Method for Making a Composite Substrate Circulator Component

Abstract

A method for making a composite substrate circulator comprising disposing a plurality of sleeves about a plurality of rods, disposing the plurality of rods and the plurality of sleeves in a plurality of openings in a block to form an assembly, and dividing the assembly to form a plurality of plates. Each plate includes a portion of the plurality of sleeves and the plurality of rods. The magnetic saturation (4PiMs) values of the rods and sleeves are chosen to decrease radially (rod has the highest 4PiMs).

What is claimed is: 
     
         1 . A method for making a composite substrate circulator component, comprising:
 forming a plurality of longitudinally spaced recesses in a plurality of rods or a plurality of sleeves;   disposing the plurality of sleeves about the plurality of rods, respectively;   disposing the plurality of rods and the plurality of sleeves in a plurality of openings in a block to form an assembly; and   dividing the assembly to form a plurality of plates, each of the plurality of plates comprising:
 a portion of the plurality of sleeves to form at least one ring, 
 a portion of the plurality of rods to form at least one disk surrounded by the at least one ring, and 
 a portion of the block to form a matrix surrounding the at least one disk and the at least one ring, the matrix being a structure of a composite substrate circulator component that is operable in a circulator. 
   
     
     
         2 . The method of  claim 1 , further comprising forming the plurality of longitudinally spaced recesses in the plurality of rods or the plurality of sleeves that extend circumferentially around the plurality of rods or the plurality of sleeves. 
     
     
         3 . The method of  claim 1 , wherein dividing the assembly to form a plurality of plates comprises dividing the assembly at the longitudinally spaced recesses. 
     
     
         4 . The method of  claim 1 , further comprising dividing the plurality of plates to form a plurality of composite substrate circulator components, wherein each of the composite substrate circulator components comprise a portion of at least one of the plurality of rods and a portion of at least one of the plurality of sleeves. 
     
     
         5 . The method of  claim 1 , further comprising bonding a rod among the plurality of rods and a sleeve among the plurality of sleeves to one another. 
     
     
         6 . The method of  claim 1 , further comprising bonding the plurality of sleeves and the block to one another. 
     
     
         7 . The method of  claim 1 , wherein forming a plurality of longitudinally spaced recesses in a plurality of rods or a plurality of sleeves comprises forming a plurality of longitudinally spaced recesses in a plurality of rods, having a cylindrical configuration, or a plurality of sleeves. 
     
     
         8 . The method of  claim 1 , wherein disposing the plurality of sleeves about the plurality of rods comprises disposing multiple sleeves among the plurality of sleeves about at least some of the plurality of rods, and wherein a portion of the multiple sleeves in each of the plurality of plates forms multiple rings that surround an associated disk. 
     
     
         9 . The method of  claim 1 , wherein at least one of the plurality of rods or at least one of the plurality of sleeves comprises a magnetic material. 
     
     
         10 . The method of  claim 9 , wherein the magnetic material is selected from at least the group consisting of ferrite, garnet, spinel, and hexaferrite. 
     
     
         11 . The method of  claim 9 , wherein a magnetic saturation value of the at least one rod of the plurality of rods is different than a magnetic saturation value of the at least one sleeve of the plurality of sleeves to radially vary the magnetic saturation values of the at least one rod and the at least one sleeve. 
     
     
         12 . The method of  claim 9 , wherein a magnetic saturation value of the at least one rod of the plurality of rods rod is greater than a magnetic saturation value of the at least one sleeve of the plurality of sleeves. 
     
     
         13 . The method of  claim 1 , wherein the block comprises a dielectric material. 
     
     
         14 . The method of  claim 1 , wherein the block has a cuboid configuration. 
     
     
         15 . A method for making a composite substrate circulator component, comprising:
 obtaining a sleeve, a rod, and a block;   forming a plurality of longitudinally spaced recesses in at least one of the rod or the sleeve;   disposing the sleeve about the rod;   disposing the rod and the sleeve in an opening in the block to form an assembly; and   dividing the assembly at the longitudinally spaced recesses to form a plurality of plates, each plate having a portion of the sleeve and the rod.   
     
     
         16 . The method of  claim 15 , wherein forming a plurality of longitudinally spaced recesses in at least one of the rod or the sleeve comprises forming the longitudinally spaced recesses such that they extend circumferentially around the at least one of the rod or the sleeve. 
     
     
         17 . The method of  claim 15 , further comprising bonding the rod and the sleeve to one another. 
     
     
         18 . The method of  claim 15 , further comprising bonding the sleeve and the block to one another. 
     
     
         19 . The method of  claim 15 , wherein the obtaining a rod comprises obtaining a rod having a cylindrical configuration. 
     
     
         20 . The method of  claim 15 , wherein disposing the sleeve about the rod comprises disposing a plurality of sleeves about the rod. 
     
     
         21 . The method of  claim 15 , wherein the obtaining a rod and the obtaining a sleeve comprises obtaining a rod made of a ferrite material and obtaining a sleeve made of a ferrite material. 
     
     
         22 . The method of  claim 15 , wherein the obtaining a block comprises obtaining a block of a dielectric material. 
     
     
         23 . The method of  claim 15 , wherein the obtaining a block comprises obtaining a block having a cuboid configuration. 
     
     
         24 . The method of  claim 15 , wherein each plate forms a composite substrate circulator component. 
     
     
         25 . The method of  claim 15 , wherein the obtaining a rod and the obtaining a sleeve comprises obtaining a plurality of rods and a plurality of sleeves, and wherein disposing the sleeve about the rod comprises disposing the plurality of sleeves about the plurality of rods, respectively, and wherein disposing the rod and the sleeve in the opening in the block comprises disposing the plurality of rods and the plurality of sleeves in a plurality of openings in the block, and wherein each plate includes a portion of the plurality of sleeves and the plurality of rods. 
     
     
         26 . The method of  claim 15 , wherein dividing the assembly at the longitudinally spaced recesses to form a plurality of plates comprises dividing the assembly, such that each of the plurality of plates forms a composite substrate circulator component. 
     
     
         27 . The method of  claim 25 , further comprising dividing the plurality of plates to form a plurality of composite substrate circulator components, wherein each composite substrate circulator component comprises a portion of at least one of the plurality of rods and a portion of at least one of the plurality of sleeves. 
     
     
         28 . A composite substrate circulator component prepared by a process comprising:
 forming a plurality of longitudinally spaced recesses in a plurality of rods or a plurality of sleeves;   disposing the plurality of sleeves about the plurality of rods, respectively;   disposing the plurality of rods and the plurality of sleeves in a plurality of openings in a block to form an assembly; and   dividing the assembly to form a plurality of plates, each of the plurality of plates comprising:
 a portion of the plurality of sleeves to form at least one ring, 
 a portion of the plurality of rods to form at least one disk surrounded by the at least one ring, and 
 a portion of the block to form a matrix surrounding the at least one disk and the at least one ring, the matrix being a structure of a composite substrate circulator component that is operable in a circulator. 
   
     
     
         29 . The composite substrate circulator component of  claim 28 , wherein the longitudinally spaced recesses extend circumferentially around the plurality of rods or the plurality of sleeves. 
     
     
         30 . The composite substrate circulator component of  claim 28 , wherein the assembly is divided at the longitudinally spaced recesses.