Gridded Cathode Assembly for Thermal-Stable Grid Alignment
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Solution Overview
Problem
Manufacturing of gridded cathode heads with insulation between grid components and the base material results in lower yields due to movement of grid components relative to the base material during manufacturing, leading to potential failure.
Innovation Solution
The use of posts to attach the grid components to an insulating substrate, which are made of materials with coefficients of thermal expansion that match or are intermediate between those of the substrate and the grid and base, reducing thermal stress and improving alignment, thereby increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If grid components are attached directly to the base material without insulation, then manufacturing yield improves, but electrical insulation between grid components and base material is lost
Solution Approach 1:
The patent introduces an insulating substrate as an intermediary component between the grid components and the base material. This insulating substrate serves as a mediator that provides both mechanical support and electrical insulation, allowing the grid components to be securely attached while maintaining the necessary electrical isolation from the base material, thus resolving the contradiction between manufacturing yield and electrical insulation reliability
2Reliability
If insulation is added between grid components and base material, then electrical insulation is improved, but manufacturing precision deteriorates due to component movement
Solution Approach 1:
The patent employs preliminary action by pre-attaching the grid components to the insulating substrate before final assembly. This pre-attachment process establishes precise alignment and positional relationships between components in advance, creating a stable configuration that prevents movement during subsequent manufacturing steps, thereby maintaining manufacturing precision while still providing the necessary electrical insulation
3Ease of manufacture
If different materials with different coefficients of thermal expansion are used, then material compatibility improves, but thermal stress increases causing component movement
Solution Approach 1:
The patent applies parameter changes by carefully selecting materials for the insulating substrate and grid components with matched or compatible coefficients of thermal expansion. By adjusting and optimizing this thermal parameter, the patent reduces thermal stress differential during temperature variations, preventing unwanted component movement and maintaining dimensional stability while still achieving material compatibility for ease of manufacture
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 enhances the manufacturing yield by reducing thermal stress and alignment issues, ensuring that dimensions remain within acceptable ranges and minimizing component movement during manufacturing.
Implementation Method 1
posts made of materials with coefficients of thermal expansion that match or are intermediate between those of the substrate and the grid and base
Data Source
AI summary
Embodiments include an apparatus, comprising: a conductive base; an insulating substrate; an electron emitter disposed on the insulating substrate; a grid disposed adjacent to the electron emitter, the grid including a first conductive side and a second conductive side separate from the first conductive side; a plurality of posts; wherein: the first conductive side is attached to the insulating substrate through a first group of the posts; the second conductive side is attached to the insulating substrate through a second group of the posts; and the conductive base is attached to the insulating substrate through a third group of the posts.