Vacuum tube insertion assembly with feedthrough pin plug and mating socket

Abstract

We provide a vacuum tube insertion assembly that prevents incorrect connections. [Solution] The vacuum tube insertion assembly includes a flared insertion part 40, each constructed from glass, having an annular flange 45 and a stem 46. The stem 46 extends axially from the flange 45, which surrounds the outer edge 47 of a plug recess 44 defined by the stem 46. A feedthrough pin 42 passes axially through the stem 46 and is sealed to the stem 46. The feedthrough pin 42 terminates inside the plug recess 44 to form the plug. The socket includes a receptacle that connects to the plug within the plug recess and is removably coupled to the feedthrough pin.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 217,019, filed Jun. 30, 2021, which is hereby incorporated by reference in its entirety.

Background Art

[0002] Vacuum tubes are used in a wide range of applications to control the flow of electric current between separated electrodes within a sealed vacuum chamber. X - ray tubes are a special type of vacuum tube commonly used to generate and direct X - ray radiation for various purposes such as medical imaging, radiology, diagnosis, radiography, tomography, non - destructive testing, material analysis, security applications, and inspections.

[0003] Conventional X - ray tubes operate by using a heated cathode to emit a focused electron beam and then directing the emitted electron beam towards a target to which an anode is attached. The emitted electrons gain energy and are accelerated based on a large potential difference across the space intervening between the anode and the cathode. A portion of the accelerated electrons collide with the target surface on the anode, and a small portion of the incident electron - beam energy is converted into useful X - ray radiation. The remaining energy mostly takes the form of heat that is dissipated from the X - ray tube, usually through some type of cooling system.

[0004] The drawings described herein are for illustrative purposes only and are essentially schematic and are intended to be illustrative rather than limiting the scope of the present disclosure.

Brief Description of the Drawings

[0005] [Figure 1] A diagram of an exemplary vacuum - tube insertion assembly for an X - ray tube, the assembly having a feed - through pin that forms a plug and also having the mating socket described herein. [Figure 2]Figure 1 is a perspective view of one embodiment of the vacuum tube insertion assembly shown. [Figure 3] This is a schematic diagram of a typical double-filament apparatus for use with the cathode assembly shown in Figure 1. [Figure 4] This is a perspective view of a typical portion of a flared insert constructed as described herein. [Figure 5] This is a perspective view of a typical portion of a flared insert constructed as described herein. [Figure 6] Figures 4 and 5 are perspective views of a socket configured to connect to the plug of a flared insertion component. [Figure 7] Figures 4 and 5 are perspective views of a socket configured to connect to the plug of a flared insertion component. [Figure 8] Figure 7 schematically shows the alternative engagement feature configuration of the socket. [Figure 9] Figures 1 and 2 are perspective views of the pin fasteners used during the assembly of the flared insert components and vacuum tube inserts. [Figure 10] Figures 1 and 2 are perspective views of the pin fasteners used during the assembly of the flared insert components and vacuum tube inserts. [Figure 11] This is a flowchart illustrating an exemplary method for constructing a vacuum tube insert in accordance with this disclosure. [Modes for carrying out the invention]

[0006] Embodiments of the present disclosure are described herein. The disclosed embodiments are provided as examples and illustrations of various solutions. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to illustrate specific details of the subject matter. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds for teaching those skilled in the art to employ the disclosed structures and methods in various ways.

[0007] The numbers provided in the flowcharts and process descriptions are for the purpose of improving clarity and do not necessarily indicate a specific order or sequence. For the purposes of carrying out the present invention, approximate words such as “about,” “substantially,” “generally,” and “approximately” may be used to mean “at or approximately,” or “within the range of 0 to 5% of,” or “within the range of acceptable manufacturing tolerances,” or any logical combination thereof.

[0008] Some embodiments described herein generally relate to X-ray tubes and other types of vacuum tubes, glass inserts constructed for use with such vacuum tubes, and methods for creating and using the vacuum tubes and glass inserts described herein. In particular, the following disclosure relates to the extension of substantially rigid, conductive feedthrough posts or feedthrough pins into a bowl-shaped cavity ("concave") of a defined open end of a flared insert for a glass vacuum tube, the insert eventually melting and fusing with the glass encapsulation or glass enclosure. The feedthrough pins are positioned to present a plug that allows the operator to removably connect a mating socket. The structure of the socket may vary with certain temperatures, as well as with other expected loads applied during testing, loading, and other stages of manufacturing and use.

[0009] In contrast to existing methods in which flexible wires are individually welded to the ends of mating feedthrough wires, the rigid feedthrough pins intended herein are less susceptible to breakage, fraying, burning, and electrical short-circuit conditions due to their enhanced rigidity and extension into the concave volume as a predetermined spaced and oriented plug. Furthermore, the unique plug-socket couplings described below are far less prone to accidental wiring errors. Moreover, since the sockets intended for a particular configuration can be installed in only a specified orientation, the plug-socket connections reduce errors during manufacturing, installation, and maintenance.

[0010] Referring here to the drawings, similar numbers refer to similar components, and the vacuum tube insertion assembly 10 includes plugging means described herein, such as a typical plug 12 schematically shown in Figure 1. A mating socket means, exemplified as a socket 14, is located at the end 15 of a flexible cable 16 and is detachably coupled to the plug 12, as indicated by arrow A, for supplying power, for example, to the vacuum tube insertion assembly 10 or to a device assembled using the vacuum tube insertion assembly 10. As understood in the art, when the vacuum tube insertion assembly 10 is used as part of an X-ray tube, the vacuum tube insertion assembly 10 may be positioned within a lead-lined protective alloy or machined housing (omitted for clarity) or within another suitable protective external structure to provide stable mechanical support and thermal insulation.

[0011] The exemplary vacuum tube insertion assembly 10 shown in Figure 1, in a non-limiting X-ray tube embodiment, includes various components that collectively generate X-ray radiation (arrow 18) and emit it through the window 20 toward an object 22, such as the chest or appendages of a patient. Such components include glass means such as a encapsulation or enclosure 24 that defines an internal volume 25 in which a positively charged anode assembly 26 and a negatively charged cathode assembly 28 are positioned, as understood in the art. As described herein in various exemplary embodiments, the enclosure 24 may be constructed from borosilicate glass or another hard, application-appropriate glass material, without limiting the material of the structure to glass, and is therefore hereafter referred to as the glass enclosure 24.

[0012] Although simplified in Figure 1 for illustrative purposes, the anode assembly 26 includes a rotor 30 fitted with a cylindrical bearing having a rotation axis 31. The stator 32 surrounds the neck 33 of the glass enclosure 24, and the stator 32 defines the extent of the rotor 30. Thus, when the stator 32 is energized, the rotor 30 rotates around the rotation axis 31 due to alternating electromagnetic attractive and repulsive forces, and similarly, such rotation causes the rotation of an anode target disk 34, which is mounted to the rotor 30 via, for example, an anode stem 35, constructed, for example, from tungsten. As understood in the art, the target disk 34 provides a material target for interaction with electrons emitted by the cathode assembly 28, and X-rays ultimately result from such interaction.

[0013] In the simplified embodiment shown in Figure 1, the cathode assembly 28 includes a cathode head 36 to which a focusing cup 38 is connected. The focusing cup 38 similarly includes or is connected to one or more conductive filaments 39, each filament 39 similarly can be constructed from tungsten or another material suitable for the application. When the cathode assembly 28 is energized, an electric current flows through the filament(s) 39, heating the filament(s) 39. The heated filament(s) 39 react by emitting electrons through the process of thermionic emission.

[0014] High voltages of approximately 1 kilovolt (kV) or more are typically applied between the anode assembly 26 and the cathode assembly 28. Therefore, the glass enclosure 24 is typically 10 -6 It functions as a sealed vacuum enclosure that maintains a high vacuum of less than mmHg. In addition to maintaining such a strong vacuum, the glass enclosure 24 also isolates the anode assembly 26 from the cathode assembly 28 with a potential difference as high as 150kV or more maintained between them, without significant leakage or spurious discharge.

[0015] The glass enclosure 24 contemplated herein includes a flared insert 40 positioned adjacent to the cathode assembly 28, as shown in detail in Figures 4 and 5. As described in more detail below, the flared insert 40 is ultimately melted and thereafter fused to and / or integrally formed with feedthrough pin means, each exemplified as a plurality of feedthrough pins 42 similarly passing axially through the flared insert 40, and / or formed integrally with the feedthrough pin means, and thus vacuum-sealed to the feedthrough pin means. The feedthrough pins 42 collectively form a plug 12 within a plug recess 44 defined by the flared insert 40. The plug 12 is thus easily accessible to receive power at various production stages.

[0016] For this purpose, the socket 14 is removably coupled to the plug 12 within the plug recess 44, which is accomplished with the corresponding minimum level of effort. After connecting the various components of the vacuum tube insertion assembly 10 shown in Figures 1 and 2, the flared insertion component 40, described below with respect to Figures 3 to 9, is connected to the glass enclosure 24, after which the internal volume 25 is emptied using a pump and other related equipment.

[0017] Referring briefly to Figure 3, the number of feedthrough pins 42 (see Figures 1 and 2) may vary depending on the structure of the vacuum tube insertion assembly 10. In some embodiments, for example, the filament(s) 39 may include multiple filaments, such as the dual-focus type shown having filaments 139 and 239. Filaments 139 and 239 are shown with their corresponding terminals or nodes, with filament 139 having nodes 57A and 57B, and filament 239 having nodes 57B and 57C. Also shown are a getter 70 with getter node 57D, and a grid 72 with grid node 57E. The corresponding notations “S small”, “C common”, and “L large” can be used to connect a single “small” filament (e.g., filament 139 extending between nodes 57A and 57B) or a single “large” filament (e.g., filament 239 extending between nodes 57B and 57C). Filaments 139 and 239 can be connected in series by connecting nodes 57A and 57C. Filaments 139 and 239 can be connected in parallel by connecting nodes 57A, 57B, and 57C. As is understood in the art, using smaller filaments produces a smaller focal spot suitable for imaging, for example, a narrower area. Conversely, using multiple / larger filaments produces a larger focal spot with a larger corresponding imaging area.

[0018] In addition to nodes 57A, 57B, and 57C, the feedthrough pins 42 in Figures 1 and 2 may also include “getter” nodes and “grid” nodes 57D and 57E, respectively, for a total of five related feedthrough pins 42 in this embodiment. The specific identity of nodes 57A through R may vary depending on the application, and therefore the location shown in the five-pin embodiment of Figure 3 represents only one possible embodiment. In this specification and as used in the art, getters also serve to absorb off-gas particles during manufacturing and maintain a vacuum after sealing. Thus, getter node 57D provides one of the electrical connections to getter 70. Grids can be used to focus electrons or, for fast switching speeds, to restrict or even block the flow of electrons when the X-ray source is turned on and off. Thus, grid node 57E provides one of the electrical connections to grid 72. Furthermore, it is conceivable that some of the shown nodes will not be used, or rather, will not be connected to each other, for example, grid node 57, getter node 57E, and common node 57B, which may be connected to each other either inside or outside the tube. Consequently, the cable 16 in Figure 1 may not supply the same number of voltage inputs as the feedthrough pins 42, for example, in the 4-pin or 3-pin configuration example. However, for illustrative consistency, the vacuum tube insertion assembly 10 will be described below as a typical 5-pin configuration.

[0019] Referring now to FIGS. 4 and 5, the flare-shaped insert part 40 includes an annular flange 45, such as, for example, a substantially flat disk as shown. The annular flange 45 is integrally formed with an axially extending stem 46. The axially extending stem 46 similarly defines a plug recess 44 having an outer peripheral edge 47 which is shown but not labeled in FIG. 2. The plug recess 44 may, for example, generally have a hemispherical or rounded conical shape, such that the plug recess 44 has a bowl-shaped appearance recessed from the perspective of FIG. 4. The tubular flange 45 surrounds the outer peripheral edge 47 of the plug recess 44, and the outer diameter and thickness of the annular flange 45 match the outer diameter and thickness of the remaining structure of the glass envelope 24 into which the insert part is ultimately fused or connected.

[0020] As best shown in FIG. 4, the feed-through pin 42 passes axially through the stem 46 and melts or fuses to the stem 46. As the glass cools to provide the necessary vacuum-tight integrity between the vacuum side within the evacuated internal volume 25 of the glass envelope 24 (see FIG. 1) and the surrounding external / atmospheric pressure side of the vacuum tube insertion assembly 10 shown in FIG. 2, the feed-through pin 42 thus becomes integral with the glass surrounding the stem 46.

[0021] The feed-through pin 42 of FIG. 5 can include a central post 50 with at least two pins 52 positioned on the side, and the four pins 52 surround the central post 50 in the non-limiting exemplary structure of FIG. 5. The central post 50 can have a first radial dimension, such as a diameter, when the central post 50 is cylindrical, while each of the pins 52 can have a smaller second radial dimension. For example, the second radial dimension can be less than about 80 percent of the first radial dimension, such as from about 40 percent to 60 percent of the first dimension, or from about 25 percent to 75 percent of the first dimension, in various exemplary embodiments. By using a more robust or thicker structure for the central post 50, for example, by providing a substantially rigid central indexing feature by which other components and / or fixtures can be aligned or referenced, the construction of the vacuum tube insertion assembly 10 of FIGS. 1 and 2 is facilitated. Although a cylindrical feed-through pin is shown, the feed-through pin can have various cross-sections including, but not limited to, circular, elliptical, rectangular, or other polygonal or other shapes. The engagement features described in more detail below can be formed when two or more different cross-sectional shapes (or cross-sectional regions) are used for the corresponding engagement mating receptacles 56 of the feed-through pin and the socket 14 (FIGS. 7-8) such that the plug 12 is received by the socket 14 in a specified and / or unique orientation. Other engagement features can be formed by other variations of the features, as in the examples provided below, so long as the plug 12 is received by the socket 14 in a specified and / or unique orientation.

[0022] Proper fusion and bonding of the glass material of the stem 46 to the feedthrough pin 42 can be carried out by various means, one of which is the use of a press and a heat source. As understood in the art and used herein, such a press may be used to sandwich / concentrate the heated glass material of the stem 46 together with the softened viscous glass material so that it flows around the feedthrough pin 42 and surrounds the feedthrough pin 42. As the glass cools, the feedthrough pin 42 becomes integral with the stem 46 with no intervening gaps or spaces at the interface between the feedthrough pin 42 and the surrounding glass.

[0023] To facilitate the required vacuum sealing properties, the material used to construct the feedthrough pin 42 must have a coefficient of thermal expansion similar to that of the glass of the glass enclosure 24, so that cracks or gaps do not occur during the cooling and solidification of the glass. One possible combination suitable for such a vacuum seal is borosilicate glass or another hard glass for constructing the flared insert 40, and a plated or unplated metal such as tungsten (W), molybdenum (Mo), or nickel-cobalt alloy (Ni-Co-Fe) such as Kovar®, both of which are suitable for constructing the feedthrough pin 42. That is, the feedthrough pin 42 can be constructed from a first metal which may optionally be plated with a second metal. When plated, a suitable conductive metal may be used to ensure continuity and reduce resistance, and the elements nickel (Ni), gold (Au), copper (Cu), or silver (Ag) are some possible plating materials. The plated material may have high thermal resistance, reducing damage due to thermal stress.

[0024] As best shown in Figure 4, the feed-through pin 42 terminates in a position inside the plug recess 44, collectively forming the plug 12. The plug 12 is thus presented at a convenient height above the stem 46 to connect power as needed to the vacuum tube insertion assembly 10 in Figures 1 and 2, with power compositions and levels that may vary depending on the specific stage of assembly, testing, or loading. For example, the length of the feed-through pin 42 exposed within the volume of the plug recess 44 may be at least 4 mm to about 10 mm, or another suitable length sufficient to enter and firmly engage with the mating receptacle 56 of the socket 14, as described herein.

[0025] Referring here to Figure 6, the flared insert 40 is shown so that it would be visible when viewed from the outside / atmospheric pressure side of the vacuum tube insertion assembly 10 in Figures 1 and 2. The non-flexible / substantially rigid appearance of the plug 12 (see Figure 4) within the plug recess 44 eliminates the need to weld individual flexible wires to each of the feedthrough pins 42 when installing the cathode assembly 28 in Figure 1, which could be prone to manufacturing or operator errors. Instead, the exposed feedthrough pins 42 of the plug 12 within the plug recess 44 are simply engaged with the socket 14, and an annular flange 45 may surround the outer edge 47 of the plug recess 44.

[0026] Socket 14 terminates the wires 160 that form the cable 16, and the individual electrical contacts of the wires 160 are housed within the socket 14. Each of the wires 160 shown in Figure 6 corresponds to one of the small node, large node, common node, getter node, or grid node described above in the typical 5-pin embodiment of Figure 6. To facilitate assembly, the socket 14 may define a separate through channel 49 for each of the wires 160, thereby allowing the wires 160 to pass cleanly through the socket 14 and engage with a mating receptacle 56 housed therein, as shown in Figure 7. For current limiting, current sensing, or other useful purposes, any or all of the receptacles 56 may include resistors in or in series with them.

[0027] As intended herein, each of the receptacles 56 can be constructed using various alternative forms and application-appropriate internal contact structures to receive and then securely hold one of each of the feedthrough pins 42. That is, an elastic internal conductive connection or interference fit is provided between the mating feedthrough pin 42 and the receptacle 56 to ensure good electrical connection and continuity between the plug 12 and the socket 14. Alternative types of plug-socket connections, such as but not limited to male-female plug-socket configurations, hyperbolic contact points, or other suitable embodiments, may be used within the scope of this disclosure. Additional retaining mechanisms, such as keyways or similar structures, which require a partial rotation of the connected socket 14 after the plug 12 has been inserted to securely lock the plug 12 in place, may also be used in other embodiments, although they are omitted for the sake of simplicity of illustration.

[0028] The material used to construct the socket 14 may vary depending on the stage of manufacturing. For example, stages requiring the socket 14 to be exposed to higher temperatures or power levels would be constructed from high-temperature resin, while lower-temperature or steady-state operating stages may use lower-temperature materials such as polycarbonate. Lower-temperature materials may be used in part because cooling oil and other thermal control structures are present in fully assembled vacuum tube devices, such as X-ray tubes, which also reduces the thermal load on the socket 14. In some embodiments, three-dimensional (3D) printing or additive manufacturing techniques may be used to construct the socket 14 shown in Figure 6 in order to form the desired geometric shape.

[0029] Furthermore, with respect to the socket 14, installation errors are reduced by an engagement feature 60 configured to allow the plug 12 to accept the socket 14 in a specified orientation and vice versa. As described below, the socket 14 or the plug 12 may include the engagement feature 60 separately or together in various embodiments to allow the plug 12 to accept the socket 14 in a specified orientation and vice versa. For this purpose, an option for the plug 12 is to form at least one feedthrough pin 42 having a different height or length from the other feedthrough pins 42 to create a symmetry breaking at a defined height. For example, the engagement feature 60 may be implemented by leaving one or more feedthrough pins 42 longer than the remaining feedthrough pins 42, such feedthrough pins 42 are referred to herein as elongated pins 142 for clarity (see Figures 1 and 4). For simplicity, one such elongated pin 142 is shown, but in other configurations two or more feedthrough pins 42 may be elongated.

[0030] As shown in Figure 7, the use of the elongated pin 142 allows the socket 14 to optionally include a radial end face 340 connected to a stepped radial intermediate wall 140 via an axial wall 240. The radial intermediate wall 140 may include at least one receptacle 56, the remaining receptacle 56 being housed within and opening from the radial end face 340, as shown. The receptacle(s) 56 located on the intermediate wall 140 may be configured to accept the elongated pin 142 (see Figure 1) in this particular exemplary embodiment, and the identity of the elongated pin 142 for connections to short, long, common, getter, or grid nodes or feeds as described above will vary depending on the desired application.

[0031] By using multiple such elongated pins 142 in this manner, it is ensured that the operator can connect the socket 14 to the plug 12 in Figures 1, 2, and 4 in the specified orientation. This feature also “error-proofs” the installation by reducing or preventing the possibility of incorrect connections of the type typically established by individual manual connections performed, for example, using alligator clips or direct wire connections. However, the elongated pins 142 are only one possible embodiment of the engagement feature 60.

[0032] For example, with a brief reference to the alternative engagement feature 600 in Figure 8, the plugs 12 in Figures 1, 2, and 4 may include a keyed or splined surface 420 by forming the keyed or splined surface 420 on the surface of, for example, a central post 50 or another feedthrough pin 42. In such embodiments, the socket 14 includes a mating keyed or splined surface 61, and the specified orientation of the socket 14 allows the central post 50 to enter the corresponding receptacle 56. The use of elongated pins 142 and / or keyed / splined surfaces 420 and 61 is merely illustrative means to enable the plug 12 to be coupled to the socket 14 in the specified orientation described above, as other possibilities for implementing the engagement feature 60 may exist.

[0033] Referring to Figure 9, the central post 50 described above may be used as an indexable feature for the purpose of ensuring proper spacing and leveling of the feedthrough pins 42 before, for example, the stem 46 is melted and the feedthrough pins 42 are sealed therein. To facilitate installation, for example, the stem 46 may be leveled using a pin fixture 65 that indexes or aligns the stem 46 in the same orientation each time. Since the central post 50 is also used for alignment in later stages of manufacturing, including final sealing, the stem 46 needs to maintain a straight axial alignment. Such alignment is made possible by a typical pin fixture 65, such as a solid planar base 66 connected to or integrally formed with an axially extending fixture post 68.

[0034] During operation, the operator may axially insert the individual feedthrough pins 42 that form the plug 12 into the mating openings 156 of the pin fixture, in this example, the fixture post 68, through the stem 46 which is fixed relative to each other, and the fixture post 68 eventually enters the plug recess 44. The fixture has the same number of openings 156 as the feedthrough pins 42, as the fixture is designed to hold the feedthrough pins 42 in place while the stem 46 is sealed. The radial surface 69 of the annular flange 45 then rests firmly on the base, as best shown in Figure 10. The cathode assembly 10 shown in Figure 10 (see also Figure 1) is then electrically connected to the free end E1 of the passthrough pins 42 extending from the stem 46 in Figure 9. This fixing and leveling method may be in contrast to conventional methods in which the stem 46 is leveled on the radial surface 69 of the glass flare component 40, which is rarely, if any, perfectly flat. As a result, the cathode head 36 (see Figure 1) may sometimes appear slightly bent, which can lead to a biased focus.

[0035] Figure 11 shows an exemplary method 100 for constructing a vacuum tube insertion assembly 10 for a vacuum tube, such as an X-ray tube, as described above with reference to Figures 1 to 10, for example. A possible embodiment of method 100 begins in block B102, which includes providing a flared insertion part 40 having an annular flange 45 surrounding a plug recess 44 and a stem 46 formed integrally with the annular flange 45 and extending axially from the annular flange 45, as best shown in Figure 4. Method 100 then proceeds to block B104.

[0036] Block B104 involves axially inserting multiple feedthrough pins 42 through the stem 46 in a fixed position relative to each other, such that the feedthrough pins 42 are collectively arranged within the plug recess 44 as the plug 12. In some embodiments of Method 100, this may involve inserting the feedthrough pins 42 into the openings 156 within the pin fixture 65, with a fixed spacing between the openings 156 (see Figure 9). The feedthrough pins 42 can then be pushed through the stem 56, for example, using a pinch press. Thus, the use of the pin fixture 65 has the advantage of maintaining the plane of the annular flange 45 perpendicular to the center post 50. Method 100 then proceeds to block B106.

[0037] Block B106 includes sealing the stem 46 to the feedthrough pin 42 such that the stem 46 is vacuum-sealed to the feedthrough pin 42, thereby forming the plug 12. Sealing may involve forming partially molten or viscous, thermo-softened glass of the stem 46 using a glass lathe and / or press while the flared insert 40 is oriented, horizontalized, and held within the pin fixture 65 or similar fixture of Figure 9. The stem 46 is thus vacuum-sealed to the feedthrough pin 42, with the feedthrough pin 42 extending through the glass surrounding the stem 46, and there is no intervening space between them that would break the vacuum. Method 100 then proceeds to block B108.

[0038] Block B108 in Figure 11 may include connecting the feedthrough pin 42 to the corresponding connector of the cathode head 36 and then setting the filament(s) 39 therein. As described above, the feedthrough pin 42 is integrally formed with the thermo-softened glass material of the stem 46 so that all potentially vacuum-depleting leak paths are sealed. Once the cathode assembly 28 is connected in this manner, method 100 proceeds to block B110.

[0039] In block B110, method 100 includes completing the construction of the vacuum tube insertion assembly 10. This may involve installing the remaining components of Figure 1 in a non-limiting exemplary construction of the X-ray tube insert. For example, the anode assembly 26 in Figure 1 may be screwed directly into the neck 33 and anode shank (not shown), while the cathode assembly 28 is placed on the center post 50. The stem 46 is horizontally positioned from the center post 50 using a pin holder 65, so that the cathode head 36 is straight during sealing. As part of this effort, the flared insertion component 40 is connected to the glass enclosure 24 in Figure 1, thereby sealing the cathode assembly 28 and the remaining components of Figure 1 within the defined volume 25 of the glass enclosure 24. The glass enclosure 24 may be emptied to form a vacuum. Method 100 then proceeds to block B112.

[0040] Block B112 of Method 100 includes removably coupling the mating receptacle 56 of the socket 14, best shown in Figure 7, to the feedthrough pin 42 of the plug 12, which is itself located within the plug recess 44 (see Figure 4). Power is thereby supplied to the vacuum tube insertion assembly 10.

[0041] As described above with particular reference to Figures 7 and 8, block B112 may include orienting the socket 14 to a specified orientation when connecting the socket 14 to the plug 12. Different configurations of the socket 14 may be used to perform different stages of assembly and testing, including final sealing, pumping, bake-out, radio frequency (RF), high-pressure testing, and tanking, the latter being used for leveling and removing high-electric-field areas / irregularities such as small burrs.

[0042] Similarly, different sockets 14 will be used for sign-off at critical points such as voltage and pressure, and for connecting the vacuum tube insertion assembly 10 to external power, and the sockets 14 will simply be plugged directly into the exposed plug 12 to affect the electrical connection. Loading will also be easier, as the operator will not need to feed the individual wires through small holes in the insulator and connect the wires individually to the cathode assembly 28. Instead, the housing will be modified with sockets 14 that plug directly onto the feedthrough pins 42, as described above.

[0043] According to one embodiment of the present disclosure, a vacuum tube insertion assembly 10 includes a flared insertion component 40 having an annular flange 45 and a stem 46, each constructed from glass. The stem extends axially from the annular flange 45 and defines a plug recess 44. The annular flange 45 surrounds the outer periphery 47 of the plug recess 44. A plurality of feedthrough pins 42 are configured to connect to components of the vacuum tube insertion assembly 10, passing axially through the stem 46 and sealing to the stem 46. The feedthrough pins 42 terminate at a predetermined distance from the stem 46 inside the plug recess 44 to collectively form a plug 12. A socket 14 is configured to connect to the plug 12 within the plug recess 44, and the socket 14 includes a plurality of receptacles 56 collectively configured to removably couple to the feedthrough pins 42. The socket 14 or plug 12 includes, separately or together, engaging features 60, 600 configured to allow the plug 12 to accept the socket 14 in a specified orientation.

[0044] In one embodiment, the feedthrough pins 42 include a central post 50 and one or more remaining feedthrough pins 52. The central post 50 has a radial dimension that exceeds the radial dimension of each of the remaining feedthrough pins 52. The central post 50 and the feedthrough pins 42, 52 may be cylindrical in a possible configuration, and the one or more remaining feedthrough pins 52 include four feedthrough pins.

[0045] In another embodiment, the socket 14 further includes a flexible cable 16 coupled to a plurality of receptacles 56.

[0046] The plug 12 may include an engagement feature 60 configured to allow the plug 12 to accept the socket 14 in a specified orientation. In a possible embodiment, the engagement feature 60 includes at least one feedthrough pin 42 having a length extended compared to the length of each of the one or more remaining feedthrough pins 42. The engagement feature 60 may also include a stepped radial intermediate wall surface 140 that accommodates at least one receptacle 56, at least one of which is configured to accept each of the feedthrough pins 42 having the extended length into itself.

[0047] The plug 12 and socket 14 include an engagement feature 600, the engagement feature 600 in the disclosed embodiment including a keyed or splined surface 420 of the plug 12. In such an embodiment, the socket 14 includes a mating keyed or splined surface 61 configured to receive the keyed or splined surface 420 of the plug 12 into it.

[0048] The feedthrough pin 42 may optionally be constructed from a tungsten (W), molybdenum (Mo), or nickel-cobalt-iron (Ni-Co-Fe) alloy.

[0049] In another possible embodiment, the feedthrough pin 42 is constructed from a first metal plated with a second metal.

[0050] As part of any of the embodiments described above, the cathode assembly 28 may be surrounded by a glass enclosure 24, and the flared insert 40 may be connected to or integrally formed with the glass enclosure 24. A feedthrough pin 42 is connected to the cathode assembly 28.

[0051] In one embodiment of this disclosure, the vacuum tube insertion assembly 10 is configured as an X-ray tube insertion assembly 10.

[0052] According to another embodiment of the present disclosure, a method 100 for constructing a vacuum tube insertion assembly 10 comprises constructing a flared insertion component 40 and a stem 46 from glass, the flared insertion component 40 having an annular flange 45 surrounding a plug recess 44 and a stem 46 formed integrally with the annular flange 45 and extending axially therefrom. Method 100 in this embodiment comprises axially inserting a plurality of feedthrough pins 42 through the stem 46 in fixed positions relative to each other such that the feedthrough pins 42 are collectively arranged as a plug 12 within the plug recess 44, and at least one of the feedthrough pins 142 is longer than the remaining amount of feedthrough pins 42. Method 100 also comprises sealing the stem 46 to the feedthrough pins 42, thereby forming the plug 12. Method 100 may also comprise removably coupling a mating receptacle 56 of a socket 14 to the feedthrough pins 42 of the plug 12 of the vacuum tube insertion assembly 10.

[0053] According to another embodiment of the present disclosure, a method 100 for constructing a vacuum tube insertion assembly 10 comprises constructing a flared insertion component 40 and a stem 46 from glass, the flared insertion component 40 having an annular flange 45 surrounding a plug recess 44 and a stem 46 formed integrally with the annular flange 45 and extending axially from the annular flange 45. Method 100 in this embodiment involves axially inserting a plurality of feedthrough pins 42 through the stem 46 in fixed positions relative to each other, such that the feedthrough pins 42 are collectively arranged within the plug recess 44 as a plug 12. Method 100 also includes sealing the stem 46 to the feedthrough pins 42, thereby forming the plug 12. The socket 14 or the plug 12 includes, separately or together, engaging features 60, 600 configured to allow the plug 12 to accept the socket 14 in a specified orientation of the socket 14. Method 100 may also include removably coupling the mating receptacle 56 of the socket 14 to the feedthrough pin 42 of the plug 12 of the vacuum tube insertion assembly 10.

[0054] Inserting multiple feedthrough pins 42 axially through the stem 46 in a fixed position relative to each other may include inserting the feedthrough pins 42 into multiple openings 156 of the pin holder 65, wherein the pin holder 65 is inserted with a fixed spacing between the openings 156, and pushing the feedthrough pins 42 through the stem 46.

[0055] In a possible embodiment, method 100 includes connecting the feedthrough pin 42 to the corresponding connection portion of the cathode assembly 28 and connecting the flared insert 40 to the glass enclosure 24, thereby enclosing the cathode assembly 28 within the volume 25 of the glass enclosure 24.

[0056] In one embodiment, method 100 includes positioning the socket 14 in a specified orientation via engaging features 60, 600 before connecting the socket 14 to the plug 12. The engaging features 60, 600 include at least one feedthrough pin 142 that is longer than the remaining amount of the feedthrough pin 42.

[0057] Removably coupling the mating receptacle 56 of the socket 14 to the feed-through pin 42 of the plug 12 within the plug recess 44 includes, in a possible embodiment, inserting the elongated feed-through pin 42 into one of the mating receptacles 56 located on the stepped radial intermediate wall surface 140 of the socket 14.

[0058] Removably coupling the mating receptacle 56 of the socket 14 to the feedthrough pin 42 of the plug 12 within the plug recess 44 may include inserting one or more keyed or splined surfaces 420 of the feedthrough pin 42 into one mating keyed or splined surface 61 of the mating receptacle 56.

[0059] Some embodiments of the disclosed vacuum tube insertion assembly 10 include annular flange means and stem means. For example, the vacuum tube insertion assembly may include glass means including annular flange means formed integrally with axially extending stem means, the stem means defining a plug recess means. The annular flange means surrounds the outer periphery of the plug recess means. The plug means includes a plurality of feedthrough pin means that pass axially through the glass means, are sealed in the glass means, and terminate inside the plug recess means. Socket means may be configured to connect to the plug means within the plug recess means. A plurality of receptacle means of the socket means are configured to be removably coupled to the feedthrough pin means of the plug means. The socket means or the plug means includes, separately or together, engaging features configured to allow the plug means to accept the socket means in a specified orientation of the socket means, and vice versa.

[0060] The engaging feature means may optionally include a keyed or splined surface of the plugging means and a mating keyed or splined surface of a socket means configured to receive the keyed or splined surface of the plugging means.

[0061] An example of an annular flange means includes an annular flange 42. An example of a stem means includes an axially extending stem 46 formed integrally with the glass enclosure 24, the stem 46 defining a plug recess means. Furthermore, an example of a plug recess means includes the plug recess 44 described above, and the annular flange means surrounds the outer periphery of the plug recess means. An example of a plug means includes the plug 12 described above, which includes a plurality of feed-through means, an example of which includes the feed-through pin 42 described above, which passes axially through the glass means, is sealed in the glass means, and terminates inside the plug recess means. A socket means in this embodiment of the disclosure, exemplified as a socket 14, is configured to connect to the plug means within the plug recess means. A plurality of receptacle means of the socket means are configured to be removably coupled to the feed-through pin means of the plug means, an example of a receptacle means is the receptacle 56 described above.

[0062] In some embodiments, the plug means includes engaging feature means configured to allow the plug means to receive the socket means in a specified orientation, and examples of engaging feature means include the engaging features 60, 600 described above.

[0063] The following provisions provide typical configurations of vacuum tube insertion assemblies and methods for assembling vacuum tube insertion assemblies, as disclosed herein.

[0064] Clause 1: A vacuum tube insertion assembly comprising: a flared insertion component, each having an annular flange and a stem constructed from glass, wherein the stem extends axially from the annular flange and defines a plug recess, and the annular flange surrounds the outer periphery of the plug recess; a plurality of feedthrough pins configured to couple to a component of the vacuum tube insertion assembly, passing axially through the stem and sealing to the stem, wherein the feedthrough pins terminate at a predetermined distance from the stem inside the plug recess to collectively form a plug; and a socket configured to couple to the plug within the plug recess, wherein the socket comprises a plurality of receptacles collectively configured to couple removably to the feedthrough pins, and the socket or the plug separately or together include engagement features configured to allow the plug to accept the socket in a specified orientation of the socket.

[0065] Clause 2: The vacuum tube insertion assembly according to Clause 1, wherein the feedthrough pins include a center post and one or more remaining feedthrough pins, and the center post has a radial dimension exceeding the radial dimension of each of the remaining feedthrough pins.

[0066] Clause 3: The vacuum tube insertion assembly according to Clause 2, wherein the center post and the pins are cylindrical, and the one or more remaining feedthrough pins include four feedthrough pins.

[0067] Clause 4: The vacuum tube insertion assembly according to any one of Clauses 1 to 3, wherein the socket further comprises a flexible cable coupled to the plurality of receptacles.

[0068] Clause 5: A vacuum tube insertion assembly according to any one of Clauses 1 to 4, wherein the plug includes the engagement feature.

[0069] Clause 6: The vacuum tube insertion assembly according to Clause 5, wherein the engaging feature comprises at least one of the feedthrough pins having a length extended compared to the length of each of the one or more remaining feedthrough pins.

[0070] Clause 7: The vacuum tube insertion assembly according to Clause 6, wherein the engaging feature includes a stepped radial intermediate wall surface that accommodates at least one of the receptacles, and the at least one of the receptacles is configured to receive into each of the feedthrough pins of the extended feedthrough pins.

[0071] Clause 8: The vacuum tube insertion assembly according to Clause 5, wherein the plug and the socket include the engagement feature, the engagement feature includes a keyed or splined surface of the plug, and the socket includes a mating keyed or splined surface configured to receive the keyed or splined surface of the plug into it.

[0072] Clause 9: A vacuum tube insertion assembly according to any one of Clauses 1 to 8, wherein the feedthrough pin is constructed from tungsten (W), molybdenum (Mo), or nickel-cobalt iron (Ni-Co-Fe) alloy.

[0073] Clause 10: A vacuum tube insertion assembly according to any one of Clauses 1 to 9, wherein the feedthrough pin is constructed from a first metal that is plated with a second metal.

[0074] Clause 11: A vacuum tube insertion assembly according to any one of Clauses 1 to 10, comprising the cathode assembly, wherein the flared insertion component is connected to the glass enclosure or formed integrally with the glass enclosure, and the feedthrough pin is connected to the cathode assembly.

[0075] Clause 12: The vacuum tube insertion assembly described in Clause 11, wherein the vacuum tube insertion assembly is configured as an X-ray tube insertion assembly.

[0076] Clause 13: A method for constructing a vacuum tube insertion assembly, comprising constructing a flared insertion component and a stem from glass, wherein the flared insertion component has an annular flange surrounding a plug recess, and the stem is integrally formed with the annular flange and extends axially from the annular flange; inserting a plurality of feedthrough pins axially through the stem in fixed positions relative to each other such that the feedthrough pins are collectively arranged as a plug within the plug recess; sealing the stem with the feedthrough pins to form the plug, wherein the plug or mating socket includes engaging features that enable the plug to accept the socket in a specified orientation.

[0077] Clause 14: The method of Clause 13, wherein inserting the plurality of feedthrough pins axially through the stem in fixed positions relative to each other is inserting the feedthrough pins into a plurality of openings of a pin fixture, the pin fixture further comprising inserting with fixed spacing between the openings and pushing the feedthrough pins through the stem.

[0078] Clause 15: The method according to either Clause 13 or 14, further comprising removably coupling the mating receptacle of the socket to the feedthrough pin of the plug of the vacuum tube insertion assembly.

[0079] Clause 16: The method of Clause 15, further comprising positioning the socket in the specified orientation via the engagement feature before connecting the socket to the plug, wherein the engagement feature includes at least one of the feedthrough pins which is an elongated feedthrough pin longer than the remaining amount of the feedthrough pins.

[0080] Clause 17: The method of Clause 15, wherein the removable coupling of the mating receptacle of the socket to the feedthrough pin of the plug within the recess of the plug includes inserting the elongated feedthrough pin into one of the mating receptacles located on the stepped radial intermediate wall surface of the socket.

[0081] Clause 18: The method according to any one of Clauses 15 to 17, wherein the mating receptacle of the socket is removably coupled to the feedthrough pin of the plug within the recess of the plug, comprising inserting one or more keyed or splined surfaces of the feedthrough pin into the mating keyed or splined surface of the mating receptacle.

[0082] Clause 19: A vacuum tube insertion assembly comprising: a glass means including an annular flange means integrally formed with an axially extending stem means, wherein the stem means defines a plug recess means, and the annular flange means surrounds the outer periphery of the plug recess means; a plug means including a plurality of feed-through pin means passing axially through the glass means, sealed to the glass means, and terminating inside the plug recess means; and a socket means configured to connect the plug means within the plug recess means, wherein a plurality of receptacle means of the socket means are configured to be removably coupled to the feed-through pin means of the plug means, and the socket means or the plug means separately or together include engagement feature means configured to enable the plug means to accept the socket means in a specified orientation of the socket means.

[0083] Clause 20: The vacuum tube insertion assembly according to Clause 19, wherein the engaging feature means includes a keyed or splined surface of the plug means and a mating keyed or splined surface of the socket means configured to receive the keyed or splined surface of the plug means into it.

[0084] While these systems and methods are described in relation to exemplary embodiments, it will be understood by those skilled in the art that various modifications can be made without departing from the scope of the claims, and that equivalents can be substituted to adapt these teachings to other problems, materials, and technologies. Features, aspects, components, or operations of one embodiment may be combined with features, aspects, components, or operations of other embodiments described herein. Thus, the present invention is not limited to the specific examples disclosed, but encompasses all embodiments included in the appended claims.

[0085] The claims following the disclosure in this document are hereby explicitly incorporated into the disclosure in this document, and each claim stands on its own as a separate embodiment. This disclosure includes all variations of the independent claims with dependent claims. Furthermore, additional embodiments that can be derived from the following independent and dependent claims are also explicitly incorporated into the description in this document. These additional embodiments are determined by replacing the dependency of a given dependent claim with the phrase "any of the claims beginning with claim [x] and ending with the claim immediately preceding this claim," where the parenthetical term "[x]" is replaced with the number of the most recently described independent claim. For example, for a first set of claims beginning with independent claim 1, claim 3 may depend on either claim 1 or 2, and these separate dependencies may result in two different embodiments; claim 4 may depend on any one of claims 1, 2, or 3, and these separate dependencies may result in three different embodiments; claim 5 may depend on any one of claims 1, 2, 3, or 4, and these separate dependencies may result in four different embodiments, and so on.

[0086] The description in the claim of "First" feature or element does not necessarily imply the existence of a second or additional such feature or element. Where present, elements specifically described in means-plus-function form are intended to be interpreted in accordance with Section 112(f) of the U.S. Patent Act to encompass the corresponding structures, materials or functions and their equivalents described herein. Embodiments of the Invention for which exclusive rights or privileges are claimed are defined as follows:

Claims

1. A vacuum tube insertion assembly, A flared insert component having an annular flange and a stem, each constructed from glass, wherein the stem extends axially from the annular flange and defines a plug recess, and the annular flange surrounds the outer edge of the plug recess, A plurality of feedthrough pins configured to be coupled to the components of the vacuum tube insertion assembly, passing axially through the stem and sealing to the stem, wherein the feedthrough pins terminate at a predetermined distance from the stem inside the plug recess to collectively form a plug, A socket configured to connect to the plug within the recess of the plug, wherein the socket comprises a plurality of receptacles collectively configured to be removably coupled to the feedthrough pin, and the socket or the plug separately or together comprises engaging features configured to allow the plug to accept the socket in a specified orientation of the socket and The vacuum tube insertion assembly comprising the above.

2. The vacuum tube insertion assembly according to claim 1, wherein the feedthrough pins include a central post and one or more remaining feedthrough pins, and the central post has a radial dimension exceeding the radial dimension of each of the remaining feedthrough pins.

3. The vacuum tube insertion assembly according to claim 2, wherein the central post and the feedthrough pins are cylindrical, and the one or more remaining feedthrough pins include four feedthrough pins.

4. The vacuum tube insertion assembly according to any one of claims 1 to 3, wherein the socket further comprises a flexible cable coupled to the plurality of receptacles.

5. The vacuum tube insertion assembly according to claim 1, wherein the plug includes the engagement feature.

6. The vacuum tube insertion assembly according to claim 5, wherein the engagement feature includes at least one of the feedthrough pins having a length extended compared to the length of each of the one or more remaining feedthrough pins.

7. The vacuum tube insertion assembly according to claim 6, wherein the engagement feature includes a stepped radial intermediate wall surface that accommodates at least one of the receptacles, and the at least one of the receptacles is configured to receive into each of the feedthrough pins of the extended feedthrough pins.

8. The vacuum tube insertion assembly according to claim 5, wherein the plug and the socket include the engagement feature, the engagement feature includes a keyed or splined surface of the plug, and the socket includes a mating keyed or splined surface configured to receive the keyed or splined surface of the plug into it.

9. The vacuum tube insertion assembly according to claim 1, wherein the feedthrough pin is constructed from tungsten (W), molybdenum (Mo), or nickel-cobalt iron (Ni-Co-Fe) alloy.

10. The vacuum tube insertion assembly according to claim 1, wherein the feedthrough pin is constructed from a first metal that is plated with a second metal.

11. A vacuum tube insertion assembly according to claim 1, comprising a cathode assembly surrounded by a glass enclosure, wherein the flared insertion component is connected to the glass enclosure or integrally formed with the glass enclosure, and the feedthrough pin is connected to the cathode assembly.

12. The vacuum tube insertion assembly according to claim 11, wherein the vacuum tube insertion assembly is configured as an X-ray tube insertion assembly.

13. A method for constructing a vacuum tube insertion assembly, The construction of a flared insert and a stem from glass, wherein the flared insert has an annular flange surrounding the plug recess, and the stem is integrally formed with the annular flange and extends axially from the annular flange, Multiple feedthrough pins are inserted axially through the stem in fixed positions relative to each other, such that the feedthrough pins are collectively arranged as a plug within the recess of the plug. The process involves sealing the stem onto the feedthrough pin, thereby forming the plug, wherein the plug or mating socket includes engaging features that enable the plug to accept the mating socket in a specified orientation. The method, including the method described above.

14. Inserting the multiple feedthrough pins axially through the stem in a fixed position relative to each other is Inserting the feedthrough pins into multiple openings of a pin holder, wherein the pin holder has a fixed spacing between the openings for insertion. Pushing the feedthrough pin through the stem and The method according to claim 13, further comprising:

15. The method according to claim 13 or 14, further comprising removably coupling the mating receptacle of the mating socket to the feedthrough pin of the plug of the vacuum tube insertion assembly.

16. The method according to claim 15, wherein, before connecting the mating socket to the plug, the mating socket is positioned in the specified orientation via the engaging feature, the engaging feature comprising at least one of the feedthrough pins being longer than the remaining feedthrough pins.

17. The method according to claim 15, wherein the removable coupling of the mating receptacle of the mating socket to the feedthrough pin of the plug within the recess of the plug includes inserting the elongated feedthrough pin into one of the mating receptacles located on the stepped radial intermediate wall surface of the mating socket.

18. The method according to claim 15, wherein the removable coupling of the mating receptacle of the mating socket to the feedthrough pin of the plug within the recess of the plug includes inserting one or more keyed or splined surfaces of the feedthrough pin into the mating keyed or splined surface of the mating receptacle.

19. A vacuum tube insertion assembly, A glass means including an annular flange means integrally formed with an axially extending stem means, wherein the stem means defines a plug recess means, and the annular flange means surrounds the outer peripheral edge of the plug recess means, A plug means including a plurality of feedthrough pin means that pass through the glass means in the axial direction, are sealed by the glass means, and terminate inside the plug recess means, A socket means configured to connect the plug means within the plug recess means, wherein a plurality of receptacle means of the socket means are configured to be removably coupled to the feedthrough pin means of the plug means, and the socket means or the plug means separately or together include engagement feature means configured to enable the plug means to accept the socket means in a specified orientation of the socket means. The vacuum tube insertion assembly comprising the above.

20. The vacuum tube insertion assembly according to claim 19, wherein the engaging feature means includes a keyed or splined surface of the plug means and a mating keyed or splined surface of the socket means configured to receive the keyed or splined surface of the plug means into it.

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