Monolithic Electron Collector for X-ray Tube Heat Management
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Solution Overview
Problem
Existing x-ray tubes face issues with backscattered electrons reducing image quality and generating excess heat due to the use of separate components for electron collection and heat transfer, which are often inefficiently joined using brazed joints.
Innovation Solution
An electron collector is designed with a body formed by particles of a first material within a matrix of a second material, allowing for improved absorption of backscattered electrons and heat conduction, eliminating the need for separate collimation and heat exchanging components and brazed joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate heat exchanging components are mounted onto the body of an electron collector using brazed joints, then heat transfer capability is improved, but the manufacturing complexity and joint reliability deteriorate due to unwetted zones and complex assembly processes
Solution Approach 1:
The patent combines the heat exchanging components and the electron collector body into a single monolithic structure formed by additive manufacturing. This eliminates the need for separate components and brazed joints, resolving the contradiction by integrating heat transfer functionality directly into the collector body while simplifying manufacturing to a single process step.
Solution Approach 2:
The patent uses composite materials in the additive manufacturing process to create the monolithic structure, combining materials with different thermal and mechanical properties within a single component. This allows optimization of both heat transfer and structural integrity without requiring assembly of separate parts.
2Temperature
If separate heat exchanging components are mounted onto the body of an electron collector, then heat transfer capability is improved, but the reliability deteriorates due to unwetted zones in brazed joints
Solution Approach 1:
The patent merges the heat exchanging components and electron collector body into one monolithic structure, eliminating brazed joints and their associated reliability issues such as unwetted zones. The integrated structure ensures continuous material flow and eliminates weak interfaces between components.
3Object-affected harmful factors
If materials good at attenuating electromagnetic rays (e.g., tungsten, molybdenum) are used for the electron collector body, then x-ray attenuation is improved, but thermal conductivity deteriorates compared to copper
Solution Approach 1:
The patent employs composite materials containing high-Z elements (tungsten, molybdenum) dispersed in a copper or copper-alloy matrix. This composite structure provides both superior x-ray attenuation from the high-Z particles and excellent thermal conductivity from the copper continuous phase, resolving the contradiction between radiation shielding and heat transfer.
Solution Approach 2:
The patent applies local quality by distributing high-Z material particles throughout the copper matrix, creating regions of high x-ray attenuation while maintaining overall good thermal conductivity through the continuous copper phase. This allows different functional requirements to be met at different locations within the same component.
4Device complexity
If traditional machining methods are used to fabricate heat exchangers into the electron collector body, then integration is improved, but manufacturing complexity and cost deteriorate
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing technology. This substitution enables direct fabrication of complex monolithic structures with integrated heat exchanging features, eliminating the need for separate machining operations and reducing manufacturing complexity while maintaining full integration.
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
The solution enhances x-ray attenuation and heat conduction efficiency, reducing radiation leakage and the need for additional shielding, while maintaining hermeticity and improving durability by integrating radiation shielding and heat transfer within a monolithic structure.
Implementation Method 1
absorb the backscattered electrons, convert the kinetic energy of the absorbed backscattered electrons into heat
Implementation Method 2
The body is operative to absorb the backscattered electrons and is formed by particles of a first material disposed within a matrix of a second material
Data Source
AI summary
An electron collector for an electromagnetic ray generating device is provided. The electron collector includes a body having a surface configured to intercept backscattered electrons produced by an electron beam striking an anode to generate electromagnetic rays. The body is operative to absorb the backscattered electrons and is formed by particles of a first material disposed within a matrix of a second material.