Ceramic X-ray Generator Housing with Active Soldering
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Solution Overview
Problem
Existing X-ray generators face challenges in cost-effectiveness, reproducibility of dimensions, and service life due to complex manufacturing processes and material limitations, particularly in achieving sufficient surface conductivity and vacuum tightness.
Innovation Solution
The X-ray generator features a ceramic housing with a low coefficient of thermal expansion and high vacuum tightness, utilizing doped aluminum oxide ceramic for improved surface conductivity, eliminating the need for a separate conductive coating and simplifying assembly through active soldering, and integrating the exit window as a milled ceramic layer within the tube body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a glass bulb housing is used for the X-ray tube, then the manufacturing process is simple and cost-effective, but the dimensional accuracy for positioning anode to cathode deteriorates
Solution Approach 1:
The patent employs a composite housing structure combining ceramic materials (alumina or alumino-magnesium ceramic) with metal components. The ceramic tube body provides the necessary dimensional stability and precision for anode-cathode positioning, while metal end caps and active soldering materials enable reliable electrical connections. This composite approach resolves the contradiction by selecting materials that simultaneously achieve manufacturing feasibility and precise dimensional control.
2Manufacturing precision
If ceramic material is used for the housing, then the dimensional accuracy and vacuum tightness are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent modifies the electrical parameters of the ceramic material by doping it with conductive additives to achieve surface conductivity of at least 10^-9 Siemens. This parameter change allows the ceramic to serve dual functions: maintaining vacuum tightness and dimensional precision while also providing necessary electrical conductivity, thereby reducing manufacturing complexity by eliminating separate conductive coating steps.
Solution Approach 2:
The doped ceramic housing performs multiple functions simultaneously: it maintains vacuum tightness, provides dimensional stability, and offers inherent surface conductivity without requiring additional protective layers or conductive coatings. The ceramic material essentially serves itself by incorporating conductive properties during manufacturing, eliminating the need for separate metallizing or coating processes.
3Reliability
If the ceramic is doped to achieve surface conductivity, then the conductivity is sufficient to prevent charge nests, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the doping process for achieving surface conductivity with the primary ceramic manufacturing process. The conductive additives are incorporated during ceramic formation rather than requiring separate doping steps, protective layers, or post-processing treatments. This merging of functions into a single integrated manufacturing process achieves the necessary reliability while minimizing manufacturing complexity.
4Reliability
If a separate window is introduced for X-ray exit, then the X-ray transmission is improved, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent integrates the X-ray exit window function directly into the ceramic tube body by creating a localized thinned region during the ceramic manufacturing process. This merged design eliminates the need for separate window components and their associated mounting, sealing, and alignment operations, thereby reducing assembly complexity while maintaining effective X-ray transmission through the optimized ceramic structure.
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 approach results in a more cost-effective, reproducibly dimensioned X-ray generator with enhanced surface conductivity and reduced risk of electron breakthrough, suitable for secure inspection devices like luggage scanners, while maintaining high performance and reliability.
Implementation Method 1
The ceramic is selected to have a certain surface conductivity sufficient to prevent charge nests. The desired surface conductivity can be achieved by doping the ceramic.
Implementation Method 2
They can be connected to the tube body in a simplified and safe manner by means of an active soldering process
Implementation Method 3
The exit window required for the X-rays is milled into the tube body as a thinned ceramic layer.
Data Source
Figure 1
AI summary
X-ray generators (1) are known which have a housing (2) and assemblies arranged therein for generating one or more X-rays. According to the invention, the housing (2) is formed by a tubular body (3) made of ceramic.