X-ray Tube Target Repair via Segmented Track Replacement
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Solution Overview
Problem
Current methods for repairing damaged x-ray tube anode targets are costly and inefficient, relying on expensive layer deposition processes that are not feasible for widespread reuse, especially with increased peak power demands leading to higher temperatures and reliability issues.
Innovation Solution
A method involving the removal of damaged target tracks and substrates from anode targets, followed by the attachment of new target tracks and substrates using brazing or other bonding methods to create a repaired anode target, avoiding the need for costly deposition processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If layer deposition processes (plasma spray, CVD, PVD, LENS, electroplating) are used to repair damaged anode targets, then the target track can be restored, but the repair cost becomes excessively high
Solution Approach 1:
The patent segments the anode target into replaceable modules: a reusable base structure and a detachable target track assembly. The damaged target track can be removed and replaced with a new one without affecting the base structure, allowing incremental repair rather than complete replacement. This segmentation enables cost-effective maintenance by replacing only the damaged component rather than the entire target assembly through expensive deposition processes.
Solution Approach 2:
The patent implements a recovery system where damaged target tracks are removed and discarded, while the expensive base structure is recovered and reused. The reusable base structure can accommodate multiple target track replacements over time, amortizing the high initial cost across multiple repair cycles. This approach transforms a single high-cost deposition repair into multiple low-cost track replacements.
2Temperature
If the anode target is spun faster to counteract higher peak temperatures from increased peak power, then temperature management improves, but reliability and performance of other components deteriorate
Solution Approach 1:
The patent divides the anode target into a stationary base structure and a rotating target track assembly. The base structure containing expensive components can remain stationary or rotate at lower speeds, while only the target track rotates at high speeds during operation. This segmentation allows optimized rotational speeds for different components, protecting sensitive parts from excessive mechanical stress while maintaining effective heat management at the target track.
Solution Approach 2:
The patent implements dynamic speed control where the target track rotation speed can be independently optimized for heat dissipation without compromising the reliability of other components. The modular design allows the system to adapt rotational speeds dynamically based on operating conditions, maintaining thermal management effectiveness while preserving component reliability.
3Ease of repair
If track thinning is used to remove damaged material, then repair is possible for targets with minor damage, but the method is limited to damage less than full thickness of the focal track layer
Solution Approach 1:
The patent creates a separable target assembly where the target track is a distinct, removable component from the base structure. This segmentation enables complete removal and replacement of the target track regardless of damage severity, overcoming the limitation of track thinning methods that can only handle minor damage. The modular design makes the repair method versatile for all damage levels from superficial to complete track failure.
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
Enables the cost-effective reuse of damaged anode targets by replacing damaged components without the high costs associated with layer deposition methods, improving the reliability and performance of x-ray tubes.
Implementation Method 1
The cathode assembly typically includes a cathode that emits electrons in the form of a focused electron beam that is accelerated across the voltage difference of a cathode to anode vacuum gap
Implementation Method 2
As the electrons impact the target track, the kinetic energy of the electrons is converted to high-energy electromagnetic radiation, or x-rays
Implementation Method 3
attaching a new target track to a new portion of a target substrate
Data Source
AI summary
An x-ray tube target and method of repairing a damaged x-ray tube target. The x-ray tube target includes an original substrate and a portion of the original substrate that includes a new portion of a substrate and a new target track that is attached to a void in the original substrate. The method includes removal and replacement of damaged materials on used anode targets of x-ray tubes, thereby enabling recovery of used anode targets without the use of expensive and time consuming layer deposition methods. The method also avoids the high costs and long development cycles associated with known repair and refabrication methods for anode targets of x-ray tubes.