Multi-layer X-ray Source Target with Diamond Thermal Management
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Solution Overview
Problem
Conventional X-ray sources face limitations in generating high X-ray flux due to heat buildup, which can damage the target and restrict electron beam power, leading to reduced X-ray flux and operational limitations, especially in high-resolution applications.
Innovation Solution
A multi-layer X-ray source structure is fabricated using bulk structures with alternating layers of X-ray generating material (e.g., tungsten) and thermally conductive material (e.g., diamond), where a single thermal cycle and compressive load are applied to enhance bonding and reduce processing time, preventing delamination and allowing for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (rotation or active cooling) are used, then heat removal capability is improved, but X-ray flux is reduced due to limited electron beam power and larger device size
Solution Approach 1:
The target is segmented into multiple alternating layers of X-ray generating material and thermally conductive material. This segmentation allows heat to be conducted away through the thermally conductive layers while maintaining a stationary target configuration, enabling higher electron beam power without the limitations of rotating or actively cooled single-layer targets.
Solution Approach 2:
The invention uses composite material structure with alternating layers of different functional materials: high-Z materials (tungsten, molybdenum, silver) for X-ray generation and thermally conductive materials (diamond, copper, aluminum) for heat dissipation. This composite structure enables simultaneous optimization of X-ray flux generation and heat removal capability.
2Temperature
If multi-layer diamond tungsten structure is used, then heat dissipation is improved and X-ray flux density increases, but layer delamination occurs due to insufficient interfacial bonding
Solution Approach 1:
The invention changes the bonding parameters by applying controlled compression forces and thermal cycling during fabrication. This creates strong interfacial bonds between the diamond and tungsten layers, preventing delamination while maintaining the heat dissipation and X-ray generation functionality of the multi-layer structure.
Solution Approach 2:
The invention performs preliminary bonding actions during fabrication by applying compression and thermal cycling before the target enters service. This preliminary bonding prevents delamination during operation, ensuring long-term reliability of the multi-layer structure.
3Temperature
If rotating target is used, then heat distribution is improved, but device size and weight increase
Solution Approach 1:
Instead of rotating the target to distribute heat, the invention inverts the approach by using a stationary target with alternating thermally conductive layers that conduct heat away radially. This eliminates the need for rotation mechanisms, reducing device weight and complexity while achieving effective heat distribution.
4Temperature
If actively cooled target is used, then heat removal is improved, but electron beam power is limited due to cooling location distance from impact area
Solution Approach 1:
The invention applies local quality by placing thermally conductive material directly at the electron beam impact site in alternating layers with the X-ray generating material. This local thermal management enables high electron beam power to be applied without overheating, as heat is conducted away immediately at the impact location rather than from a distant cooling point.
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 enables higher power densities and longer operational lifetimes by effectively managing heat, allowing for continuous high X-ray flux production without the need for rotating targets, thus improving throughput and reducing maintenance costs.
Implementation Method 1
layers of X-ray generating material are interleaved with layers of heat-conductive material to facilitate heat dissipation
Implementation Method 2
An electron beam emitter within the cathode emits a stream of electrons toward an anode that includes a target that is impacted by the electrons
Implementation Method 3
A large portion of the energy deposited into the target by the electron beam produces heat within the target
Implementation Method 4
another portion of the energy resulting in the production of X-ray radiation
Data Source
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AI summary
Fabrication of a multi-layer X-ray source is disclosed using bulk structures to fabricate a multi-layer target structure. In one implementation, layers of X-ray generating material, such as tungsten, are interleaved with thermally conductive layers, such as diamond layers. To prevent delamination of the layers, various mechanical, chemical, and/or structural approaches may also be employed.