X-ray Tube Cathode Flat Emitter Welding
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Solution Overview
Problem
In X-ray tubes, the precise and reliable electrical connection of angularly positioned flat emitters to the cathode support structure is challenging due to the small size and angular configuration, leading to misalignment and sub-optimal welds when using filler materials for attachment.
Innovation Solution
The use of mounting members integrated with the emitter support structure, which are heated to form direct welds with the emitters, eliminating the need for filler materials and enhancing manufacturing efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filler materials are used to attach angularly positioned flat emitters to the cathode support structure, then the emitters can be connected electrically, but misalignment and sub-optimal welds occur due to the small size and angular configuration
Solution Approach 1:
The patent removes the filler material from the attachment process entirely. Instead of using filler materials that cause misalignment and sub-optimal welds, the invention uses direct welding between the mounting members and the flat emitters, eliminating the source of the alignment problems while maintaining electrical connection reliability
Solution Approach 2:
The patent replaces the mechanical filler material attachment system with a thermal welding system. By using direct welding instead of filler materials, the invention achieves more precise and reliable electrical connections without the alignment issues that plague filler material-based attachment methods
2Reliability
If filler materials are used for emitter attachment, then electrical connection can be achieved, but manufacturing speed decreases and variability increases
Solution Approach 1:
The patent eliminates the filler material step from the manufacturing process. By using direct welding between mounting members and emitters, the invention reduces manufacturing steps and time while improving consistency, thereby increasing productivity without sacrificing attachment reliability
Solution Approach 2:
The patent enables continuous welding operations without the interruptions required by filler material application and positioning. The direct welding process allows for uninterrupted manufacturing flow, improving manufacturing speed and reducing variability in cathode assembly production
3Adaptability or versatility
If angular positioning of emitters is implemented to improve electron beam focusing, then focusing capacity increases, but electrical connection difficulty increases due to inability to create connections during emitter formation
Solution Approach 1:
The patent separates the emitter formation process from the electrical connection process. By using pre-formed mounting members that are subsequently welded to the angularly positioned emitters, the invention allows emitters to be formed independently at their required angles and then connected electrically through a separate welding step, making the manufacturing process more manageable
Solution Approach 2:
The patent replaces the mechanical connection method (which fails for angularly positioned emitters) with thermal welding. This substitution enables electrical connection of angularly positioned emitters by melting and fusing the mounting members directly to the emitter surfaces, overcoming the limitations of mechanical attachment methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures reliable and precise emitter attachment, improving manufacturing speed and reducing variability in cathode assembly production while maintaining emitter alignment and electrical connectivity.
Implementation Method 1
heated to form welds securing the at least one emitter to the emitter support structure
Implementation Method 2
an emitter is included that may be induced to release electrons through a thermionic effect, i.e., in response to being heated
Data Source
AI summary
At least one emitter formed of an electron emissive material is positioned on a cathode assembly and is readily and reliably connected to at least one mounting member of the cathode assembly. The connections between the at least one emitter and an emitter support structure are formed directly between the at least one emitter and the emitter support structure by utilizing the at one mounting member on the emitter support structure that are positioned adjacent the at least one emitter and heated to secure the at least one emitter to the emitter support structure by welding the at least one mounting member to the at least one emitter and emitter support structure.