Television Manufacture and Repair – Wikibooks, open books for an open world

Tv image tubes (CRTs): black and white elements, manufacturing steps, makes use of, and detailed description/directions of learn how to course of the cathode ray tube (CRT).

Parts of the image tube (CRT)[edit]

  • Glass bulb; often known as bulb, tube, or CRT
  • Electron gun, with related elements see Electron gun beneath.
  • Phosphor coating
  • Liquid paint, inside conductive coating; often known as Aguadag or Dixonac
  • Bakelite base (plastic)
  • Spray, exterior conductive coating

Electron gun[edit]

Components of an electrostatic focus electron gun (so as of sequence)
  1. Glass Wafer with encapsulated wires, for exterior/inner entry to the gun correct. The inner connections include thick, stiff wires hooked up to supporting glass, and a couple of or Three rods (relying on gun sort), which maintain the gun elements rigidly in place (very important). Different stiff wires provide a base for connections to the elements. For exterior use (NOT beneath vacuum), tender copper wires are prolonged from the underside of the glass wafer (to which a Bakelite base might be hooked up in a later operation). This base will present simple electrical entry from the chassis to the weather of the gun.

Filament, a wound tungsten component (very like a component in a lightweight bulb) coated with {an electrical}, non-conductive coating. The filament produces greater than 1,472 Levels F of warmth at 6.Three Volts, @ 600 Milliamps. For correct conversion/activation of the coating, elevated voltages are mandatory as excessive as 13 half of volts. The coating resides atop the cathode cylinder, whereas the filament resides inside the identical cathode cylinder electrode. This initiates a course of referred to as “thermionic emission”, which releases many electrons and ions in a cloud-like kind. These particles are then propelled by utilized voltages (voltage differential), via the first grid aperture, and thereby accelerated by, and thru. the 2nd grid aperture. The beam is then shaped, directed and centered, by different related parts inherent within the electron gun (See the next further elements:

  1. Cathode Cylinder, hole metallic electrode which is enclosed within the G 1 construction, the highest of which is coated with with a mixture of Three chemical coatings. There may be extra in regards to the composition and rationalization of the three coatings later on this ebook. These coatings readily emit electrons/ions when heated in a vacuum. The filament (simply described) is located inside that cylinder, which provides the warmth wanted for the technology of the electrons/ions.
  1. First grid [G1], Utilized voltage differentials, management the preliminary amount of electrons/ions, which might be launched by the cathode-generated electron/ion stream on command from a broadcast sign despatched from an exterior supply. Then, the potential distinction between the cathode and G 1 begins to speed up that stream into the affect/area, the place the second grid takes command.
  1. Second grid: [G2], (often 300 Volts optimistic), accelerates the electron beam (stream) even sooner to and thru the anode electrode.

Break up-anode: the place 2 buildings are bodily separated, however joined collectively,{electrically}, with a wire, {in order the two buildings, could also be thought of as one and the identical, voltage-wise}.

Be aware: In electromagnetic-focus electron weapons, focusing is achieved by means of a everlasting magnetic-generating system, hooked up to, (or a part of), the YOKE, which encircled the skin of the neck of the CRT, (like a hoop in your finger). That is generally known as THE FOCUS COIL. These kinds of weapons have a one-piece, Anode construction.

Focus ring: A metallic ring, showing, (however not linked to), and residing, between two buildings, {see above, “split-anode”}. Such a gun was referred to as an “Electrostatic Focus Gun”, indicating that focus was achieved INTERNALLY, mechanically, by utilized voltage, because it was a part of the Gun-structure meeting itself. It was accountable for SHAPING the Electron/Ion Stream, which in the end reduces the Electron Stream to a pin-point DOT, precisely on the level of impression, on the Phosphor display screen. ALL mandatory voltages, to create the required magnetic fields, which do the work, are offered by the circuitry of the TV set. See “Magnetic Focus Electron Gun” beneath.

Crown: The very prime of the Electron Gun [Anode], (cylinder), upon which “Spiders” and “Getters” are hooked up. See subsequent:

“Spiders”: 10 to 12 items of bendable metallic,( formed like a spider’s legs ), emanating in a full circle, from the Crown , (TOP) of the anode. The Spiders made contact with electrical coating, which might be put contained in the tube (glass envelope).

Be aware: The Spider’s major perform was, to make contact with a conductive coating (Aquadag), painted uniformly all through the entire inside of the CRT. This, was wanted to hold the excessive voltage, (10,000 to 25,000 volts), mandatory for the tube to perform correctly. The Aquadag, extremely electrical-conductive coating, is painted over the metallic button, (“anode button”), which is melted into the aspect of the glass bulb. This Anode button connection, is widespread to each the within and the skin of the bulb. When a heavy-duty wire, emanating from the high-voltage provide circuit of the T V set, is hooked up to it, {the electrical} circuit is accomplished, offering Excessive Voltage to the Electron Gun half. Sadly, it’s ALSO referred to as the “ANODE”, alongwith the Gun construction component. The secondary use was, that it held the Electron gun in place, through the SEALING-in course of, linking the Electron Gun, into the Bulb, (described later herein).

“Getter”: A “U-shaped” component, with a bar throughout the highest, hooked up to, and sitting upon, the very prime of the “Crown”, (prime a part of the [Anode], Gun Construction). This bar accommodates a component referred to as “Barium”. The bar is heated up, by an exterior supply of radio-frequency waves {“R F”}, (very like a kitchen microwave oven heats microwavable merchandise ). Besides that, that the kind of R F tools, supplying this power, was meant particularly to warmth metallic. The R F utilized, was from a hand-held coil, emanating from the R F generator, [BOMBARDER], which is hooked up to a non-conductive, pole-like stick, which is supposed to isolate you, from the Electrical power, when in use. That utility of R F, is completed instantly after processing the Gun, [Cathode coating,] and eradicating the CRT from the Oven [Tipping-off]. When the R F heats the Barium, embedded within the Cross-piece, it prompts it. This causes a Chemical response, which absorbs any gasoline, remaining contained in the CRT. It additionally leaves a deposit,on the glass of the neck of the tube, immediately reverse of the “Getter” location.

Be aware: A great indication, of whether or not or not, there was a excessive diploma of vacuum, coupled with a low residual gaseous situation is, that when the Barium is activated, [by R.F. heating of the Getter] , it has the flexibility to soak up any/all gasses. If few gasses are absorbed, the inside aspect of the glass neck, the place the getter is positioned, assumes a BRIGHT SILVERY LOOK, [like a highly-polished mirror]. If there’s a poor vacuum, and/or, a excessive gasoline content material, a smokey-black or dirty-brown coating, deposits on the neck, as an alternative of the intense silvery impact.

Afterward, when Oxygen enters the tube, {for any cause}, the coating, (whether or not silvery, smokey-black, or dirty-brown), registers its look on the glass neck, by one other Chemical response, hereby changing into CHALK WHITE. If excessive voltage is offered to the CRT at THAT time, giant sparks (and splats), are heard , seen, (like lightening bolts ), bouncing between the weather, (Grids and Gun-Anode of the Electron Gun ). At that time, the CRT will NOT perform. If left on lengthy sufficient, harm to {the electrical} circuitry within the T V set, will ensue, to the purpose, if left on but, even longer, the whole T V set, must be scrapped. ( See Bombarder afterward herein,… SPIDERS singing and hammering the neck of the CRT ).

All of those parts, are offered a method, to have Electrical expenses launched to them, by way of a Wafer-like glass piece, (as beforehand disclosed), which is hooked up as a part of the Gun construction, and helps all of the Gun Components. They successfully present the leads, from the skin, (the T V chassis), to the weather themselves, that are contained in the vacuum. These voltages are mandatory, for the CRT, to perform usually.

“Yoke”: Final, however not least, and NOT a linked a part of the Electron Gun, however mandatory for the Gun to be correctly operated, is a sequence of coils,(though constructed as one piece). It’s positioned on, and across the exterior of the neck of the CRT. When the CRT is inserted neck-first into the yoke, the yoke is positioned cosy up in opposition to the bulb, the place the neck of the CRT, joins the bulb correct. In regular working circumstances, when completely different voltages are utilized, in line with directions from the indicators acquired, such causes the Electron Stream to be directed, left-to-right,(horizontally), and up-and-down (vertically). Be aware: in some TV units, an exterior focus coil, [magnetically-focused], can also be hooked up to the Yoke.

The Yoke perform/association,(NOT together with the Focus coil), is mostly referred to, as “SWEEP CIRCUITS”. ( Provided that title as a result of the Yoke is accountable for the Electron Beam to be “swept”, [Horizontally], from left to proper, AND to be “swept” [Vertically], from the highest of the display screen to the underside of the Display). It’s accountable for breaking apart the image into 525 evenly spaced Strains, of data, (American System), versus 1,080 traces for the HDTV System, (which offers extra element), than the 525-Line System).

Magnetic Focus Electron Weapons[edit]

  • Be aware: Among the many first tv tubes showing within the U.S. have been these of the “Magnetic Focus” sort. The Electron gun in these tubes, did NOT have “break up Anode” components, as indicated earlier, however a single gun construction, (Electrode), merely famous because the “Anode”. It additionally did NOT include a “Focus Ring” as an integral a part of the Electron Gun, as focusing was achieved by one other coil, constructed as an integral a part of the Yoke, which encircled the skin finish of the neck of the CRT .

NOTE: An “ELECTRON”, is a sub-atomic particle, of an atom. first found in 1897 by J J Thomson who estimated its cost to mass ratio to be over a thousand occasions that of the hydrogen atom. Its mass is accepted to be 9.1093826E-31 kg.
An ION consists of no less than One full Atom, which is known as a “Monoatomic Ion” containing many components. Different IONS may additionally be composed of a bunch of atoms; these are referred to as “Polyatomic Ions”. It has been calculated that Monoatomic Ions, would possibly weigh as a lot as 2,000 occasions, or extra, than an Electron. Subsequently, Polyatomic Ions would possibly weigh as a lot as Ten 1000’s, or extra, than an Electron. Ions with unfavourable expenses are referred to as “Anions”, and positively-charged Ions are referred to as “Cations”. The kind of Ions, launched from the Cathode Coating, after all, relies on the sort(s), of Coatings used, to compose the Coating. (Typically, the three coatings will include a mix of any of the next chemical substances: Calcium, Barium, Strontium or Cesium, depending on the Gun Producer’s desire/selection).

Electrons are simply manipulated, whereas Ions, (many occasions heavier than Electrons), as simply disclosed, are a lot more durable to affect, (with the same-strength magnetic subject, of an Ion-Entice). The Ion-Entice, simply bends the Electron Stream, however due to the Ion’s a lot heavier mass, there’s little or no, if any, impact on the Ions, (whether or not optimistic or unfavourable). Ions, in a Vacuum, when concentrated, is usually a very DESTRUCTIVE power drive, notably on the Phosphor Coating. The Phosphor Coating, was meant to show video info, NOT resist, ION bombardment. See beneath Aluminizing Preparation, additionally, the energy of concentrated, managed IONS.

Be aware: Afterward, a skinny coating of aluminum utilized in entrance of the Phosphor Display, once more allowed the “Straight Gun”, (wanted no ION TRAP),for use. There, the Aluminum took the brunt of the impression by the IONS, accompanied by Electrons, within the mixed Electron/Ion stream. It went via the aluminum coating and delivered the knowledge to “draw” the image, which was signaled by the sending supply. The magnetic subject, generated by the “YOKE”, was/is, highly effective sufficient to regulate the Ions (whereas the Electrons went alongside for the experience), however none-the-less, they induced the display screen to mild up (fluoresce) even brighter, than that of Electrons alone, for any given quantity of particles [generally referred to as Electron Stream]. (See “Aluminizing” beneath).

The Electron/ION pinpoint Stream, initially has the ability to penetrate the aluminum layer, going ahead, however NOT have sufficient drive, to bounce again out, [in the opposite direction]. Additional, that Aluminum Defend, additionally causes all mild to be directed/ mirrored, towards the viewer, making a far brighter image, than that, with a phosphor-alone, NON-aluminum protected, Bent-gun CRT.

Cathode Coating[edit]

This emitting of Electrons/Ions, are produced by a heating component, (very like a traditional 100-watt mild bulb), which is fitted into the hole Cathode cylinder, immediately beneath the flat, and reverse the coated aspect, of the Cathode Cylinder. These coatings, (stimulated by the extraordinary warmth of the Filament {800 Levels C, 1,472 Levels F and upwards}. And upwards, as a result of within the conversion and activation of the Cathode Coating, voltages, as excessive as 13 half of Volts, are utilized to the filament. Then, by way of directions from the set-up, of the T.V., obeying instructions from the Televising supply, the Cathode Coating, via the G1 meeting, releases various quantity of Electrons. This various depth of the mixed Electron/Ion Stream, dictated whether or not the Phosphor would glow brighter, much less brighter, or have NO brightness in any respect. SEE testing, afterward herein, for the attribute, often known as, “Minimize-off”. That is how the image might depict White and all shades of Grey, finally to Black, [lack of Electrons impacting the Phosphor Coating].

Typically there’s a mixture of Three (3) supplies, containing many numerous Ions, that are deposited on the flat, top-side of the spherical metallic cylinder,(CATHODE), which is to be the recipient of the warmth, generated by the filament.

The FIRST Coating of the Triple-combination, was chosen as a result of it liberated Electrons/Ions in a short time, after the filament lights up, however, would solely accomplish that, for a number of years.

The SECOND coating, took a bit of longer to begin offering the Electrons/Ions, however, it might proceed to take action, for 5 (5) to Ten (10) years.

The THIRD coating, took longer but to start to provide the Electrons/Ions, however, might proceed to take action for a very long time. NOTE: As soon as the Third Coating, was heated lengthy sufficient, it might then proceed to offer sufficient Electrons, to current a very good image for Twenty (20) years or longer. NOTE: That’s the reason, as units aged, they’d take longer and longer to offer a very good image, however finally labored fairly good.

The Cathode Coating, {bodily, about1/2 the diameter of a #2 pencil-eraser and as thick as Three (3) sheets of 20 lb Paper}, was deposited on the flat, outer top-surface of the Cathode Cylinder, (which contained the heating component, the “Filament”).

NOTE: That tiny quantity of Cathode coating, (theoretically), might produce sufficient Electrons for the CRT, for over 100 years.The mixed coatings, usually consisted of the chemical substances, Calcium, Barium and Cesium.

As disclosed earlier, in contemplating a Black and White Image Tube, the extra Electrons current within the pinpoint stream of electrons, the brighter the phosphor glowed in that one spot (PIXEL/Image Factor). The lesser quantity of electrons that are contained within the Electron Stream, (much less mass), a much less lighter/darker picture is portrayed. This fashion, all shades of black-to-gray-to-white, might be portrayed. As shade Tv Tubes have been beginning to seem within the Nineteen-Fifties, the various quantity of Electrons, elevated/decreased, the Coloration of the impacted Phosphor, (INTENSITY).

In keeping with ONE (1 )of the legal guidelines of physics, entitled “Double-Quadruple Principal”, the Japanese 1,080 Horizontal-line system, (double the quantity of Horizontal traces projected than that of the American 525 Line-system ), offers a 4 (4 )occasions BETTER image that the U.S. 525 line system. See EXPLANATION, of Double-Quadruple precept NEXT.

EXPLANATION: of “Double-Quadruple Principal“. If a One (1 ) inch hose, can pump 100 gallons of water per minute, then a Two ( 2 ) inch hose can pump, 400 gallons of water, NOT the 200 gallons per minute, that “widespread sense” would dictate. The Double Quadruple regulation, [Principle,] impacts many different common-day occurrences, maybe unknown to put folks and even a lot of the populace.
NOTE: Since 2004, A PURPORTED NEW TECHNOLOGY, once more sponsored by the Japanese, makes use of a BLUE laser beam prime create/learn DVD’s. They cite that the Blue laser beam is thinner than the RED laser beam. THIS IS TRUE! BUT THEN THEY SAY, THAT BECAUSE USING THE THINNER BLUE LASER BEAM, IN CONJUNCTION WITH A “CHANGE OF THE NUMERICAL APERTURE 0F 0.85, THEY ARE ABLE TO WRITE/READ, AS MUCH AS 5 TIMES AS MUCH INFORMATION AS THEY COULD WHEN USING THE RED LASER BEAM. The creator herein, thinks that with a special change of numerical index, the RED laser COULD do the identical factor. However then they do NOT have the citing of superior know-how, as a way to promote the system/product. IT DOES HAVE THE ABILITY FOR MORE AND MORE INFORMATION TO BE RECORDED/DISSEMINATED. That’s the reason, a GROUP of 14 main main shopper electronics,private pc and media producers, that are world-known firms, (Blu-ray Disc Affiliation), have banded collectively to use this excellent NEW know-how! ? ! ?

Again To the Double-quadruple principal, because it refers to “Wind Turbines”, (one other misnomer).

One other MORE COMPLEX Instance: A sure “Wind Generator” produces One Thousand Watts of electrical energy in a 7 mile an hour wind. Should you improve the wind velocity to 14 MPH the identical windmill will produce 4 (4) Thousand watts of electrical energy. Then if the unique diameter of the Wind-Blades are Three (3) toes, and also you improve the Wind-Blade diameter to Six (6) toes, you then produce 4,000 Watts of electrical energy within the 7 MPH wind. Now should you do each upgrades without delay, (double the wind velocity AND double the blade diameter), you now will produce Sixteen (16) Thousand Watts of Electrical energy, within the Six (6) foot Wind-Blade, within the 14 MPH wind ). See cifaldi,carmine in GOOGLE, relative to Patent #6,372,978 B1,[4-16-2002]. It discloses full particulars, of an Hybrid Photo voltaic Heating System, with prolonged Storage Functionality. It makes use of the Solar and the Wind, because the sources for producing warmth, via what is usually termed, “Renewable-Vitality” Sources.

Many of the info herein relative to “Electron Weapons” has reference to these “GUNS” used for presentation in Black & White Tv. The next, is a few additional info relating to “Electron-Beam Coloration Weapons”.

Coloration Image Tubes[edit]

Geomertic ideas of a shade CRT

Inaccurate colours as a consequence of magnetization. The shadow masks can’t perform correctly

In a REGULAR Coloration CRT, there are Three (3), {Black and White} weapons, bodily organized collectively, as One unit in a triangular configuration. The one unit, comprised of the Three (3)gun association, are referred to as, the “Pink Gun”, the “Blue Gun” and the “Inexperienced Gun”. Nonetheless, all of them produce Electrons, which are COLORLESS. The Colours ascribed to the GUNS, are actually for the sake of comfort and ease of debate. The Tube accommodates Three (3), Phosphors, deposited on the face of the CRT, within the type of minute dots, EACH, DOT BEING, all RED, OR all BLUE OR all GREEN, solely. They are additionally organized in a triangular configuration. For a 25″ shade tube, there are roughly 333,000 dots of Phosphor, of every Coloration.

The Electron weapons, located in TRIANGULAR array, within the far finish of the neck of the CRT, are positioned such, that Electrons emanating from the “RED” gun might impinge ONLY the Pink-colored Phosphor dots, however NOT Blue nor Inexperienced Phosphor Dots. This was due to an ingenious use of a “SHADOW MASK SCREEN”, ( very like a standard window display screen ).

This Shadow Masks Display is mounted in place, a brief distance in entrance of the Coloration Dots of Phosphor, the {TRI-COLOR} SCREEN. It’s positioned between the highest of the Electron Gun and the Tri-color Display. In flip, the “BLUE” Gun, might solely impression the Blue Phosphor Dots, (however NOT the Pink Nor the Inexperienced Dots). Equally the “GREEN” Gun Electron Stream might solely impression Inexperienced Phosphor Dots, however like-wise, might NOT impression the Pink, NOR the Blue Phosphor Dots.

Later superior fashions Coloration CRTs,with a special association, consisted of BANDS (strips ), of the Three colours (in vertical array). The extraordinarily tremendous parts of all Three shade Bands have been bounded {by darkish Blue bands, within the Horizontal Axis). The Bands of TRI-Coloration bits, likewise have been used to realize all colours and 1000’s of variations, which was potential, with the “Tri-Coloration Dot” Phosphor association.

HOW TELEVISION IS PROVIDED THROUGH THE ELECTRON GUN[edit]

Typical voltages and/or utilized voltages for common Tv Tubes have been as follows, {with all voltages DC optimistic, besides the place indicated}:

Filament 6.Three V AC @ 600 MA;

Cathode -5 V ;

(G1) 10 to 30 volts ;

(G2 ) 250 to 400 V ;

Focus Ring 0 to 300 V ;

Anode/Spit-anode 8,000 V to 30,000 Volts.

Electron Weapons, working at greater than 25,000 Volts, required “WARNING-LABELS”, of potential radiation side-effects.

NOTE: The Warning Label suggestion was, that there ought to be no less than Three (3) toes or extra, between the viewer and the face of the Tube! As Tube sizes elevated, so did the need for elevated Excessive (Anode) Voltages. Subsequently, a correct Viewing-Distance Chart, was thereby developed.

This was not as dangerous because it sounds as a result of the X-ray radiation was sure by the “INVERSE SQUARE LAW”, (as you double the Distance away from an X-ray supply, Radiation, [in Millirems], decreases by the inverse of the Sq. of the Distance, in Centimeters, from the supply. The Inverse-square regulation ought to NOT be confused with the INVERSE of the Double-quadruple regulation. THEY ARE MILES APART!

At a meager 6.Three volts, A.C., drawing 600 milliamps of present, there was warmth generated to roughly 800 levels (C ), or 1,472 levels ( F ), in order to trigger the Electrons and Ions to be emitted in a cloud. Then, completely different voltages, offered by, and to, the gun, formed the Electron/Ion beam, centered it and in the end propelled it as a pinpoint stream into the Phosphor Display. Then by directions from the transmitting sign, both to the Cathode or G1,(each kinds of sign management, have been used), it directed the resultant, centered electron-beam, to show a “mirror picture” image, of the one being despatched from the Televised supply onto the phosphor display screen, to be seen.

The filament ( Heater ), equipped the warmth essential to liberate Electrons/Ions
from the Three (3) coatings. TECHNICALLY, there was sufficient coating to provide Electrons/Ions for One Hundred (100 ) years. Some CRT’s, have been discovered to be nonetheless working, (with a suitable image), after Fifty (50) years

REPROCESSING OF USED CRT’S, or in, TUBES WHICH FAILED IN-PLANT[edit]

Initially, (circa 1944), DUMONT T.V. units, used a magnetically-deflected, electronically-focused “straight-gun”, the place the Electron/Ion beam was despatched on to the display screen. Sadly, it was discovered, after a interval of One (1) to Three (3) years, that the Straight Gun, produced a burn within the seen display screen, which RESEMBLED the sample, being broadcast by the T.V. Station. In 1946, tv programming was solely broadcast One (1) or Two (2 ) hours a day, within the New York, METROPOLITAN AREA), which included components of New Jersey and Connecticut. At 5 P.M., on Ch 5, Allen B. Dumont, (WABD), confirmed “HOWDY-DOODIE”, 5 days per week. However, none-the-less, some folks left their T V. lit up all day, hoping to see no matter else MIGHT be broadcast (therefore the sign being bombarded/burned into the Phosphor Display ). Come to consider it, was it good or dangerous promoting to see the WABD Sign (sample ), burned into your display screen, whereas the set was NOT even turned on ? ! ?

Worse but, with T.V. being a novelty, folks have been NOT positive learn how to use the T.V.,so that they all the time left their T.V. units turned on, Ten (10) to Fifteen (15) hours a day. Even when there was NO station-identification sign being broadcast, they STILL left their T.V. units turned ON. Nonetheless, the entire propelling voltages, relative to the Electron Stream, have been nonetheless being carried out, (albeit with no video info), exhibiting a fully-illuminated, vivid display screen). In these circumstances, after X quantity of hours, within the various to having the WABD Take a look at Sample displayed, you had an un-interesting “Cranium and Crossbones-like impact, because the phosphor started to have that picture etched onto itself. It will now NEVER disappear, even when regular video info was solely meant to be seen. This clearly, was un-acceptably ever-present, on the Phosphor Display Display.

The one treatment was to chop the CRT open, wash out that burned display screen and trigger a new display screen to be deposited. Nonetheless, some tubes, which have been uncovered to that fixed Ion/Electron bombardment for a few years, ignored that distracting, ever-present incidence, continued to undergo that annoying impact, as a result of, changing the CRT was the most costly half within the T.V. Set.

NOTE: Even when that burned-screen tube was returned for substitute, the Producer trying to reprocess, (“REBUILD” OR “RE-GUN “) the CRT, discovered that even when eradicating the previous phosphor display screen, such nonetheless revealed, that “Cranium and Crossbones” or “TEST-PATTERN” impact. That was as a result of that “Image” of a Cranium and Crossbones was etched/BURNED-INTO the glass itself, after which the Bulb would thereby be ineffective. That is without doubt one of the causes, now we have “Display Savers” at this time. However, “Straight” Electron Weapons, EVENTUALLY have been/are, those of selection, with the appearance of perfection of the Aluminizing course of/strategies.

Be aware: For the reason that Tv bulb WAS far the most costly a part of the T.V. Tube, many enterprising “Re-Builders”, afterward, bought that “ineffective’ CRT, (despite the fact that, the Cranium and Crossbones was BURNT into the Glass itself), for under a small fraction of the unique Bulb value. It then underwent remedial motion (involving acids), which have been used to obliterate that defect, by ETCHING, uniformly, the whole inside face of the CRT. After that remedy, there was completely NO WABD sample nor the Cranium and Crossbones defect, seen. In fact, you now additionally want a new Electron Gun and all of the supplies and work wanted to manufacture a working CRT. The top results of this course of, got here to be often known as a “Rebuilt Image Tube”. It not solely value a lot much less cash, however many occasions, it contained an upgraded (extra trendy), Electron Gun and using newer, higher, Phosphors. Thereby it truly produced a SUPERIOR image, than that offered initially. That Rebuilding course of, additionally conserved uncooked supplies AND power, and at a worth, extra folks might AFFORD.

NOTE: Rebuilt image Tubes wanted 2 further steps, in its manufacture. The FIRST, (“RE-NECKING”) was, chopping the neck of the (under-vacuum, of the used CRT). A brand new piece needed to be added, in order that the CRT might then undergo the manufacturing course of. This was performed on a GLASS LATHE. The Glass Lathe had a “HEAD”, which might maintain the Tube firmly in place, whereas rotating. On the opposite finish of that lathe mattress, was a a lot smaller “Head”, (resembling) a three-jawed unit, (spring- loaded), which held the brand new neck, to be sealed into the CRT. This jawed head, additionally revolved on the identical velocity, because the Head finish (holding the Bulb).

Beneath the neck space, there was a sequence of Gasoline Jets, (Eight to 10 in quantity), depending on the mannequin of the lathe), arrayed in a mild, u-shaped, upward setting. This sequence of jets had entry to Oxygen and Illuminating Gasoline and/or Oxygen and Hydrogen Gasoline, [Oxy/Hydro], (as wanted). The Oxy/Hydro, was NEEDED, when glass work needed to be performed on the Bulb correct, as a result of it was a special sort of Glass, than the neck, which required a warmer working temperature, than that which might be achieved by the Illuminating-gas/oxygen mixture. The Glass neck itself, was composed of “lead glass”, which might be labored a a lot decrease temperature, that that, of the BULB correct), Subsequently, it was a lot simpler to work with, on the lathe and at a later to be carried out, Sealing-in course of, of the Electron Gun. The within environment of the Bulb correct and the neck, had entry to a gentle stream of air,(upon command from the lathe operator), in order to counteract the driving drive of the Gasoline-fired Jets, when the Glass of every, Bulb and new neck, was melted collectively.

NOTE: An necessary a part of the “RE-NECKING” operation, was a BUNSEN BURNER. This was used to pre-heat the glass, that was to be heated, melted and for cooling (annealing), after the excessive temperature work was performed. The u-shaped setup-up of gasoline jets have been additionally accessible to pre-heat and/or anneal, however was not of a lot use, when engaged on the BULB correct.

The Second step, was to take away all labels and coatings (Aquadag-like), current on the OUTSIDE of the glass Bulb. This was usually performed by “STRIPPER”, designed particularly to emulsify, or in any other case take away the coating from the skin of the Glass Bulb. It was then rinsed off, with clear Metropolis water. The within of the bulb was additionally washed, (to do away with all the fabric beforehand used to fabricate the unique), with a weak delicate acid, resembling Ammonia Hydroxide. When the Bulb, lastly resembled that, of a model new Bulb (Clean), it was then despatched to the Screening Room, to be processed with different like-bulbs, in addition to the model new Bulbs. (See Precise Screening Course of, later herein).

BENT ELECTRON GUNS AND ION-TRAPS[edit]

An important Electron Gun UPGRADE, for “Straight-gun” Tubes, because the substitute Tube, was the “Bent Gun”, which allowed few, if any Ions to bombard the Phosphor Display. The “Straight gun”, went out of favor, as a result of the Bent Gun was designed in order that the Electrons and Ions, which have been generated, have been separated, and MOST of the Ions, have been NOT permitted, to impression the Phosphor Display. Then, the Electrons have been gathered collectively, formed to kind an Electron Stream {Electron Beam}, accelerated within the preliminary a part of the electron gun, and propelled, to permit the stream to impinge on the Phosphor Display. The separation system, referred to as an “Ion-Entice”, allowed the Electron Stream (solely), to proceed to its assigned process. The Ion-trap was a spring-loaded everlasting magnet, which match across the exterior neck of the CRT,(like a hoop on a finger), that when rotated/aligned correctly, allowed solely the Electrons to offer the acquired broadcast, video directions. For some time Straight Weapons have been out of favor. NOTE: As know-how evolves the “Straight Gun” will once more be revived. (See later herein).

NOTE: That time period “Ion-Entice” is a misnomer. It ought to have been termed an “Electron Beam Bender”, as a result of principally it did NOT lure Ions, however it had that impact. As a result of each Ions and Electrons, emanated from the Cathode coating in a straight line, neither might be despatched to on to impression the Phosphor Display, due to the purposeful mis-alignment of the Gun construction. The Ion Entice Magnetic subject interceded, by bending the Electrons within the stream, in order that THEY COULD be directed into the Phosphor Display. The ION-TRAP was of enough power to, and DID, affect the Electrons, however Ions which have been, THOUSANDS of occasions heavier, than an Electron, have been much less affected. Subsequently, the stream of Electrons, was bent by the magnetic subject of the Ion-trap, and transmitted the video info, onto the display screen. The IONS have been usually allowed to dissipate, harmlessly. Nonetheless, there was no less than one exception to this rule, within the Creator’s private information, (See EXCEPTION later herein).

EXPLANATION: of Ion-Entice’s restricted capacity.

For the reason that Electrons generated, contained {an electrical} cost (unfavourable), they have been influenced (bent) by the everlasting magnet, and allowed to be collected, formed, {centered}, propelled, in order to impression the Phosphor Display. So long as the Ion-Entice, was correctly organized/positioned on the neck of the CRT, it retarded tremendously, if NOT, stopped the display screen Ion Burning. The a lot HEAVIER Ions, whether or not Constructive or Damaging, (despite the fact that each include electrical expenses),{though most IONS, derived from the Cathode-material composition, WERE unfavourable), such was irrelevant. BOTH Constructive and Damaging Ions, have been LITTLE-effected, by the restricted power, of the Ion-Entice Magnetic Area. In the principle), they COULD NOT/DID-NOT, impression the Phosphor Display.

The creator feels that there’s an analogy right here, between a “BLACK HOLE”, as proposed by STEPHEN HAWKING, that some mild particles might escape the Black-hole, {HAWKING RADIATION) due to their location across the periphery of the Black-hole. In that regard, by the identical reasoning, there in all probability ARE some Ions, (due to THEIR location), which ARE in a position to impression the Phosphor Display. They’d be solely barely affected by the weak magnetic subject of the Ion-trap however some Ions, might impression the Phosphor Display. (See CROSSOVER-POINT, LATER HEREIN). The a lot stronger Magnetic Area, generated by the Focus Coil, CAN EASILY deal with the IONS. Due to their a lot heavier weight (THOUSANDS of Instances heavier than the Electrons), compounded by that incontrovertible fact that their velocity, [see Herman Minkowski and Einstein below], elevated their weight by 200 occasions, added their contribution, to the penetration of the Aluminum Coating. The brightness achieved, (definitely NOT, minimal), was evident. The mixed Electron/Ion Stream is a doubtlessly harmful supply of power. (Keep in mind, the trace, of Phosphor Display, AND, Glass burns, which in the end led to (“Display Savers”)

“EXCEPTION”

The “Trapped” IONS, often proceed to rattle round within the Electron-Gun construction, till they’re lastly dissipated and do NOT impact the specified outcome. In a RARE CASE, a mis-positioned Ion -Entice, (across the neck of the CRT), one way or the other, WAS POSITIONED (BY a technician), such that it induced the Ions, NOT, to be instantly dissipated, however as an alternative, to really focus and blast a round gap, within the Anode Electrode, of the Electron Gun, (in regards to the dimension of half a #2 Pencil eraser). NOTE: JUST LIKE BUCK ROGERS OR FLASH GORDON, A HAND-CARRIED PISTOL-LIKE WEAPON, THEY CALLED A “BLASTER”, or a RAY-GUN! See WWW.cifaldi.org, clik on images, clik on Carmine, clik on Ray Gun , for a hand-drawn image of a hypothetical “RAY GUN” dated Jan 17, 1965
NOTE: The “Ion-Entice” magnet system, was discontinued, and for the reason that 1970’s, is NO longer getting used.

Afterward, it was accepted by the Scientific Group that Electrons, DO have some weight, {trillionths of a gram ?}, (454 grams to the lb ; 28.375 Grams to the ounce}. Touring within the vacuum, at close to the velocity of sunshine, the Electron stream, impacts the T.V. Phosphor display screen AND causes TINY PARTICLES of phosphor to fluoresce, {“mild up”). That is achieved, in line with directions, as coded, from the sending supply, by way of the Electron Gun. Though, the Electrons are just about weightless, in line with MR. Hermann MINKOWSKI),{one in all Einstein’s Professors},(they do have some mass). He had rightly urged, that “SPEED INCREASES MASS”). Neither man, suspected that the Electron DID have mass.

Afterward, as EINSTEIN (1879 to 1955) HIMSELF, TAUGHT, that any object, attaining close to the Pace of Gentle, (186,300 Miles per second), can have its Mass {weight}, multiplied by 200 occasions or extra. “EXPLANATION”, of Pace rising Mass: Since extra electrons are NOT added, to a single Electron, then the additional mass, (weight), should come from one thing/some other place. It comes from the Vitality, (referred to as Kinetic power), put in, to get the Electron, (or any particle/mass), to maneuver that quick. The Kinetic Vitality, is subsequently added to the Vitality, of the Electron at relaxation. Then subsequently, since E =’s M C squared, {during which Mass may be transformed to power and Vitality may be transformed to mass}, then, the Electron, or Ion, or ANY particle, WILL get heavier, due to the Vitality put into it, to make it go that quick.

Subsequently, for the reason that Electron Beam proceeds at, or close to, the velocity of sunshine, its impression, causes the chosen portion of the impacted particles of Phosphor to mild up, {Fluoresce,when it comes to DECAY TIME}, momentarily. That impact, (on a selected particle of Phosphor, was later outlined as a “PIXEL”, [Picture Element]. FOR MORE INFORMATION ON “PHOSPHOR”, and “DECAY TIME”, see Sections LATER HEREIN, labeled “PHOSPHOR” and “DECAY TIME”.

Then, when the Electron Beam moved on to the following Phosphor particle, the Phosphor mild slowly died out,[“DECAYED“]. NOTE: The smaller the diameter, of the projected Electron Stream, the smaller quantity of Phosphor particles, that are to be impacted. The “down-sizing”, (discount of the diameter), of the Electron Beam, permits the manufacturing of a finer, MORE lifelike, image, (which is characterised as “DEFINITION”). HDTV achieves wonderful Definition, due to associated circuitry, which offers info on 1,080 HORIZONTAL traces, as an alternative of 525 HORIZONTAL traces. This implies extra/smaller element could also be proven as a result of it breaks the image into extra components. Subsequently, 4 (4 ) occasions as a lot info is ready to be displayed,by HDTV, than the 525-line system, as dictated by the “DOUBLE-QUADRUPLE LAW” (SEE Rationalization later herein).

NOTE: The mixed, (elevated) mass of Electrons/Ions, propelled at such a velocity, might simply penetrate the aluminum, impinge on and light-weight up, the phosphor particles. Nonetheless they don’t include sufficient power, to reverse course and re-penetrate, out, the Aluminum defend, again in direction of the Electron gun. Moreover, the Aluminum cowl, which is vivid and glossy, moreover features, as a reflector. Subsequently all (100 %), of the accessible light-energy, is directed towards the viewer.

PHOSPHORS[edit]

“Electro-luminescent” supplies, deposited on the inside face of CRT’s, when impacted by energetic expenses, causes them to “FLUORESCE”. When struck by the Electron/Ion Stream, they “GLOW” brightly after which begin to lose power after which the glow FADES out. That incidence, in impact, is characterised by the phrase “PERSISTENCE”. The period of time it takes PERSISTENCE to happen/be measured, is called “DECAY” time. Phosphors come in numerous DECAY occasions, which depend upon the last word use, for which the CRT might be used, {Particular Function Tubes}.

The Phosphors come within the following Persistence ranges: Extraordinarily Quick; Extremely Quick; Very Quick; Quick; Medium Quick; Medium; Medium Lengthy; and Lengthy. The Phosphor utilized in Black and White Image Tubes, is known as ” P4 “, and is of Medium Persistence, and the Phosphor, which is yellow, tends to favor a faint bluish caste. The popular Phosphor, for use in Particular Function Tubes, for direct photographic functions, was a P1 sort. It additionally was a medium persistence phosphor. The Phosphors utilized in Coloration Tubes (P31), [Red, Blue and Green], are additionally of Medium Persistence. There are Three small {5″) CRT’s contained in projection T.V. Units. Every of them, are composed of One shade, [their own], ONLY, masking the entire face, of every CRT.

“DECAY TIME”[edit]

“Decay Time” is ascribed, because the time frame, (in Milliseconds ), it takes the Phosphor to lose brightness, from One (1) Foot Candle, to lower than One (1 ) % of that quantity, for a Pixel to return from its excited (brightest) state, to little, or NO brightness. For instance: for a Radar Tube, you wished a phosphor with a protracted persistence. You didn’t need the blips, {which do signify a relatively giant airplane}, to vanish, or blink on and off, (until this system referred to as on it to take action).

However, for a Little one’s Arcade-like Recreation, you desire a phosphor with a particularly brief persistence, (very like a ”REFRESH RATE” ABILITY), as to forestall “BLEEDING” {Colours mixing into the sting(s), of different colours}, thus the blurring of data, when it’s offered at excessive velocity. It is because, the extra intricate (life-like), footage of persons are portrayed, in an motion program, (when calling for terribly quick motion), calls for that the Phosphor particles dim in a short time. If they don’t dim quick sufficient, the brightness of One (1) Pixel, mixes in with the excitation, (INCREASING OR DIMINUTION), of one other.

NOTE: Phosphors, are examined for Decay-time, however such course of will also be referred to as PERSISTENCE. Phosphors, additionally come in numerous tints/colours. The mixture usually used for a Black & White Image Tubes is a “P4” Phosphor, which has a Medium Persistence, with a Blue/White tint. Coloration Tubes make use of “P 31” Phosphors, with Medium Persistence additionally. For Photographic makes use of, sure Particular Function, Black & White CRT’s, used a “P 1” Phosphor. That was as a result of the EXPERTS doing the filming, decided that the Greenish Tint hue, was higher than the Tint of the P Four Phosphor, (extra Blue), for filming, with a Movement Image Movie Digicam, [DIRECTLY from the face of the CRT], (pre-VCR/DVD time).

SWEEP CIRCUITS[edit]

“Sweep” circuits, offered by an exterior system surrounding the neck, [called a YOKE,] are accountable for “DEFLECTION”, {shifting the Electron Stream from Left to Proper and from the highest to the underside}, which presents the image. Within the American Model (pre H D T V ), 525 traces of video info, per second, is produced onto the display screen. (extra later ). In sure tubes, resembling Oscilloscope tubes, [Sweep-circuits,] DEFLECTION, is created by electrodes, hooked up to the Electron Gun itself (internally). That sort of Gun was often known as an “Electrostatic-Deflection Sort”.

INTERLACED SCANNING, 525 HORIZONTAL LINES OF INFORMATION[edit]

The American Tv system was based mostly on the SWEEP Circuits offering 525′ traces of Horizontal info, by way of a system referred to as “INTER-LACED” scanning”. This was managed by the Horizontal frequency of 16,750 Cycles (now Hertz), per second, which drew footage, based mostly on the next process: First, 262½ ODD traces of data a (“Area”) have been transmitted/acquired. Then, 262 half of EVEN traces, of data had the identical factor performed. Each, the Even and the Odd-numbered Fields, have been mixed, which was then referred to as a “Body”. The rationale between breaking a Body in (2) sections, was as a result of it took much less Bandwidth to ship over the airwaves. (With the appearance of Cable and “Streaming”, that rationale is now irrelevant). Every Body was then repeated twice, making a complete of ‘(60) Frames per second.

(60) frames a second corresponded with (60) Cycle Alternating Present, within the U.S., which at the moment, confirmed that such actions would forestall/scale back flickering results. This occurs so quickly, that mixed with the RETENTIVITY of the phosphor to carry and slowly scale back the sunshine generated by the high-velocity impression of the concentrated centered pinpoint electron beam, (referred to as DECAY TIME), fools the eyes into seeing an entire picture (“SNAPSHOT}”), thus producing a full accomplished shifting image, in “actual time”.

COMPUTER makes use of, favor “PROGRESSIVE SCANNING”, (transmitting of info of the Horizontal, in sequential kind. That scanning methodology scans (traces 1, 2, 3, 4, 5, 6, and so on.. so as), versus “Interlaced” scanning, and can also be projected at (60) Frames/second.

ELECTRON GUN[edit]

An Electron Gun, an early improve of the Straight gun, often known as a “BENT GUN” sort, has electro-magnetic focusing offered externally, by a “focus ring,” (encircling the glass neck and an related a part of the YOKE). The gun was designed in order to have the ability to separate Electrons from Ions. Each, are generated/liberated from the “Cathode COATING, (usually a mix of Calcium/Barium/Strontium or Cesium Oxides).

Think about the Electron Gun, analogous with the operation of an car.

1. Turning on T.V. Set Applies Voltage to Filament….. (Begin the Engine)

2. Apply 10 Volts of optimistic voltage to G 1………. (Put Automobile in FIRST gear & begin shifting)

3. Apply 300 Volts, optimistic to the 2nd Grid……… (Put Automobile in Second gear & speed up)

4. Apply mandatory voltage to realize Focus………..(Head for the right vacation spot)

5. Apply 14,000 Volts to the anode …………….. (Ground Throttle to realize prime Pace)

6. Electrons mild up Phosphor coating …………. (Skill to see the vacation spot)

MANEUVERING, SHAPING, THE ELECTRON STREAM (BEAM),“DRAWING “A PICTURE.[edit]

This info applies to the “bent-gun”, Electro-magnetically centered GUN. Image the round-shaped Cathode coating, releasing Electrons/Ions in a “cloud”. Then by utilized voltage differentials, between the Cathode (unfavourable cost) and G 1 (Constructive cost), the Electron/Ion cloud, turns into a “STREAM” of Electrons and are accelerated via the spherical gap (aperture) of G 1. Now comes the laborious half to check:

FOCUS ACHIEVEMENT[edit]

First, let’s do away with the Ions. A “Bent-gun” is so aligned, that NO Ions, NOR Electrons can impression the Phosphor Coating, due to the Electron-Gun’s, purposeful mis-alignment. An externally-mounted everlasting magnet, (referred to as an ION TRAP ), spring-loaded, matches across the exterior of the neck of the CRT. This magnet could also be moved Ahead or Backward, in addition to with the ability to be rotated by a Technician, in a 360 Diploma alignment, across the neck of the CRT.

With the T.V. turned on and producing all mandatory voltages, correct alignment, influences the stream of ELECTRONS to be “bent”, and efficiently undergo the G 2 aperture. The electrons, ARE, simply influenced by the restricted power, produced by the Ion-Entice’s magnetic subject. Nearly all of the IONS generated/launched by the Cathode Coating are NOT in a position to be bent by that weak magnetic subject, generated by the ION-Entice, as a result of they’regreater than 2,000 occasions, extra huge (heavier), or extra, than the Electrons. NOTE: Some Ions could also be EVEN 10,000 occasions extra huge than the Electrons, {ALL Electrons, unfavourable or optimistic (Positrons) have the SAME weight} Subsequently most Ions can’t entry the G 2 aperture (therefore, the title “ION-TRAP”). Having mentioned that, some IONS do entry the G 2 aperture, as a result of they emanate from the peripheral areas of the cathode coating. The few Ions which do evade seize by the Ion-Entice, proceed alongwith the Electrons. Later, of their journey Ions, are simply dealt with, by the extra highly effective magnetic subject(s), generated by the SWEEP-CIRCUITS AND the FOCUS COIL, whether or not inner or exterior.

Right here comes the difficult half: For the reason that precise Cathode coating deposition, has a a lot bigger diameter than the G1 aperture, Electrons emitted from the LEFT aspect of the Cathode, have to maneuver Up and In, the place finally they are going to “Criss-Cross” one another. The Electrons emitted from the LEFT aspect of the Cathode Coating will head towards the RIGHT aspect of the G2 aperture, whereas the Electrons emitted from the RIGHT aspect of the Cathode Coating, will head to the LEFT aspect of the G 2 aperture.

But once more, Electrons from the TOP-SIDE of the Cathode Coating, head to the BOTTOM-SIDE of G 2. Equally, Electrons from the BOTTOM-SIDE of the Cathode head towards the TOP-SIDE of the G2 aperture. In reality, Electrons from each level (in a 360 Diploma Circle ),every and ALL, head for THEIR reverse location, ever-narrowing a funnel-like form, till it reaches into a really FINE POINT ( DOT ). Nonetheless, it does NOT keep in that tremendous level. The CROSSING MOMENTUM CONTINUES, in order that the Electron Stream , begins to kind a new funnel association. At that transition level, when the very tremendous Dot begins its enlargement, is known as the “CROSS-OVER POINT”) and once more, begins to increase (funnel-like).

Because the Electrons carry on heading, towards the Phosphor Display(image), with the brand new momentum of increasing ever bigger, it enters the affect of the Focus-generated magnetic subject. Then, the Electron stream is then subjected/compelled to once more to start to aim one other “Cross-over”, which in the end outcomes, into the specified focus achievement, EXACTLY AT THE POINT OF IMPACT OF THE PHOSPHOR SCREEN.

The Focus Coil, to be used with a BENT-GUN, is mounted on the skin of the neck, adjoining to, and instantly to the rear of, half, of the “YOKE” meeting. The YOKE sees/controls, the ENTIRE COLLECTION OF the ELECTRONS (STREAM), and by numerous voltage indicators [creating varying strength magnetic fields], transfer the Electron Stream, Left or Proper, Up or Down, with the Stream being handled as One full half. ( See extra of “YOKE”, later herein).

At the moment, the funnel, absolutely opened, begins to slim once more, trying but once more, to realize a CROSSOVER someplace within the Bulb correct. Underneath the affect of the Focus Coil’s sturdy magnetic subject, the Electron Stream is heading to impression the Phosphor, whereas additionally attempting to realize a 2nd Crossover. If the Focus Coil voltage is just too LITTLE, the Electron Stream desires to CROSSOVER, far BEYOND the place the Phosphor coating is (technically, past the skin of the CRT). If too MUCH voltage is utilized to the Focus Coil, it creates a stronger Magnetic Area, and ACHIEVES CROSSOVER, far in FRONT of the Phosphor Display, (trying a third Cross-over, by the point it hits the phosphor Display, making a big, [silver-dollar size], dot stream of Electrons).

However, with the right Focus Voltage utilized, the Pinpoint Dot of the Electron Stream, lands EXACTLY on the Phosphor Particle DEPOSITION. Subsequently the Electron Stream is STOPPED from effecting the third Crossover, (PERFECT FOCUS). The smallest pinpoint Electron Stream is impacting precisely on the Phosphor particles. That’s precisely what’s NEEDED to impact most sharpness/readability, of the transmitted video materials.

An excessive amount of/too little Focus voltage, and the Electron Stream does NOT impression the Phosphor particle(s), precisely have been they’re purported to, subsequently exhibiting a “FUZZY” (OUT OF FOCUS ) image. However, by fine-tuning the Focus Voltage, we make the Electron Stream try to begin the “CROSSOVER”, immediately on the Phosphor coating, thereby permitting all of the Electrons to go to their broadcasted (sign) positions. This creates a SHARP, in-focus picture, (UNLESS) there are too many Gasoline Molecules current contained in the CRT. If the Electron Stream collides with too many GAS molecules, even when the Electron Stream is completely effected, the hanging of too many Gasoline molecules, WILL deflect the Electron Stream, in order to current a “Blurry” image, DESPITE the Focus Coil’s good functioning. The Pin-point stream, might be deflected up or down or left or proper of the place it’s purported to go. Because of the decay time concerned, you’ll then see an AVERAGE, of all these factors, therefore BLURRY. The extra Gasoline Molecules current, the extra collisions, the much more BLURRY the image.

HIGH DEFINITION TELEVISION (HDTV),[edit]

HDTV is a 1,080 horizontal traces SYSTEM, promoted by the Japanese, which is changing into highly regarded within the U.S. (circa 2003). Unknown by the Tv Trade, a 1,050-line System, Extremely Excessive Definition (UHD), was truly INVENTED, constructed and utilized by an American, Carmine A. Cifaldi, in his CRT-manufacturing firm, in Paterson, New Jersey,(in 1956). At a request from a Medical Facility in Philadelphia, he hand-crafted a special-purpose Electron Gun, (later,used as an integral a part of his Patented, Video Phone System, 12-30-1999 entitled, HIGH RESOLUTION OPTICAL COMMUNICATION SYSTEM). He constructed the modified Electron Gun, in mixture with, a particular, excessive decay-speed, Inexperienced-tinted Phosphor, [P11}, in the Special-purpose CRT. The P11 phosphor was superior to all other phosphors, for motion picture photography,(pre-VCR/DVD times).

ULTRA HIGH DEFINITION SYSTEM ( UHD )[edit]

Cifaldi’s ULTRA-HIGH DEFINITION (UHD) Electron Gun, was utilized in a CRT, which had a medium persistence Phosphor,(P11), [which has a greenish appearance]. It was meant for use, together with, an high-quality, super-fast, Movement Image Digicam, which used Excessive-speed movie, to {photograph} immediately, from the face of, the CRT. It recorded an precise, reside, laproscopic gall-bladder-removal operation. The movie was then used for future reference, and as a coaching instrument, for educating potential/future surgeons, (particularly for Third-world international locations). That Electron gun/system, (see EXPLANATION, HOW UHD WAS ACCOMPLISHED and EXPLANATION of gun design beneath), was NOT patented, as a result of the Tv Trade was NOT ready/prepared to make use of it, (primarily due to “Bandwidth” constrictions, the best way the sign was transmitted, via the air). Nonetheless, HDTV is routinely credited at this time, as being of Japanese origin. Regardless of the case, HDTV, when coupled with “Flat Panel” gadgets, utilizing digitalization of sign, produces footage, rivaling, (even exceeding), the best images of the day,(circa 2003).

HOW UHD WAS ACCOMPLISHED[edit]

Be aware: Cifaldi’s 1,050-line system, can produce a (4) occasions higher image (finer element), than the 525-line system, as dictated by the “Double-Quadruple Precept.” Additional, NO additional tools is required by the home-viewer, as a result of the required circuitry, might be already constructed into the T.V. Set. Cifaldi’s U H D’ system was achieved in 1956,’ by utilizing the “INVERSE” of the Double-quadruple Precept, within the following method:

EXPLANATION as to how the “Double-Quadruple Precept” was used, to achieve the specified outcome. Usually, the APERTURE, [hole] in Grid One (G 1),of the Electron gun, is roughly 40,000 of an inch in diameter. Utilizing an Electron Gun, containing a G1 aperture of (20,000) of an inch, [1/2 the diameter of the normal], has decreased the spherical, round form of the electron beam, (2) occasions). Subsequently, the electron beam impacts twice as many smaller particles of phosphor, in (2) methods. That’s (2) occasions from East to West, (info ON the traces themselves), and but (2) occasions, from North to South, (variety of traces, from 525 to 1,050 traces, therefore the “double-quadruple” appellation!

NOTE: (See Blu-ray Know-how), later herein, which makes use of principally the identical principal for a Blue/violet Laser beam, to write down/learn, as pioneered by Cifaldi in Electron Tube know-how in 1956. It might produce as a lot as (5) occasions extra info, than the heretofore-used red-laser beam).

In 1956, that’s precisely what Medical folks wished, together with, an easier-to- {photograph}, [in pre-color, black & white days], alongwith a Inexperienced-tinted (Phosphor) Display (P 11). They wished to {photograph} a laproscopic Gall-bladder elimination operation, immediately from the face of the CRT. [That was pre-VCR/DVD time].

Full implementation of the 1,050 line system, is the actual fact, that T.V., units in use within the 1970’s might NOT use these indicators, (as mandated by the FCC). Subsequently they have been NOT allowed to be Broadcast over the air-waves, due to restricted Broadcasting Bandwidth house. EXCEPT,

BEGINNING IN THE 1980’S, we NOW had wide-spread use of Digital signalization, being broadcast via Cable, [first, co-axial, then fiber-optically}. Satellites [for a fee,] additionally fed tv via “STREAMING”,

STREAMING breaks the image down,(1) line at a time, converts the knowledge into digital format, compresses the knowledge, after which transmits it, over the airwaves. The T.V set, receives the sign, (one line at a time), and decompresses it, transfers it to the phosphor display screen. It does this so quickly, that together with the persistence, (decay time),of the phosphor, it presents a full, full image, to the attention.

Such strategies,(digitizing indicators), undertaking lovely replica of video info. Due to these advances in know-how, the photographs being proven, [circa 2,000,] can, many occasions, usually look far prettier/extra real looking, than these in precise life. This consists of the flexibility to switch the photographs, by eradicating blemishes, lightening-up some function/darkening others, including extra/much less shade, even altering the tint or the colour, and so on.

NOTE: Efficient June 12, 2009, ONLY digital signalization might be used. Analog tv units, will nonetheless have the ability to obtain the sign, over the air, with the help of a converter field, (converts digital indicators into analog indicators). Digital indicators acquired over cable,to analog units will nonetheless be O.Okay., as a result of the cable firm, could have THAT capacity already included additionally, with its service.

STREAMING[edit]

The usage of “STREAMING”, encoding of “DIGITAL SIGNALS” (CODED AS A SERIES OF 0’S AND 1’S). In that format, they’re offering even finer, higher element of knowledge. Digitizing indicators, are actually permitting PREVIOUSLY un-allowed transmission of indicators to be Broadcast,(outfitted with Conversion bins), on to Tv units by the Satellite tv for pc suppliers. Over-the-air, Station Broadcasting, as practiced within the early days of Tv, within the 1950’s, and nonetheless dome at this time, (by RADIO), isn’t used (circa 1990). Tv indicators acquired from Satellites in Geo-synchronous orbit, with related tools, is one more necessary, viable use, of transmission.

The unfavourable aspect’, for that sort of transmission is, that inclement climate circumstances might interrupt sign receipt at any time. The receiving DISH should NOT grow to be mis-aligned, as a result of that may results of weakening and even the overall lack of sign. On the plus aspect, the indicators could also be acquired, the place there are NO Cable traces. With sure tools, resembling an INVERTER, [changes Direct Current into A.C.], (Alternating Present)], {as in your house}], coupled with using batteries, [as in your car]. Then SOME indicators might EVEN be acquired/used, the place NO Electrical energy, is on the market from conventional sources, (the place there’s NO Cable NOR Electrical line availability). One wire, of a daily electrical extension wire, serving as an Antenna will suffice, to carry these T.V. Station indicators in, to the TV Set, which can obtain air-borne indicators [T,V.]. That is pursuant to an order, issued a few years in the past and STILL in drive, [circa 2007,] as mandated by the F T C}. NOTE: Nonetheless, beginning in June 12, 2009, these indicators will NO longer be broadcast over the air.’

HOW THE TELEVISION PICTURE TUBE (CRT) IS MANUFACTURED:[edit]

STEP ONE

Making ready the Glass-Bulb (Tube) for Phosphor Acceptance:

  1. 1A A transparent, clear Tv Bulb, (as manufactured by Corning Glass), whose neck is positioned over a standpipe, is linked to a fluid (water-like) pumping station which re-circulates a gentle acid (Bi-fluoride or Caustic Soda ), for 30 seconds after which rinsed with recent, clear Faucet-water (10 to 15 seconds).
  1. 1B It’s then positioned and CLAMPED on an hydraulically-operated “Tilt Desk”, which is able to have the ability to rotate easily, in a 240 diploma arc, in order to not trigger ripples when pouring A SLURRY, of PHOSPHOR, and DISTILLED/DE-IONIZED water, which might be launched into the Tubes, within the subsequent step of manufacture. This equipment, (Tilt Desk), can rotate FROM the Horizontal upright Tube (neck up) place, TO the Horizontal reverse or neck-down place

PURE WATER, REQUIRED FOR DEPOSITION OF PHOSPHOR, IN PICTURE TUBES[edit]

There are solely 2 kinds of water acceptable, for use, within the manufacturing course of, (deposition of Phosphor on the within face of the Tube). The very best, after all, is DISTILLED water. The issue with that’s, the price of the quantity of distilled water, for use, is prohibitive. All the water might be instantly discarded, after the Phosphor is dispersed. Having mentioned that, there are occasions within the yr, when distilled water is completely required, until extraordinary steps are taken. De-ionized water issues, EXPLANATION LATER herein.

The opposite sort is “DE-IONIZED” water. The preliminary drawback with using DE-IONIZED water, is that it requires a considerable quantity of capital, to buy a UNIT. You want a UNIT, able to producing water, on the dimension commensurate with the quantity of Tubes, anticipated to be manufactured, on a day by day function. See UNIT composition, subsequent.

One unit, consists of the next components:

A. De-ionizer Machine.

B. At the least a One Thousand Gallon Stainless-Metal, ( S. S. ) Storage Tank,

C. At the least TWO, 250-400 Gallon, ( S. S.) “BATCH” Tanks, (relying on manufacturing necessities).

D. An appropriate-sized, Rock/Sand/Activated-charcoal Filter.

E. An Excessive-Quantity Stainless Metal Water Filter.

F. An Excessive-Quantity Stainless-Metal Water Pump.

G. All of the accent Stainless-Metal and/or plastic piping, valves, fittings and hoses, relative thereto.

The 1,000 Gallon (S.S.) Tank, is the recipient, of the water being frequently being De-ionized, and despatched to it, to be used, or for Storage, (each time there is no such thing as a screening happening).

The 2 Batch Tanks, every obtain a full tank of water, on command, for use within the following method: Since ALL dissolved metals/ions, have been eliminated, the Water has a PH of seven.0 (impartial). Above 7.Zero the water is taken into account ALKALINE. Beneath 7.0, the water is taken into account ACIDIC. In preparation to obtain the Phosphor, the water is conditioned within the following method: Add a gallon of water, containing an applicable quantity of Barium Acetate,
(which assists the Potassium Silicate, [“KASIL],”which might be added to the Phosphor slurry afterward). This assists the Phosphor, to stick to the Glass face, performed within the subsequent step. Water, drawn from the primary tank, might be used for the screening. The Barium is then allowed to be dispersed all through the Batch Tank, by itself, for no less than half an hour.

If mandatory, the disbursement could also be accelerated, within the following method. That is performed by means of a Stainless Metal Pump, drawing water from, and emptying again into, (Re-circulating), the S.S. Tank, for no less than 5 minutes. Whereas the water within the first Batch Tank, is getting used, the opposite Batch Tank is made prepared the identical method, so IT, is prepared for fast use. When the primary Batch Tank has been drained of all it is water, then the 2nd is available and used. Then the First Batch Tank, is once more crammed, from the 1,000 Gallon Storage Tank, and made READY, but, for one more cycle.

There are 2 kinds of De-ionizers: The primary, is a unit which has Four Columns, which include Resins to take away Dissolved Metals, each of the ANION and CATION selection, from the water being processed. The Columns are organized, in sequential use; Anion-extraction Resins within the 1st and third columns and Cation-extraction Resins within the 2nd an 4th columns. There’s a electrical resistance meter, which continuously measures the resistance of the water passing via. For water containing little or no dissolved metals, the meter will present 2 Million Ohms, (or HIGHER), resistance. Because the Resins ADSORB the dissolved metals, the Resistance Meter, retains dropping decrease and decrease.

When the Meter exhibits round 50,000 Ohms, (exhibiting higher and higher conductivity, which is NO good for our functions, as a result of because it exhibits increasingly metals being extracted from the water), The adsorbing powers are badly diminished. At that time, it’s time to do away with the metals, that the Resins adsorbed, from the water passing via. That is achieved, by a course of referred to as “REGENERATION”. Via using Muriatic Acid (in a single set of columns, and Caustic Soda, within the different set of columns, the metals, which have been “ADSORBED” (on the floor of the Resins), are stripped off, and flushed into the Sewer line. The DE-i is then able to take away the dissolved metals, for one more Cycle, (relying on the hardness of the water provide), for, from 100 to 150 Thousand gallons of water. The regeneration course of is all the time the identical, in utilizing each the Muriatic Acid and the Caustic Soda, and is fairly straight ahead within the 4-Column DEi. It’s trickier to perform within the MONO-BED DE-i. Subsequently, we’ll solely talk about the entire Regeneration course of, of the second sort of DE-i, the MONO-BED.

The Second sort of De-i unit, is known as a MONO-BED. It is a tall, (7 or extra, toes excessive), about 18″ in diameter, single column unit, (usually a Excessive-Capability feed-through, (200 gallons per hour, or extra). It accommodates each Anion and Cation-extracting Resins, [called BEDS,] combined collectively. There’s a “porthole” window, within the aspect of the mono-bed, which allows you to see the Resins within the unit. When it’s working correctly, in eradicating dissolved metals, you may see a homogeneous combine of light-brown Resins and dark-brown Resins. These resins not solely look completely different, in addition they are of very completely different weights. This weight distinction is for an important cause. To regenerate the Resins, (when the Conductivity meter reads about 50,000 Ohms ), the Resins should first be separated, and stratified. The
mild shade [tan], resins, [also lighter in weight], kind the higher layer, above the decrease layer, and likewise heavier, dark-colored [Brown] Resins.

CAUTION: Do NOT enable the conductivity to get too low, as meaning the Resins are saturated, and the Resins lose the adsorbing traits. Water containing metals, might be within the processing the place you then run the danger of poisoning the Phosphor Coating, [which will not be immediately seen]. You WILL see it, after an Oven-Baking course of, however even then, it might NOT be seen with the bare eye. An Extremely-violet mild could be wanted, to make the Phosphor fluoresce, as it could be seen, when the Tube is beneath Vacuum and being bombarded by the Electron Stream. If poison spots are detected at the moment, then all that point, labor and energy are LOST, and you need to re-wash the within of the Bulb, and begin once more.

Regular water-flow operation, begins from the highest of the Column, down via the Resins after which into the 1,000 Gallon S.S. Storage Tank. The Regeneration of the Resins, begins out with the separation of the Two Resins, performed within the following method: Metropolis water, at a managed, diminished, water move, is launched into the DE-i, from the underside of the unit, in direction of the highest, (reverse regular operating-procedure). The water will go up although the Resin Mattress and out to the Sewer system, by way of a “Sight-drain”. You’ll be able to see and “really feel” the water popping out of the De-i, because it enters the sight drain [water pouring out of a pipe, into a funnel like arrangement drain. Looking into the Porthole, and adjusting the water flow, you will see the lighter [Tan] Resins, begin to separate from the combined Mattress, and “HOVER” (stratify), over the Brown [Resins], a part of the mattress.

Whenever you begin to see that taking place, you need to test the water emanating the DE-i, because it enters the sight drain. By placing your hand within the water-flow, and rubbing your thumb and forefinger collectively, it is possible for you to to establish, whether or not any resins, (usually the lighter ones), are additionally being expelled from the unit. For the reason that lightly-colored, [Tan] resins, are additionally the lightest, they aren’t readily discerned, as being dis-charged from the outgoing water. The thumb-forefinger monitoring will “see”, (really feel), the resins emanating, [if any].

With cautious monitoring,, of water strain/move, you may separate the 2 kinds of Resins and never discharge the Resins, out with the waste water. CAUTION: In case you are not cautious, you could lose the entire Mattress, if the strain/water-flow is just too excessive. At the moment, the Unit could have NO functionable capacity. The result’s that, the unit have to be put out of service, opened up and a brand new mixture of Resins have to be added. THIS IS COSTLY IN TERMS OF MONEY AND TIME. However, you do have some leeway, due to the Peak of the Column, it takes extra power, for the Resins, to combat the results of gravity, (which assist hold the Resins, from being water-flowed out). Generally you could lose ONLY the lighter Resins. Even then, you’ll nonetheless have to switch these, should you lose them. There isn’t any simple option to substitute the misplaced Resins. You should pull aside, (nuts, bolts, and gaskets), the Mono-bed Column.

Assuming you efficiently separated the Mattress, then via a sequence of valves and bypasses, Caustic Soda is launched to strip the dissolved metals adsorbed of one of many separated Resin beds, with out impinging on the opposite. Then Muriatic Acid, is launched to strip the dissolved metals from the opposite mattress (once more, with out impinging on the opposite Mattress). That is achieved by a intelligent association of piping and valves, inherent with the development of the MONO-BED. When that’s performed, Metropolis water, is launched, sequentially, from the highest, to the underside and out the Common Sewer Drain. This flushes all acids and dissolved metals, into the Sewer system. Checking the Conductivity Meter, because the recent water is flushing, will reveal that conductivity is heading again as much as 1 Million Ohms. The water could also be used, for Screening functions, at any time when the meter rises as much as 250,000 Ohms, even whereas it continues on the best way up [to Millions of Ohms, resistance].

Now, to place the unit again into operation, first, you need to RE-MIX the Mattress. That is achieved by water, directing the water-flow, rising from the underside upward. Will probably be assisted by compressed air, on command by the operator. This may trigger an agitated disturbance, via the bubbling-up of ALL resins, ( however by a valve association, in a closed loop, so you may NOT lose any resins). It’s possible you’ll proceed this “merry-go-round” association, till you attain the homogeneous Gentle/darkish Mattress, as soon as once more. The De-i is then prepared for a brand new cycle.

Prior, to the water coming into both De-i, it should first be particle-free of all solids and most organisms. With both sort of “DE-I”, water from the native Water Firm begins its journey, via the Rock/Sand/Activated-Charcoal filter, the place it filters out all solids, current within the water. (There are greater than you assume, or want to know). NOTE: Regular water-flow is from the highest of the unit to the underside. On the prime you’ve gotten a layer of rocks, (in regards to the dimension of marbles). Beneath that, you’ll have one other layer of stones, (in regards to the dimension of peas). Then, comes a layer of Activated charcoal. Lastly there comes a considerable quantity of sand. Beneath the sand, you’ve gotten a Display filter (tremendous sufficient to NOT let the Sand escape, however porous sufficient to permit, an un-restrictive water move)

The layer of Rocks, Stones and Sand, lure the most important particles first, then smaller particles, then even smaller particles but. Activated-Charcoal, additionally neutralizes many various organisms, contained within the water, which might be eliminated, later, by the Stainless Metal Filter. NOTE: Regular water move is from the highest of the Filter down via the combination, then to the following separate, (further), S. S. Filter. You should flush out the solids, periodically, that the Rock/Sand/and so on. Filter, has trapped. That is generally referred to as “BACK-WASHING”. You do that, by reversing the water move, (AGAIN THROUGH A SERIES OF VALVES AND PIPING), with the water coming from the underside of the unit, via the highest of the unit, after which, out to the Sewer drain.

On to the S.S. filter. This filter has the flexibility to lure all particles AND organisms, all the way down to 1 Micron in dimension. NOTE: In the summertime time, through the Sizzling climate, algae and different micro-organisms proliferate. By use of a cloth referred to as “filter-aid”, the S.S, filter might the lure particles as small as One Tenth of a Micron.

Lastly, from the S.S. Filter, the water is directed into the 1,000 Gallon S.S. Storage Tank. From there it’s launched into the Batch Tank, (as wanted). The Two Batch Tanks, are serviced by 1 Stainless Metal Pump, via a sequence of piping and valving, which permits water to be drawn from both tank, on command.

EXPLANATION: As acknowledged earlier, De-ionized Water issues, FORCE EXTRAORDINARY METHODS TO BE USED.

Earlier herein, it was acknowledged that, throughout sure occasions of the yr,(prolonged warm-climate intervals), the Distilled water HAD for use. That’s due to an abnormally excessive Micro organism depend, coupled with inadequate Chlorine remedy by the Water Firm, supplying Metropolis water. It has overwhelmed the filtering capability, of the DE-i UNIT. Myriads of the “BUGS,” are killed within the DE-i unit, and their stays, degenerate right into a non-soluble oil. When the Water containing them, is launched into the Tube for screening, the useless organism’s stays, kind protecting bubbles round themselves. After the Tube is screened and the Phosphor is correctly launched, it’s time for “DECANTING”, (POURING THE WATER OUT OF THE TUBE). The bubbles, shaped on the water line, drag traces via the Phosphor, to an un-acceptable degree, within the completed product, thereby ensuing within the necessity of washing out the unacceptable display screen, to strive once more.

There are 2 potential cures for such an issue. The first, is to make use of a WATER-Softener, added with an “eye-dropper”, immediately into the bulb, after the slurry is launched. This may dissolve bubbles with air in them. Generally, it’ll additionally dissolve the BUGS’s protecting bubbles, however generally it’ll NOT. These bubbles, {not like bubbles usually present in water}, have little or no air in them, as a result of they’re tightly wrapped round, the useless organism.

The 2nd answer ALWAYS works, nevertheless it entails an additional step, “PUMPING”,utilizing vacuum, EQUIPMENT and additional labor. Nonetheless, assuming you’ve gotten Ten Tubes on the Screening desk, they might ALL be linked, concurrently, by way of a 2″ diameter metallic manifold to the Vacuum pump. From the manifold, this Excessive-Vacuum rubber hosing, [3″ in diameter], is jammed into the neck(s) of each tube, connecting the Tube(s), to the Vacuum Pump. When the mechanical vacuum pump is turned on, in about Three minutes, sufficient air has been evacuated from the system, that the air strain diminishes [reluctantly], very quickly. The Bubbles, (even with minute particles of air), might be seen to get bigger and bigger, (as they resist being ruptured), however, then they ALL burst, leaving the water, bubble-free. At that time, when the settling time of the Phosphor is accomplished, the connections between the Vacuum Pump and the Tubes, are dis-connected. Then, the tubes could also be safely decanted.

ACTUAL SCREENING PROCESS[edit]

INTRODUCE WATER IN THE BULB TO A THICKNESS OF Three to Four INCHES.

  1. 1 One (1) to Three (3) gallons, (relying on dimension), of pure De-ionized or Distilled water, (containing the 1/10 th % Barium Acetate reagent), is launched into the bulb. Subsequent, to begin the precise screening course of, a water/phosphor slurry, is launched, from a shower-like dishing out piece of hand-held tools, referred to as a “THISTLE-TUBE” (described later herein).

INTRODUCE PHOSPHOR SLURRY INTO BULB, USING THE THISTLE TUBE[edit]

The quantity of phosphor for every Tube proportioned therein, ranges from approx., 5 (5) to Fifteen (15) Grams of Phosphor, (28 1/Three Grams to the Ounce), relative to the dimensions of the Bulb. A PHOSPHOR SLURRY composed of Water, Phosphor AND Potassium Chloride, might dispense wherever between Three Hundred (300) and Seven (7) Hundred Cubic Centimeters (C C ‘s), [relative to tube size]. The Potassium Chloride, {alongwith the Barium Acetate, beforehand put into the Batch Tank}, are mixed. This may support within the distribution of the phosphor-settling process. The Potassium Silicate additionally assists in uniform distribution of the Phosphor, by stopping “CLUMPING” of Phosphor particles, in addition to “Pin-holing,” [as the name implies: small open areas, of NO phosphor coating].

Be aware: An Electron Beam, can NOT painting video info, the place there’s NO phosphor. Extra importantly, the Potassium Silicate acts like a “glue”, to assist the Phosphor particles adhere to the glass face, when the water is being poured out of the bulb, and when it’s dried. With out the addition of the Two chemical substances, (Barium Acetate & Potassium Silicate), or perhaps a poor ratio of 1 to the opposite, 90 % of the phosphor would exit the Bulb, when the water/slurry is pouring out, after the allotted SETTLING time.

A Thistle-Tube, consists of a Three ( 3 ) inch I. D., funnel-like prime, about 4 ( 4 ) inches excessive, which additionally has a Fifteen (15 ) inch lengthy, hole, plastic tube, that has a, half of inch INNER diameter. On the backside finish of the tube is a THIMBLE-like Cap, which has Fifteen (15 )or Twenty ( 20 ) holes, uniformly distributed in all sides, with 4 ( 4 ) angled outward holes, ( North; East; South; & West), within the rounded convex backside of the Thimble-Cap.

PHOSPHOR DEPOSITS ON INNER FACE OF TUBE:[edit]

The Phosphor slurry, is poured into the highest of the funnel, drops down the lengthy 15″ Plastic pipe and exits the Thimble-Cap finish, which thereby disperses the Slurry, very like a bathe head. Whereas the Slurry is pouring out, the whole Thistle-tube is rotated, frequently, 360 levels, till emptied, in order that the phosphor is uniformly dispersed into the water. The outer stream of slurry, ought to be directed at a degree, simply earlier than the place the highest of the water degree, meets the wall of the Bulb. The phosphor is then allowed, undisturbed, to “SETTLE”, deposit uniformly, on the inner-side of the glass face.

To help a uniform deposition of the Phosphor on the Glass, a stream of scorching water, is directed ( by a hose), on the skin of the Bulb, (the place the Waterline is). The distinction in Temperature, between the water within the bulb AND the skin periphery of the Bulb, units up CONVECTION CURRENTS, which help the Phosphor to be deposited evenly on the face, (versus a heavy focus within the middle, and far lighter edges). When Settling is accomplished, it leaves an nearly completely clear answer, with the Phosphor laying down on the inside face of the Tube. The Settling time is Ten (10 ) minutes.

Then the desk is slowly, evenly tilted, (Tilt-Desk Hydraulically “DECANTED”), in order that the water pours out utterly, (taking care to not encourage a GURGLE, { air trying to enter into the Bulb, whereas water is trying to go away the Bulb }. Should you enable water to pour out and depart sufficient room for air to return in to switch the water pouring out, the newly deposited Phosphor will NOT be unduly disturbed. To be completely sure that air-intake and water outflow, can each be accommodated, do the next: Get a half of” I.D. plastic or polyethylene tubing about 14″ in size, heat in scorching water, till it turns into pliable, Bend it in a half of “U’ form, and pour or douse chilly water via it, and it’ll retain THAT form. When the Slurry has completed being launched, insert the bent plastic/polyethylene tubing within the neck of the Bulb, such that each ends will level within the “UP” course when the desk has been decanted 90 Levels. Irrespective of how briskly the water pours out, there’s completely NO likelihood, for any screen-disturbing gurgles, to happen.

Complete elapsed Phosphor-coating time, together with “settling” time , is about 13 (13 ) minutes, for a Desk-Load of Eight (8) to Ten (10 ) Bulbs.

FORCED-AIR DRYING OF NEWLY-DEPOSITED PHOSPHOR COATING ( SCREEN )[edit]

  1. 2 When ALL water has left the Bulb, leaving it utterly empty, un-clamp the Tube from the desk (when the neck is pointed to the bottom and do NOT enable any residual water to move again onto the display screen. Place the tube (neck first), over a skinny Standpipe which is linked to a gentle, slow-speed, warm-air dryer (very like a hair dryer), which is able to dry the moist display screen (together with the inside of the bulb). NOTE: The highest of that pipe ought to be closed-off, in order to NOT blow air, immediately on the freshly-deposited phosphor. However the Pipe, WILL have holes emanating from throughout the perimeters of the pipe, close to the highest, [NOT in the neck]. The Display-dry time takes about Ten (10 ) Minutes.

PREPARING SCREEN FOR LACQUER DEPOSITION FOR THE ALUMINIZING PROCESS:[edit]

  1. Three Take away the Bulb from the Dryer, and gently, lay the Tube on its aspect. Whereas the bulb, is on its aspect, with the opening within the neck, (going through you), re-wet the phosphor display screen, utilizing a 3/Eight th or half of” curved, inner-diameter, polyethylene tube (approx half of“ lengthy), with an answer containing distilled or de-ionized water. The answer accommodates a 3% Potassium Chloride addition, [the Phosphor-binding/anti clumping chemical]. When re-wetting, care ought to be taken, NOT to pour the answer immediately on the Phosphor Display. Let it’s began, to be poured, right into a aspect of the tube, after which, when there’s about 250 CC’s poured in, carry the tube and swirl the water all around the Phosphor face, re-wetting the whole Display. Do NOT unduly disturb the phosphor coating.

NOTE: Do NOT use faucet water, as it will completely contaminate (“poison”) the display screen. This contamination is not going to be readily discernible within the preliminary levels of manufacture, however after baking (a later step), you will note spherical coloured spots, [even though this is a black and white screen (tube)], showing all around the display screen. These coloured spots, would ALWAYS be seen and subsequently unacceptable to the viewer). Subsequent: Permit the Tube to empty, momentarily, after which place the tube on a bit of apparatus, which can rotate the Tube. The centrifugal drive generated will even out any extra water remaining on the face. Place the Tube on a ‘Display-dryer”, and dry the display screen. After baking, an Extremely Violet shining on the tube face, (in broad daylight, would make the display screen mild up) {fluoresce}, as if it have been being impacted by the Electron Beam whereas beneath vacuum. Inexperienced spots,(like measles), would point out COPPER contamination, Brass spots present as Blue, whereas Purple-colored spot will point out IRON contamination. If the bulb is allowed to proceed to completion, finally, when video info is displayed, Inexperienced, Purple and Blue spots, (in stationary positions), in ALL White show scenes, would make the image(s) un-acceptable. This could be very like Station identification burns/cranium and crossbones burns that have been the bane of the previous Straight-Gun, non aluminized, Black and White Dumont Tv Tubes, (circa 1945). Besides, this time, the Coloration spots will present up in Black And White, Image Tubes.

APPLICATION OF LACQUER COATING:[edit]

Once more, re-wet the simply dried display screen, (as we simply did), however this time, introduce WATER, with a Twenty % (30 %) combine, of a tremendous polymer lacquer, and a (10 %) Potassium Chloride, gently onto the identical Display. Permit to drip for One ( 1 ) minute. Place the newly-lacquered Bulb on a spinning machine {at Thirty (30 ) RPM}. The centrifugal drive, as earlier than, generated, causes the lacquer to unfold evenly, over the whole display screen space. Elapsed time about Three (3) minutes.

WASH AWAY LACQUER IN ALL AREAS OF THE INSIDE OF THE BULB, EXCEPT THE SCREEN:[edit]

  1. Four Since we do Not need residual lacquer to be positioned over the whole inside the Bulb, ( we actually do NOT need it on the Display both), nevertheless it serves a particularly necessary perform, {which might be revealed later}, and MUST BE DONE [temporarily]. Place the neck of CRT round a flexibly-curved, [1/2 U-shaped], plastic pipe on one other spinning, [6 RPM] machine, which dispenses water in a tremendous non-splashing stream of water. This may wash out, trim, away) all lacquer and water, from the inside of the bulb (whereas spinning), EXCEPT the Phosphor Display. Begin the washing on the inside of the bulb, (whereas revolving), starting at about Three (3) inches from the highest inside face, of the Bulb, from the place the Phosphor Display lies. Elapsed time about Three (3) minutes.

NOTE: This lacquer might be baked out in a later operation, however for now, will shield the Phosphor Display from the Aluminizing utility to be carried out subsequent. If the lacquer just isn’t eliminated correctly, then in that case, when the CRT is functioning in a traditional T.V. set, it will likely be diminished to a Gasoline, the place its molecules will intervene with Electron Beam and trigger a “Fuzzy” of “Blurry image, when in use. Extra importantly, the Gasoline molecules will assault the Cathode Coating, by depositing a BLACK, non-Electron-releasing substance, which might intervene with, and dramatically shorten the lifetime of the Cathode Coating, therefore the Tube.

NOTE, some extra: Sure erudite Engineers, developed a tool, which might apparently re-activate the Electron-creating Cathode Coating, by eradicating the Black layer of substance, from its floor. The coating beneath was nonetheless in a position to produce Electrons, however the black floor coating prevented their launch. They referred to as this course of “re-activation” or “rejuvenation” of the CRT. It REALLY WORKED and will restore, IMMEDIATELY, the presentation of the image from a low mild output image to a phenomenal excessive mild (regular) image. In reality some tubes have been even higher than new, as a result of there was all the time a slight layer of black deposition, deposited thereon, from different sources. The terrific optimistic end-result was due to the best way the Reactivation system labored.

Right here IS THE SECRET:’ A Excessive Voltage, in all probability as excessive as 1,000 volts, was positioned for (1) fraction of a second solely, between the cathode and G1 (when usually they’re NOT interconnected). In reality they needed to be separate, for the T.V. Tube/Set to perform correctly. That Excessive-Voltage created an ARC, which blasted/vaporized, the undesirable coating, away. As a result of that course of additionally created a large amount of warmth, the resultant was noticed instantly. Keep in mind, Electrons are generated from the Cathode Coating, by the warmth,(800 Levels C), equipped by the filament.

RE-DRY THE WET LACQUERED SCREEN:

  1. 5 Put the principally lacquer-free Bulb again on the dryer and dry every part, as soon as once more. Elapsed time about Ten (10) minutes.

COAT THE INSIDE WITH AN HIGHLY-ELECTRIC, CONDUCTIVE COATING:[edit]

  1. 6 Place the screened tube on a bit of apparatus, which can be rotated, that has a tube holder, and is ready to spin the Bulb as gradual, or as quick, because the operator needs. Utilizing a tiny brush (about Two (2) inches in size, and about 3/8ths” extensive, containing bristles about half of “ lengthy. Apply, [paint], a black conductive coating (AQUADAG/ Dixonac), to the whole inside the bulb. Make it possible for the coating touches, and utterly contacts/surrounds, the Anode button, (the metallic anode button fused into the bulb). That metallic button, is widespread to the INSIDE of the tube, in addition to to the OUTSIDE. In the end, it’ll grow to be the path for Excessive Voltage to return into the Electron Gun).

It could be “PAINTED”, with hand-brush-applying strokes, (all through the whole bulb), or by spinning the bulb, whereas holding the comb nonetheless. The spinning-machine motion, causes the paint to be unfold, uniformly, all through the entire inside. Spinning and portray spherical Tubes is not any drawback. Rectangular tubes are a bit extra difficult to so do. NOTE: Take care, that the coating does NOT splash/impression,(from the comb), onto the Phosphor Display. Elapsed time to realize portray about, Three (3) minutes. DRY THE INSIDE AGAIN

  1. 7 Place the Bulb neck, round one other low-speed-air Display Dryer, to dry the conductive coating portray. Time to dry Dixonac coating about Seven (7) minutes.

PLACE TUBE UNDER VACUUM TO APPLY ALUMINUM OVER THE WHOLE INSIDE OF THE BULB[edit]

  1. 8 ALUMINIZING PROCESS: Take away the tube from the dryer. Place the neck, round a Electrode, protruding upward in an Aluminizing Machine, as much as the “Yoke” space, (the place the neck, joins the bulb correct). That confirms that the Tube is tightly enclosed within the machine, so the Tube could also be put beneath Vacuum. The Electrode, accommodates a (Tungsten), heavy-duty-use-cycle Coil. Place a pre-measured piece (slug) of aluminum, (about 3/Eight ths lengthy by a 1/Four of an inch thick) within the Coil, (very like the filament in a lightweight bulb, which is in a horizontal alignment. Beginning the Aluminizing Machine up, a Vacuum Pump, (a part of the machine/operation), attracts a vacuum on the enclosed CRT.

VAPORIZE ALUMINUM SLUG, WHICH DEPOSITS THE ALUMINUM, THROUGHOUT THE ENTIRE INTERIOR.EXCEPT, SEE BELOW

When the Vacuum is accomplished, on command, the Tungsten coil, (at 12 to 14 Volts), dishing out between 45 to 60 Amps of electrical energy, causes the aluminum slug (pellet), to slowly soften right into a liquid ball. It then lastly disburses, (like a cloud of steam), till the entire slug of Aluminum has been evaporated from the Coil, (additionally referred to as “SPUTTERING”). The resultant cloud of Aluminum particles would then condense/solidify, thereby hooked up, uniformly, (SEE EXCEPT BELOW), over the whole inside the Bulb, (together with the Phosphor Display AND the Aquadag conductive coating). Elapsed time about Twenty (20) Minutes. Some techniques could possibly draw a Vacuum on as many as 6 tubes, at a time, in any given occasion. However, they’re “SPUTTERED”, sequentially, thereby effectuating the method, in as little as 30 minutes, [5 minutes per tube].

EXCEPT: In cases of poor vacuum-achievement, (at any time, for any cause), then in that case(s), the aluminization leads to a heavy deposition, [in the form of a BULLS-EYE], within the middle of the display screen, with a lot much less of an ALUMINUM deposition, across the periphery. The poor vacuum attained, could also be due to improper seating/sealing of the bulb into the unit, or as a result of the method is timer-controlled, {prepared or not, right here I come}. This may increasingly happen as completely different tube sizes are processed, and the timer just isn’t adjusted accordingly. Or maybe, NOT beneath direct command of an operator, OR even as a result of, it WAS beneath operator command, and he made an error. Generally, [depending on the system used], when the sputtering is NOT managed by a gas-pressure system, [or for many other reasons], when the vacuum is NOT low sufficient, the resultant might be poor.

Sadly, this outcome will NOT be seen, till the CRT is absolutely processed and at one of many closing levels of manufacturing-“TESTING”. Few check regimes, plan for detecting this drawback, and most CRT producers by no means detected it, till it was returned from the buyer. SEE “BLANK-OFF”, in TESTING. SEE HYPOTHESIS subsequent. In reality, this creator is the one particular person/producer recognized, [including ALL the well-known major manufacturers, such as RCA, Sylvania, GE], ever, even testing, for it.

The HYPOTHESIS for this anomaly is as follows: When the filament within the unit is activated, the great quantity of warmth generated, forces all gasses, [developed or residual], to compress these gasses, in an equal diameter, in ALL DIRECTIONS, to the outer extremities of the within of the evacuated tube, away from the great warmth. This situation, presents little or no opposition, for the vaporizing Aluminum which is to be deposited, within the middle of the bulb. Whereas, it additionally presents extra opposition, to the vaporizing aluminum particles, which have been purported to be deposited, within the extremities. Subsequently, there’s a higher quantity of Aluminum vaporized/positioned, within the middle space, than that, of the extremities.

The REASON FOR THEBULLSEYE ! The search for BLANK-OFF! See BLANK-OFF beneath. The Electron Stream, wants the ability of no less than 5,000-10,000 Volts [dependent on tube size], positioned on the Anode, for the Electron/Ion stream, to have the ability to penetrate, {and illuminate), the Phosphor, residing in entrance of the deposited, solidified aluminum. Whereas the Electron Stream has the velocity/energy, to penetrate the thinner parts of the Aluminum deposition, it’s NOT in a position to penetrate the thicker center-parts of the aluminum, (presenting a Black BULLS-EYE,picture). Should you proceed to cut back the excessive voltage, the BULLSEYE attains an ever-widening diameter. Decreasing the excessive voltage in direction of 5,000 Volts, would reveal the BULLSEYE DARK AREA, rising such, that it now occupies extra space, than the lighted portion, (outer edges), of the CRT.

BLANK-OFF happens, when the Excessive Voltage is frequently diminished, (all the way down to roughly 5,000 Volts), with NO look of the darkish BULLS-EYE, and the Display goes to black. Yow will discover that, that brightness of the RASTER, [a fully-illuminated WHITE screen, displayed with NO video information], is superb. This BLANK-OFF of the raster, whereas by no means approaching precise exterior use, is necessary, as a result of it signifies that the Aluminum was deposited, in a superb, low-gas atmosphere. NOTE: Every time such an ideal Aluminized Tube Raster is displayed, good focus is well demonstrated, by the looks of sharp, horizontal scan traces, going into, or out of focus, as the main focus voltage is elevated/decreased.

WHY DOES THE BULLS-EYE OCCUR IN THE PERSON’S HOME, BUT NOT IN THE COMMON TESTING PROCEDURE(s) ? The ANSWER to that query is: Many various voltages, are generated from STEP-UP/STEP DOWN TRANSFORMERS, inherent within the T.V. Chassis’s. The Excessive Voltage circuit, (FLY-BACK TRANSFORMER), mainly accountable for accelerating the Electron Stream, is extraordinarily delicate, to the various voltage inputs from the native Energy Firm(ies). Typically, the Energy Firm(s), will ship NO decrease than 108 Volts A.C., however NO greater than 125 volts. Extended publicity to both extremity, will trigger issues, in numerous chassis voltages, however particularly within the Excessive-Voltage technology. Additional, many occasions, because the set ages, voltages grow to be vital, as a result of in these days, the additionally have been managed by small tubes, in related circuits. These tubes began dropping energy, with age, additionally.

Within the closing evaluation, the BULLSEYE drawback happens:

1), when the CRT has been poorly sputtered,

2), coupled with the decrease minimal A.C. Voltage, and

3), at sure vital mild/darkish scenes being acquired/portrayed by the video info despatched to it. This can be a fleeting, non permanent incidence, or a prolonged, [of several minute duration], occasion. See EXAMPLE subsequent.

EXAMPLE A 16″/17″ Tv set, could have a requirement for an Anode Voltage of some 14,000 Volts. At that voltage, the BULLSEYE will NEVER seem. However, when the Enter A.C. voltage approaches 108 Volts, and the video does NOT require sure lightening/darkening of the image, it might be of such minimal period, that the persistence of the phosphor, negates that drawback. However, when there’s extended minimal input-voltage, (108 Volts), the Bullseye would seem extra often, than NOT. In apply, when this may occur, and if beneath Guarantee, the buyer would demand and obtain, a FREE substitute CRT. Afterward [years], because the T.V. set ages, there might be a traditional degradation of voltage(s), from the chassis tube suppliers, and be of such rare discover, that the buyer will choose, [because of monetary consideration], to disregard identical.

GET RID OF ALL TRACES OF LACQUER IN THE TUBE INCLUDING THAT, DEPOSITED ON SCREEN:[edit]

BAKING THE BULB AT HIGH TEMPERATURE

  1. 9 Place the Aluminized tube in an Excessive Temperature Heating Oven and bake at 410 Levels C , {barely greater that of the common processing Temperature (400 C)}, which might be performed later. Primarily, this baking cycle, will completely dry all materials, put into the bulb, for processing, and to initialize de-gasification. Most significantly, the Excessive Temperature will vaporize, to the environment, ALL Lacquer put in, (together with that, which additionally coated the Phosphor Display), by way of the earlier operation. When the Excessive Temperature Baking course of is accomplished, there’s an infinitely small house between the Aluminum and the Phosphor Display. The aluminum might be held in place by electrostatic motion, assisted by the solidified aluminum, (nevertheless skinny), coating. Elapsed time about Forty-five (45) minutes.

VISUAL INSPECTION OF ELECTRON GUN, BEFORE SEALING INTO THE TUBE NECK:[edit]

First, put together a tray ( 5 X 12 ), of “DRESSED” weapons, to be sealed into the neck of the Bulb, so {that a} vacuum could also be achieved solely via the tubulation, which is a part of the Gun construction. Give a fast test to see if the filament is within the appropriate place within the Cathode Cylinder, (Two turns of the “HEATER” {Filament} coil is optimum ). If there are greater than Two ( 2 ) turns seen, use a Tweezers (available and wanted for the sealing operation), and press them in gently, to the required Two (2) turns. If LESS than Two (2) turns, gently pull again the connecting hyperlinks to show Two(2) turns.

NOTE: EXTREMELY IMPORTANT

When MORE THAN Two (2) turns are seen, the Filament might be positioned too distant from the inside prime of the Cathode Cylinder, which holds the Coating, (on the floor of that Cathode Cylinder. That can have an effect on the conversion/processing, (changing the Coating Oxides into Carbonates). If the conversion course of just isn’t accomplished when beneath vacuum, then when the Tube is sealed off from the Vacuum system, that course of, will launch further gasoline, which is able to shorten the lifetime of the Cathode (Tube). Additionally, the Filament being positioned additional away from the Cathode will create an extended WARM-UP time, [more that Ten (10) seconds], which isn’t fascinating, when within the T.V. Set.

If LESS than Two (2) turns are seen, then that implies that the Filament has be squeezed right into a a lot smaller configuration, which might make it compress/enlarge, thereby making it nearer to the partitions and even pushed in opposition to the partitions of the Cathode Cylinder. This could trigger Electrical leakage, between the Two (2) Components {Filament in A. C. and Cathode in D.C.}. It might additionally generate, visually and acoustically, a 60 Cycle hum. Ultimately, it could trigger a “Quick Circuit” and burn out the Filament.

Subsequent examine the Grid connections and the Cathode connections. Ensure they’re NOT touching different parts, and even, NOT linked, [broken or failed weld]. Regulate (DRESS) all wires to remain near the tubulation of the gun, so that will simply match into the pin of the un-movable portion of the person revolving heads, of the Sealing Machine. When visually O.Okay., match the glass tubulation(s) into the glass tubulation-diameter holes, [Sixty (60), IN A(5) BY (12)-HOLED-TRAY], to be used, as wanted, within the Sealing Operation.

PREPARING FOR THE ACTUAL SEALING OPERATION[edit]

  1. 10 When the Bulb has cooled sufficiently, it’s prepared for the “SEALING” operation. Insert the Electron Gun into the Tube neck, ensuring the SPIDERS are touching the Aquadag Coating. NOTE: The SPIDERS, due to their spring-like capacity, maintain the Gun in place earlier than sealing. Then place the chosen to-be-sealed GUN into the chosen Tube in a small pre-heating Oven-Field, which is positioned close to the sealing machine and positioned, NECK ONLY, in that preheated, 250 Levels F oven. This small oven accommodates temperature-controlled, Gasoline-air fired, burners. This preheats the neck solely, the place work might be performed.

The Sealing Machine joins the glass, WAFER-LIKE Glass-part, of the Electron gun,(which accommodates already encapsulated, sealed wires), to the glass neck of the Tube. It does this by melting part of the glass neck, (at a predetermined distance from the place the neck joins the Bulb correct), merging/ becoming a member of the Bulb neck and the gun, into One piece. The Electron Gun Components/Construction, can also be hooked up to those wires. They are going to present Electrical connections to these Components, (which might be beneath vacuum), to the Voltage-providing circuits of the CHASSIS, that are positioned OUTSIDE of the vacuum. Time elapsed in oven pre-heat, roughly 5 (5) Minutes..

SEALING-MACHINE DESCRIPTION AND PROCESS[edit]

  1. 11 A big Plate, (Three to five toes in diameter), on the SEALING MACHINE, revolves at One (1) full Revolution each Six (6) minutes. The Plate is programmed, to go to Eight (8) mounted positions, per each 45 seconds. Of the Eight positions, the 1st, is for loading the Tube, (NOT in a Fireplace-zone); the subsequent 2 positions are in pre-heat Fireplace-Zones, (Gasoline/air); then the following 2 positions are within the WORKING-fires, Zones, (Gasoline/Oxygen); once more, adopted by 2 extra Zones, (Gasoline/Air), of Annealing Fires; lastly One, Fireplace-free Zone, for unloading the sealed-gun tube.

On this massive diameter revolving plate, there are a variety of revolving “HEADS”, (from Two to Four Heads, (depending on the dimension of the machine), positioned on the outer circumference of the principle plate. These revolving, (15 RPM) Heads, are constructed resembling, to carry the Tube, in an upright place, (neck down). Situated within the middle of every, is a fixed-height, hole STANDPIPE. This standpipe association, all the time stays mounted, on the identical top, (for ALL heads), always, whereas the head could also be moved up or down. On the very prime of the Standpipe association, there are detachable components referred to as “PINS”. These pins, (about 1 1/Four inches in top), could also be extracted and different varieties put as a replacement. (I do NOT know why they name them PINS, as a result of they positive do NOT appear like a PIN).

These Pins could also be exchanged, after they put on out, as a result of the tops of them are uncovered to GAS/OXYGEN fires, within the regular operation of the SEALING MACHINE, which finally burns away the highest of the pin. That is NOT fascinating, as a result of the glass-working fires are positioned relative to the peak of the pin. When the pin is lowered, (due to degradation), the working fires, (Gasoline/Oxygen), are NOT then within the correct place. The cut-off positioning would then be ABOVE the glass wafer of the gun, NOT
beneath, the place it belongs. In any other case, the principal cause for alternate is to accommodate completely different glass diameters of the tubulations, [from Twenty Millimeters (20 MM), to 3/4 “ I.D., which of course also has varying wafer sizes], for the multiplicity of various tube sizes. Whereas the heads, holding the gunned tubes might rotate about 15 occasions a minute, the principle plate, is timed to rotate at solely One (1) mounted POSITION per 45 seconds, {of Eight (8) positions}, or Six ( 6 ) minutes, to make One (1) full revolution). As beforehand disclosed, One place is to load the Tube on the Head, whereas one other place is used to unload the sealed-in Electron gun.

Due to the numerous variations in Tube shapes/varieties, (Spherical, rectangular), and ranging Deflection Angles, the Tube neck-Lengths fluctuate in size, (wherever between Three (3) to Seven (7) inches). Measurements, on the time of sealing, are achieved by a cardboard, (corrugated), Ruler, marked-off for numerous Neck lengths. Any metallic ruler used, would crack the Sizzling Glass neck.

In positioning the size and sealing the Glass of the Electron Construction to the neck, an area is allotted for the molten, remnant, backside a part of the neck to have the ability to drop after sealing,[assisting the gravity drop], (of no less than One ( 1 ) inch, however no more the Two ( 2 ) inches). This dropping motion, each thins the glass on the applicable level, but in addition assists the molten Glass of the neck, to be compelled into (by the thrust of the GAS/Oxygen fires), the neck. Thus it seals, AND severs the molten glass, from the CRT and the piece to be discarded. That could be a reminder, that Pin top is essential. Severing, is then achieved, by utilizing a Tweezers (about 4 (4) to 5(5) inches in size), which when used together with air pumped into that space, plucks the glass away. The chopping/melting of the Glass wafer, completes the Electron Gun sealing-in course of.

At that time, air is launched into the Tube itself, via the Tubulation, as to counter-act the drive/strain of the Gasoline/Oxygen Jets and to ROUND out the realm which was molten, as it’s now beginning to cool and harden (arrange). Glass, does NOT like/need, sharp edges, heavy corners nor thick-and-thin, adjoining areas. (Annealing/cooling intervals for every are so completely different, that they arrange a pressure within the glass at that time. Glass is all the time a lot stronger, when it’s rounded out. IF it have to be thick for any cause, then appreciable time and care ought to be allotted to SLOWLY
cool/(anneal) it, or it’ll certainly crack at a later date.

SEALING-MACHINE PARTS:[edit]

There are no less than Two (2) clusters of Gasoline-air positions of PRE-HEATING fires, (so the glass doesn’t crack from being too quickly heated). Subsequent, there are Two (2) units of clusters, of Gasoline-Oxygen fires. These fires do the precise work, ( melting the glass of the neck, into that of the glass of the Electron Gun ), which additionally accommodates the Electrical wires for future connections), AND the tubulation, (straw-shaped, with a 3/8” inside diameter). The tubulation, might be used for attachment to the Vacuum Pumps, {the following step, when annealing is accomplished}. Then, there are Two positions of clusters of Gasoline-Air units of fires (to permit the heated molten glass to decelerate within the “cooling” course of, of the sealing operation. In glass work, this cooling course of is ALWAYS USED and referred to as “ANNEALING”.

ANNEALING PROCESS AFTER SEALING:[edit]

The tube is then positioned in a “cooling”-oven (neck and gun solely), which is about at roughly 150 Levels F, in order to chill the fused glass slowly, for about Three (3) Minutes. Complete elapsed time to seal One (1) tube with a single-headed machine is roughly Fourteen (14) minutes. NOTE: If a Two (2) headed machine is used, then that point could also be diminished to Seven (7) Minutes. A 4 Headed machine might scale back the time to Three (3) minutes. Excessive-production machines often have the flexibility, and the required sources, to seal One Tube, per Minute.

“PUMPING”: PUTTING THE TUBE UNDER HIGH VACUUM [edit]

  1. 12 Now the “gunned” bulb is prepared for the Excessive Vacuum step and de-gasification, process, generally referred to as “PUMPING”. The bulb, with the gun sealed in, accommodates the glass tubulation, as part of the entire Gun construction. This tubulation is used to connect the Tube to the VACUUM-PRODUCING PUMPS. That is achieved both of Two (2) methods: #1. When utilizing Glass-Oil Diffusion Pumps, (see DESCRIPTION of GLASS and/or METAL DIFFUSION PUMPS), a Glass-to-Glass becoming a member of of the CRT, referred to as SPLICING, [VIA THE TUBULATION], and the Vacuum system, is made with a gasoline/air torch, within the following method: Minimize the glass “RISER,” [tubulation], protruding UP from the Glass manifold, (by scoring it with a knife file), and snap it off along with your fingers. Then measure the glass tubulation, emanating from the Glass wafer of the Electron Gun, (by eye, coupled with expertise). Match it up with the Diffusion-pump riser, simply ready/minimize, and rating IT with the knife-file and snap that off additionally. Then, utilizing a hand-held, 2-headed gasoline/air torch, (held collectively by a U-shaped torch, with jets going through one another], pre-heat the glass [both ends], regularly rising the warmth, till each ends are molten. Then place one finish on prime of the opposite, till melted collectively. To help within the splicing maneuver, entry to the within of the Diffusion pump manifold/system, (together with the Tube being sealed in), is offered by a small tubulation, through which the operator might blow into. That is additionally a part of the Glass manifold, in addition to part of the Diffusion-Pump system).

That is so that you could be counter the drive exerted, {whereas becoming a member of the two items of glass}, from the Gasoline/air flame (Torch) . A rubber tubing when affixed to the small tubulation, is utilized by the Sealer, within the following method: One finish is hooked up to that manifold tubulation, whereas the opposite finish of the rubber tubing, is fitted with a hand-made glass mouthpiece. This enables the Sealer, to blow air (from his mouth}, on the applicable time, within the splicing operation. When the splicing is accomplished,AND annealed, then the Gasoline-air torch, is used to shut off that small tubulation additionally, so the entire system is Vacuum-tight/prepared.

A small CRT producer, would possibly use 2 STATIONARY OVENS, every able to containing 2 movable items, (on rails), with every unit containing 6 Image tubes, which have been sealed in (as simply mentioned). The glass manifold linked 2 tubes, (on reverse sides of one another), on each movable unit. There have been Four movable items, (every unit, comprised of three pairs, for a complete of 6 Tubes. Every 2-tube mixture, joined by a Glass manifold, was hooked up to, and an integral a part of the system, which was powered by 1 Mechanical Vacuum Pump and 1, 3-stage Diffusion pump. There have been 2 operators, to deal with these Four items. The ovens, might every maintain 2 movable items, on the identical time. Every operator would work on 1 Unit at a time, within the following method:

Assume the Ovens have been located in an East/West alignment. One unit, located on the South aspect, is pulled out of the Oven, by East Operator #1, (every leaving a unit nonetheless of their respective, [East/West], aspect(s) of the Oven.) West Operator #2 pulls a Unit out of the Oven on the North aspect. Every operator works concurrently, however independently, of the opposite. When every Operator is completed, (tipped off), his unit, of six Tubes, he then seals in one other 6 tubes , to be processed, and shoves it again into the Oven, (the place just one Unit stays). Within the meantime the opposite operator does the identical on his aspect of the oven. Then East Operator #1, pulls a Unit from the North aspect of the Oven, whereas West Operator #2, pulls a Unit out of the South aspect of the Oven. Every full cycle (as hereinbefore defined), takes 2 Hours. Since this “PUMPING” operation, continues around-the-clock, on a 6-day foundation, the utmost quantity of tubes, anticipated to be Pumped, (manufactured), at this plant, is 864 Tubes. Any tubes misplaced within the course of might be deducted from the Complete. NOTE: Having 2 tubes on a manifold is more cost effective for preliminary begin up and even for upkeep necessities, the weak level is, that whenever you lose 1 Tube, you additionally lose the opposite as a result of they’re each hooked up to the identical Exhaust system.

As this small producer grew, he usually opted for a steady in-line Tube-Exhaust system, utilizing Steel Diffusion Pumps. This method, consists of a protracted Oven, 75 to 100 toes lengthy, (relying on manufacturing necessities). The Oven is compartmented off, in order that the Tube(s) going via the size of it, are:

1. Preheated;

2. Incrementally introduced as much as temperature (in Three or extra Zones);

3. Saved at 400 Levels C., 732 Levels F., for half of hour;

4. Cooled/annealed, (in Three or extra descending-heat-supplied Zones); and a couple of or Three Zones of no-heat-supplied Zones.

Every unit, [DOLLY’s], are hooked up like practice automobiles, and include a Mechanical Pump, (fundamental vacuum-producing pump), AND a Steel Diffusion Pump, (gas-removal), pump. Every Tube is mounted, [neck-end through], an R.F.-producing coil, when the R.F. generator calls upon it, in order that the Electron Gun could also be heated, for de-gasification. Wires emanating from the Electron gun, are then hooked up to a power-supply, by spring loaded copper fingers, emanating from every dolly. Every Dolly additionally has means to entry the R.F. (mechanically). The filament voltages, are fed, (incrementally), up, to a “hot-shot,” and down once more. Every Dolly has a big piece of metallic, that acts like a defend, (for cover from IMPLOSIONS from different Tubes, within the assembly-line Dollies).

The metallic diffusion pump receives the tubulation of the Glass wafer of the Electron gun, which is fitted right into a “compression port”, (which is a part of the Vacuum association). That compression Port, is a part of the 3-stage oil-diffusion pump, (generally known as a (FRACTIONATING PUMP). It’s continuously water-cooled, because it IS within the heated oven. The first, high-speed Mechanical Vacuum Pump, for each the Glass or Steel diffusion pumps, is similar, in each circumstances.

TYPES, COMPOSITION, LOCATION and FUNCTION OF VACUUM PUMPS[edit]

The Glass 3-stage Diffusion Pump, is a Three half of” diameter Glass manifold, (Primary physique), which has Three spherical glass Pots, [two of which have 2″ diameter and one, at the end, of 1″ Diameter, [called a “condensing pot). The Pots are arranged below, and connected to, the Main body, and also inter-connected to each other. One part of the Glass pump is connected to the Glass manifold, through a Glass trap, (much like the one under your sink). That connection is made with a high temperature sealing wax, coating the “GROUND-Glass”, male end, of the manifold, to the Ground-glass female part of the Glass Trap.

BACK TO THE POTS: Each of these Pots, contain a heating element, {which looks like a thick element in a light bulb}. When the Vacuum system is in operation, the Three stages, each individually vaporize the oil in them. As the Oil-vapor rises, it goes through the Main body, until they each enter their own section of water-jacketed parts of the Main body. Then, the vapor, mixed with the molecules of gas being generated from the Tube, condense and full back toward the original source, the Pots. This is basically, a re-circulation of the oil, but it does have the effect that, it compresses the gas molecules, and passes them over to the Mechanical Pump, where the gasses are then transferred to the atmosphere.

There were several types of oil used, in both Glass and Metal Diffusion pumps. Two of the most Common were “OCTOIL S” AND “SILICONE” OIL. In the 1950’s, the Octoil S, was priced at $10.00 Dollars a gallon, while the Silicone Oil, was priced at $125.00 a Gallon. Octoil S had to be replaced, every time the system was reduced to air, while the oil was at operating temperature. This was because the oil oxidized and was NO longer efficient, at de-gassing the system.

1. The Glass Manifold above the trap, was first removed;

2. the connection to the Mechanical pump was dis-connected;

3. then the pump was loosened from the supports underneath the Oven, and removed.

4. The Diffusion pump was then emptied, cleaned out, dried, and new OIL,[Oct-Oil S,] launched. This occurred each time, there was an implosion, and/or, for no matter cause, the Vacuum system was uncovered to air, whereas the oil was scorching.

NOTE: Silicone Oil, costly because it was, had a number of distinct benefits over the Octoil S.
It was steady to air, at working temperatures”.

Very importantly, [with the Silicone oil,] decrease, higher gasoline pressures, have been all the time reached. Some Glass manifolds had an “Ionization” gasoline Bulb hooked up additionally. When gasoline pressures reached the 5 occasions Ten to the Minus 5 vary, or higher [lower,] after processing, [immediately before “TIPPING-off”,] the CRT’s might be eliminated. It was common to search out the tubes within the Minus 7 vary. When working with small tubes, such because the 5″, 7″, 10″, 12,” 13″, or 14′ rectangular, pressures within the 1 occasions 10, to the minus Eight vary, might be achieved. EXPLANATION: The velocity of the pumps was the identical, however smaller Tubes, had much less quantity to be evacuated. In fact then, there was much less materials contained therein, to generate further gasses. Therefore higher/decrease, Vacuum strain(s), might/WOULD BE ACHIEVED.

The METAL DIFFUSION PUMPS:

Principally, the Steel Pumps, have been composed of an upright 3″ diameter piping, (metallic sleeve), about 14 inches in top. To warmth the oil, [which effected the gas-removing aspects of the pump], it contained, an Insulated Steel Coil, [so it wouldn’t short out], as a result of every part was made out of metallic. This coil was positioned within the pot, [at the bottom of the cylinder]. The highest of the pump, had a Compression association, which acquired the tubulation of the CRT. A copper 1/4″ tubing, was wound across the total physique of the pump. This copper tubing, was sealed 100% to the pump, in order that it got here with, and was a part of the pump. This was linked, on set up within the oven, to a water line. If no water, is used, then the pump is not going to work. Worse but, if no water is used, then the oil vapors, rise into the Tube itself, and poison the Display AND the Cathode coating. At that time, all supplies AND work are misplaced, and the Tube(s) have to be re-built. Contained in the Steel pump, is an insert composed of a metallic cylinder, formed not not like a Christmas tree, the underside of which resides within the pool of Oil. When the Oil is heated, there are Three separate exits within the Insert, (in impact a 3-stage pump], for the Oil vapor to rise, combine with gasoline generated, condense and switch the compacted gasoline molecules, to the Mechanical pump, for evacuation from the system.

All pumps, are all the time positioned, BELOW the Glass manifold/compression port, (NOT within the gas-heated portion of the oven), BUT ARE a part of the Vacuum System, which IS, within the 400 Diploma C , (752 Levels F ), Excessive-Temperature Oven. There are TWO (2) Vacuum Pumps, for every tube to be processed, on the identical time, as they’re being baked. The rationale for Two (2) Pumps is, as a result of there is no such thing as a single pump which can pull the excessive vacuum, mandatory, for proper-functioning and lengthy life,of the Tube, at a particularly excessive velocity, as economics demand.

The Mechanical pump is required, to pump out quickly, the great quantities of gasses concerned in manufacture. These gasses are each inherent in all supplies used for its development, as nicely gasses being generated by the nice quantity of warmth by the excessive temperatures utilized in processing. On the identical time, they’re required to supply a particularly low gas-containing situation. NOTE: Since water,(which consists of Oxygen and Hydrogen), was utilized in copious quantities, it was discovered that to finish dis-association, (separating Oxygen from Hydrogen), in water, temperatures beneath vacuum circumstances, would require no less than 385 Levels C, (725 Levels F), to so do.

TYPES OF VACUUM SYSTEMS (PUMPS)[edit]

1. The Excessive-Pace mechanical vacuum pump, very quickly, (4 (4) to Six (6) minutes, ( relying on the tube dimension, together with the velocity of the pump ), evacuates the system, {which accommodates a secondary pump, referred to as a Three (3) stage “Oil Diffusion Pump”. That Diffusion Pump, is accountable for reaching very low gasoline circumstances, whereas the Tube is being baked. Moreover, it’s eradicating the Gasoline which can also be being generated/liberated, by the 400 Levels C., (752 F), warmth of the Oven. It can proceed to take away gasoline, generated from processing, (to return), of the Cathode Coating(s), AND the Electron Gun.

Up to now, Mercury-Diffusion Pumps have been additionally used, however have lengthy been discontinued as a consequence of Mercury’s extraordinarily poisonous nature. The truth that Liquid Nitrogen was mandatory/HAD for use, for them to perform correctly, was harmful to make use of, laborious to retailer, [because it had to be kept cool], and expensive, induced their abandonment. Liquid Nitrogen’s regular temperature is about 250 Levels BELOW ZERO. Even whenever you have been NOT utilizing it, the provision was all the time being diminished, due to it is excessive temperature distinction, with the ambient room temperature. Even supposing it was saved in a big vacuum sort container, (NOT not like a THERMOS BOTTLE), it frequently was evaporating, throughout Holidays, weekends, and so on., each time the Tube plant was not working.

2. The Diffusion Pumps, are very efficient for pulling gasoline molecules out of the system, (regardless whether or not the Gasses are Oxygen, Hydrogen, or of every other sort. There are a lot of Gasses, whether or not residual, or, that are continuously being generated on the time of processing, which have to be faraway from the system. Myriads of OTHER gasses, which could have been ADSORBED, (hooked up to the skin of the components, supplies, utilized in processing, development), OR through the Electron Gun’s Electrodes (components), additionally needed to be eliminated. The Gasses are frequently, effectively, gathered collectively and expelled to the environment. Gasoline causes issues, aptly demonstrated, in use, by “Fuzzy” footage. You simply can NOT get a clear, clear image, with a excessive gaseous inner Tube situation. In excessive Gaseous circumstances, it all the time appears like the image is out of focus. EXPLANATION to observe:

EXPLANATION: Because the Electron Beam tries to go to its assigned place(s), it encounters molecules of gasoline and collides with them, which causes the Electron Stream to be deflected (nudged), left or proper, or up, or down, and/or, even in a mix of ALL instructions. Subsequently, the Beam impacts completely different parts of the Phosphor Display. It does this, so many occasions, every second, in order that an AVERAGE, (sum of all of the completely different ELECTRON-BEAM landings), video-picture, is definitely displayed. That is additionally aided, exacerbated, by the DECAY-time issue, therefore a “blurry” image, (despite the fact that the Electron Stream is completely centered).

Extreme gasoline ensures a SHORT life for the completed CRT, as a result of the cathode which accommodates a Damaging cost, attracts POSITIVELY-CHARGED GAS PARTICLES. These particles condense/are deposited, on the cathode-coating floor. The coating beneath that deposition of Gasoline Particles, does NOT include sufficient power to undergo that deposited, non electron-releasing, coating. Worse but, it reverses, has a dampening impact/capacity, for Electron-generation, within the good, Cathode coating. This smothering impact, encourages an ever-slowing, Electron-generation capacity, which finally results in the purported demise of the Cathode/Tube. (IF YOU DON’T USE IT… YOU LOSE IT)! SEE NOTE subsequent.

NOTE. It was discovered, that despite the fact that it appeared {that a} CRT was “useless”, an equipment, operated by a Technician, might apply a couple of 1,000 volt (RE-ACTIVIZATION), momentary spike, between the Cathode and G 1, the coating might be disintegrated, and the Cathode Coating would once more have the ability to perform correctly, for a lot of, many, extra years.

HEAT TREATMENT(S) OF BULB AND ELECTRON GUN[edit]

  1. 13 The oven is then heated to 400 Levels C, (752 Levels F.), in levels of incrementally-higher heating intervals), in about 15 to 25 minutes relying on Tube dimension/mass. It stays at prime temperature for Thirty (30) minutes. NOTE: Care have to be taken to NOT exceed this temperature by an excessive amount of, as a result of at round 425 Levels C, some skinny glass Tubes will begin to go plastic, (particularly Tubes resembling DUMONT spherical 12″), and begin to deform. That’s because of the reality, that the bulb inside being in a Vacuum, topics the skin of the tube(s) to the Atmospheric strain of Sixteen kilos +, per sq. inch, exacerbated by the extraordinarily excessive temperature, to begin to soften the Glass Bulb AND truly start to collapse.

After the highest temperature time of Thirty (30) minutes, has been met, the Oven is then directed to chill down (once more, incrementally). NOTE: Glass NEVER desires to be heated hurriedly and ALWAYS desires to be COOLED, in an extended time, (ANNEALED), than that which might be pure, if ALL warmth is instantly eliminated. To disregard this rule might trigger the glass to crack and NOT have the ability to preserve a vacuum, and even worse but, “IMPLODE”. Definition of Implode: reverse of “EXPLODE”, however with simply as loud a Bang/sound. Additional, implosion can nonetheless hurl damaged glass components/shards, so far as Thirty (30) toes away as a result of the items rush to, and, THROUGH one another (very like the “crossing level” phenomena, however with harmful results. Time elapsed in baking process, about One (1) hour or so..

PROCESSING THE TUBE (CRT) AND THE CATHODE COATING[edit]

  1. 14. When the Oven temperature is cooled to about 250 Levels C , (482 F), the Oven doorways could also be cracked open sufficient, to attach wires from a D.C. provide unit, to the filaments (solely). Voltages beginning at 6.Three Volts are raised, incrementally, to a Thirty (30) second “HOT-SHOT” (12 V to 13 Volts), after which incrementally again down once more, however by no means lower than Six (6) Volts. Concurrently, [from time to time], the door(s), to the oven, are opened increasingly, whereas the Voltages are being utilized. Complete cool-down time, and voltage utility cycle, roughly 30 minutes.

Concurrently, with the voltage utility and the cooling of the oven, one other crucial a part of manufacture can also be happening, particularly: Supplying an extra supply of warmth, to the Electron Gun itself. It’s achieved by utility of an R. F. supply by way of a BOMBARDER, (DADDY of the Microwave Oven, in everybody’s kitchen). This system was designed and powered particularly, to HEAT-TREAT metallic.

NOTE: The KITCHEN MICROWAVE was NOT/SHOULD NOT, be allowed to warmth any metallic. DANGER, IT COULD CAUSE AN EXPLOSION)

First, the BOMBARDER heats the G 1, [along with the Cathode Cylinder], and G 2, to a bright-red diploma, for One minute. Then individually, the Electron Gun Anode construction, can also be heated at that Pink Brightness, for One (1) Minute. That is performed for Two (2) causes:

1 of two To expel any gases which have been used within the manufacture of the Electron Gun, and/or to drive any and all gasses, adsorbed/absorbed in ALL of the components enclosed with/inside, the G 1 construction, in addition to the Anode itself. NOTE: Care ought to be taken NOT to warmth the SPIDERS. If the Spiders are heated to that Pink Brightness, then in that case, the Spiders will lose their rigidity and doubtless will trigger failure of the CRT at a later date. See subsequent Two Paragraphs.

When the tube is completed and put into operation, at first, the Tube will perform usually. Later, as early as a number of weeks, due to warmth generated within the regular operation of the T.V. set, the Spiders will begin to vibrate, “SING”,, making a high-pitched ringing sound. The video (PICTURE), WILL SHOW BLACK HORIZONTAL BARS ACROSS THE SCREEN and instantly be NOT viewable. In fact, the CRT must get replaced.

However, if for any cause, the set stays on for longer than a couple of minutes, after the “singing” commences, the mix of Excessive Voltage and vibrating Spiders “CHATTERING”, will truly trigger the glass neck to be “HAMMERED” and crack. The CRT will lose its vacuum and naturally , NOT have the ability to perform. If the T.V. Set continues to be NOT turned off, IRREPARABLE harm will happen to the circuitry of the T.V. set, such that, the total T.V. set have to be discarded.

CONVERSION AND ACTIVATION OF THE CATHODE-COATING:[edit]

2 of two. To help the Filament-generated warmth, to help in conversion of the Triple (3) coating oxides,into Carbonates, that are deposited onto the Cathode Cylinder, (encased inside G 1), R. F., [low-range Radio Frequencies], (as earlier herein mentioned), is utilized. This helps to begin uniform conversion/activation of that Cathode coating. Then, that transformed coating, might readily produce Electrons/Ions, when referred to as upon to take action. NOTE: Within the major manufacture of the Electron Gun, a mixture of Three (3) Cathode coatings, (in liquid-powdery kind), are sprayed on by a Paint-sprayer system. Then the deposited coating dries, and is formed to an EVEN floor, with few, if any irregular (excessive spots).Then the sequence of electrical voltages utilized, rising up, in increments, from 6.Three Volts to a One (1) minute “Sizzling Shot,” (12 ½ to 13 Volts), after which incrementally being decreased again to the unique 6.Three Volts, completes the conversion and activation of the Coatings.

  1. 15 Now that, the conversion/conditioning, of the CRT (Cathode Coating), is accomplished, the wires hooked up to the filament are disconnected and the CRT is separated from the Exhaust System. Care ought to be taken NOT to permit air to be launched into the CRT). The separation process, could also be effected, in any of the next method(s).

SEPARATING A PROCESSED TUBE, FROM THE VACUUM PUMPS ( TIPPING OFF )[edit]

a. The previous trend method: With a gas-air torch, warmth the realm, during which you need the top of the CRT- glass-tubulation to be. Do NOT neglect to preheat, or the glass might crack, at which level all that point is wasted AND the Electron gun is ineffective and the Cathode-Coating is destroyed). Because the glass turns into tender and pliable, the method referred to as (“TIPPING OFF” ), commences. The Atmospheric- strain, coupled with the drive of the Gasoline-Air Torch, causes the Tubulation to begin to collapse. Because the Tubulation begins to lose diameter and the Glass turns into even softer, the CRT is slowly raised to creating the diameter even smaller/much less. Persevering with the heating/lifting the CRT, till it involves a skinny thread of string, and in the end, the flame truly severs the CRT glass, from the Vacuum System.

Then, the perfect end-result is sort of a “hand-sharpened” pencil referred to as a TIP . You should NOT simply let the glass collapse right into a thick “BLOB’. If for any cause, you’ve gotten let it go right into a BLOB situation, then in that case you need to spend a number of minutes “Annealing” that Blob, or it’ll certainly crack at a later time, principally, as a result of when going from THICK to THIN, every ought to every have their very own annealing minimums, and they’re too dis-similar. This separating operation, requires some power and definitely talent, in maneuvering the torch AND the lifting process, being performed concurrently.

b. With a purpose to scale back the talent {and pay requirement(s)}, sure producers used a ceramic coil, containing a heating component, to be put across the tubulation, within the preliminary a part of attaching the Tube to the Vacuum System. When separation time got here, the coil offered the next: PRE-HEATING the glass tubulation took Two (2) to Three (3) minutes, to carry the tubulation as much as softening/ melting, then one other minute to effectuate the entire closing off (right into a BLOB), of glass. Then the coil had the impact of retaining the enclosed warmth, therefore (ANNEALING)the BLOB. This cooling interval took about two (2) of Three (3) minutes. When that was accomplished, the coil was lowered to the a part of the tubulation, nonetheless hooked up to the Vacuum System. A metallic file, (formed like a knife), made a FIRM, QUICK scratch, “SCORE MARK” to the center of the Blob. Then making a fast blow to the blob, causes the glass to be separated, on the Rating mark.

The “GETTERS”, are then activated by the hand-held R.F. coils, by the operator, (as beforehand mentioned). This absorbs any further gasses, which could have been generated, by the heating/melting of the glass, within the separation/processing, [tipping-off], of the CRT.

The Tube might then be eliminated for the following step. The Oil-diffusion pump is shut off first, for no less than One (1) minute, to permit the Oil to chill from working temperature. [Most Hi-Vacuum Oils used in Diffusion pumps, did not like to be exposed to air at Operating temperatures]. The Oil degraded very quickly, to the purpose, that the Diffusion Pump labored much less and fewer effectively. Then the Mechanical Pump was additionally turned off. Then air was launched into the system, (the Vacuum system was damaged). The remaining piece of Tubulation, was then withdrawn from the system and discarded, (preparatory for the following pumping operation). Complete elapsed time, within the oven, {turn-around time, Two (2) hours}.

ATTACHING THE BASE TO THE CRT.[edit]

  1. 16 Eradicating the CRT from the oven, it’s put (face-down) on a tender floor, in order to not scratch the face. A Bakelite cement, composed of a particular powder, combined with de-natured Alcohol, which attains the constituency, {and appears like}, peanut-butter is utilized inside a Bakelite base. This base, in flip has a number of features. The primary is that it protects the Glass tip from unintended breakage, in regular dealing with. Subsequent, it accommodates a hoop of hole metallic tubings, via which wires will feed although from the evacuated tube. This offers electrical entry to the Components of the Electron gun and chassis-supplied voltages (directions). Once more, the filament wires are linked to a Energy Provide and a sequence of electrical voltages are utilized. The Voltages vary from 6.Three Volts to a Sizzling Shot of 13 Volts for One (1) minute after which again down, incrementally, and at last to six.Three Volts, which completes the activation of the Cathode Coating and “AGES” it. That’s to guarantee, it might produce sufficient Electrons in Ten (10) seconds, within the T.V. set, resembling to offer an entire viewable image, for a few years. See “Ageing” of Cathode Life-cycle beneath.

The solidifying course of, (evaporating of the de-natured alcohol), concurrent with the AGING course of, usually takes about Thirty (30) minutes.

NOTE: “AGING” THE CATHODE is critical, so {that a} CRT might final a few years. It ought to NOT be allowed to fail, no less than for the first Eighteen (18 ) months. Typically, there was a One-year assure given. If the CRT was returned “beneath guarantee”, then, a brand new one must be despatched at NO CHARGE, (however at appreciable value ).

LIFE-CYCLE OF THE CATHODE COATING/CRT[edit]

A. Initially the coating is in a non-active state and can NOT readily launch Electrons/Ions.

B. Because the Coating is heated, (in a Vacuum situation), it completes a chemical re-action, (conversion of Oxides to Carbonates, which makes it begin to grow to be, more and more lively .

C. The rationale for the rising exercise, is that the coating, (beneath a microscope), reveals many excessive spots, combined in with many low spots. The low spots, (thinner layer if coating), react faster. Subsequently, some areas will convert/be activated, before others, (the thicker components).

D. Life-cycle rationalization: When the Cathode Coating is correctly transformed and simply producing electrons, it begins out, (on a curve), such that it will get higher and higher at producing Electrons. If for some cause, the Cathode just isn’t absolutely activated, and at, or close to the underside of the curve, the Coating will NOT proceed to enhance, however the truth is recede, to much less favorable electron-generating circumstances. At that time the tube may be despatched again to the manufacturing line for added “Ageing”. If once more, it shows “unsatisfactory” readings, (on the Take a look at Set), then the CRT, must be minimize open and undergo the manufacturing course of as soon as once more, (with the Electron Gun wasted).

NOTE: Afterward, these “WASTED” Electron Weapons have been themselves rejuvenated by eradicating the G 1 Construction (containing the whole Cathode Meeting) and changed it with a BRAND-NEW G1 Meeting, {with the brand new Cathode Meeting additionally}. This was performed at half of the price of a brand new Gun.

NOTE Failures within the manufacturing are often known as “SHRINKAGE”. The optimum cathode activation, could be at a degree on the curve which is a bit of earlier than, (however nonetheless rising), to a “Plateau”, (the following degree of activation).

E. When it’s producing the utmost quantity of electrons, it’ll keep on a plateau producing plentiful Electrons, for from, (5) years, to 15 years, or extra. NOTE: Many tubes have been discovered to nonetheless be producing an honest image, 50 years later!

F. It can then begin on the down-slope of the curve, which ought to be one other (20) months or so. NOTE: When the Cathode Coating is OVER-PROCESSED, you could be nicely throughout the plateau and even on the down-slope, even BEFORE, the CRT is put in in a shopper’s T.V. It would then fail, in lower than the assured minimal. This failed CRT, entitles the buyer, to a free substitute beneath Guarantee.

G. In the end, again to a state the place enough electrons might NOT be generated, (coating expended), Life-cycle ended! NOTE: By that point, shoppers could have bought newer T.V. units.

ACTUAL AFFIXING OF BASE AND “AGING” OF CATHODE COATING.[edit]

The Bakelite cement initially comes as a powder. When combined with pure, [de-natured] alcohol, which is an (simple, non-contaminating, evaporation materials), it’s labored to the consistency of “Peanut Butter”. A 3/8 ” thick ring, of Bakelite cement, is utilized contained in the Bakelite base, which additionally has hole metallic pins mounted in place. The wires from the Electron Gun are threaded via these metallic pins and pulled tight to mount and repair the Bakelite Base and cement, to the glass of the CRT neck. [That is where the Glass–like Wafer of the Electron gun was melted into the neck of the Tube]. That additionally protects the Glass tip, from being damaged, with the resultant lack of Vacuum.

These wires additionally held the bottom on straight, till the alcohol is evaporated and the Bakelite cement turns into as laborious as plastic. It turned out when tubes have been separated from the Vacuum PUMPS, within the Blob configuration, {that a} very excessive un-acceptable quantity, suffered leaks. Then new tubes needed to be equipped. REASON FOR FAILURE: It was confirmed later, that the INSIDE of the tubulation was NOT as clear because it ought to have been, and subsequently, a particularly tremendous line left within the middle of the blob, was truly leaking air, into the completed tube. The leak was so minute, that it took a number of months of rising gasoline content material, finally air, to be found. However, it was in a position to be successfully closed off, with a Excessive Vacuum, Pink-Paint sealant, [was specifically formulated for just such a purpose(s)]. This Sealant was utilized to the Blob-end of the CRT, at first of the base-attachment course of. The sealant was NOT wanted, for hand-tipped tubulations. It additionally had electricity-insulating traits.

To supply the required warmth, for the Bakelite Cement-hardening course of, the Filament wires are once more linked to an A C provide, to additional age the cathode, (with the compulsory “Sizzling Shot” {12 half of V … to…13 half of V for Thirty (30 ) seconds}. Relying on the ambient room temperature, generally “spot lights,” shining on the bottom, may be mandatory, to finish the evaporation of the alcohol and the hardening course of, of the Bakelite cement.

At 6.Three Volts A C, the filament generated roughly 800 Levels Centigrade of warmth, or about 1472 Levels Fahrenheit,(and better, as voltages have been incrementally superior), in order that the Glass within the base space, will get scorching to the contact and thereby hardens the Bakelite Cement. When the Bakelite cement is hardened and the socket referred to as the BASE, containing the wires are firmly affixed to the top of the CRT neck. Subsequent, the wires are snipped off on the prime of the pins lead soldered, (in order to guarantee connections with the pins, are securely, completely made).

Time lapsed about Thirty (30) minutes from the final tube linked (often performed in Oven masses or Twenty (20) to Thirty (30)tubes tied in parallel collectively, to the A C Energy provide. Ageing, base hardening elapsed time roughly Thirty (30) minutes.

GETTING RID OF PARTICLES WHICH MAY BE ON THE ELECTRON GUN PARTS[edit]

  1. 17 On a tube holder, the CRT is positioned, (face up, neck down), and a socket is plugged in to the metallic pins of the bottom, during which all pins are joined collectively by a heavy-duty wire. This different finish of the wire is anchored to “GROUND”. One other heavy-duty wire is linked, (clipped in), to the anode button of the CRT. The Anode is fed from a tool, whose sole function is present the Excessive Voltage mandatory, to wash unknown/undesirable particles, by utilizing (Twenty-five (25) to Thirty-five (35) Thousand Volts. When turned on, the H.V. disintegrates any materials nonetheless current on the Electron Gun, with the (CRACKLE) sound, made by electrical energy. Bigger tubes get the 35,000 volt remedy as a result of the T.V. units they’re positioned in, usually ship extra H. V., to work correctly, than that of the smaller ones. If not performed correctly, the Electron Gun will begin to snap, crackle and pop, within the clients house, which makes the client apprehensive, (despite the fact that it’ll NOT do any harm). Nonetheless, if the Tube develops air in it, within the T.V. Tube shopper’s house, THAT, might do severe harm. That system, which was used to wash up the electrodes, was generally referred to as, a “SPARK-KNOCKER”.

TESTING THE FINISHED PROCESS[edit]

  1. 18 Testing the completed product, was achieved by connecting the completed product, in an T V set-simulating tools process. All voltages, (and present drains, after which some), have been accessible (inherent), and dial-monitored by controllable sources, (some computerized, with others on command of the Take a look at-set operator.

For instance:

Excessive Voltage was equipped from Zero (“0”) volts, all the best way as much as Thirty-five (35) Thousand volts.
(NO T.V. set, operated at greater than 30 Thousand Volts).

Different variable voltages accessible within the TEST-SET are:

Filament voltage from (Zero V) to (15 V), w/ computerized present drain in Milliamps. (most CRT’s operates at 6.Three volts).

G 1 (“0”) V to 40 V

Cathode (-10 V) to (“0”) V + present drain (referred to as “EMISSION,” the mixture of electrons passing from the Cathode although the aperture of G 1 ), in MICROAMPS.

NOTE: There’s a relationship to the quantity of Electrons passing from the Cathode, via G 1 and the quantity of voltage essential to utterly halt that motion, which permits the T.V. present, the colour “BLACK”. That additionally implies that, that various the voltage, in line with the sign acquired from the Transmitting supply, might enable various quantities of Electrons to be despatched to impression the Phosphor Display, thereby drawing the Image and making the image darker or lighter.

G 2 (“0” V) to 500 V

Focus (“0” V ) to 450 V

Anode (“0” V) to 35,000 V

The TEST SET has the flexibility to check for “LEAKAGE” between the Cathode (A.C.), & the G 1
(D. C.). An excessive amount of leakage, would introduce a Sixty (60) Cycle “Hum” within the Image, (un-desirable), getting progressively worse. It additionally assured that finally, the filament will brief in opposition to the Cathode Cylinder, and burn out. (See SEALING the ELECTRON GUN hereinbefore, to PREVENT leakage).

ASSESSING THE POSSIBLE LIFE OF THE CRT[edit]

The Take a look at-set additionally had the flexibility to disengage the “SWEEP” circuits. It is a beneficial instrument, in assessing the effectiveness of your manufacturing course of, as a result of it allows you to see a “PICTURE” of the floor of the cathode coating, which was referred to as the “CATHODE IMAGE”. The precise coating was hid from seen sight, as a result of it’s an integral a part of the G 1 meeting electrode.

To get a “view”, (a VIRTUAL look), on the Cathode coating, do the next, (VERY IMPORTANT), on this order as proven. FIRST, scale back the Focus Voltage all the way down to “0” Volts; SECOND, scale back the excessive Voltage to five,000 Volts; THIRD, dis-engage the Sweep Circuits. These actions, have NOW produced the next impact: BECAUSE, the Focus Voltage, was diminished to “0” Volts, the Electron Beam might NOT be introduced down, to an intense, very small, sharp level; Subsequent, BECAUSE the Anode (Excessive) Voltage was introduced down to five,000 Volts, that eradicated any risk of the Electron Beam burning the Phosphor Display; As a result of, the Sweeps have been dis-connected, the Beam couldn’t traverse up/down nor left/proper, thereby presenting a stationary picture.

The IMAGE, then solid upon the Display, (in regards to the dimension of a Silver Greenback), was in a position to be learn like an M D READS AN X-RAY. To a talented particular person, this CATHODE IMAGE (“Scan”), might current a remarkably correct image of the anticipated lifetime of the CRT, or within the various, if additional “Ageing” was mandatory. After re-aging, the CRT needed to be examined once more. An necessary perform, relative to the proportion of tubes requiring re-aging, was very important, (NEVER greater than 10%, nor lower than 5 %) in figuring out the efficacy of the Conversion and Activation of the Cathode Coating. NOTE: Should you acquired lower than 5%, that meant, you have been OVER-PROCESSING the cathodes, thereby utilizing up helpful life (hours), and the place, on the plateau, or down-slope of the lifetime of the Cathode coating, you have been in, for the batches of Tubes processed that day. (Plateau interpretation, mentioned earlier herein, within the Ageing course of).

NOTE: Generally, when trying to check a CRT, upon attempting to show/look at, the Cathode picture, as an alternative of the “dollar-size” picture being displayed, a relatively dim picture, [smaller than a dime], was displayed. When that show was acquired, it indicated 2 issues. 1). The Cathode tab, [the connection between the Glass wafer and the Cathode cylinder], was damaged, and subsequently the CRT might NOT perform correctly. 2). The CRT needed to be minimize open, a brand new neck needed to be hooked up, the whole inside coating needed to be washed out and the entire course of needed to be began out once more, from the start. In on the lookout for the “open Cathode,” just a few have been as a result of the two welds made, [to attach the tab], have been NOT performed correctly. This could have been detected within the preliminary examination of the Electrodes, previous to the “sealing-in” course of.

Nonetheless, after intensive investigation, the creator decided that the overwhelming majority, of “open-cathodes,” happened due to the next: Pre Korean Battle, the tab consisted of a “Nickel” composition. Since a number of Nickel was wanted for army functions, the gun producers chosen a special metallic for use as a Tab. This metallic, [because of the intense heat, generated in affixing it to the Cathode cylinder], grew to become brittle, at that time of the weld. For the reason that filament of the CRT generates 1,472 levels F, when the T.V. set was turned on, the Cathode cylinder expanded. When the T.V. set was turned off, the filament cooled off, and the Cathode cylinder contracted. Generally, the welder was undecided the he/she made a very good weld, and subsequently gave it one other shot. Since these double welds, offered extra warmth than the only weld, they generally broke, even whereas the CRT was going via the method, (Cathode conversion, “Ageing,” and so on.)

This drawback was addressed by the creator, and was the topic of his first Patent, [circa 1952]. Though the tab materials was nonetheless of inferior grade, by lengthening the tab after which looping identical, it was discovered that the whole loop, absorbed the stress of the increasing/contracting Cathode cylinder. This was as an alternative of, solely the a part of the tab, the place the weld was made, being made to bear the brunt of the on/off warmth technology, (of the filament). This was discovered to be 100% efficient, in all later CRT’s, from then on.

The completed CRT’s, are also visually inspected for imperfections, which could seem within the Phosphor Coating. Every tube was examined/timed to the 10 Second (or higher), criterion, [in which a raster must appear]. The Quantity of Electrons, emanating from the Cathode, is displayed, (which exhibits up as Present drain, in Milliamps). It additionally measures the quantity G 1 Voltage mandatory, to extinguish the Electron Stream from view, (referred to as Minimize-off Voltage). There may be additionally a mandatory ratio, between emission and CUT-OFF, [total extinguishing of the Electron Beam on Screen]. It is a mandatory requirement, (in order that black parts of any image could also be faithfully reproduced). The flexibility to focus/de-focus, the Electron stream, is examined. It’s also examined for “SHORTS”/”Open Circuits”, and/or mis-alignment of the Gun Construction. Such might come about, due to a damaged Glass-support rod, which holds all of the Electrodes firmly in place, {“ALIGNMENT”}, or every other Electron-Gun, manufacturing defect.

NOTE: Testing for gasoline, usually current within the CRT, after manufacture, ought to be at a minimal. Within the regular operation of the Tv Set, (image tube), the electron beam WILL generate small quantities of gasoline. Within the subject, T V repairmen, when unable to realize an appropriate focus, by manipulating the main focus management, rightly decide the CRT as being “gassy”. That’s appropriate… however what does gasoline should do with it? The actual tube has many particular person gasoline molecules evenly separated all through the whole inside quantity of the CRT. That’s as a result of like particles repel.

Within the regular functioning of the CRT, The pinpoint electron-beam, which “attracts” an image on the display screen, the (persistence) of the phosphor lighting up, when struck by the beam, after which dying out, “decay-time”), permits the display screen to painting an entire image. Allow us to take a single show of the impression of the Electron beam to strike the display screen at level A. Because the spot is struck 60 occasions a second, some occasions it’ll strike level A. Different occasions the electron beam will encounter gasoline molecules, thereby deflecting the pinpoint-spot level A+1, or A+2 and even A+3. At occasions the beam , encountering the all the time shifting gasoline particles, could also be defected to factors A-1, A-2,or A-3.

Then some electron-point beams, could also be deflected UP A+1, UP A+2, and even Up A+3. The beam may additionally be deflected DOWN+1, DOWN+2, or DOWN+3. Compounding that drawback, the pinpoint beam could also be deflected in many various combos of the +, -, UP, or DOWN. The ultimate outcome would then show/mild up 90 or extra particles of phosphor, INSTEAD of ONLY 1. This after all occurs to level B, Level C, level D and so on. The top outcome, is a really blurry image, despite the fact that all components of the T.V. are functioning completely

After the testing is accomplished, it’s then scrutinized for scratches on the face of the CRT. If any are discovered, they’re eliminated, utilizing grinding disks, together with “Jewelers Rouge,” [see “BUFFING”, scratch-removal later, herein].

SOMETHING TO THINK ABOUT[edit]

Allow us to enlarge the standard “Straight Gun”, as indicated, and place it in Earth Orbit. No envelope is required, because the Universe will might be, the Vacuum Container:

AVERAGE ELECTRON GUN ………. EXTRAPOLATED, LARGER AS NOTED

LENGTH 5 INCHES … 42 FEET (100 TIMES LARGER), [ROUNDED UP FROM 41.66 FEET]

FILAMENT VOLTAGE 6.Three VOLTS …… 18.9 VOLTS …(Three TIMES LARGER)

FILAMENT CURRENT .600 MA ….. 1.Eight AMPS … (Three TIMES MORE)

CATHODE VOLTAGE -5 V ….. -15 VOLTS … (Three TIMES LARGER)

G 1 APERTURE 0.040 INCHES ….. .12 INCHES … (Three TIMES LARGER)

G 1 VOLTAGE 5 V TO 40 V ….. 15 V TO 120 VOLTS …(Three TIMES LARGER)

G 2 VOLTAGE 100 V TO 450 V ….. 500 V TO 2,250 V … (5 TIMES LARGER)

ANODE VOLTAGE 15,000 V TO 30,000 V….. 150,000 V TO 3,000,000 V …( 100 TIMES LARGER )

Common “Throw” distance, [between the top aperture of the Gun-Cathode, to the Phosphor Screen], in a 25″ CRT, is about 2 toes. Extrapolating that 100 occasions yields 200 toes (to anticipated Focus level, [2nd cross-over point,]). From expertise with regular CRT’s, the 2ND “CROSSOVER-POINT”, could also be one other 6 inches, previous the skin of the Glass face. 100 occasions extrapolation offers one other 50 toes. Subsequently the Electron Beam could also be centered on any goal, (for welding, blasting, and so on.), as much as roughly 250 toes. An prolonged focus coil association, positioned 200 toes additional out, might create a third “CROSSOVER-POINT”, AND giving that an additional 200 foot vary.

NOTE: Since a Straight-Gun association is envisioned right here, the Electron Stream, will then include all of the Electrons’ heavyweight, brother particles,(IONS), each Damaging AND Constructive.

“BUFFING”, POLISHING THE FACE OF THE FINISHED CRT [edit]

  1. 19 SCRATCH REMOVAL:

The face of the completed CRT is rigorously scanned for scratches or different blemishes within the Viewing areas. If discovered, a Grinding wheel removes the deep scratches, by creating various less-deep scratches. Then, a less-grainy grinding disc, removes these smaller scratches with the impact that now the face is left in a tremendous haze, [FEATHERED]. Then a Felt sprucing wheel, assisted by JEWELERS ROUGE, POLISHES the haze, in order that it utterly matches that of the remainder of the Glass face. NOTE: This operation, performed correctly, requires persistence, laborious work, and a excessive diploma of talent! The work is characterised as laborious, as a result of whenever you end one tube, then you definately go on to the following, and the following, and the following, and so on. for Eight hours.

MAKING THE CRT “IMPLOSION-PROOF” (LAMINATING)[edit]

  1. 20 Since there have been many accidents as a result of CRT’s “IMPLODED”, THE public demanded safer CRT’s. The “QUICK-FIX was to offer a system referred to as “LAMINATION”. There have been a number of varieties tried. ALL required using EPOXY RESINS. Most resins grew to become laborious as a rock. The primary method was for Corning Glass and different Glass makers to make a “dish-like” cowl to contour the bulb in query.

The CRT, with the matching face-plate, is heated in a small Oven, to roughly 200 levels F, for a number of minutes. Then the CRT and the matching Plate, are suspended in a Jig, so that there’s approx 1/4″ inch house distinction, between them. An applicable, clear-view (comparatively pliable, when composed ), Epoxy Resin, consisting of two (2) separate fluid elements, are combined collectively. This initiates a chemical response, which begins to warmth up relatively rapidly, (Two to Three minutes). The ever-heating Two-part, Epoxy Resin, is poured, gently, (in order to NOT make air bubbles), between the contoured plate and the CRT. The Resin takes about Three (3)minutes to harden (within the agency, binding, but pliable state).

Yet one more method, offers various kinds of metallic banding , (together with non-resin coating, Compression BANDING. This entails placing s Steel Strap across the edges of the Tube and rigidity stretching it, in order that this can be very tight. There might be completely no slack nor house, between the Band and the CRT. The opposite kinds of metallic containment use one other sort of Two-part Epoxy Resins, to EPOXY (Glue), these metallic items to the Glass. That is the “laborious as a rock” selection. No matter system is used, they’re all 100 % dependable, as a result of ALL the techniques maintain the Glass collectively, when a blow is delivered with drive, to the Bulb, or when it’s unintentionally dropped… ALL kinds of implosion safety for the CRT’s, which have been employed, have been very efficient.

PREPARATION FOR SHIPPING:[edit]

  1. 21 The final step earlier than boxing for transport, was to have a black highly-conductive Electrical coating, (AQUADAG), sprayed over the whole outer Bulb space { however NOT inside a 4 (4 ) inch circle of the Anode and no less than 5 ( 5 ) inches from the place the neck joins the bulb correct, as a result of that’s the place the Yoke will reside} This coating permits the Tube to amass a Capacitive impact, (shops electrons to provide a smoother working motion, to fluctuations in voltages {often as a consequence of exterior sources}

DISCARDING/REPLACING THE CRT[edit]

NOTE: Earlier than doing something, to the within of the cupboard containing the CRT, make it possible for the T V set is turned off. (Most units have an computerized dis-connect, however generally, they might be inoperative). When eradicating the CRT, from the T V Set, you need to additionally take away the Excessive Voltage, Anode connection RED wire, hooked into the anode button, within the aspect of the CRT. Ensure, you utilize an insulated Screw Driver, to pry beneath the compulsory, spherical rubber insulator, surrounding the button. Each precaution has been taken, by T V Set Producers,to guard the particular person going into the Unit, from unintentionally coming into contact with the button. Do NOT contact the Anode Button, with naked arms. It might offer you a really dangerous Electrical jolt. It has truly killed folks, beneath sure circumstances.

Earlier than dealing with/eradicating the tube, floor the anode’ to an exterior supply of GROUND, and even the metallic chassis of the TV set. No matter you utilize to floor the Anode with, make sure that the wire/half/instrument, you might be utilizing, is INSULATED. There may be often a fairly good quantity of Electrical power left within the CRT, due to the Capacitive impact. Even dis-connected from the T V Set, it could nonetheless shock you. It will (NOT ) kill you, nevertheless it might STARTLE you, in order that you could drop the CRT. ”’THAT …COULD HURT YOU.’

#22 DYING, (nearly useless), TELEVISION TUBE MANUFACTURING INDUSTRY (circa 1980’s)[edit]

There are only some cases at this time, the place Tv Tube capacity is left/wanted at this time, which aren’t supplanted with “Flat-Display” Know-how,(circa 2000), whether or not they be of the LCD’ or the Plasma sort selection. Even projection-type TV Units, are being phased out, primarily, as a result of they’re too cumbersome. One other crucial cause for his or her demise, is that, ‘you STILL want Three CRT’s, (approx. 5″ spherical), for EVERY 1 PROJECTION-TV SET: ONE ALL-RED Phosphor-screened CRT; ONE ALL BLUE, Phosphor-Screened CRT and ONE ALL GREEN Phosphor-screened CRT), [PER SET].

METAL PICTURE TUBES,…. ALREADY A DEAD INDUSTRY ![edit]

TELEVISION set producers are all the time involved with “Upgrading”; “appears”; “Weight”; “Competitors”: “Prices”; and final, however not least, “PROFITS”. A great a part of the price of producing, promoting and supply, concerned two crucial concerns. The 1st is WEIGHT. The 2nd is BULK. In trying to resolve the burden drawback, they resorted to using metallic, for the majority of the TUBE, (the place the glass was usually the heaviest).

Even then, the following battle, was to chop the Bulk of the Steel Tube. As new Tube Sorts have been formulated, they rec’d the appellation of letters of the Alphabet, which have been utilized, to point their very own explicit sort. NOTE: The DIFFERENCES, may be due to adjustments in filament voltages/currents, Grid/Focus voltages, Focus deflection association, Excessive voltages, Bulb Form, Gun sort, Deflection Angle, and so on. On the time when Flat Screens started to dominate the market, there have been actually THOUSANDS of various Tube Sorts.

Steel tube varieties launched over time embody: a 12″ spherical; 16″ spherical; 17″ rectangular; 19″ spherical; 21″ Rectangular (each GREEN GLASS (extra in a minute), and common lead Glass; and the 30″ spherical {monster). The 21″ Inexperienced Glass (lime glass, as an alternative of lead glass), was tried for a short while, to be able to minimize down on “SHRINKAGE,” (TUBES LOST, IN PART OR WHOLE, to manufacturing issues – it created MORE issues, not much less.

New Tubes being manufactured for the primary time, acquired the next designations: The tube dimension, an alphabetical letter in date order and at last the kind of Phosphor used. For instance: the 1st 16″ metallic, was designated as a “16A P4”. The Steel cone was roughly 20″ lengthy. The following Tube was referred to as a “16E P4”. Its Steel cone was roughly 15″ lengthy. The third 16″ metallic was labeled a 16G P4, Its Steel cone was roughly 10″ lengthy.

This diminished bulk, for the T.V. Tube, meant that the T.V. Set would additionally be much less cumbersome. [Not only, would more T.V. boxes, (containing the CRT), be able to be put in a Trailer, Boxcar or a Sea-Ship’s cargo hold], however they might accommodate MORE T.V. Units, additionally, {decreasing the value per unit, for transport prices}. NOTE: Fairly often, there could be 2 separate modes, or extra, of transport, relying on origin and vacation spot. Ex. T.V. Units/Tubes from the U.S. to Europe, concerned transport by sea, [perhaps even shipping by train, and then finally by truck]. Reverse transport, was additionally wanted, to return/substitute, freed from cost, faulty/ failed/broken items, again to the U.S. So, weight and bulk, of CRT’s AND T.V. Units, have been an necessary a part of decreasing manufacturing prices.
Glass Tube streamlining, was achieved by making the deflection angle (quantity of levels, the Electron Beam might be deflected/[bent]). CRT’s began out with deflection angles about 60 Levels and labored their method up through 90 Levels, and even 114 Levels (making for a particularly shut front-to-rear relationship for the T.V. Set). The target, for the reason that early 1950’s, was all the time to make “the image on the wall,” [which obviously could NOT be a CRT].

END OF STORY!

SPECIAL MANUFACTURING STEPS, REQUIRED TO PROCESS METAL TUBES, IN ADDITION TO THE NORMAL CRT PROCESSING[edit]

PREPARING THE METAL CONE FOR THE FIRST STEP

The Steel cones are shipped to the Tube Producer, closely greased up (to forestall any rust or deterioration to happen to the Cone). Subsequently, step one could be to do away with the heavy coating. The popular solvent for the kind of grease concerned, is “Carbon Tetra-chloride”. NOTE: Solely as many cones ought to be cleaned, as could be wanted for manufacturing, for that day.

SANDBLASTING

A Glass-funnel-like association might be hooked up to the smaller opening of the Steel cone, whereas a Glass face-plate might be sealed into the bigger a part of the metallic cone. Subsequently each edges are closely sand-blasted, for two causes. The 1st is to make it possible for all traces of any substance is faraway from these areas. The 2nd is, to make an other-wise easy metallic to be roughed-up/ etched, in order to offer 1000’s of “Valleys” and “Pits”, in order that the glass has a greater likelihood to stick to the Steel cone. NOTE: Care ought to be taken, NOT to place your fingers on any of the Sand-blasted areas, because the oils in your pores and skin might intervene with the adhesion/marriage, of the Glass and metallic.

EXPLANATION,” OF CO-EFFICIENTS OF EXPANSION PROBLEM AND SOLUTION,”

Variations of “Co-efficients of enlargement”, implies that one materials (on this case (Glass), is slower, to warmth/cool, than one other materials, (on this case metallic). Glass does NOT increase as a lot, or as rapidly, as metallic. To impact a everlasting marriage, of the 2 dis-similar substances, is NOT a simple process. Analysis by main glass firms (resembling Corning Glass), have provide you with a substance, which does NOT increase as rapidly as metallic, nevertheless it DOES increase, sooner than glass. It is available in a powder-like kind, and is called “FRIT” GLASS. Positioned between the face-plate and the metallic, FRIT helps bridge the hole, between the variations of the glass and metallic. It is a gigantic help, to the wedding of the metallic to the glass. In any other case it could be very troublesome to impact the wedding. This marriage is exacerbated by the truth that, is that if there’s a
minute, [“hairline”] crack, such signifies the demise of the tube. Even when, the seal is completed completely, any leak, regardless of how minuscule, can NOT include a Vacuum, and can stop to perform in a matter of weeks. At that time, NOT solely that the client is allowed a “NO-COST” substitute, however the whole bulb have to be discarded], even AFTER return transport expenses should even be paid by the producer. In poor health will, among the many final Buyer, Distributor, and T.V. Technician (who should substitute the CRT, on his time, with out further receipt of cash, is a significant issue for the CRT producer.

GLASS LATHE, FUSES GLASS CONE, TO METAL CONE.

The metallic cone is hooked up to the top of a “GLASS-LATHE,” which additionally encloses the open half, of the Steel cone, (in order that when air is pumped in, on the lathe-operator’s command), the air, can counter-act the drive, of the gas-oxygen fires, when the glass is in a pliable, molten state. First, FRIT glass is APPLIED TO THE GLASS FUNNEL, on the level the place the glass is predicted to be fused into the Steel Tube. When the fusing operation is accomplished, then at this level, now we have the decrease a part of the Tube, [including the neck], prepared for future use. Evidently, pre-heating/annealing actions, take longer than the preheating/annealing of Glass-to-Glass seals. Settle down might take as a lot as 30 minutes.

Faceplate sealed into metallic tube[edit]

The metallic cone, mow fitted with the glass cone and neck portion of the tube, was made able to have the face-plate sealed into the principle portion of the Tube. On a specially-designed machine, {extra in a minute}, the neck of the tube had an entry to air being offered, which might be launched into the Tube, {on command from the operator), whereas the unit was in operation. This offered, that when the glass grow to be molten, the face-plate wouldn’t try to fall into the metallic physique, (spherical or rectangular).

No matter dimension or form, FRIT glass was positioned into the rim of the metallic Tube and the faceplate placed on prime of the FRIT. The sealing unit had the standard spinning functionality, in addition to 20 to 40 Jet fires (relying on dimension of Tube). As common, the Jets might be moved up or down and left or proper. To seal within the spherical tubes, was just about straight ahead: warmth the metallic Tube, which in flip heats the FRIT AND the faceplate. Because the seal takes place, sufficient air is pumped into the tube, in order to counter-act the drive of gravity, however not an excessive amount of, in order to make the glass face-plate puff out. That might stretch the glass out an excessive amount of, in order that it could be too skinny.

The oblong Steel Tubes, offered an issue for positioning the Jets. There have been additional gasoline/air heating burners (for pre-heating), whereas the Jets, (that did the work), have been Gasoline/oxygen fed. You could not set the Jets as much as the slim a part of the Steel Tube, as a result of they’d be hit by the big a part of the Tube, when the metallic Tube spun. This drawback was solved, by setting the Jets in line with the big a part of the tube. Then, by indexing, jets have been frequently moved out and in, as the form modified, (very like a machine gun firing out the entrance of a propeller-driven airplane, so it could NOT shoot its personal propeller off). Massive, thick asbestos gloves, allowed the Tube to be faraway from the machine and positioned within the compulsory, cooling/annealing oven. One single sealing process, might take so long as Eight minutes, (together with pre-heating/annealing).


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