Microchannel Plate Corner Fiber Reinforcement
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Solution Overview
Problem
The miniaturization of microchannel plates leads to increased probabilities of the missing wall and Rosetta phenomena during fusion-bonding, making it difficult to manufacture high-yield microchannel plates with high accuracy and high density, and resulting in image defects and luminance issues.
Innovation Solution
A method involving the fabrication of multifibers with a polygonal cross-section, where a first fiber with a predetermined-component glass outer circumference and a second fiber with both a core and outer circumference made of the same glass material are bundled, with the second fiber acting as a dummy at corners to thicken channel walls and reduce failure probabilities, and subsequent solvent treatment to uniformly remove soluble glass material, ensuring consistent channel thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If channels are miniaturized to increase channel density, then the open area ratio widens and manufacturing precision improves, but the probability of missing wall phenomenon and Rosetta phenomenon increases during fusion-bonding
Solution Approach 1:
The patent applies local quality by differentiating fiber types based on their positions in the hexagonal bundle. Corner positions receive special treatment with thicker-cladding fibers to provide enhanced wall strength where misalignment risks are highest, while central positions use standard fibers. This localized adaptation of fiber properties resolves the contradiction by strengthening vulnerable corner regions without compromising overall channel miniaturization.
Solution Approach 2:
The patent implements beforehand cushioning by pre-positioning thicker-cladding fibers at corner locations before the fusion-bonding process. These reinforced fibers act as a cushion or buffer against the misalignment stresses that occur during heating and pressurization, preventing the missing wall and Rosetta phenomena before they can occur. This proactive reinforcement enables reliable miniaturized channel fabrication.
2Strength
If thicker cladding glass tube walls are used at corners to prevent missing wall phenomenon, then channel wall strength improves, but the probability of missing wall and Rosetta phenomenon increases during fusion-bonding of miniaturized channels
Solution Approach 1:
The patent applies local quality by differentiating fiber types based on their positions in the hexagonal bundle. Corner positions receive special treatment with thicker-cladding fibers to provide enhanced wall strength where misalignment risks are highest, while central positions use standard fibers. This localized adaptation of fiber properties resolves the contradiction by strengthening vulnerable corner regions without compromising overall channel miniaturization.
Solution Approach 2:
The patent implements parameter changes by modifying the cladding thickness parameter of fibers specifically at corner positions. By adjusting this physical parameter locally rather than uniformly across all fibers, the invention optimizes the balance between wall strength and fusion-bonding reliability for miniaturized channels.
3Reliability
If second fiber is arranged at corner positions to thicken channel walls, then missing wall and Rosetta phenomena are reduced, but the number of channels at corners decreases causing luminance decline
Solution Approach 1:
The patent accepts a localized reduction in channel count at corner positions as a necessary trade-off to achieve global reliability. The thicker-cladding fibers at corners prevent catastrophic failures (missing wall and Rosetta phenomena) that would affect the entire device. This local sacrifice of channel density preserves overall luminance by preventing widespread channel failures while maintaining structural integrity.
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 reduces the occurrence of missing wall and Rosetta phenomena, maintains high channel density and accuracy, and minimizes luminance decline, preventing image defects and electrical discharge issues, while allowing for further miniaturization and improved sensitivity.
Implementation Method 1
the predetermined-component glass material has an insolubility in response to a predetermined-component solvent, the center part of the first fiber is formed of a glass material having solubility in response to the predetermined-component solvent, and the third step includes a step of exposing a sliced flat plate to the predetermined-component solvent
Implementation Method 2
the probability of occurrence of the missing wall phenomenon and Rosetta phenomenon increases during a process of fusion-bonding of the fibers to each other by heating and pressurization
Data Source
AI summary
A method of manufacturing microchannel plate according to an embodiment of the present invention includes: a first step of fabricating a multifiber having a polygonal cross-section by bundling a plurality of fibers; a second step of fabricating a microchannel plate base material by use of a plurality of the multifibers; and a third step of fabricating a microchannel plate out of the microchannel plate base material. The plurality of fibers include: a first fiber whose predetermined-thickness outer circumferential part surrounding a center part including a core is formed of a predetermined-component glass material; and a second fiber whose both center part including a core and outer circumferential part surrounding the same are formed of the predetermined-component glass material. The second fiber is arranged at, at least, one corner of a polygonal cross-section of the multifiber.