Magnet Array Holder for Precise Vacuum Electron Beam Alignment

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Solution Overview

Problem

Challenges in assembling vacuum electronic devices arise from misalignment of beam tunnels, magnetic centers, and inadequate magnet material quality, leading to non-uniform magnetic fields and prolonged assembly times, especially in high-frequency devices, with conventional gluing methods causing inaccuracies and safety hazards.

Innovation Solution

A magnet array holder and assembly method using mechanical fixturing to securely position and align magnet pieces, minimizing tolerance stack-up and eliminating reliance on glue, suitable for automated assembly and robotic operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional gluing methods are used to secure magnet pieces, then magnets can be held in place during assembly, but assembly time is significantly prolonged and alignment accuracy deteriorates due to glue thickness variation

Engineering Contradiction:

ImproveEase of magnet assemblyVSAvoidAssembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces the chemical bonding mechanism (glue) with a mechanical retention system consisting of pockets, slots, and retention features that physically hold magnet pieces in place through mechanical interference and geometric constraints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional gluing methods are used to secure magnet pieces, then magnets can be held in place during assembly, but alignment accuracy deteriorates due to glue thickness variation

Engineering Contradiction:

ImproveEase of magnet assemblyVSAvoidMagnet alignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent substitutes the unreliable chemical bonding system with a precision mechanical retention system where pockets, slots, and retention features provide deterministic geometric constraints that ensure consistent magnet alignment and positioning

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If high-grade magnet materials with strong magnetization are used, then magnetic field strength is improved, but handling difficulty increases and safety hazards arise from strong attractive and repulsive forces

Engineering Contradiction:

ImproveMagnetic field strengthVSAvoidEase of magnet handling

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The magnet array holder serves as an intermediary device that provides mechanical retention features (pockets, slots, retention structures) to safely handle and position high-strength magnets during assembly, mediating between the operator and the dangerous magnetic forces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct manual handling of high-strength magnets with a mechanical retention system where pockets, slots, and retention features securely hold magnets during assembly, eliminating the need for operators to directly manipulate dangerous magnetic forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If magnets are secured with glue requiring extended curing time, then magnets can be held in place, but assembly productivity decreases and additional inaccuracies are introduced

Engineering Contradiction:

ImproveMagnet position stabilityVSAvoidAssembly productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent substitutes the time-dependent chemical bonding process with an immediate mechanical retention system where pockets, slots, and retention features provide instant and permanent magnet securing, eliminating productivity losses from curing wait time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Device complexity

If conventional assembly methods are used, then assembly can be performed with simple tools, but alignment accuracy deteriorates due to tolerance stack-up from multiple joint interfaces

Engineering Contradiction:

ImproveAssembly process simplicityVSAvoidMagnet array alignment accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent implements preliminary action by pre-establishing a common reference frame and precision mechanical retention features in the magnet array holder before magnet assembly, ensuring that all subsequent magnet placements are accurately positioned relative to this pre-established reference, thereby preventing alignment errors

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260011476A1Magnet array holder for accelerated assembly and improved alignment in vacuum electronic devices

Publication Date: 2026.01.08 ELVE INC

AI summary

A magnet array holder configured to retain magnet pieces and/or non-magnet pieces to form a magnet array, the magnet array configured to manipulate one or more electron beams in a vacuum electronic device when assembled, the magnet array holder comprising a set of slots configured to receive magnet and/or non-magnet pieces; a set of pockets to receive magnet and/or non-magnet pieces; and one or more attachment interfaces configured to couple the magnet array holder to a vacuum electronic device.