Magnet Array Holder Assembly for Precise Electron Beam Alignment

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Solution Overview

Problem

Challenges in assembling vacuum electronic devices arise from misalignment of beam tunnels, magnetic center lines, and injection locations due to manufacturing irregularities, inadequate magnet material quality, and the use of glue, which slows assembly and introduces inaccuracies, especially in high-frequency devices.

Innovation Solution

A magnet array holder and assembly method that uses mechanical fixturing to support and control precise positioning of magnets, allowing for automated assembly and eliminating the need for immediate glue application, while accommodating high-strength magnets and varying magnet types.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If magnets are secured with glue, then magnets are held in appropriate locations, but assembly time increases significantly and alignment accuracy decreases

Engineering Contradiction:

Improvemagnet positioning stabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The magnet array holder is pre-configured with precisely positioned slots and mechanical retention features before magnet assembly. Magnets are inserted into pre-positioned locations with predetermined spacing, eliminating the need for glue application and curing time. The holder structure itself provides the retention function that would otherwise require adhesive.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The glue application process is completely removed from the assembly system. Instead of using adhesive to secure magnets, the design extracts the retention function and implements it through mechanical features of the holder structure, such as recesses, slots, and physical constraints that hold magnets in place without chemical bonding.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If high-strength magnet materials are used, then magnetization strength is maximized, but handling difficulty increases and safety risks arise from strong attractive and repulsive forces

Engineering Contradiction:

Improvemagnetization strengthVSAvoidhandling ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The magnet array holder serves as an intermediary structure between the operator and the high-strength magnets. The holder provides a controlled environment for magnet assembly, with features that guide magnet placement and contain the strong magnetic forces. By working with magnets already secured in the holder structure, operators avoid direct handling of loose high-strength magnets, reducing safety risks while maintaining magnet performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional assembly methods are used, then manufacturing simplicity is maintained, but alignment precision between beam tunnel, magnetic center line, and injection location deteriorates

Engineering Contradiction:

Improveassembly simplicityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The magnet array holder merges multiple functions into a single integrated component: it provides mechanical support for magnets, establishes precise spacing between magnet pieces, defines the magnetic center line position, and ensures alignment with the beam tunnel and injection location. This consolidation of alignment and support functions into one structure achieves high precision without complicating the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The design replaces manual alignment procedures with a pre-engineered mechanical structure. The holder incorporates built-in geometric constraints, precision-machined reference surfaces, and fixed spacing features that automatically ensure correct alignment between the beam tunnel, magnetic center line, and injection location when the holder is installed, eliminating the need for time-consuming manual trimming and adjustment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If magnet pieces are assembled with varying glue thickness, then assembly flexibility is maintained, but position accuracy and magnetic field uniformity decrease

Engineering Contradiction:

Improveassembly flexibilityVSAvoidmagnet piece position accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The magnet array holder provides locally optimized features for each magnet position, including precisely dimensioned slots and recesses that accommodate individual magnet pieces with exact spacing. Each location in the holder is locally configured to receive a specific magnet with predetermined orientation and position, ensuring uniform magnetic field generation while maintaining the flexibility to assemble different magnet configurations by simply changing the magnet array arrangement within the holder structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12417868B2Magnet array holder accelerated assembly and improved alignment in vacuum electronic devices

Publication Date: 2025.09.16 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.