# US 12,103,069 B2 · System and method for making a structured material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,103,069 B2 - Document ID: US12103069B2 - Status: Granted - Kind: B2 - Application number: 18/122,808 - Filed: 2023-03-17 - Published: 2023-07-27 - Granted: 2024-10-01 - Earliest claimed: 2011-06-30 - Assignees: Persimmon Technologies Corporation - Applicants: Persimmon Technologies Corporation - Inventors: Martin Hosek - Web page: https://patentgrep.com/patent/US12103069B2 ## CPC - B22D 23/003: {Moulding by spraying metal on a surface} - B05C 5/001: {incorporating means for heating or cooling the liquid or other fluent material (B05C11/1042 takes precedence)} - B05C 5/002: {the work consisting of separate articles (B05C5/0208 takes precedence)} - B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting - C23C 4/18: After-treatment - C23C 6/00: Coating by casting molten material on the substrate - H01F 1/24: the particles being insulated - H01F 3/08: made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) - H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)} - Y10T 428/24413: Metal or metal compound - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries. ## Claims ### Claim 1 A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material, the system comprising: a heating device; a deposition device; a charging plate; a coating device; and a support configured to support the bulk material; wherein the heating device heats the metal material to form particles having a softened or molten state, the charging plate creates an electric charge on the particles in the softened or molten state, and the coating device coats the metal material with the insulating material from the source and the deposition device deposits the particles of the metal material in the softened or molten state on the support to form the bulk material having the insulated boundaries. ### Claim 2 (depends on 1) The system of claim 1 wherein the source of the insulating material comprises a reactive chemical source and the deposition device deposits the particles of the metal material in the softened or molten state on the support in a deposition path such that the insulated boundaries are formed on the metal material by the coating device from a chemical reaction of the reactive chemical source in the deposition path. ### Claim 3 (depends on 1) The system of claim 1 wherein the source of the insulating material comprises a reactive chemical source and insulated boundaries are formed on the metal material by the coating device from a chemical reaction of the reactive chemical source after the deposition device deposits the particles of the metal material in the softened or molten state on to the support. ### Claim 4 (depends on 1) The system of claim 1 wherein the source of the insulating material comprises a reactive chemical source and the coating device coats the metal material with the insulating material to form insulated boundaries from a chemical reaction of the reactive chemical source at the surface of the particles. ### Claim 5 (depends on 1) The system of claim 1 wherein the deposition device comprises a uniform droplet spray deposition device. ### Claim 6 (depends on 1) The system of claim 1 wherein the source of the insulating material comprises a reactive chemical source and the coating device coats the metal material with the insulating material to form insulated boundaries formed from a chemical reaction of the reactive chemical source in a reactive atmosphere. ### Claim 7 (depends on 1) The system of claim 1 wherein the source of the insulating material comprises a reactive chemical source and an agent and the coating device coats the metal material with the insulating material to form insulated boundaries formed from a chemical reaction of the reactive chemical source in a reactive atmosphere stimulated by a co-spraying of the agent. ### Claim 8 (depends on 1) The system of claim 1 wherein the bulk material includes domains formed from the metal material with the insulated boundaries. ### Claim 9 (depends on 1) The system of claim 1 wherein the softened or molten state is at a temperature below the melting point of the metal material. ### Claim 10 (depends on 1) The system of claim 1 wherein the charging plate is coupled to a direct current source. ### Claim 11 (depends on 1) The system of claim 1 wherein the charging plate is configured to create the electric charge on the particles in the softened or molten state to cause the particles to repel each other.