two preferred aperture ramping methods of
apertured cover plate 139.
[0125]FIG. 17 shows a side view of gear assembly 168 of lower magnetizer
base-assembly 110. Preferably, gear assembly 168 comprises a train of
intermeshed toothed gears 210, preferably located within gear housing
182, as shown. The mechanical train of gear assembly 168 preferably
functions as a rotation-rate coordinator functioning to coordinate the
rotation rates of first resilient roller 162, second resilient roller
164, and third resilient roller 166 during operation.
[0126]Preferably, toothed gears 210 comprise 14.5-degree pressure angle
spur gears. Preferably, each resilient roller comprises a roller gear
212, as shown. Preferably, each roller gear 212 comprises a 20-diameter
pitch by 36 teeth by 1.8 pitch-diameter gear-element. Preferably, power
applied to first resilient roller 162 is transferred by first roller gear
212A to second roller gear 212B (of second resilient roller 164) by first
transfer gear 214A, as shown. Preferably, power applied to second
resilient roller 164 is transferred by second roller gear 212B to third
roller gear 212C (of third resilient roller 166) by second transfer gear
214B, as shown. Preferably, both first transfer gear 214A and first
transfer gear 214B comprise a 20-diameter pitch by 15 teeth by 0.75
pitch-diameter gear-element. Upon reading the teachings of this
specification, those of ordinary skill in the art will now understand
that, under appropriate circumstances, considering such issues as
intended use, cost, etc., other coordination arrangements, such as belts,
electronically controlled step motors, physical surface contact between
rollers, etc., may suffice.
[0127]FIG. 18 shows top view of a preferred resilient roller configuration
of lower magnetizer base-assembly 110. Preferably, first resilient roller
162, second resilient roller 164, and third resilient roller 166 each
comprise an elongated cylindrical member having a resilient outer surface
215, as shown. Preferably, resilient outer surface 215 comprises a
synthetic rubber, most preferably a neoprene material having about
75-durometer composition. Preferably, resilient outer surface 215
comprises an outer diameter Q of about 1.5 inches, as shown. Preferably,
first resilient roller 162, second resilient roller 164, and third
resilient roller 166 each comprise shaft extensions 180 that preferably
project into gear housing 182, as previously described. Extended input
shaft 178 of first resilient roller 162 preferably extends through gear
housing 182 as it projects horizontally to engage sleeve-type coupler
176, as previously described. For the 13-inch embodiment of high-energy
sheet magnetizer 102, resilient outer surface 215 comprises a width R of
about 13 inches.
[0128]FIG. 19 shows a side view of first endplate 188 and second endplate
190 of lower magnetizer base assembly 110. Preferably, first endplate 188
and second endplate 190 each comprise a substantially symmetrical
arrangement of recessed receivers 220 adapted to receive and position
low-friction bearings 174 of the above-described rotating elements of
lower magnetizer base assembly 110, as shown. Preferably, first endplate
188 and second endplate 190 are each constructed from a solid billet of
non-magnetic material, more preferably a non-magnetic metal, most
preferably a 0.75-inch thick aluminum block. Preferably, recessed
receivers 220 are preferably milled to a depth of about 0.25 inch.
[0129]FIG. 20 shows a flow diagram illustrating a preferred method of
operation according to the present invention. Upon reading the prior
teachings of this specification, those of ordinary skill in the art will
now understand that the preferred embodiments, as described herein,
preferably enable at least one method related to magnetization of
flexible magnetic sheet 104, such method comprising the following series
of preferred steps. In a first preferred step, identified herein as step
250, high-energy sheet magnetizer 102 is preferably structured and
arranged to produce at least one first magnetic field by providing at
least one first magnet. Furthermore, the preferred arrangements of
high-energy sheet magnetizer 102 preferably provide at least one second
magnet structured and arranged to produce at least one second magnetic
field, as noted in preferred step 252. Preferably, the first and second
magnets produce at least one high-flux field region by the geometrical
positioning, preferably vertical alignment, of the magnets by upper
magnetizer unit 112 and magnetizer base-assembly 110. As previously
described, this preferred arrangement of magnet preferably produces at
least one high-flux gap between the magnets, as noted in preferred step
254.
[0130]Preferably, at least one of the second magnets, most preferably at
least one of the lower magnets is manipulated to feed advance flexible
magnetic sheet 104 through the high-flux gap, as indicated by preferred
step 256. This is preferably accomplished by rotating the second magnet
after forming at least one frictional surface contact between at least
one of the second magnets and the planar unprinted side 108 of flexible
magnetic sheet 104. This preferably results in at least partial
magnetization of flexible magnetic sheet 104, as indicated in preferred
step 258.
[0131]FIG. 21 shows a top view of a modular hand-held magnetizer 260
according to a preferred embodiment of the present invention. FIG. 22
shows a side view of modular hand-held magnetizer 260 of FIG. 21. FIG. 23
shows an end view illustrating modular hand-held magnetizer 260 of FIG.
21. FIG. 24A shows a first exploded view of modular hand-held magnetizer
260 of FIG. 21.
[0132]FIG. 24B shows a second exploded view illustrating a set of
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