Recrystallized Helical X-Ray Tube Cathode Assembly
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Solution Overview
Problem
The existing assembly processes for X-ray tube cathodes are complex and prone to misalignment, requiring numerous steps and potential for filament misalignment due to stress and deformation, which affects the precision and reliability of X-ray beam generation.
Innovation Solution
A cathode design featuring a totally recrystallized filament with a helical structure, supported by precision-fabricated components with a locking mechanism, reducing assembly steps to five and eliminating the need for additional alignment, with the helical structure ensuring correct alignment and thermal stability through external heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and multiple alignment steps are used during cathode assembly, then the filament positioning precision can be improved, but the assembly complexity and time increase significantly
Solution Approach 1:
The filament is pre-aligned and pre-positioned within the cathode cup assembly before final installation. The support structures are designed with built-in alignment features that automatically position the filament correctly during assembly, eliminating the need for multiple post-assembly alignment steps and manual adjustments.
Solution Approach 2:
The cathode assembly is designed with self-aligning features where the filament, support structures, and cathode cup work together to automatically position the filament correctly without requiring external alignment tools or manual intervention. The geometry of the components themselves provides the alignment function.
2Reliability
If the filament is not totally recrystallized, then the assembly process is simpler, but plastic deformation occurs during operation leading to misalignment and reduced lifetime
Solution Approach 1:
The filament undergoes total recrystallization treatment that fundamentally changes its microstructural parameters, transforming it from a cold-worked state with residual stresses to a fully recrystallized state with uniform grain structure. This parameter change eliminates plastic deformation during operation while the recrystallization process itself is integrated into the manufacturing flow.
3Manufacturing precision
If the filament alignment is not precise in the electron emitting direction, then the assembly is easier, but the X-ray beam quality and focal spot precision deteriorate
Solution Approach 1:
The cathode assembly utilizes asymmetric design elements where the support structures have different geometries on different sides, creating inherent directional guidance that automatically aligns the filament in the correct electron emitting direction. This asymmetric geometry provides built-in alignment references that simplify the assembly process while ensuring precise positioning.
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 design enhances the precision and reliability of X-ray tube assembly, reduces plastic deformation, and extends the filament's lifetime by minimizing failure modes and thermal drift, resulting in improved operational stability and reduced assembly complexity.
Implementation Method 1
a filament is provided for emitting electrons to impinge on a surface, thereby generating X-ray radiation
Implementation Method 2
The filament is totally recrystallized. The support structures comprise a reception end for releasably receiving two ends of the filament by means of a locking mechanism
Data Source
AI summary
The invention relates to a cathode for an X-ray tube and a corresponding method for assembly. The cathode comprises a filament (22), at least two support structures (21), a body structure comprising a recess for the filament. The filament is provided to emit electrons towards an anode in an electron emitting direction (25). The filament is held by the support structures, which are fixedly connected to the body structure. The filament is totally recrystallized before assembly and has an at least partial helical structure. The support structures comprise a reception end (24) for releasably receiving two ends of the filament by means of a locking mechanism and the complete alignment of the filament and the recess is given by the geometry of the filament, the at least two support structures and the body structure which comprises a recess for the filament. An improved and facilitated cathode assembly with increased reliability of the precision of the positioning in operation is achieved.