Additive manufacturing systems and methods for magnetic materials

Patent metadata

Field	Value
Publication number	US-9731445-B2
Application number	US-201514831737-A
Country	US
Kind code	B2
Filing date	Aug 20, 2015
Priority date	Aug 20, 2015
Publication date	Aug 15, 2017
Grant date	Aug 15, 2017

Abstract

Techniques are disclosed for systems and methods to provide a magnetic materials additive manufacturing system (MMAMS) configured to form compact magnetic structures and/or devices. A MMAMS includes a controller and one or more dispensers configured to dispense magnetic material matrix in a high resolution pattern in order to form the compact magnetic structures and/or devices. The MMAMS receives a magnetic device design including a magnetic structure to be formed from a magnetic material matrix, where the magnetic material matrix is configured to be used in the MMAMS. The MMAMS receives magnetic material matrix and dispenses the magnetic material matrix to form the magnetic structure.

First claim

What is claimed is:

1. A system ( 530 ), comprising:
a transmission line ( 534 ) coupled between a signal source ( 532 ) and a signal sink ( 536 ), wherein:
the transmission line comprises a center conductor ( 340 , 440 , 440 B) separated from an outer conductor ( 346 , 446 ) by at least one dielectric ( 328 , 348 );
the at least one dielectric comprises a ferrite matrix ( 328 ) dispensed by a magnetic materials additive manufacturing system “MMAMS” ( 110 ); and
at least one of the center conductor and the outer conductor comprise a ferromagnetic matrix ( 338 , 438 , 438 B-C) dispensed by the MMAMS and configured to provide a poling field to the ferrite matrix to modify an electromagnetic propagation characteristic of an electromagnetic wave while it propagates between the signal source and the signal sink.

2. The system of claim 1 , wherein:
the poling field comprises at least one of a strength and an orientation relative to a propagation direction of the electromagnetic wave that is selected to modify at least one of a phase shift and a delay associated with the electromagnetic wave.

3. The system of claim 1 , wherein:
the ferromagnetic matrix is disposed within the center conductor; and
a thickness of a nonmagnetic portion of the center conductor surrounding the ferromagnetic matrix is greater than or equal to approximately two to three times a skin depth corresponding to the electromagnetic wave.

4. The system of claim 1 , wherein:
the ferromagnetic matrix is disposed within the center conductor;
the center conductor comprises a nonmagnetic conductive polymer ( 340 , 440 , 440 B) and a metallic surface layer ( 330 , 350 ); and
the ferrite matrix is separated from the ferromagnetic matrix by the metallic surface layer.

5. The system of claim 1 , wherein:
the ferromagnetic matrix comprises a first ferromagnetic matrix ( 438 B) disposed within a first portion of the outer conductor;
the outer conductor comprises a second ferromagnetic matrix ( 438 C) disposed within a second portion of the outer conductor opposite the center conductor;
the ferrite matrix is disposed at least between the first and second portions of the outer conductor; and
the first and second ferromagnetic matrixes are configured to provide the poling field.

6. The system of claim 1 , wherein:
the transmission line comprises a rectangular coaxial transmission line; and
the at least one dielectric comprises an air gap disposed on three of four cross sectional sides of the center conductor.

Assignees

• Boeing Co

Inventors

• Williams John D

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

• B29K2505/08

  Transition metals · CPC title

• B22F3/20

  by extruding · CPC title