Magnet array holder for accelerating assembly and improving alignment in vacuum electronic devices

Abstract

A magnet array unit holder configured to hold magnetic components and / or non-magnetic components for forming a magnet array unit, wherein the magnet array unit is configured to manipulate one or more electron beams within a vacuum electronic device when assembled, and the magnet array unit holder includes a set of slots configured to receive magnetic components and / or non-magnetic components, a set of pockets configured to receive magnetic components and / or non-magnetic components, and one or more mounting interfaces configured to couple the magnet array unit holder to the vacuum electronic device.

Description

[Technical Field]

[0001] Embodiments of the present invention relate generally to vacuum electronic devices, and more particularly to providing a magnet array holder that accelerates assembly and improves alignment in vacuum electronic devices, especially when operating at millimeter wave frequencies and above. [Background technology]

[0002] Vacuum electron devices utilize the interaction between one or more electron beams and one or more electromagnetic waves generated within an interaction region. The construction of a vacuum electron device requires the integration of metallic, ceramic, magnetic, and / or other types of materials into a single assembly. The assembly encloses a vacuum chamber or cavity in which the interaction between the electron beam(s) and the electromagnetic wave(s) takes place. Examples of vacuum electron devices include, but are not limited to, particle accelerators, klystrons, gyrotrons, gyro-klystrons, traveling wave tubes (TWTs), gyro-TWTs, backward wave oscillators, magnetrons, crossed-field amplifiers, free electron lasers, ubitrons, etc.

[0003] The propagation of electron beams through the beam tunnels of vacuum electron devices is traditionally achieved using magnetic and / or electrostatic fields. For vacuum electron devices operating at millimeter and near-terahertz frequencies, magnetic fields are predominantly used. Permanent magnets, electromagnets, and periodic magnet arrays are commonly employed to confine the beam in the beam tunnel.

[0004] Difficulties arise when assembling and preparing vacuum electron devices for operation. First, the beam tunnel, magnetic centerline, and beam entry point are often misaligned due to manufacturing and assembly irregularities. This difficulty is particularly pronounced in higher-frequency devices. Second, the quality of the magnetic material is typically insufficient to ensure that the magnetic domains of individual magnets are aligned with the design domains with the required precision, resulting in inhomogeneities in the magnetic field. Therefore, after fabricating a vacuum electron beam device, specialist engineers spend a significant amount of time (e.g., several months) trimming the magnetic field around the vacuum electron device to achieve optimal beam penetration. Furthermore, the magnetic materials typically utilized in vacuum electron devices have the highest grade of magnetization strength and are therefore extremely difficult to handle. The attractive and repulsive forces of the magnetic materials can be strong enough to cause breakage or misplacement of the magnetic materials, making assembly not only inefficient but also dangerous for the assembly personnel.

[0005] Finally, magnets are typically secured with some type of adhesive, which requires a long curing time and, due to this long curing time, significant effort to hold the magnets precisely in place. This slows the assembly process and introduces further inaccuracies. Furthermore, adhesives can introduce inaccuracies in the placement of magnetic components due to variations in the adhesive joint thickness. Misalignments can be linear, angular, height, and numerous other types of imperfections. Conventionally assembled magnet arrays can deviate from the design at significant rates, thus resulting in less-than-ideal magnetic field profiles. This problem is exacerbated in devices operating at high frequencies or requiring small magnetic component sizes (millimeter to submillimeter scale) because joint tolerances generally remain the same, thus allowing significant inconsistencies to accumulate. Summary of the Invention [Problem to be solved by the invention]

[0006] The systems and methods help aid in the construction of vacuum electron devices. [Means for solving the problem]

[0007] Disclosed herein are magnet array holders, magnet array assemblies, and corresponding methods. The magnet arrays enable improved confinement, focusing, and other types of manipulation of electron beams in vacuum electronic devices. The magnet array holders enable accelerated assembly of magnet arrays and are particularly suited to automated production of vacuum electronic devices. In some embodiments, the magnet array holders utilize mechanical fixtures that support and / or control the precise placement of each magnetic and non-magnetic component while minimizing tolerance stackup. The magnet array holders also assist in controlling the shape and size of the magnetic and non-magnetic components themselves. The magnet array holders also support insertion of magnetic and non-magnetic components from one direction, simplifying process automation. The magnet array holders are further suited to holding and assembling periodic permanent magnet arrays, Halbach magnet arrays, wiggler arrays, quadrupole magnet arrays, dipole magnet arrays, and combinations of multiple types of magnet arrays (e.g., periodic permanent magnet arrays and quadrupole or dipole magnet arrays). The magnetic materials of the magnetic components may include ferromagnetic, diamagnetic, and paramagnetic materials. A magnet array holder may be employed to secure the permanent magnet and electromagnet arrays to achieve desired alignment accuracy and magnetic circuit performance. Non-magnetic components may be used to space the magnetic components at a desired distance, which affects the magnetic circuit characteristics.

[0008] In some embodiments, the magnet array holder allows for the assembly of highly ferromagnetic components that may be subject to attractive or repulsive forces during assembly, thereby avoiding significant difficulties in manipulating the highly ferromagnetic components into the appropriate locations. The magnet array holder significantly facilitates manual assembly of the magnet array and also facilitates automation of the assembly process by robotic operations (e.g., pick-and-place systems).

[0009] The magnet array holder precisely positions the magnetic components in the appropriate locations relative to each other and relative to other magnet arrays that require alignment. The positions of the magnetic components can be precisely manufactured into the magnet holder with consistent precision using modern manufacturing techniques, directly transferring this precision to the magnetic component assembly on the vacuum electronic device. The magnet array holder can reliably capture each magnetic component individually, allowing the magnet array to be built without having to hold each magnet in place while the adhesive hardens. In some embodiments, the magnet array holder and corresponding methods of assembling magnet arrays eliminate the reliance on achieving a uniform adhesive thickness, whether assembling individual components or between components.

[0010] The magnet array holder is particularly useful for flat magnet structures employed in sheet electron beam devices or devices employing wiggler or undulator magnets. In other cases, the magnet array holder may be adapted for application in round, hollow, spiral, distributed, focusing, and multi-beam magnet structures.

[0011] The present invention further provides an automated computer-implemented method for designing magnet array holders for precisely steering electron beams in vacuum electron devices, employing mechanical features to precisely position and secure magnetic components and accelerate assembly. The magnet array holders may employ features to capture magnetic and non-magnetic components, marking features to align magnet polarities, heights of features to hold and position magnetic and non-magnetic components, variations in height, features of various lengths, additional features to combine multiple types of magnetic components, depths designed to position magnets, single features to position individual magnetic components and magnet array locations relative to other external magnetic and non-magnetic features, fixtures to shield additional magnetic components, features to combine depth with walls of other components, designs to predict minimum and maximum magnet misalignment, misalignment calculations to model magnetic circuit performance, and methods for a variety of permanent magnets and electro-permanent magnets.

[0012] The magnet array holders and techniques disclosed herein are useful for achieving high quality alignment, and are particularly useful in the fabrication of vacuum electronic devices at millimeter wave and near THz frequencies. Vacuum electronic devices using the magnet array holders designed herein may be configured to amplify electromagnetic signals at frequencies ranging from 1 GHz to 1000 GHz, and up to 3 THz and / or 30 THz.

[0013] In some embodiments, the present invention provides a magnet array holder configured to hold magnetic and / or non-magnetic components to form a magnet array, the magnet array being configured to steer one or more electron beams within a vacuum electronic device when assembled, the magnet array holder comprising a set of slots configured to receive the magnetic and / or non-magnetic components, a set of pockets configured to receive the magnetic and / or non-magnetic components, and one or more attachment interfaces (hole(s), pin(s), adhesive(s), fastener(s), weld(s), attachment material, etc.) configured to couple the magnet array holder to the vacuum electronic device. In some embodiments, the magnet array holder 202 may be integrated as part of the vacuum electronic device 100.

[0014] Each slot of the set of slots may have a first shape and each pocket of the set of pockets may have a second shape different from the first shape. Each pocket of the set of pockets may have a bridge portion spanning the pocket. Each pocket of the set of pockets may include indicia indicating the orientation of the magnetic component to assist in alignment of the magnetic component. The indicia may include a written key. Each pocket may have a size, shape, and position that controls the size, shape, and position of the magnetic and non-magnetic components received therein. Each slot may have a size, shape, and position that controls the size, shape, and position of the magnetic and non-magnetic components received therein. The magnet array holder may further include a set of additional portions configured to receive additional magnetic or non-magnetic components. Each portion of the set of additional portions may include indicia indicating the orientation of the magnetic component to assist in alignment of the additional magnetic components. At least one slot of the set of slots may extend through the magnet array holder. The magnet array holder may hold both magnetic and non-magnetic components. The magnet array holder may hold only magnetic components. The magnet array holder may hold only a portion of the magnetic circuit necessary for the operation of the vacuum electronic device.

[0015] In some embodiments, the present invention provides a method of assembling a magnet array configured to manipulate one or more electron beams within a vacuum electronic device, the method including: preparing a magnet array holder configured to hold magnetic and / or non-magnetic components, the magnet array holder having a set of slots configured to receive the magnetic and / or non-magnetic components, a set of pockets to receive the magnetic and / or non-magnetic components, and one or more fastening or mounting interfaces for coupling to the vacuum electronic device; disposing at least a pair of magnetic or non-magnetic components within a set of slots adjacent to a particular pocket of the set of pockets; and disposing a particular magnetic component within the particular pocket of the set of pockets, wherein the pair of magnetic or non-magnetic components acts as a wall to support insertion of the particular magnetic component.

[0016] Each pocket of the set of pockets may have a bridge portion spanning the pocket. Each set of slots may be configured to receive a respective non-magnetic component. Each set of slots may be configured to receive a magnetic component having an up or down polarity orientation. Placing a particular magnetic component in a particular pocket may include orienting the polarity of the magnetic component according to the indicia. The magnet array holder may further include a set of additional regions configured to receive additional magnetic and / or non-magnetic components, and the method may further include placing the additional magnetic components in the additional regions. Placing the additional magnetic and / or non-magnetic components may include orienting the polarity according to the indicia.

[0017] The disclosure herein provides an example of applying slotting techniques to rectangular magnet assemblies. The same approach of using slot depths and varying part heights can be employed in cylindrically symmetric magnet and non-magnet assemblies. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a diagram of components of an exemplary vacuum electron device, e.g., an exemplary traveling wave tube (TWT), according to some embodiments of the present invention, showing an exemplary magnet arrangement affixed to the exemplary vacuum electron device. [Figure 2a] 1 is a top perspective view of an exemplary magnet arrangement according to some first embodiments of the present invention. FIG. [Figure 2b] 1 is a bottom perspective view of an exemplary magnet arrangement according to some first embodiments of the present invention. FIG. [Figure 2c] 1A-1C are top and bottom views of an exemplary magnet array holder according to some first embodiments of the present invention. [Figure 2d] FIG. 2 is a top perspective view of an exemplary magnet array holder according to some first embodiments of the present invention. [Figure 2e] FIG. 2 is a bottom perspective view of an exemplary magnet array holder according to some first embodiments of the present invention. [Figure 2f]1A-1C illustrate top and bottom views of an exemplary magnet arrangement according to some first embodiments of the present invention. [Figure 2g] 1 is a side view of an exemplary magnet arrangement according to some first embodiments of the present invention. FIG. [Figure 2h] 1 is a cross-sectional side view of an exemplary magnet arrangement according to some first embodiments of the present invention. [Figure 3a] FIG. 2 is a top perspective view of an exemplary magnet array holder according to some first embodiments of the present invention. [Figure 3b] 1 illustrates a top perspective view of an exemplary magnet array holder with one magnetic component disposed therein, according to some first embodiments of the present invention. [Figure 3c] 1 illustrates a top perspective view of an exemplary magnet array holder having one magnetic component and one non-magnetic component disposed therein, according to some first embodiments of the present invention. [Figure 3d] 1 illustrates a top perspective view of an exemplary magnet array holder with all magnetic and all non-magnetic components disposed therein, according to some first embodiments of the present invention. [Figure 4a] FIG. 10 is a top perspective view of an exemplary magnet arrangement according to some second embodiments of the present invention. [Figure 4b] FIG. 10 is a bottom perspective view of an exemplary magnet arrangement according to some second embodiments of the present invention. [Figure 4c] FIG. 10 is a bottom perspective view of an exemplary magnet arrangement according to some third embodiments of the present invention. [Figure 4d] 10A-10C illustrate top and bottom views of an exemplary magnet array holder according to some second embodiments of the present invention. [Figure 4e] FIG. 10 is a top perspective view of an exemplary magnet array holder according to some second embodiments of the present invention. [Figure 4f] FIG. 10 is a bottom perspective view of an exemplary magnet array holder according to some second embodiments of the present invention. [Figure 4g] FIG. 10 is a bottom view of an exemplary magnet array holder according to some third embodiments of the present invention. [Figure 4h]FIG. 10 is a top perspective view of an exemplary magnet array holder according to some third embodiments of the present invention. [Figure 4i] FIG. 10 is a bottom perspective view of an exemplary magnet array holder according to some third embodiments of the present invention. [Figure 4j] 10A-10C illustrate top and bottom views of an exemplary magnet arrangement according to some second embodiments of the present invention. [Figure 4k] FIG. 10 is a side view of an exemplary magnet arrangement according to some second embodiments of the present invention. [Figure 4l] FIG. 10 is a cross-sectional side view of an exemplary magnet arrangement according to some second embodiments of the present invention. [Figure 4m] FIG. 10 is a bottom view of an exemplary magnet arrangement according to some third embodiments of the present invention. [Figure 5a] FIG. 10 is a top perspective view of an exemplary magnet array holder according to some second embodiments of the present invention. [Figure 5b] FIG. 10 is a top perspective view of an exemplary magnet array holder with one magnetic component disposed therein, according to some second embodiments of the present invention. [Figure 5c] FIG. 10 is a top perspective view of an exemplary magnet array holder having one magnetic component and one non-magnetic component disposed therein, according to some second embodiments of the present invention. [Figure 5d] FIG. 10 is a top perspective view of an exemplary magnet array holder with all magnetic and all non-magnetic components disposed therein, according to some second embodiments of the present invention. [Figure 6a] FIG. 10 is a bottom perspective view of an exemplary magnet array holder with one magnetic component disposed therein, according to some third embodiments of the present invention. [Figure 6b] FIG. 10 is a bottom perspective view of an exemplary magnet array holder with all magnetic components disposed therein, according to some third embodiments of the present invention. [Figure 7a] 1 is a side view of an exemplary upper magnet arrangement according to some embodiments of the present invention. FIG. [Figure 7b] 1A-1C are side views of an exemplary bottom magnet array according to some embodiments of the present invention. [Figure 7c] 1 is a cross-sectional side view of an exemplary upper magnet arrangement according to some embodiments of the present invention. [Figure 7d] 1A-1C are cross-sectional side views of exemplary bottom magnet arrays according to some embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] Disclosed herein are magnet array holders, magnet array assemblies, and corresponding methods. The magnet arrays enable improved confinement, focusing, and other types of manipulation of electron beams in vacuum electronic devices. The magnet array holders enable accelerated assembly of magnet arrays and are particularly suited to automated production of vacuum electronic devices. In some embodiments, the magnet array holders utilize mechanical fixtures to support and / or control the precise placement of each magnetic and non-magnetic component while minimizing tolerance stackup. The magnet array holders also assist in controlling the shape and size of the magnetic and non-magnetic components themselves. The magnet array holders also support insertion of magnetic and non-magnetic components from one direction, simplifying process automation. The magnet array holders are further suited to holding and assembling periodic permanent magnet arrays, Halbach magnet arrays, wiggler arrays, quadrupole magnet arrays, dipole magnet arrays, and combinations of multiple types of magnet arrays (e.g., periodic permanent magnet arrays and quadrupole magnet arrays or dipole magnet arrays). The magnetic materials of the magnetic components may include ferromagnetic, diamagnetic, and paramagnetic materials. A magnet array holder may be employed to secure the permanent magnet and electromagnet arrays to achieve desired alignment accuracy and magnetic circuit performance. Non-magnetic components may be used to space the magnetic components at a desired distance, which affects magnetic circuit performance.

[0020] In some embodiments, the magnet array holder allows for the assembly of highly ferromagnetic components that may be subject to attractive or repulsive forces during assembly, thereby avoiding significant difficulties in manipulating the highly ferromagnetic components into the appropriate locations. The magnet array holder significantly facilitates manual assembly of the magnet array and also facilitates automation of the assembly process by robotic operations (e.g., pick-and-place systems).

[0021] The magnet array holder precisely positions the magnetic components in the appropriate locations relative to each other and to other magnet arrays that require alignment. The magnet array holder can securely capture each magnetic component individually, allowing the magnet array to be built without having to hold each magnet in place while the adhesive hardens. In some embodiments, the magnet array holder and corresponding method of assembling the magnet array eliminates the reliance on achieving a uniform adhesive thickness, whether assembling individual components or between components.

[0022] The magnet array holder is particularly useful for flat magnet structures employed in sheet electron beam devices or devices employing wiggler or undulator magnets. In other cases, the magnet array holder may be adapted for application to round, hollow, spiral, distributed, focusing, and multiple beam magnet structures.

[0023] The present invention further provides an automated computer-implemented method for designing magnet array holders for precisely steering electron beams in vacuum electron devices, employing mechanical features to precisely position and secure magnetic components and accelerate assembly. The magnet array holder may employ features for capturing magnetic and non-magnetic components, marking features for aligning magnet polarity, heights, varying heights, and varying lengths of features for holding and locating magnetic and non-magnetic components, additional features for combining multiple types of magnetic components, depths designed to locate magnets, single features for locating individual magnetic components and magnet arrays relative to other external magnetic and non-magnetic features, fixtures for shielding additional magnetic components, features for combining depth with walls of other components, designs to predict minimum and maximum magnet misalignment, misalignment calculations to model magnetic circuit performance, and methods for a variety of permanent magnets and electro-permanent magnets.

[0024] The magnet array holders and techniques disclosed herein are useful for achieving high quality alignment, and are particularly useful in the fabrication of vacuum electronic devices at millimeter-wave and near-THz frequencies. Vacuum electronic devices using the magnet array holders designed herein can be configured to amplify electromagnetic signals at frequencies ranging from 1 GHz to 1000 GHz.

[0025] 1 illustrates components of an exemplary vacuum electron device 100, e.g., an exemplary traveling wave tube (TWT) 100, according to some embodiments of the present invention, having a magnet array 110 (magnet array assembly) affixed to the exemplary traveling wave tube (TWT) 100. While FIG. 1 is illustrated with respect to a TWT, the magnet array 110 herein may be used in any vacuum electron device 100 that uses a magnet assembly to steer one or more electron beams within an interaction region.

[0026] The TWT 100 includes a TWT gun 102 configured to generate one or more electron beams (transmitted in the z-direction). The TWT gun 102 may be adapted for sheet beams, hollow beams, pencil beams, diverging beams, multiple beams, etc. The TWT 100 further includes an interaction circuit, which includes an RF input window 104, an RF output window 106, and two magnet arrays 110 configured to guide and shape the one or more electron beams through the interaction circuit. The two magnet arrays 110 include a top magnet array 110 shown at the top of the TWT 100 and a bottom magnet array 110 shown as a mirror image at the bottom of the TWT 100. The bottom magnet array 110 is not explicitly shown in FIG. 1 , but iron shielding for both the top and bottom magnet arrays 110 is shown. The TWT 100 further includes a TWT collector 108 configured to collect one or more electron beams transmitted through the TWT 100 .

[0027] 2a shows a top perspective view of an exemplary magnet array 110 according to some first embodiments of the present invention. The magnet array 110 includes a magnet array holder 202, a magnetic component 204 disposed within a portion of the magnet array holder 202, a non-magnetic component 206 disposed within a portion of the magnet array holder 202, and an iron shield 208 disposed on the leading edge of the magnet array holder (the side of the TWT 100 adjacent the TWT gun 102).

[0028] The magnet array holder 202 may be made from a non-magnetic material such as aluminum or an aluminum alloy, titanium or a titanium alloy, copper or a copper alloy, stainless steel, etc. Magnetic materials may be employed to create all or part of the magnet array holder 202 to achieve the desired magnetic circuit characteristics and therefore magnetic field.

[0029] These locations provide exemplary mechanical features that precisely secure the magnetic and non-magnetic components in the appropriate locations. Exemplary locations (specifically shown at least in FIGS. 2d and 2e) can be slots (e.g., with guide rails), pockets, notches, or other types of receiving features. In some embodiments, the magnetic component 204 can be located in a pocket and the non-magnetic component 206 can be located in a slot. Alternatively, both can be located in a pocket, or both can be located in a slot, or the magnetic component 204 can be located in a pocket and / or slot, and / or the non-magnetic component 206 can be located in a pocket and / or slot. Any combination is possible.

[0030] Each region (pocket, slot, or notch) controls the position, size, and orientation of a magnetic component 204 and / or a non-magnetic component 206. The position and size include length, depth, width, vertical position (y-axis), lateral position (x-axis), longitudinal position (z-axis), etc. The regions may be implemented symmetrically or asymmetrically to achieve a desired result. The position and size of each region, and the corresponding magnetic component 204 and non-magnetic component 206 placed within each region, may be shaped to achieve a desired magnetic interaction circuit performance.

[0031] The magnetic components 204 and non-magnetic components 206 may be secured to their respective locations without the need for direct application of adhesive. In some embodiments, if adhesive is added, the adhesive does not affect the placement of the magnetic components 204 and / or non-magnetic components 206. In some embodiments, each location may be configured to accommodate two or more magnetic components 204, two or more non-magnetic components 206, and / or a combination of magnetic and non-magnetic components 204 and 206.

[0032] It should be appreciated that the height of the magnetic components 204 and / or non-magnetic components 206 may be varied to provide a desired gap between the individual magnetic and non-magnetic components 204, 206. An automated assembly process may utilize the extra height to grip and insert the magnetic and non-magnetic components 204, 206 into their respective locations. Height variations may be employed to insert the magnetic and / or non-magnetic components 204, 206 in a desired order. The height of the magnetic and / or non-magnetic components 204, 206 may also be shaped to achieve desired magnetic interaction circuit performance.

[0033] The depth of the magnetic and non-magnetic components 204, 206, as well as the length, height, and width, can be used to provide additional levels of separation and alignment between the various types of magnetic and / or non-magnetic components 204, 206 in an assembly. The site walls can be configured to act as additional constraints for the magnetic components 204 during and after insertion into the site. Depth can provide location accuracy.

[0034] As shown, the exposed side of the exemplary magnet array 110 includes an alternating sequence of magnetic components 204 and non-magnetic components 206 along the length of the magnet array holder 202, although other sequences are possible based on the desired magnetic interaction circuit performance. As shown, the magnetic components 204 are positioned such that the top surfaces of the magnetic components 204 terminate vertically in a single plane that is higher than the non-magnetic components 206, which also terminate in a single plane.

[0035] While the magnet array holder 202 can be configured for vacuum electronic devices operating at a variety of frequencies, the magnet array holder 202 particularly benefits devices operating between 25 GHz and 1 THz. The magnet array holder 202 is particularly well-suited for electronic devices ranging in size from micrometers to millimeters, and therefore supports the fabrication and alignment required for the propagation of electron beams through interaction circuits. The magnet array 110 can be configured to amplify electromagnetic signals having frequencies ranging from 1 GHz to 25 GHz, 25 GHz to 100 GHz, 100 GHz to 250 GHz, 250 GHz to 500 GHz, or 500 GHz to 1000 GHz. Other frequency ranges are possible.

[0036] Although the magnet array holder 202 is illustrated as including slots 214 throughout the magnet array holder 202, in some embodiments the magnet array holder 202 may include a hard floor, for example, on the bottom side of the magnet array holder 202, so that the non-magnetic components 206 cannot extend beyond the floor.

[0037] The disclosure herein provides an example of applying slotting techniques to rectangular magnet assemblies. The same approach of using slot depths and varying part heights can be employed for cylindrically symmetric magnet and non-magnet assemblies.

[0038] FIG. 2b shows a bottom perspective view of an exemplary magnet arrangement 110 according to some first embodiments of the present invention. Additional magnetic components 210 may be included to combine multiple magnetic circuit types. The additional magnetic components 210 may be quadrupole and / or dipole magnetic components 210 configured to add additional magnetic control to one or more electron beams. The additional magnetic components 210 may be located within a pocket-type region (shown in more detail in FIG. 2e). As shown, the additional magnetic components 210 may be located as part of an array of two additional components 210 below each magnetic component 204 in the series of magnetic components 204. As shown below, the additional magnetic components 210 may be located in any other position, such as above, adjacent, etc.

[0039] In some embodiments, the magnetic component 204 and the non-magnetic component 206 are configured to control one or more electron beams in the y-direction, and in some embodiments, the additional magnetic component 210 is configured to control one or more electron beams in the x-direction.

[0040] FIG. 2c shows top and bottom views of a magnet array holder 202 according to some first embodiments of the present invention.

[0041] In some embodiments, as shown, the top side of the magnet array holder 202 includes a slot 214 for receiving the non-magnetic component 206 and a pocket 216 for receiving the magnetic component 204. In some embodiments, as shown, the bottom side of the magnet array holder 202 includes a pocket 218 for receiving an additional (four-pole) magnetic component 210. The slot 214, the pocket 216, and the pocket 218 may be referred to collectively as a portion 228.

[0042] Indicia 212 may be added to pockets 216 of magnet array holder 202 to identify the polarity of the magnets of magnetic components 204 placed therein, allowing an assembler to match indicia 212 to ensure proper magnetic orientation during the assembly process. Indicia 212 may be added to either or both of magnetic components 204 and magnet array holder 202. It will be appreciated that indicia 212 may include written indicia 212 or physical indicia 212 (i.e., a key) to ensure proper orientation of magnetic components 204 during assembly.

[0043] In some embodiments, as shown, indicia 212 on the top (exposed) side of magnet array holder 202 indicate an alternating pattern where north- and south-facing magnetic components 204 are placed in pockets 216. In some embodiments, as shown, indicia 212 on the bottom side (the side facing the TWT 100) of magnet array holder 202 indicate an array where additional (four-pole) magnetic components 204 of south or north or opposite orientation are placed in pockets 218.

[0044] In some embodiments, the size and shape of each of the slots 214 may be the same, the size and shape of each of the pockets 216 may be the same, and the size and shape of each of the pockets 218 may be the same. In some embodiments, the size and shape of each of the slots 214, pockets 216, and pockets 218 may be the same or different. In some embodiments, there may be variations in the size and shape of each of the slots 214, the size and shape of each of the pockets 216, and the size and shape of each of the pockets 218. Any combination is possible.

[0045] The fixture may also serve to align additional external magnetic components outside the magnet array 110, such as magnetic shields. Additional external pockets or notches and alignment features may be added to position and secure the magnetic components in place. The external magnetic components may be part of a complete or partial magnetic circuit.

[0046] 2d shows a top perspective view of the magnet array holder 202 according to some first embodiments of the present invention. The magnet array holder 202 includes an alternating sequence of slots 214 for receiving non-magnetic components 206 and pockets 216 for receiving magnetic components 204. The magnet array holder 202 further includes one or more (in this case, three) attachment interfaces 220 (e.g., rectangular protrusions with threaded hole(s) as shown, or additionally or alternatively, pin(s), adhesive(s), fastener(s), weld(s), attachment material, etc.) that secure the magnet array holder 202 to the vacuum electronic device 100. In some embodiments, the magnet array holder 202 may be integrated as part of the vacuum electronic device 100.

[0047] 2e shows a bottom perspective view of the magnet array holder 202 according to some first embodiments of the present invention. The magnet array holder 202 includes an array of pockets 216 for receiving additional magnetic components 210 (e.g., four-pole magnetic components).

[0048] 2f shows top and bottom views of the magnet array 110 according to some first embodiments of the present invention. As shown, the magnet array 110 includes holes 224 for aligning the magnet array 110.

[0049] 2g shows a side view of a magnet array 110 according to some first embodiments of the present invention. As shown, the magnet array 110 includes a magnet array holder 202 having an iron shield 208 attached to a leading edge thereof, followed in this embodiment by alternating magnetic and non-magnetic components 204 and 206. Other patterns of magnetic and non-magnetic components 204 and 206 are possible to achieve the desired interaction.

[0050] FIG. 2h shows a cross-sectional side view of the magnet array 110 according to some first embodiments of the present invention. The magnet array 110 in FIG. 2h helps illustrate the depth, height, and elevation of the magnetic and non-magnetic components 204, 206. In some embodiments, as shown, the magnetic components 204 rest on top of a series of bridges 226 disposed at the bottom of the magnet array holder 202, with the non-magnetic components 206 extending between and past the bridges 226 all the way to (or in some embodiments, past) the bottom surface of the magnet array holder 202. In some embodiments, the magnet array holder 202 includes a series of bridges below the non-magnetic components 206 but does not include a series of bridges below the magnetic components 204. In some embodiments, the magnet array holder 202 may include a series of bridges below (e.g., some or all of) the combination of the magnetic components 204 and non-magnetic components 206. In some embodiments, the magnet array holder 202 may include a series of ceiling portions instead of or in addition to bridge portions, particularly if the magnetic components 204 and / or non-magnetic components 206 are assembled from below rather than from above. Similarly, in some embodiments, the magnet array holder 202 may include walls instead of or in addition to bridge portions or ceiling portions, particularly if the magnetic components 204 and / or non-magnetic components 206 are assembled from the side rather than from above or below. Other orientations are possible. Combinations of various orientations are also possible.

[0051] 3a-3d illustrate an exemplary assembly process for the magnet array 110 using an exemplary magnet array holder 202. FIG. 3a illustrates a top perspective view of the magnet array holder 202 according to some first embodiments of the present invention. As shown, an iron shield 208 is attached to the front edge of the magnet array holder 202. FIG. 3b illustrates a top perspective view of the magnet array holder 202 according to some first embodiments of the present invention, in which one magnetic part 204 is positioned adjacent to the iron shield 208, and the magnetic part 204 can serve as a fixture for inserting the next component. FIG. 3c illustrates a top perspective view of the magnet array holder 202 according to some first embodiments of the present invention, in which one magnetic part 204 and one non-magnetic part 206 positioned adjacent to the magnetic part 204 can serve as a fixture for inserting the next component. FIG. 3d shows a top perspective view of the magnet array holder 202 according to some first embodiments of the present invention, with all magnetic components 204 and all magnetic components 206 disposed therein to form the magnet array 110.

[0052] In some embodiments, the pattern for assembling the magnet array 110 begins with inserting a non-magnetic component 206, or at least a pair of magnetic components 206, into each slot 214. Because the non-magnetic components 206 do not interfere with one another, the non-magnetic components 206 can be inserted with little or no effort. The magnetic component 204 can then be inserted into the pocket 216 between the pair of non-magnetic components 206. The pair of non-magnetic components 206 establishes a fixture / wall for the magnetic component 204, which can support attractive and repulsive forces during insertion, thereby reducing the risk of damaging the (potentially fragile) magnetic component 204 and the risk of advancing the magnetic component 204. It will be appreciated that the pattern can be similar to the assembly of the magnet array 400, including alternating sequences of up-down and left-right polarized magnetic components. The pattern may begin by placing top-to-bottom or left-to-right polarized magnetic components in the slots, and then add left-to-right or top-to-bottom polarized magnetic components between each pair of top-to-bottom polarized components.

[0053] Assembly time is accelerated by approximately 10 times compared to conventional assembly. Alignment is predictable and can be accurately calculated. This allows detailed study of the effects of tolerances on the individual magnetic components 204 and the magnet array holder 202 itself as they relate to magnet circuit design and the performance of the magnetic field generated to steer the electron beam.

[0054] 4a shows a top perspective view of an exemplary magnet array 400 according to some second embodiments of the present invention. Like magnet array 110, magnet array 400 includes a magnet array holder 402, an iron shielding portion 408, magnetic components 404 in pockets, and non-magnetic components 406 in slots. Magnet array 400 is similar to magnet array 110, except that the shapes of magnet array holder 402, magnetic components 404, non-magnetic components 406, and iron shielding portion 408 are different.

[0055] 4b shows a bottom perspective view of an exemplary magnet array 400 according to some second embodiments of the present invention. The magnet array holder 402 does not include additional pockets on the bottom side for additional magnetic components (e.g., four-pole magnetic components).

[0056] 4c shows a bottom perspective view of an exemplary magnet array 410 according to some third embodiments of the present invention. The magnet array 410 may include the same top side as the magnet array 400. However, the magnet array 410 may include a magnet array holder 412 having a different bottom side, which includes an additional pocket configured to receive an additional (four-pole) magnetic component 414 for containment therein.

[0057] FIG. 4d shows top and bottom views of a magnet array holder 402 according to some second embodiments of the present invention. In some embodiments, as shown, the top side of the magnet array holder 402 includes a slot 418 for receiving a non-magnetic component 406 and a pocket 420 for receiving a magnetic component 404. The slot 418 and the pocket 420 may be generally referred to as a portion 428. Indicia 416 may be added to the pocket 420 of the magnet array holder 402 to identify the polarity of the magnet of the magnetic component 404 placed therein, allowing an assembler to match the indicia 416 and ensure proper magnet orientation during the assembly process. The indicia 416 may be added to either or both of the magnetic component 404 and the magnet array holder 402. It will be appreciated that the indicia 416 may include written indicia 416 or physical indicia 416 (i.e., a key) to ensure proper orientation of the magnetic component 404.

[0058] In some embodiments, as shown, indicia 212 on the top (exposed) side of magnet array holder 202 indicate an alternating pattern in which north-facing and south-facing magnetic components 204 are positioned within pockets 216 .

[0059] 4e shows a top perspective view of a magnet array holder 402 according to some second embodiments of the present invention. The magnet array holder 402 includes an alternating sequence of slots 418 for receiving non-magnetic components 406 and pockets 420 for receiving magnetic components 404. The magnet array holder 402 further shows bridges at the bottom of the pockets 420.

[0060] 4f shows a bottom perspective view of a magnet array holder 402 according to some second embodiments of the present invention. The magnet array holder 402 does not include an array of pockets for receiving additional magnetic components (e.g., four-pole magnetic components). The magnet array holder 402 shows a slot opening for receiving a non-magnetic component 406.

[0061] 4g shows a bottom view of the magnet array holder 412 according to some third embodiments of the present invention. In some embodiments, as shown, the bottom side of the exemplary magnet array holder 412 includes a pocket 424 that receives an additional (quad-pole) magnetic component 414.

[0062] Indicia 422 may be added to the pockets 424 of the magnet array holder 402 to identify the polarity of the magnets of the magnetic component 414 to be placed therein, allowing an assembler to align the indicia 414 to ensure proper magnet orientation during the assembly process. The indicia 414 may be added to either or both the magnetic component 414 and the magnet array holder 412. It will be appreciated that the indicia 422 may include written indicia 422 or physical indicia 422 (i.e., a key) to ensure proper orientation of the magnetic component 414. In some embodiments, as shown, the indicia 422 on the bottom side of the magnet array holder 412 (the side positioned relative to the TWT 100) indicates the pattern in which an additional (four-pole) magnetic component 414 of the opposite orientation is placed in the pocket 424, either south-facing or north-facing.

[0063] 4h shows a top perspective view of a magnet array holder 412 according to some third embodiments of the present invention. The magnet array holder 412 includes an alternating sequence of slots 418 for receiving non-magnetic components 406 and pockets 420 for receiving magnetic components 404.

[0064] 4i shows a bottom perspective view of a magnet array holder 412 according to some third embodiments of the present invention. The magnet array holder 412 includes an array of pockets 424 for receiving additional magnetic components 414 (e.g., four-pole magnetic components).

[0065] 4j shows top and bottom views of a magnet array 400 according to some second embodiments of the present invention. As shown, the magnet array 400 includes holes 420 for aligning the magnet array 110.

[0066] 4k shows a side view of a magnet array 400 / 410 according to some second embodiments of the present invention. As shown, the magnet array 400 / 410 includes a magnet array holder 402 / 412 having an iron shield 408 attached to a leading edge thereof, followed in this embodiment by alternating magnetic and non-magnetic components 404, 406. Other patterns of magnetic and non-magnetic components 404, 406 are possible to achieve the desired interaction.

[0067] Figure 4l shows a cross-sectional side view of a magnet array 400 / 410 according to some second embodiments of the present invention. The magnet array 400 / 410 in Figure 4l helps illustrate the depth, height position, and height of the magnetic component 404 and non-magnetic component 406. In some embodiments, as shown, the magnetic component 404 rests on top of a series of bridges 434 disposed at the bottom of the magnet array holder 402, and the non-magnetic component 406 extends between and past the bridges 434 all the way to the bottom of the magnet array holder 402 (or past the bottom of the magnet array holder 202 in some embodiments).

[0068] 4m shows a bottom view of a magnet array 410 according to some third embodiments of the present invention. As shown, the magnet array 410 includes holes 432 for aligning the magnet array 410.

[0069] 5a-5d illustrate an exemplary assembly process for the magnet array 400 using an exemplary magnet array holder 402. FIG. 5a illustrates a top perspective view of the magnet array holder 402 according to some first embodiments of the present invention. As shown, an iron shield 408 is attached to the front edge of the magnet array holder 402. FIG. 5b illustrates a top perspective view of the magnet array holder 402 according to some first embodiments of the present invention, with one magnetic part 404 positioned adjacent to the iron shield 408 and capable of serving as a fixture for inserting the next component. FIG. 5c illustrates a top perspective view of the magnet array holder 402 according to some first embodiments of the present invention, with one magnetic part 404 and one non-magnetic part 406 positioned adjacent to the magnetic part 404 and capable of serving as a fixture for inserting the next component. FIG. 5d shows a top perspective view of a magnet array holder 402 having all magnetic components 404 and all non-magnetic components 406 arranged therein to form a magnet array 400, according to some first embodiments of the present invention.

[0070] Similar to FIGS. 3a-3d, in some embodiments, the pattern for assembling the magnet array 400 begins with inserting a non-magnetic component 406, or at least a pair of non-magnetic components 406, into each slot 418. Because the non-magnetic components 406 do not interfere with one another, the non-magnetic components 406 may be inserted with little or no effort. The magnetic component 404 may then be inserted into the pocket 420 between the pair of non-magnetic components 406. The pair of non-magnetic components 406 may assist with attractive and repulsive forces during insertion to establish a fixture / wall for the magnetic component 404, thereby reducing the risk of damaging the (potentially fragile) magnetic component 404 and the risk of advancing the magnetic component 404. It will be appreciated that the pattern may be similar to an assembly of magnet arrays 400 including alternating top-to-bottom and left-to-right polarity oriented magnetic components. The pattern may begin by placing top-to-bottom or left-to-right polarized magnetic components or at least pairs of top-to-bottom polarized magnetic components in the slots, and then add left-to-right or top-to-bottom polarized magnetic components between each pair of top-to-bottom or left-to-right polarized components.

[0071] 6a-6b illustrate an exemplary assembly process of the magnet array 410 using an exemplary magnet array holder 412. Fig. 6a illustrates a bottom perspective view of the magnet array holder 412 with one magnetic component 414 disposed therein, according to some third embodiments of the present invention. Fig. 6b illustrates a bottom perspective view of the magnet array holder 412 with all magnetic components 414 disposed therein, according to some third embodiments of the present invention.

[0072] 7a-7d illustrate exemplary top and bottom magnet arrays 700 and 702 for establishing the confinement and manipulation of one or more electron beams. The placement of individual magnetic components 404 relative to the top and bottom magnet arrays 700 and 702 can be critical to the performance of the vacuum electron device 100. FIG. 7a illustrates a side view of the top magnet array 700 in accordance with some embodiments of the present invention. Magnet arrays 110, 400, and 410 are examples of each of the top magnet arrays 700. FIG. 7b illustrates a side view of the bottom magnet array 702 in accordance with some embodiments of the present invention. Magnet arrays 110, 400, and 410 are examples of each of the bottom magnet arrays 702. FIG. 7c illustrates a cross-sectional side view of the top magnet array 700 in accordance with some embodiments of the present invention. FIG. 7d illustrates a cross-sectional side view of the bottom magnet array 702 in accordance with some embodiments of the present invention.

[0073] In some embodiments, the magnet array holder 202 / 402 / 412 may support only magnetic components. In some embodiments, non-magnetic partitions may be constructed within the magnet array holder 202 / 402 / 412 instead of some or all of the non-magnetic components. In some embodiments, the magnet array holder 202 / 402 / 412 may be designed to contain only a portion of the interaction circuit, allowing other magnets to be placed elsewhere, such as on one or more second magnet array holders, on the vacuum electronic device itself, etc. In some embodiments, the magnet array holder 202 / 402 / 412 may include a magnet portion instead of a portion of the magnetic components. In some embodiments, the various sections 202 / 402 / 412 may be designed to receive alternating sets of magnetic components 204 / 404 and non-magnetic components 206 / 406 of opposite polarity. Other combinations are possible.

[0074] The above description of preferred embodiments of the present invention is by way of example only, and other variations and modifications of the above embodiments and methods are possible in light of the above teachings. The embodiments described herein are not intended to be exhaustive or limiting. The present invention is limited only by the following claims.

Claims

1. 1. A magnet array holder configured to hold magnetic and non-magnetic components to form a magnet array, the magnet array being configured, when assembled, to steer one or more electron beams within a vacuum electron device, the magnet array holder comprising: a set of slots configured to receive the non-magnetic components, each slot of the set of slots having a guide rail for supporting the non-magnetic components, and a pair of the non-magnetic components disposed in the pair of slots configured to support each of the magnetic components; a set of pockets configured to receive the magnetic components and disposed between the pairs of slots; one or more attachment interfaces configured to couple the magnet array holder to a vacuum electronic device; A magnet array holder comprising:

2. 2. The magnet array holder of claim 1, wherein each slot in the set of slots has a first shape and each pocket in the set of pockets has a second shape different from the first shape.

3. The magnet array holder of claim 1 , wherein each pocket of the set of pockets has a bridge portion that traverses the pocket.

4. The magnet array holder of claim 1 , wherein each pocket of the set of pockets includes indicia indicating an orientation of the magnetic component to aid in alignment of the magnetic component.

5. 5. The magnet array holder of claim 4, wherein the indicia is a written key.

6. The magnet array holder of claim 1 , wherein each said pocket has a size, shape and position that controls the size, shape and position of the magnetic component received therein.

7. The magnet array holder of claim 1 , wherein each said slot has a size, shape and position that controls the size, shape and position of the non-magnetic component received therein.

8. A magnet array holder as described in claim 1, further comprising a set of further portions configured to receive further magnetic or non-magnetic components, separate from the set of slots and the set of pockets.

9. 9. The magnet array holder of claim 8, wherein each portion of the set of further portions includes further indicia indicating a magnetic component orientation to assist in alignment of a particular further magnetic component when receiving the particular further magnetic component.

10. The magnet array holder of claim 1 , wherein at least one slot of the set of slots extends through the magnet array holder.

11. The magnet array holder of claim 1 , wherein the magnet array holder holds only a portion of the interacting circuit of the vacuum electronic device.

12. 1. A method of assembling a magnet arrangement configured to manipulate one or more electron beams in a vacuum electron device, the method comprising: providing a magnet array holder configured to hold magnetic and non-magnetic components, the magnet array holder comprising: a set of slots configured to receive the non-magnetic components, each slot of the set of slots having a guide rail for supporting the non-magnetic component, and a pair of the non-magnetic components disposed in the pair of slots configured to support each of the magnetic components; a set of pockets configured to receive the magnetic components and disposed between the pair of slots; and one or more mounting interfaces configured to couple to the vacuum electronic device; disposing at least one pair of said non-magnetic components in a pair of slots of said set of slots adjacent to a particular pocket of said set of pockets; placing a particular magnetic component within said particular pocket of said set of pockets; wherein the pair of non-magnetic parts act as walls to support insertion of the particular magnetic part.

13. The method of claim 12 , wherein each pocket of the set of pockets has a bridge portion that traverses the pocket.

14. The method of claim 12 , wherein each pocket of the set of pockets is configured to receive a magnetic component having an up or down polarity orientation.

15. The method of claim 12 , wherein placing a particular magnetic component in a particular pocket includes orienting the polarity of the magnetic component according to indicia.

16. 13. The method of claim 12, wherein the magnet array holder further comprises a set of additional portions separate from the set of slots and the set of pockets, the set of portions being configured to receive additional magnetic components, and the method further comprises disposing the additional magnetic components within the additional portions.

17. The method of claim 16 , wherein arranging the additional magnetic component includes orienting the polarity according to indicia.

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