Patent Application
20170250051
The subject matter disclosed herein relates to X-ray tubes, and in particular, to X-ray cathode systems and X-ray cathodes.
Presently available medical X-ray tubes typically include a cathode assembly having an emitter and a cup. The cathode assembly is oriented to face an X-ray tube anode, or target, which is typically a planar metal or composite structure. The space within the X-ray tube between the cathode and anode is evacuated.
X-ray tubes typically include an electron source, such as a cathode, that releases electrons at high acceleration. Some of the released electrons may impact a target anode. The collision of the electrons with the target anode produces X-rays, which may be used in a variety of medical devices such as computed tomography (CT) imaging systems, X-ray scanners, and so forth. In thermionic cathode systems, a filament is included that may be induced to release electrons through the thermionic effect, i.e. in response to being heated. However, the distance between the cathode and the anode must be kept short so as to allow for proper electron bombardment. Further, thermionic X-ray cathodes typically emit electrons throughout the entirety of the surface of the filament. Accordingly, it is very difficult to focus all electrons into a small focal spot.
X-ray systems typically include an x-ray tube, a detector, and a support structure for the x-ray tube and the detector. In operation, an imaging table, on which an object is positioned, is located between the x-ray tube and the detector. The x-ray tube typically emits radiation, such as x-rays, toward the object. The radiation typically passes through the object on the imaging table and impinges on the detector. As radiation passes through the object, internal structures of the object cause spatial variances in the radiation received at the detector. The data acquisition system then reads the signals received in the detector, and the system then translates the radiation variances into an image, which may be used to evaluate the internal structure of the object. One skilled in the art will recognize that the object may include, but is not limited to, a patient in a medical imaging procedure and an inanimate object as in, for instance, a package in an x-ray scanner or computed tomography (CT) package scanner.
X-ray tubes typically include a rotating anode structure for the purpose of distributing the heat generated at a focal spot. An x-ray tube cathode provides an electron beam from an emitter that is accelerated using a high voltage applied across a cathode-to-anode vacuum gap to produce x-rays upon impact with the anode. The area where the electron beam impacts the anode is often referred to as the focal spot. Typically, the cathode includes one or more cylindrically wound filaments positioned within a cup for emitting electrons as a beam to create a high-power large focal spot or a high-resolution small focal spot, as examples. Imaging applications may be designed that include selecting either a small or a large focal spot having a particular shape, depending on the application.
Conventional cylindrically wound filaments, however, emit electrons in a complex pattern that is highly dependent on the circumferential position from which they emit toward the anode. Due to the complex electron emission pattern from a cylindrical filament, focal spots resulting therefrom can have non-uniform profiles that are highly sensitive to the placement of the filament within the cup. As such, cylindrically wound filament-based cathodes are manufactured having their filament positioned with very tight tolerances in order to meet the exacting focal spot requirements in an x-ray tube. In particular, X-ray tubes including coiled or cylindrically wound filament-based cathode designs require that the cathode be seated deeper within the cup in order to provide sufficient distance between the cathode and the anode for proper focusing of the more scattered electron emission from the coiled electrode.
In an attempt to generate a more uniform profile of electrons emitted from the cathode towards the anode to obtain a more uniform focal spot, wound filament-based cathodes having an approximately flat emitter surface have been developed. Typically a flat emitter may take the form of a D-shaped filament that is a wound filament having the flat of the “D” facing toward the anode, such as disclosed in U.S. Pat. No. 7,795,792 B2, incorporated herein by reference in its entirety. Such a design emits a more uniform pattern of electrons and emits far fewer electrons from the rounded surface of the filament that is facing away from the anode (that is, facing toward the cup). D-shaped filaments, however, are expensive to produce (they are typically formed about a D-shaped mandrel) and typically require very tight manufacturing and positioning tolerances with separately biased focus electrodes in order to meet focal spot requirements.
As an alternative to the coiled emitters, a flat surface emitter (or a ‘flat emitter’) may be positioned within the cathode cup with the flat surface positioned orthogonal to the anode, such as that disclosed in U.S. Pat. No. 8,831,178, incorporated herein by reference in its entirety. In the '178 patent a flat emitter with a rectangular emission area is formed with a very thin material having electrodes attached thereto, which can be significantly less costly to manufacture compared to conventionally wound (cylindrical or non-cylindrical) filaments and may have a relaxed placement tolerance when compared to a conventionally wound filament. In particular, cathodes with flat emitters are capable of directing the electrons in a more parallel direction from the emitter, and thus can be seated more shallowly within the cup.
X-ray tubes having cathodes with flat emitters may additionally include a grid electrode. The electron emission originating from the surface of a thermoionic electron emitter, the flat emitter, strongly depends on the “pulling” electric field generated by the X-ray tube's anode. For enabling fast on/off switching of the tube, it is known from the relevant prior art that X-ray tubes of the rotary-anode type may be equipped with a grid electrode placed in front of the electron emitter. To shut off the electron beam completely, a bias voltage is applied to the grid electrode which generates a repelling field and is usually given by the absolute value of the potential difference between the electron emitter and the grid electrode. The resulting electric field at the emitter surface is the sum of the grid and the anode generated field. If the total field is repelling on all locations on the electron emitter, electron emission is completely cut off.
However, X-ray tubes using a flat filament/emitter require higher negative voltages to be applied to the grid electrode compared to cathodes that utilize coiled filaments due to the geometry or shape of the flat emitter. Thus, if an X-ray tube includes a cathode with a flat emitter and both grid and focusing electrodes, large bias voltages for the grid electrode are required in excess of the typical +/−10 kV with respect to the cathode potential in order to accurately focus the electron beam from the emitter on the desired target size. Such large voltages present many difficulties for the construction of X-ray tubes, including reliability and construction cost challenges regarding the requirements for the insulation located both inside the cathode assembly and on the supply cable.
Nevertheless, flat emitters are desirable for use in X-ray tube cathodes primarily for the longer filament life provided by the flat emitter geometry. However, in order to limit the required grid voltage to within typical ranges, the aspect ratio of the filament has to be increased. In so doing, the bias voltages for the focusing electrode(s) need to become positive to reduce the size of the electrode beam from the emitter to obtain useful focal spot sizes. However, cathodes positive voltages draw electrons and make it impossible to focus the electron beam and/or obtain a stable bias voltage.
Hence it is desirable to provide an X-ray tube with a flat filament emitter/cathode which can effectively employ focus and grid electrodes within a typical bias voltage maximum of +/−10 kV with respect to cathode while also providing a large emission area.
There is a need or desire for a system and method to emit an electron beam from an X-ray tube using higher emission currents without degrading the useful life of the X-ray tube. The above-mentioned drawbacks and needs are addressed by the embodiments described herein in the following description. In the present invention, for maximum emission a cathode is formed with one or more flat emitters that are spaced from one another within a cathode cup. The cup further includes width and length focus electrodes spaced from the emitter(s) that act on the electron beams from the emitter(s) to assist in directing the emission of electrons towards the desired focal point. The width electrode assembly, or alternatively the length electrode assembly, is between the emitting surface and target or anode and includes a septum or rod-like feature positioned above the emitter(s). Bias voltages applied to this width electrode and thus the rod will either grid (negative bias) or focus (positive bias) the electron beam in the width direction. With this construction, the cathode can increase the effective emission area from the emitter(s) in the cathode while reducing the aspect ratio required for the emitter(s). In addition, the cathode with this construction can be operated within the bias voltage maximum of +/−10 kV for the grid and focus electrodes with respect to cathode to achieve large and small focal spots for the electron beam. Further, the rod can optionally be biased separately from the electrodes in order to further shift or move the focal spot for the electron beams from the emitters.
One exemplary embodiment of the invention is a cathode assembly for an X-ray tube, the cathode assembly including a cathode cup, a pair of emitters disposed within the cup and each configured to emit an electron beam therefrom and a first electrode spaced from the pair of emitters and configured to affect the shape and/or intensity of the electron beams emitted by the pair of emitters, the first electrode including a rod extending across a central aperture defined within the first electrode.
Another exemplary embodiment of the invention is a method for affecting the intensity and shape of a focal spot of an electron beam emitted from an X-ray tube, the method including the steps of providing an X-ray tube including a cathode assembly having a cathode cup in which is disposed a pair of emitters for generating a pair of electron beams and a first electrode for gridding and/or focusing the pair of electron beams, the first electrode defining a central aperture with a pair of electrode sections disposed on opposed sides of the central aperture and a rod extending across the central aperture between the electrode sections, and a target for generating X-rays when impinged upon by the electron beams, passing a current through at least one of the pair of emitters to generate an electron beam and biasing the first electrode with a voltage to grid or focus the electron beam as the electron beam passes through the central aperture to one or both sides of the rod.
Another exemplary embodiment of the invention is an electrode for gridding and/or focusing at least one electron beam from an emitter, the electrode including a ring-shaped housing defining a central aperture therein, a pair of electrode sections disposed on the housing on opposed sides of the central aperture and a rod extending across the central aperture between the electrode sections.
In another exemplary embodiment of the invention, a cathode assembly for an X-ray tube includes a cathode cup, a pair of emitters disposed within the cup and each configured to emit an electron beam therefrom and a first electrode spaced from the pair of emitters and configured to affect the shape and/or intensity of the electron beams emitted by the pair of emitters, the first electrode including opposed electrodes and a rod extending across a central aperture defined within the first electrode where the rod is further insulated from the electrodes on opposed sides. Bias voltages applied to the rod are within +/−2 kV from the electrodes on opposed sides and thus the rod is capable of further moving the focal spot position.
It should be understood that the brief description above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure
The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments, which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the embodiments. The following detailed description is, therefore, not to be taken in a limiting sense.
Exemplary embodiments of the invention relate to an X-ray tube including a cathode assembly with a robust cathode including a flat emitter to accommodate larger emission currents. The cathode also includes a grid and focusing electrode(s) that includes a central rod or septum extending across the electrode to affect the electron beam emitted from the emitters and provide the desired focal spot for the electron beam.
As shown in
A processor 20 receives the signals from the detector 18 and generates an image corresponding to the object 16 being scanned. A computer 22 communicates with processor 20 to enable an operator, using operator console 24, to control the scanning parameters and to view the generated image. That is, operator console 24 includes some form of operator interface, such as a keyboard, mouse, voice activated controller, or any other suitable input apparatus that allows an operator to control the x-ray system 10 and view the reconstructed image or other data from computer 22 on a display unit 26. Additionally, console 24 allows an operator to store the generated image in a storage device 28 which may include hard drives, flash memory, compact discs, etc. The operator may also use console 24 to provide commands and instructions to computer 22 for controlling a source controller 30 that provides power and timing signals to x-ray source 12.
Feedthrus 77 pass through an insulator 79/202 and are electrically connected to electrical leads 71 and 75. X-ray tube 12 includes a window 58 typically made of a low atomic number metal, such as beryllium, to allow passage of x-rays therethrough with minimum attenuation. Cathode assembly 60 includes a support arm 81 that supports cathode cup 200, flat emitter 55, as well as other components thereof. Support arm 81 also provides a passage for leads 71 and 75. Cathode assembly 60 may have focus pads (not shown) that are either attached to cathode cup 200 or machined into cathode cup 200. The cathode assembly 60 includes width and length electrodes 300, 400 (
In operation, target 56 is spun via a stator (not shown) external to rotor 62. An electric current is applied to flat emitter 55 via feedthrus 77 to heat emitter 55 and emit electrons 67 therefrom. A high-voltage electric potential is applied between anode 56 and cathode 60, and the difference therebetween accelerates the emitted electrons 67 from cathode 60 to anode 56. Electrons 67 impinge target 57 at target track 86 and x-rays 69 emit therefrom at a focal spot 89 and pass through window 58.
Referring now to
The cup 200 includes a pair of flat emitters 55 spaced from one another on the cup 200. The flat emitters 55 can be formed in any suitable manner and of any suitable material, such as that disclosed in co-pending and co-owned U.S. Non-Provisional patent application Ser. No. 14/586,066, entitled Low Aberration, High Intensity Electron Beam For X-Ray Tubes, filed on Dec. 30, 2014, the entirety of which is expressly incorporated herein by reference for all purposes. The pair of emitters 55 in one exemplary embodiment divide the total emission area for the emitters 55 lengthwise into two sections thereby providing a larger effective emission area for the cathode assembly 60 with smaller individual aspect ratios for each of the emitters 55 that are better suited to focus narrow focal spot widths.
The emitters 55 are each positioned on and electrically coupled to the cup 200 to be at the same potential as the cup or cathode 200 via respective first and second attachment surfaces 208,210 on the cup 200 which are electrically insulated from each other (not shown) such that no positive voltages are present around the emitters 55 as is the case in conventional cathode designs. Flat emitters 55 typically range in thickness from 200 to 500 microns but are not limited thereto. In a preferred embodiment the thickness of the emitters 55 is 300 microns or less, however one skilled in the art will recognize that the thickness can be selected as desired depending upon the particular application. Further, the sizes and/or shapes of the emitters 55 can be the same or different from one another in order to provide different focusing attributes, i.e., to obtain very large and very small focal spots, to the cathode assembly 60 based on the sizes and/or shapes of the emitters 55. In addition, the emitters 55 can be selectively operated together or separately from one another in order to achieve the desired focal spot on the target 56.
The first and second attachment surfaces 208,210 can be formed to be normal or perpendicular to the direction cathode or at an angle with respect thereto which typically ranges from 5 to 25 degrees in order to place the emitters 55 at an angle with respect to one another that causes the electrons emitted from the emitters 55 to converge at a specified distance from the surface of the emitters 55, which can be designed to be a specified distance from the emitters 55 based on the angles at which the emitters 55 are positioned. Due to the improved focusing, focal spot sizes from small to large focal spots can be obtained by adjusting the heights and/or bias voltages of one or more of the width and length electrodes 300 accordingly. To obtain focal spot sizes relevant for medical imaging, in one exemplary embodiment of the invention, the width of the emitters 55 is typically within 2-6 mm and the length is typically within 6-15 mm. The surfaces of the width electrode 300 and/or length electrode 400 are typically positioned on the cathode cup 200 3-8 mm above the surface of the emission area of the emitter 55 such that the width electrode 300 and length electrode 400 can be biased to predetermined positive or negative voltages relative to the emitter 55 to control the size of the focal spot and/or to cut off the electron beam, such as by biasing the width electrode 300 and/or length electrode 400 to predetermined negative voltages relative to the emitters 55 to cut off the electron beam.
In the exemplary embodiment of
Referring to the exemplary embodiment of the width electrode 300 illustrated in
With this configuration for the rod 308, the bias voltage applied to the width electrode 300 is conducted across the electrode sections 306 and the rod 308 to allow the voltage to affect the electron beams from one or both of the emitters 55 that pass through the bisected portions of the central aperture 304 to either side of the rod 308. In the position between and above the emitters 55, no part of the electron beams interfere with the width electrode 300, e.g., the rod 308, during normal operation of the tube 12, as the beams are directed by the emitters 55 through the portions of the central aperture 302 disposed on either side of the rod 308.
As shown in
Looking now at
In addition, in another exemplary embodiment, the rod 308 can be optionally isolated from and biased separately from the width electrode 300 and the length electrode 400, thereby further enhancing the ability of the cathode assembly 60 to shift the position of the focal spot 89. The bias voltages applied to the rod 308 are between +10 kV to −10 kV and are within +/−2 kV from the width electrodes 300 on opposite sides of the rod 308 and thus the rod 308 is capable of further moving the position of the focal spot 89 as desired.
The written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
