Ferrite composite sleeve systems and methods for coaxial applications

Patent metadata

Field	Value
Publication number	US-10005217-B2
Application number	US-201514831815-A
Country	US
Kind code	B2
Filing date	Aug 20, 2015
Priority date	Aug 20, 2015
Publication date	Jun 26, 2018
Grant date	Jun 26, 2018

Abstract

According to an embodiment, a method includes receiving a magnetic device design comprising a magnetic structure to be formed, at least in part, from a magnetic material matrix, wherein the magnetic material matrix is configured to be used in at least one of a magnetic materials additive manufacturing system (MMAMS) and a magnetic materials bulk extrusion system (MMBES); receiving the magnetic material matrix by at least one of the MMAMS and the MMBES; and dispensing the magnetic material matrix using at least one of the MMAMS and the MMBES to form the magnetic structure.

First claim

What is claimed is:

1. A method ( 900 ), comprising:
receiving ( 902 ) a magnetic device design comprising a magnetic structure ( 310 , 400 , 402 , 404 , 406 , 500 G) to be formed, at least in part, from a magnetic material matrix ( 117 , 410 , 420 , 412 , 422 , 524 , 564 ), wherein the magnetic material matrix is configured to be used in at least one of a magnetic materials additive manufacturing system “MMAMS” ( 110 ) and a magnetic materials bulk extrusion system “MMBES” ( 232 );
receiving ( 904 ) the magnetic material matrix by at least one of the MMAMS and the MMBES; and
dispensing ( 906 ) the magnetic material matrix using at least one of the MMAMS and the MMBES to form the magnetic structure, wherein the magnetic structure is configured to modify an electromagnetic propagation characteristic of a signal while it propagates through a magnetic device corresponding to the magnetic device design.

2. The method of claim 1 , wherein:
the MMAMS is at least partially implemented by a fused filament fabrication additive manufacturing system;
the magnetic material matrix comprises a magnetic matrix filament; and
the dispensing the magnetic material matrix comprises using an actuated filament extrusion nozzle to dispense the magnetic matrix filament in one or more patterned layers to form the magnetic structure.

3. The method of claim 1 , wherein:
the MMAMS is at least partially implemented by a stereolitho graphic additive manufacturing system;
the magnetic material matrix comprises a liquid magnetic matrix; and
the dispensing the magnetic material matrix comprises using an actuated liquid dispenser nozzle to dispense the magnetic matrix liquid in one or more patterned layers to form the magnetic structure.

4. The method of claim 1 , wherein:
the magnetic material matrix comprises a bulk magnetic matrix;
the MMBES comprises a pattern extrusion tool configured to form a shaped magnetic wire from the bulk magnetic matrix;
the dispensing the magnetic material matrix comprises using the pattern extrusion tool to extrude the magnetic structure from the bulk magnetic matrix.

5. The method of claim 1 , wherein:
the magnetic material matrix comprises a ferrite matrix ( 410 , 420 , 412 , 422 , 524 , 564 ); and
the magnetic structure comprises a magnetic dielectric sleeve configured to be inserted into an outer conductor ( 330 , 730 ) and to receive an inner conductor ( 320 ) to form a coaxial transmission line ( 304 , 706 , 834 ).

6. The method of claim 5 , wherein:
the magnetic structure comprises a plurality of C-shaped magnetic dielectric sleeves;
the outer conductor comprises a corresponding plurality of channels and is configured to form a common outer conductor for a corresponding plurality of transmission lines; and
the method further comprises inserting each C-shaped magnetic dielectric sleeve into one of the plurality of channels of the outer conductor.

7. The method of claim 1 , wherein:
the magnetic material matrix comprises a ferrite matrix ( 410 , 420 , 412 , 422 , 524 , 564 ) and the magnetic device comprises a transmission line ( 304 , 706 , 834 );
the transmission line comprises a inner conductor ( 320 ) separated from an outer conductor ( 330 , 730 ) by at least a dielectric sleeve ( 310 , 400 , 402 , 404 , 406 , 500 G); and
the dielectric sleeve comprises the ferrite matrix dispensed by at least one of the MMAMS and the MMBES.

8. The method of claim 7 , wherein:
the transmission line is configured to form a nonreciprocal electronic device.

9. The method of claim 7 , wherein:
the dielectric sleeve comprises a nonmagnetic material dispensed by at least one of the MMAMS and the MMBES; and
the transmission line is configured to form a nonreciprocal electronic device.

10. The method of claim 1 , further comprising preparing the magnetic material matrix by:
mixing ferrite powder with a liquid polymer resin to form bulk liquid magnetic matrix; and
providing the bulk liquid magnetic matrix to the MMAMS as the magnetic material matrix.

11. The method of claim 1 , further comprising preparing the magnetic material matrix by:
mixing ferrite powder with a liquid polymer resin to form bulk liquid magnetic matrix;
curing or solidifying the bulk liquid magnetic matrix to form bulk solid magnetic matrix;
extruding magnetic matrix filament from the bulk solid magnetic matrix; and
providing the magnetic matrix filament to the MMAMS as the magnetic material matrix.

12. The method of claim 1 , further comprising preparing the magnetic material matrix by:
mixing ferrite powder with a liquid polymer resin to form bulk liquid magnetic matrix;
curing or solidifying the bulk liquid magnetic matrix to form bulk solid or semisolid magnetic matrix; and
providing the bulk solid or semisolid magnetic matrix to the MMBES as the magnetic material matrix.

13. A system comprising a transmission line ( 304 , 706 , 834 ) formed using the method of claim 1 ,
wherein:
the magnetic device corresponding to the received magnetic device design comprises the transmission line;
the transmission line comprises an inner conductor ( 320 ) separated from an outer conductor ( 330 , 730 ) by at least a dielectric sleeve ( 310 , 400 , 402 , 404 , 406 , 500 G);
the dielectric sleeve comprises the magnetic structure of the received magnetic device design and is formed by the magnetic material matrix;
received and dispensed by the at least one of the MMAMS and the MMBES;
the magnetic material matrix comprises a ferrite matrix ( 410 , 412 , 420 , 422 , 524 , 564 ); and
the dielectric sleeve is configured to modify the electromagnetic propagation characteristic of an electromagnetic wave of the signal while it propagates through the transmission line.

14. The system of claim 13 , wherein:
the dielectric sleeve is configured to modify at least one of a phase shift and a delay associated with the electromagnetic wave.

15. The system of claim 13 , wherein:
the transmission line comprises a rectangular or a cylindrical coaxial transmission line; and
the transmission line is configured to form a reciprocal or nonreciprocal electronic device.

16. The system of claim 13 , wherein:
the outer conductor comprises a plurality of channels and is configured to form a common outer conductor for a corresponding plurality of transmission lines.

17. The method of claim 1 , wherein the magnetic device comprises a transmission line ( 534 ), the method further comprising:
receiving ( 1002 ) the signal from a signal source ( 532 ) by the transmission line;
propagating ( 1004 ) the signal between the signal source and a signal sink ( 536 ); and
providing ( 1006 ) the signal to the signal sink by the transmission line, wherein:
the transmission line comprises an inner conductor ( 320 ) separated from an outer conductor ( 330 , 730 ) by at least a dielectric sleeve ( 310 , 400 , 402 , 404 , 406 , 500 G);
the magnetic material matrix comprises a ferrite matrix ( 410 , 420 , 412 , 422 , 524 , 564 );
the dielectric sleeve comprises the ferrite matrix dispensed by at least one of the MMAMS and the MMBES; and
the ferrite matrix is configured to modify the electromagnetic propagation characteristic of the signal while it propagates between the signal source and the signal sink.

18. The method of claim 17 , wherein:
the ferrite matrix is configured to modify at least one of a phase shift and a delay associated with the signal.

19. The method of claim 17 , wherein:
the

Assignees

• Boeing Co

Inventors

• Willams John D
• Laquer Andrew George

Classifications

• B29C64/10

  Processes of additive manufacturing · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• H01P11/005

  Manufacturing coaxial lines · CPC title

• H01F41/00

  Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties · CPC title