Connector Pin Assembly Spring Annealing Prevention
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Solution Overview
Problem
Existing x-ray tube connectors experience significant downtime due to the annealing of springs caused by alternative current paths, leading to a loss of biasing capability and failure in generating x-rays, necessitating frequent replacement.
Innovation Solution
Incorporating a non-conductive element within the connector pin to restrict current flow and prevent annealing of the spring, ensuring the biasing member maintains its functionality and extending the connector's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive spring is used to provide biasing force and electrical connection, then the connector can maintain electrical contact and provide mechanical biasing, but the spring can be shifted radially creating alternative current paths that cause annealing and loss of biasing capability
Solution Approach 1:
The connector is divided into separate functional zones: an outer conductive cylinder for current entry, an inner conductive cylinder for current exit, and a non-conductive plunger for mechanical biasing. This segmentation prevents alternative current paths through the spring while maintaining electrical connection reliability.
Solution Approach 2:
A non-conductive plunger acts as an intermediary element between the inner cylinder and the contact terminal. It provides mechanical biasing force to maintain contact while being electrically isolated, preventing current from flowing through the spring and avoiding annealing.
2Ease of manufacture
If the plunger is allowed to float with respect to the cathode assembly to avoid tight-tolerance connections, then ease of assembly is improved, but the plunger can shift radially creating harmful alternative current paths
Solution Approach 1:
The non-conductive plunger serves as an intermediary that allows the floating assembly design for ease of manufacture while simultaneously blocking harmful alternative current paths. Its electrical insulation property prevents current from flowing through the spring when the plunger shifts radially.
Solution Approach 2:
The plunger is designed with localized non-conductive properties in the region where it interfaces with the spring, while maintaining conductive properties in other areas if needed. This local quality differentiation allows floating assembly ease while preventing harmful current paths.
3Reliability
If current flows through the spring to reach the plunger, then electrical connection is established, but the spring undergoes annealing and loses its biasing capability
Solution Approach 1:
The non-conductive plunger acts as an intermediary that separates the electrical current path from the mechanical biasing function. Current flows through the non-conductive plunger via capacitive coupling or surface conduction rather than through the spring material, preventing annealing while maintaining both electrical connection and spring biasing capability.
Solution Approach 2:
The patent replaces the traditional mechanical electrical contact through the spring with a non-mechanical or alternative electrical conduction path. This substitution eliminates the harmful thermal effect on the spring while maintaining the necessary electrical connection for reliable operation.
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
The solution effectively reduces downtime and extends the life of the connector by maintaining the correct current path and preventing spring annealing, thereby ensuring consistent x-ray generation.
Implementation Method 1
a non-conductive member disposed within the inner cylinder, the non-conductive member operable to restrict a current or voltage flowing through the connector pin along a path from the outer cylinder through the inner cylinder to the plunger without contacting the biasing member
Implementation Method 2
a biasing member disposed within the inner cylinder... urging the plunger axially out of the inner cylinder
Implementation Method 3
the cathode assembly typically is operated at high voltage and includes a filament or electron emitter that requires current to be run through it to in order to produce the electrons
Implementation Method 4
Some of the released electrons may impact a anode target. The collision of the electrons with the anode target produces x-rays
Data Source
AI summary
A connector pin assembly configured to engage an electrical interface. The connector pin assembly comprises a conductive outer cylinder configured to be connected to a power supply that supplies current or voltage; a conductive inner cylinder located at least partially within the outer cylinder; and a biasing member disposed within the inner cylinder. The connector pin assembly further comprises a conductive plunger slidably disposed within and engaged with the inner cylinder and the biasing member; a non-conductive member disposed within the inner cylinder, the non-conductive member operable to restrict a current or voltage flowing through the connector pin along a path from the outer cylinder through the inner cylinder to the plunger without contacting the biasing member.