Electron Beam Focusing and Steering for Batch-Built Vacuum Electron Devices
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Solution Overview
Problem
Conventional vacuum electron devices face challenges in aligning beam tunnels and magnetic field uniformity due to manufacturing and assembly variances, leading to lengthy manual trimming processes that are inadequate for high-frequency devices, and require substantial skilled labor and time.
Innovation Solution
A manufacturing process that assembles parallel sheets of materials into a stack, allowing simultaneous production of multiple VEDs, which are then cut apart, incorporating magnetic and electrostatic lenses for electron beam control, and using electrostatic focusing and steering mechanisms to optimize beam alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual alignment and trimming processes are used for VED manufacturing, then beam tunnel and magnetic field alignment can be achieved, but manufacturing time and labor requirements become excessively long
Solution Approach 1:
The patent applies preliminary action by pre-aligning the beam tunnel and magnetic field components during the initial manufacturing process rather than requiring manual alignment afterward. The device structure is designed with built-in alignment features that ensure proper positioning of magnetic fields relative to the beam tunnel before final assembly, eliminating the need for lengthy manual trimming and adjustment processes.
2Reliability
If conventional single-unit manufacturing is used for VEDs, then individual device quality can be maintained, but productivity and batch production capability are limited
Solution Approach 1:
The patent merges multiple VED manufacturing processes into a single integrated batch production system. Multiple devices are manufactured simultaneously using the same aligned tooling and manufacturing setup, ensuring that all devices in the batch receive identical treatment and maintain consistent quality. This approach combines the benefits of individual device attention with the efficiency of batch production.
3Manufacturing precision
If manual trimming processes are used to optimize magnetic field alignment, then beam transmission can be improved, but the process requires substantial skilled labor and extends manufacturing duration
Solution Approach 1:
The patent applies self-service by designing the VED with built-in self-aligning features that automatically ensure proper magnetic field alignment without requiring manual trimming. The device structure includes integrated alignment mechanisms and pre-positioned magnetic components that self-adjust during assembly, eliminating the need for skilled manual intervention and complex trimming procedures.
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
Reduces manufacturing time and cost by enabling batch production of VEDs with improved alignment and magnetic field uniformity, enhancing electron beam control and reducing the need for manual trimming.
Implementation Method 1
Electron beam propagation through the electron beam tunnel of a VED is conventionally achieved by using either magnetic fields or electrostatic fields to contain the electron beam within the electron beam tunnel
Implementation Method 2
The VEDs so produced include a combination of magnetic and electrostatic lenses for electron beam control
Implementation Method 3
Electron beam propagation through the electron beam tunnel of a VED is conventionally achieved by using either magnetic fields or electrostatic fields to contain the electron beam within the electron beam tunnel
Implementation Method 4
The VEDs so produced include a combination of magnetic and electrostatic lenses for electron beam control
Implementation Method 5
using electrostatic focusing and steering mechanisms to optimize beam alignment
Implementation Method 6
using electrostatic focusing and steering mechanisms to optimize beam alignment
Data Source
AI summary
Vacuum electron devices (VEDs) are produced having a plurality of two-dimensional layers of various materials that are bonded together to form one or more VEDs simultaneously. The two-dimensional material layers are machined to include features needed for device operation so that when assembled and bonded into a three-dimensional structure, three-dimensional features are formed. The two-dimensional layers are bonded together using brazing, diffusion bonding, assisted diffusion bonding, solid state bonding, cold welding, ultrasonic welding, and the like. The manufacturing process enables incorporation of metallic, magnetic, and ceramic materials required for VED fabrication while maintaining required positional accuracy and multiple devices per batch capability. The VEDs so produced include a combination of magnetic and electrostatic lenses for electron beam control.