Multilayer X-ray Target with Thermal Conductive Layers
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Solution Overview
Problem
Conventional X-ray sources face limitations in X-ray flux due to heat management issues, leading to reduced operational efficiency and potential damage from high temperatures, especially when trying to achieve high X-ray flux densities or small spot sizes, as existing cooling methods either restrict power or increase system complexity.
Innovation Solution
A multi-layer X-ray source target is designed with varying density X-ray generating layers and thermally-conductive layers, where the interfaces are roughened for improved adhesion and stress reduction, allowing for enhanced heat dissipation and maintaining the target at lower temperatures or enabling higher power densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electron beam power is increased to achieve higher X-ray flux, then the X-ray generation efficiency is improved, but the heat accumulation in the target increases causing potential damage
Solution Approach 1:
The target is divided into multiple alternating layers of X-ray generating material and thermally-conductive material. This segmentation allows the X-ray generating layers to produce X-rays while the thermally-conductive layers dissipate heat, enabling high electron beam power to be applied without excessive heat accumulation in any single layer.
Solution Approach 2:
The target uses a composite structure combining materials with different properties: high-Z X-ray generating materials (such as tungsten) alternating with high thermal conductivity materials (such as diamond or copper). This composite structure simultaneously optimizes X-ray generation efficiency and heat dissipation capability.
2Temperature
If conventional cooling methods are used to remove heat, then the target temperature is controlled, but the electron beam power that can be applied is significantly limited
Solution Approach 1:
Instead of using a single bulk cooling structure, the target is segmented into thin alternating layers where thermally-conductive layers are positioned immediately adjacent to X-ray generating layers. This allows heat to be conducted away at the source before it can accumulate, enabling much higher electron beam power application.
Solution Approach 2:
The thermally-conductive layers act as intermediary heat transfer pathways between the X-ray generating material and the cooling system. These intermediate layers provide efficient thermal conduction routes that allow high power application without directly contacting the electron beam impact points.
3Object-affected harmful factors
If the target is rotated to distribute heat, then the heat removal capability is improved, but the system becomes larger and heavier with additional complexity
Solution Approach 1:
The target structure itself provides the heat removal function through its internal multi-layer design. The thermally-conductive layers are integrated within the target, allowing heat to be dissipated through conduction within the stationary target structure, eliminating the need for rotation mechanisms.
Solution Approach 2:
The mechanical rotation system is replaced by a stationary multi-layer structure that uses thermal conduction through the thermally-conductive layers to achieve heat removal. This substitution eliminates moving parts, bearings, and rotation control systems while maintaining effective heat management.
4Device complexity
If the cooling system is positioned far from the electron beam impact area, then the cooling structure is simpler, but the heat removal ability is markedly reduced
Solution Approach 1:
The target is segmented into thin alternating layers where thermally-conductive layers are positioned immediately adjacent to X-ray generating layers. This segmentation places heat removal pathways directly at the heat generation sites, maximizing heat removal efficiency while maintaining a relatively simple overall structure.
Solution Approach 2:
Instead of positioning cooling structures at a distance in three-dimensional space, the thermally-conductive layers are arranged in a two-dimensional alternating pattern within the target itself. This dimensional reorganization places heat removal capability directly at the impact area without requiring distant cooling components.
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 configuration enables higher X-ray flux production, faster scan times, improved resolution, and reduced operational costs by maintaining the target at lower temperatures or allowing higher power densities without overheating, thus extending the operational lifetime of the source.
Implementation Method 1
at least one thermally-conductive layer in thermal communication with each X-ray generating layer
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
another portion of the energy resulting in the production of X-ray radiation
Data Source
AI summary
The present disclosure relates to the production and use of a multi-layer X-ray source target. In certain implementations, layers of X-ray generating material may be interleaved with thermally conductive layers. To prevent delamination of the layers, various mechanical, chemical, and structural approaches are related, including approaches for reducing the internal stress associated with the deposited layers and for increasing binding strength between layers.