Method for forming a bed of stabilized magneto-caloric material

1. A method for forming a stabilized bed of magneto-caloric material, comprising:

coating a plurality of magneto-caloric particles with a binder;

applying a magnetic field to the plurality of magneto-caloric particles such that the magneto-caloric particles align into chains within a casing; and

activating the binder on the plurality of magneto-caloric particles while the magnetic field is applied to the magneto-caloric particles such that the chains of magneto-caloric particles are coupled together with the binder, the chains of magneto-caloric particles fixed relative to one another with the binder after activating the binder;

wherein each chain of magneto-caloric particles is spaced apart from an adjacent chain of magneto-caloric particles by a respective gap within the casing, each gap being no less than fifty microns and no greater than four hundred microns, and

wherein each gap is unfilled between the chains of magneto-caloric particles such that each gap forms a channel for fluid flow and a heat transfer fluid is flowable through each gap between the chains of magneto-caloric particles within the casing.

2. The method of claim 1 , wherein each gap is no less than one hundred microns and no greater than one hundred and fifty microns.

3. The method of claim 1 , further comprising shaking the casing while the magnetic field is applied to the magneto-caloric particles within the casing.

4. The method of claim 1 , wherein the binder is a polymer and said step of activating the binder comprises heating the binder.

5. The method of claim 1 , wherein the binder is a polymer and said step of activating the binder comprises directing ultraviolet radiation onto the binder.

6. The method of claim 1 , wherein the binder is a polymer and said step of activating the binder comprises applying a liquid activator onto the binder.

7. The method of claim 1 , wherein the casing defines an interior volume, and the method further comprises:

loading the plurality of magneto-caloric particles into the interior volume of the casing, wherein when the plurality of magneto-caloric particles are loaded into the casing, a head space is defined between the plurality of magneto-caloric particles and the casing, wherein the head space is between about five (5) and thirty (30) percent of the interior volume.

8. The method of claim 1 , wherein the method further comprises:

shaking the casing while the magnetic field is applied to the magneto-caloric particles within the casing; and

fluidizing, at the same time as shaking, the magneto-caloric particles within the casing while the magnetic field is applied to the magneto-caloric particles.

9. The method of claim 1 , wherein magneto-caloric particles include one or more secondary particles, the secondary particles including at least one of iron, copper, brass, carbon nanotubes, and graphite.

10. The method of claim 1 , wherein the magnetic field is applied to the plurality of magneto-caloric particles such that the magneto-caloric particles align into chains extending along a longitudinal direction within the casing, and the heat transfer fluid is flowable along the longitudinal direction through the casing.

11. The method of claim 1 , wherein the magnetic field is applied to the plurality of magneto-caloric particles such that the magneto-caloric particles align into chains extending along a transverse direction within the casing, the heat transfer fluid is flowable along a longitudinal direction through the casing, and the transverse direction is perpendicular to the longitudinal direction.

12. The method of claim 1 , further comprising directing a gas through the casing over the chains of magneto-caloric particles within the casing while the magnetic field is applied to the magneto-caloric particles within the casing.

13. The method of claim 12 , wherein the gas is an inert gas.

14. The method of claim 13 , wherein the inert gas is nitrogen.

15. The method of claim 12 , wherein the gas is directed over the magneto-caloric particles by an air handler.

16. The method of claim 1 , further comprising fluidizing the magneto-caloric particles within the casing before the magnetic field is applied to the magneto-caloric particles, while the magnetic field is applied to the magneto-caloric particles, or both before and while the magnetic field is applied to the magneto-caloric particles.

17. The method of claim 16 , wherein during fluidizing, the method comprises:

directing a gas through the casing over the chains of magneto-caloric particles within the casing while the magnetic field is applied to the magneto-caloric particles within the casing; and

increasing a fluid flow rate of the gas through the casing.

18. The method of claim 1 , wherein a comb with a plurality of projections is positioned between the magnet and the plurality of magneto-caloric particles when the magnetic field is applied to the plurality of magneto-caloric particles.

19. The method of claim 18 , wherein the comb is positioned outside of the casing.

20. The method of claim 18 , wherein the plurality of projections are uniformly spaced on the comb.