Monolithic X-ray source housing

Abstract

Method for manufacturing a housing (141) for an X-ray source, the method comprising: Step 1: Inserting an upper form (105) into a hollow area (101) of a lower form (103), thereby forming a power supply housing cavity (111) between the upper form (105) and the lower form (103); Step 2: Inserting a pin (107, 187) from the upper form (105) into a hole (102) on a side wall of the hollow area (101), thereby forming an X-ray tube housing cavity (122) between the pin (107, 187) and walls of the hole (102); Step 3: Injecting material (133) for the housing (141) into the power supply housing cavity (111) and the X-ray tube housing cavity (122) and allowing the material (133) for the housing (141) to solidify into a housing (141) for an X-ray source, wherein the housing (141) comprises a power supply housing (11) formed in the power supply housing cavity (111) and an X-ray tube housing (12) formed in the cavity of the X-ray tube housing cavity (122); Step 4: Removing the pin (107, 187) from the hole of the lower form (103); Step 5: Removing the upper shape (105) from the hollow area of ​​the lower shape (103); and Step 6: Removing the housing (141) from the lower form (103).

Description

Field of invention

[0001] The present application relates generally to X-ray sources. background

[0002] An X-ray source can include an X-ray tube electrically coupled to a high-voltage power supply. The power supply can provide a high bias voltage for the X-ray tube. The high voltage between the cathode and anode of the X-ray tube, and sometimes a heated filament, can cause electrons to be emitted from the cathode to the anode. The anode may contain a target material. The target material can generate X-rays in response to electrons striking it from the cathode.

[0003] US 2015 / 0 098 552 A1 describes a modular X-ray source in which the X-ray tube is detachably attached to a housing and a power supply by means of a removable cap. Brief description

[0004] An X-ray source can comprise a power supply electrically coupled to an X-ray tube and a monolithic housing. The monolithic housing can include a power supply housing with a cavity and an X-ray tube housing with a recess. The cavity of the power supply housing can be connected to the recess of the X-ray tube housing. The power supply housing and the X-ray tube housing can be integrally joined. The power supply can be located in the cavity. The X-ray tube can be located in the recess. The X-ray tube housing can surround the X-ray tube in a circular fashion. The monolithic housing can contain magnesium uniformly distributed within it. Brief description of the drawings (the drawings may not be to scale) Fig. Figure 1 is a perspective view of a monolithic housing 10 for an X-ray source. The monolithic housing 10 can include a power supply housing 11 and an X-ray tube housing 12. The power supply housing 11 can be shaped to at least partially enclose the power supply 31, and the X-ray tube housing 12 can be shaped to at least partially enclose an X-ray tube 32 (see Figure 1). Fig. 3-4). Fig. Figure 2 is a perspective view of the monolithic housing 10 of Fig. 1, shown from a different angle. Fig. Figure 3 is a perspective view of an X-ray source 30 with a power supply 31 and an X-ray tube 32. Fig. Figure 4 is a perspective view of an X-ray source 40 with the power supply 31 inside the power supply housing 11 and the X-ray tube 32 inside the X-ray tube housing 12. Fig. Figure 5 is a side view of a monolithic housing 50 with a frustoconical X-ray tube housing 12. The X-ray tube housing 12 includes a frustoconical angle 51, which is a taper angle of an outer surface of the frustoconical shape. Fig. Figure 6 is an end view of a monolithic enclosure 60 with a base-side internal angle 61 between the base 11b and each of the two sides 11s that is greater than 90°. Fig. Figure 7 is a top view of a monolithic housing 70 with an end-side internal angle 71 between the end wall 11e and each of the two sides 11s that is greater than 90°. Fig. Figure 8 is a side view of a monolithic housing 80 with an arrangement of ribs 81 on the power supply housing 11 and an arrangement of ribs 82 that circularly surround the X-ray tube housing 12. The arrangement of ribs 82 that circularly surround the X-ray tube housing 12 can be perpendicular to a longitudinal axis 83 of the X-ray tube 32. Fig. Figure 9 is a side view of a monolithic housing 90 with an arrangement of ribs 81 on the power supply housing 11 and an arrangement of ribs 82 that circularly surround the X-ray tube housing 12. The arrangement of ribs 82 that circularly surround the X-ray tube housing 12 can be parallel to the longitudinal axis 83 of the X-ray tube 32. Fig. Figures 10-11 are cross-sectional side views of a step 100 of a method for manufacturing a housing 141 (see Fig. 14-17) for an X-ray source 40 (see Fig. 24). Step 100 may involve inserting an upper form 105 into a hollow area 101 of a lower form 103, thereby forming a power supply housing cavity 111 between the upper form 105 and the lower form 103. Fig. Figure 12 is a cross-sectional side view of step 120 of a method for manufacturing a housing 141 for an X-ray source 40. Step 120 may follow step 100. Step 120 may involve inserting a sliding pin 107 of upper form 105 into a hole 102 on a side wall of the hollow region 101, thereby forming an X-ray tube housing cavity 122 between the sliding pin 107 and the walls of the hole 102. Fig. Figure 13 is a cross-sectional side view of step 130 of a method for manufacturing a housing 141 for an X-ray source 40. Step 130 may follow step 120. Step 130 may involve injecting (e.g., through a port 104) a material 133 for the housing 10 into the power supply housing cavity 111 and into the X-ray tube housing cavity 122. Fig. Figure 14 is a cross-sectional side view of step 140 of a method for manufacturing a housing 141 for an X-ray source 40. Step 140 may follow step 130. Step 140 may involve allowing the material 133 to solidify into the housing 141. The housing 10 may contain a power supply housing 11 formed in the power supply housing cavity 111 and an X-ray tube housing 12 formed in the X-ray tube housing cavity 122. Fig. Figure 15 is a cross-sectional side view of step 150 of a method for manufacturing a housing 141 for an X-ray source 40. Step 150 may follow step 140. Step 150 may involve removing the sliding pin 107 from the hole 102 of the lower form 103. Fig. Figure 16 is a cross-sectional side view of step 160 of a method for manufacturing a housing 141 for an X-ray source 40. Step 160 may follow step 150. Step 160 may involve removing the upper form 105 from the hollow area 101 of the lower form 103. Fig. Figure 17 is a cross-sectional side view of step 170 of a method for manufacturing a housing 141 for an X-ray source 40. Step 170 may follow step 160. Step 170 may involve removing the housing 141 from the hollow area 101 and from the hole 102 of the lower form 103. Fig. Figures 18-19 are cross-sectional side views of a step 180 of a method for manufacturing a housing 141 (see Fig. 21-23) for an X-ray source 40 (see Fig. 24). Step 180 may include: (a) inserting an upper form 105 into a hollow region 101 of a lower form 103, thereby forming a power supply housing cavity 111 between the upper form 105 and the lower form 103, and (b) inserting a pin 187 into a hole 102 on a side wall of the hollow region 101, thereby forming an X-ray tube housing cavity 122 between the pin 187 and walls of the hole 102. Fig. Figure 20 is a cross-sectional side view of step 200 of a method for manufacturing a housing 141 for an X-ray source 40. Step 200 may follow step 180. Step 200 may involve injecting (e.g., through port 104) the material 133 into the power supply housing cavity 111 and the X-ray tube housing cavity 122. Fig. Figure 21 is a cross-sectional side view of step 210 of a method for manufacturing a housing 141 for an X-ray source 40. Step 210 may follow step 200. Step 210 may involve allowing the material 133 to solidify into the housing 141. The housing 10 may contain a power supply housing 11 formed in the power supply housing cavity 111 and an X-ray tube housing 12 formed in the X-ray tube housing cavity 122. Fig. Figure 22 is a cross-sectional side view of step 220 of a method for manufacturing a housing 10 for an X-ray source 40. Step 220 may follow step 210. Step 220 may involve removing the upper form 105 from the hollow area 101 of the lower form 103 and removing the pin 187 from the hole 102 of the lower form 103. Fig. Figure 23 is a cross-sectional side view of step 230 of a method for manufacturing a housing 141 for an X-ray source 40. Step 230 may follow step 220. Step 230 may involve removing the housing 141 from the lower form 103 and from the hole 102. Fig. Figure 24 is a cross-sectional side view of step 240 of a method for manufacturing an X-ray source 40. Step 240 can follow step 170 or step 230. Step 240 can involve inserting an X-ray tube 32 into the X-ray tube housing 12 and a power supply 31 into the power supply housing 11. Fig. Figure 25 is a cross-sectional side view of the lower form 103 with three sections 251, 252 and 253. This lower form 103 can be used in the methods described herein.

[0005] Definitions. The following definitions, including plural forms thereof, apply throughout this patent application.

[0006] As used herein, the term “evenly distributed” means exactly evenly distributed; evenly distributed within normal manufacturing tolerances; or almost exactly evenly distributed, such that any deviation from exactly evenly distributed would have a negligible effect on the ordinary use of the device.

[0007] As used herein, the term “one-piece joined” means that the one-piece joined devices are formed together at the same time and are connected without seams or joints.

[0008] As used herein, the expressions "on," "is on," "is adjacent to," and "is above" mean is directly on or is above with another material in between. The expressions "is directly on," "adjacent," "bordering on," and "adjacent" mean direct and immediate contact.

[0009] As used herein, the term "monolithic" means seamless and continuous. A monolithic structure can have the same material composition throughout. For example, a concrete wall formed at a single time in a single pouring step followed by a single curing step is monolithic. As another example, a housing formed at a single time in a single injection molding step is monolithic.

[0010] As used herein, the term “parallel” means exactly parallel; parallel within normal manufacturing tolerances; or almost exactly parallel, such that any deviation from exactly parallel would have a negligible effect on the normal use of the device.

[0011] As used herein, the term “perpendicular” means exactly perpendicular; perpendicular within normal manufacturing tolerances; or almost exactly perpendicular, such that any deviation from exactly perpendicular would have a negligible effect on the normal use of the device.

[0012] As used herein, the expression “same material composition” means exactly the same; the same within normal manufacturing tolerances; or nearly the same, such that any deviation from exactly the same would have a negligible effect on the ordinary use of the device.

[0013] As used herein, the term "X-ray tube" is not limited to tubular / cylindrical devices. The term "tube" is used because this is the standard term for devices that emit X-rays.

[0014] As used herein, the term “Al” means aluminum, “Ca” means calcium, “Cu” means copper, “Fe” means iron, “Mg” means magnesium, “Mn” means manganese, “Ni” means nickel, “Si” means silicon, “Sr” means strontium and “Zn” means zinc. Detailed description

[0015] An X-ray source 40 can comprise an X-ray tube 32 and a power supply 31 enclosed in a housing. Desirable properties of the housing include (a) low weight (for easier transport), (b) high electrical conductivity (to protect the user from electric shock), (c) high thermal conductivity (to dissipate heat generated during use), (d) corrosion resistance, (e) high strength, and (f) high shielding against electromagnetic interference (to shield power supply components from external noise, to shield other electronic components from power supply noise, or both).

[0016] The invention comprises a monolithic housing for an X-ray source 40. The monolithic housing can be part of an enclosure for the X-ray source 40. The monolithic housing can at least partially enclose the power supply 31 and the X-ray tube 32. The invention also comprises methods for manufacturing a monolithic housing for an X-ray source 40. The monolithic housings described herein, and housings manufactured by these methods, can meet the requirements of the preceding paragraph. Each exemplary housing or method can meet one, some, or all of these requirements.

[0017] A monolithic housing 10 for an X-ray source is in Fig. 1-2 shown. Properties of monolithic enclosure 10 can be combined with the properties of any other monolithic enclosure herein.

[0018] The monolithic housing 10 can contain a power supply housing 11 and an X-ray tube housing 12. The power supply housing 11 and the X-ray tube housing 12 can be joined together in one piece. Joining the power supply housing 11 and the X-ray tube housing 12 in one piece provides a consistent material structure, resulting in uniform properties throughout. Joining the power supply housing 11 and the X-ray tube housing 12 in one piece minimizes gaps and seams. Such gaps or seams could otherwise lead to undesirable flow paths for electrical charge along an edge or contact resistance across the gap or seam. Without such gaps and seams, heat flow can be uniform and less interrupted.

[0019] The power supply housing 11 can have a cavity for inserting a power supply 31. The X-ray tube housing 12 can have a cavity for inserting an X-ray tube 32. The cavity of the power supply housing 11 can adjoin the cavity of the X-ray tube housing 12 to allow the insertion of an X-ray source with an X-ray tube 32 and a power supply 31. The X-ray tube 32 can be rigidly mounted to the power supply 31.

[0020] An X-ray source 30 with a power supply 31, which is electrically coupled to an X-ray tube 32, is in Fig. 3 shown.

[0021] An X-ray source 40 with a power supply 31 inside the power supply housing 11 and an X-ray tube 32 inside the X-ray tube housing 12 is in Fig. Figure 4 shows the monolithic housing 10 extending from a distal end 31d of the power supply 31, which is furthest from the X-ray tube 32, to the X-ray tube 32. The monolithic housing 10 can extend from a distal end 32d of the X-ray tube 32, which is furthest from the power supply 31, to the power supply 31.

[0022] The X-ray tube 32 can be completely enclosed by the X-ray tube housing 12 and the power supply 31, except for a small opening to allow the emission of X-rays from the X-ray tube 32. For example, ≥ 90%, ≥ 95%, or ≥ 98% of the X-ray tube 32 can be enclosed by the X-ray tube housing 12 and the power supply 31.

[0023] The power supply housing 11 can at least partially enclose the power supply 31. The power supply housing 11 can contain three side walls 11w and a base 11b, thus enclosing the power supply 31 on four of its six sides.

[0024] One or more internal ribs 13 may be present on an inner surface of the side walls 11w of the power supply housing 11 (see Fig. 1-2 and 7). The inner rib(s) 13 can be integral with the power supply housing 11. The inner rib(s) 13 can increase the strength of the side walls 11w. A longitudinal dimension of the inner rib(s) 13 can be parallel to a longitudinal axis of the X-ray tube housing 12 to facilitate removal from a mold during manufacturing.

[0025] The X-ray tube housing 12 can at least partially enclose the X-ray tube 32. The X-ray tube housing 12 can completely surround the X-ray tube 32. The X-ray tube housing 12 can completely surround the X-ray tube 32 along a length of the X-ray tube from a cathode to an X-ray window of the X-ray tube 32. The X-ray tube housing 12 can completely surround the X-ray tube 32 along a major portion of a length of the X-ray tube 32, such as along ≥ 50%, ≥ 75%, or ≥ 90% of the length. It can be advantageous for the X-ray tube housing 12 to completely surround electrical connections between the power supply 31 and the X-ray tube 32, even if the X-ray tube housing 12 does not completely surround the X-ray tube 32 along a large part of its length.

[0026] The monolithic housing 10 can be a single, one-piece unit formed by injection molding, as described below. Pellets with the following composition can be introduced into the mold by a heated screw.

[0027] The material of the monolithic housing 10 can be selected to facilitate electrical shielding, electrical conductivity, heat dissipation, or a combination thereof. The monolithic housing 10 can contain one or more of the following chemical elements. The total weight percentage of all chemical elements is 100%.

[0028] The monolithic casing 10 may contain Mg. For example, a minimum weight percentage of Mg may be ≥ 50%, ≥ 75%, or ≥ 85%. An exemplary maximum weight percentage of Mg may be ≤ 85%, ≤ 95%, or ≤ 99%. Mg may be evenly distributed throughout the monolithic casing 10.

[0029] The monolithic casing 10 may contain Al. For example, a minimum weight percentage of Al may be ≥ 2%, ≥ 4%, or ≥ 8%. An exemplary maximum weight percentage of Al may be ≤ 8%, ≤ 14%, or ≤ 20%. Al may be evenly distributed throughout the monolithic casing 10.

[0030] The monolithic casing 10 may contain Zn. For example, a minimum weight percentage of Zn may be ≥ 0.1%, ≥ 0.3%, or ≥ 0.7%. An exemplary maximum weight percentage of Zn includes ≤ 0.8%, ≤ 1.2%, or ≤ 3%. Zn may be evenly distributed throughout the monolithic casing 10.

[0031] The monolithic casing 10 can contain Al, Mg, Mn, and Zn. The monolithic casing 10 can contain Al, Cu, Fe, Mg, Mn, Ni, Si, and Zn. The monolithic casing 10 can include Al, Ca, Cu, Fe, Mg, Mn, Ni, Si, Sr, and Zn. These chemical elements can be evenly distributed throughout the monolithic casing 10 to achieve uniform desired material properties.

[0032] A monolithic housing 50 is in Fig. 5 shown. Properties of the monolithic enclosure 50 can be combined with the properties of any other monolithic enclosure herein.

[0033] The X-ray tube housing 12 of the monolithic housing 50 has a tapered profile. The X-ray tube housing 12 can be wider closer to the power supply housing 11 and taper away from the power supply housing 11. This taper can be linear. The X-ray tube housing 12 can have a truncated cone shape. These shapes can facilitate easier removal of the X-ray tube housing 12 from a mold, easier integration of the X-ray source 40 into other tools, and easier assembly of the X-ray source 30 with the monolithic housing 10.

[0034] Fig. Figure 5 shows a truncated cone angle 51, which is the taper angle of an outer surface of the truncated cone shape. Exemplary minimum values ​​of the truncated cone angle 51 include ≥ 0.1°, ≥ 0.2°, ≥ 0.5°, and ≥ 1°. Exemplary maximum values ​​of the truncated cone angle 51 include ≤ 1°, ≤ 3°, ≤ 5°, and ≤ 15°.

[0035] Monolithic cases 60 and 70 are in Fig. 6 and Fig. Figure 7 shows the properties of these monolithic enclosures 60 and 70. The properties of these monolithic enclosures 60 and 70 can be combined with each other. The properties of these monolithic enclosures 60 and 70 can be combined with the properties of any other monolithic enclosure shown here.

[0036] As in Fig. 6 and Fig. As shown in Figure 7, the power supply housing 11 can include side walls 11w at the edges of a base 11b. The side walls 11w can comprise an end wall 11e and two sides 11s. The two sides 11s can be opposite each other. The end wall 11e can be adjacent to the X-ray tube housing 12 and the two sides 11s.

[0037] An internal base wall angle 61 is an angle between the base 11b and the sides 11s, measured inside the power supply housing 11 ( Fig. 6) The inner base wall angle 61 can be greater than 90° to facilitate assembly of the power supply 31 with the power supply housing 11. Exemplary minimum values ​​of the inner base side angle 61 include ≥ 90.1°, ≥ 90.2°, ≥ 90.5°, or ≥ 91°. Exemplary maximum values ​​of the inner base side angle 61 include ≤ 91°, ≤ 93°, ≤ 95°, ≤ 100°, ≤ 105°, or ≤ 115°. These angles can also facilitate joining the monolithic housing 60 to another tool.

[0038] An internal end-side angle 71 is an angle between the end wall 11e and each of the two sides 11s, measured inside the power supply housing 11 ( Fig. 7) The inner end-side angle 71 can be greater than 90° to facilitate assembly of the power supply 31 with the power supply housing 11. Exemplary minimum values ​​of the inner end-side angle 71 include ≥ 90.1°, ≥ 90.2°, ≥ 90.5°, and ≥ 91°. Exemplary maximum values ​​of the inner end-side angle 71 include ≤ 91°, ≤ 93°, ≤ 95°, ≤ 100°, ≤ 105°, or ≤ 115°. These angles can also facilitate joining the monolithic housing 70 to another tool.

[0039] As in Fig. As shown in Figure 7, the monolithic housing 70 can contain one or more ejection posts 72. The ejection post(s) 72 can reinforce the monolithic housing 70 where forming pins press against the monolithic housing 70 to remove it from a mold. Additionally, the ejection post(s) 72 can reinforce an interface between the power supply housing 11 and the X-ray tube housing 12. The ejection post(s) 72 can be located adjacent to a connection point between the X-ray tube housing 12 and the power supply housing 11.

[0040] Monolithic cases 80 and 90 are in Fig. 8 and Fig. Figure 9 shows the properties of these monolithic enclosures 80 and 90. The properties of these monolithic enclosures 80 and 90 can be combined with each other. The properties of these monolithic enclosures 80 and 90 can be combined with the properties of any other monolithic enclosure contained herein.

[0041] The monolithic housings 80 and 90 comprise an arrangement of ribs 81 on an outer surface of the power supply housing 11 and an arrangement of ribs 82 that circumscribe the X-ray tube housing 12. One or both arrangements of ribs 81 and 82 can be part of a monolithic housing 80 or 90 and thus integral with the rest of the monolithic housing 80 or 90. These arrangements of ribs 81 and 82 can stiffen the X-ray tube housing 12, thereby increasing its durability. These arrangements of ribs 81 and 82 can dissipate heat from the housings 80 and 90. Contact resistance between separate devices can be avoided by forming the arrangements of ribs 81 and 82 as part of the monolithic housing 80 or 90.

[0042] Both arrangements of ribs 81 and 82 can be used. Only one arrangement of ribs 81 or 82 can be used.

[0043] The arrangement of fins 81 on the power supply housing 11 can be adjacent to a transformer in the power supply 31. Thus, the arrangement of fins 81 can be aimed at heat dissipation at a location of heat generation.

[0044] As in Fig. As shown in Figure 8, each rib of the arrangement of ribs 82 can circumscribe the X-ray tube 32. Each rib of the arrangement of ribs 82 can be perpendicular to a longitudinal axis 83 of the X-ray tube 32. Additional mold sections may be required to allow the removal of this monolithic housing 80 from the mold after injection molding. As shown in Fig. As shown in Figure 9, each rib of the arrangement of ribs 82 can be parallel to the longitudinal axis 83 of the X-ray tube 32. The example of Fig. 8 or the example of Fig. 9 can be selected based on the direction of the airflow, the available space, and manufacturability (e.g., the ability to remove it from the mold). The perpendicular or parallel orientation of the arrangement of ribs 82 can provide airflow conditions for optimal cooling. First procedure

[0045] A first method for manufacturing a housing 141 for an X-ray source or for manufacturing an X-ray source 40 may comprise some or all of the following steps. These steps may be performed in the following order or in any other order if specified. Some of the steps may be performed simultaneously unless expressly stated otherwise in the claims. The housing 141 and the X-ray source 40 may have the properties of each monolithic housing described above.

[0046] Step 100 may involve inserting an upper form 105 into a hollow area 101 of a lower form 103, thereby forming a power supply housing cavity 111 between the upper form 105 and the lower form 103. See Fig. 10-11.

[0047] Step 120 may include inserting a sliding pin 107 from the upper form 105 into a hole 102 on a side wall of the hollow region 101, thereby forming an X-ray tube housing cavity 122 between the sliding pin 107 and the walls of the hole 102. The upper form 105 may include a channel 106 ( Fig. 15) to allow the sliding pin 107 to move in and out of the upper form 105. Step 120 can follow step 100. See Fig. 12.

[0048] Step 130 can involve injection (e.g., through port 104 to port 254) into Fig. 25) of material 133 for the housing include the power supply cavity 111 and the X-ray tube housing cavity 122. The material 133 can be injected by thixotropic methods. Step 130 can follow step 120. See Fig. 13 and Fig. 25.

[0049] Step 140 may involve solidifying the housing material 133 to form a housing 141 for an X-ray source 40. The housing 141 may include a power supply housing 11 formed within the power supply housing cavity 111, and an X-ray tube housing 12 formed within the X-ray tube housing cavity 122. The power supply housing 11 and the X-ray tube housing 12 may be monolithic and formed in one piece. Step 140 may follow step 130. See Fig. 14.

[0050] Step 150 may involve removing the sliding pin 107 from the hole 102 of the lower form 103. The upper form 105 may include a channel 106 to allow the sliding pin 107 to move out of the upper form 105. Step 150 may follow step 140. See Fig. 15.

[0051] Step 160 can involve removing the upper form 105 from the hollow area 101 ( Fig. 10) of the lower form 103. Step 160 can follow step 150. See Fig. 16.

[0052] Step 170 may involve removing the housing 141 from the lower mold 103. Step 170 may follow step 160. The lower mold 103 may include at least three sections 251, 252, and 253 to facilitate removal of the housing 141. Step 170 may involve pressing on one or more ejection posts 72 to eject the housing 141 from the lower mold 103. The ejection posts 72 are described above. See above. Fig. 7, Fig. 17 and Fig. 25.

[0053] Step 240 may involve inserting an X-ray tube 32 into the X-ray tube housing 12 and a power supply 31 into the power supply housing 11, thereby forming a closed X-ray source 40. Step 240 may follow step 170. See Fig. 24.

[0054] One or more additional material layers can be attached (e.g., screwed, glued, snapped, etc.) to one or more sections of the power supply that are not covered by the power supply housing 11. The material layer(s) can be metallic.

[0055] Fig. Figure 25 is a cross-sectional side view of the lower form 103 with three sections 251, 252 and 253. This lower form 103 can be used in the methods described herein. Second procedure

[0056] A second method for manufacturing a housing 141 for an X-ray source or for manufacturing an X-ray source 40 may comprise some or all of the following steps. These steps may be performed in the following order or in any other order if specified. Some of the steps may be performed simultaneously unless expressly stated otherwise in the claims. The housing 141 and the X-ray source 40 may have the properties of each monolithic housing described above.

[0057] Step 180 may involve: (a) inserting an upper form 105 into a hollow region 101 of a lower form 103, thereby forming a power supply housing cavity 111 between the upper form 105 and the lower form 103; and (b) inserting a pin 187 into a hole 102 on a side wall of the hollow region 101, thereby forming an X-ray tube housing cavity 122 between the pin 187 and the walls of the hole 102. The pin 187 may be integral and monolithic with the upper form 105. The insertion of the upper form 105 into the hollow region 101 may be performed simultaneously with the insertion of the pin 187 into the hole 102. The upper form 105 and the pin 187 may be inserted at an angle, as shown. See Fig. 18-19.

[0058] Step 200 can be used for injection (e.g., through port 104 to port 254) Fig. 25) of material 133 for the housing 141 into the power supply housing cavity 111 and into the X-ray tube housing cavity 122. The material 133 can be injected by thixotropic methods. Step 200 can follow step 180. See Fig. 20 and Fig. 25.

[0059] Step 210 may involve solidifying the housing material 133 to form a housing 141 for an X-ray source 40. The housing 141 may include a power supply housing 11 formed within the power supply housing cavity 111, and an X-ray tube housing 12 formed within the X-ray tube housing cavity 122. The power supply housing 11 and the X-ray tube housing 12 may be monolithic and formed in one piece. Step 210 may follow step 200. See Fig. 21.

[0060] Step 220 may involve removing the upper form 105 from the hollow area 101 of the lower form 103 and removing the pin 187 from the hole 102 of the lower form 103. Removing the upper form 105 from the hollow area 101 may be done simultaneously with removing the pin 187 from the hole 102. The upper form 105 and the pin 187 may be removed at an angle, as shown. Step 220 may follow step 210. See [reference]. Fig. 22.

[0061] Step 230 may involve removing the housing 141 from the lower mold 103. The housing 141 may be removed at an angle, as shown. Step 230 may follow step 220. The lower mold 103 may include at least three sections 251, 252, and 253 to facilitate removal of the housing 141. Step 230 may involve pressing on the ejector post(s) 72 to eject the housing 141 from the lower mold 103. The ejector post(s) 72 are described above. See Fig. 7, Fig. 23 and Fig. 25.

[0062] Step 240 may involve inserting an X-ray tube 32 into the X-ray tube housing 12 and a power supply 31 into the power supply housing 11, thereby forming a closed X-ray source 40. Step 240 may follow step 230. See Fig. 24.

[0063] One or more additional material layers can be attached (e.g., screwed, glued, snapped, etc.) to one or more sections of the power supply that are not covered by the power supply housing 11. The material layer(s) can be metallic.

Claims

[1] Method for manufacturing a housing (141) for an X-ray source, the method comprising: Step 1: Inserting an upper form (105) into a hollow area (101) of a lower form (103), thereby forming a power supply housing cavity (111) between the upper form (105) and the lower form (103); Step 2: Inserting a pin (107, 187) from the upper form (105) into a hole (102) on a side wall of the hollow area (101), thereby forming an X-ray tube housing cavity (122) between the pin (107, 187) and walls of the hole (102); Step 3: Injecting material (133) for the housing (141) into the power supply housing cavity (111) and the X-ray tube housing cavity (122) and allowing the material (133) for the housing (141) to solidify into a housing (141) for an X-ray source, wherein the housing (141) comprises a power supply housing (11) formed in the power supply housing cavity (111) and an X-ray tube housing (12) formed in the cavity of the X-ray tube housing cavity (122); Step 4: Removing the pin (107, 187) from the hole of the lower form (103); Step 5: Removing the upper shape (105) from the hollow area of ​​the lower shape (103); and Step 6: Removing the housing (141) from the lower form (103). [2] Method according to claim 1, wherein the pin (107, 187) is a sliding pin (107), the upper form (105) comprises a channel (106) to allow the sliding pin (107) to move into and out of the upper form (105), step 2 follows step 1, step 5 follows step 4. [3] Method according to claim 1, wherein the pin (107, 187) is integral and monolithic with the upper form (105), step 1 and step 2 are carried out simultaneously, and step 4 and step 5 are carried out simultaneously. [4] Method according to claim 1, further comprising: inserting an X-ray tube (32) into the X-ray tube housing (12) and a power supply (31) into the power supply housing (11). [5] Method according to claim 1, wherein the monolithic housing (141) further comprises ejection posts (72) and step 6 further comprises pressing on the ejection posts (72) to eject the monolithic housing (141) from the lower form (103). [6] Method according to claim 5, wherein the ejection posts (72) are adjacent to a connection point of the X-ray tube housing (12) and the power supply housing (11). [7] Method according to claim 1, wherein the monolithic housing (141) contains ≥ 75 wt% Mg distributed uniformly over the monolithic housing (141). [8] Method according to claim 1, wherein: the X-ray tube housing (12) surrounds the X-ray tube (32); the X-ray tube housing (12) has a truncated cone shape; and the truncated cone shape has a truncated cone angle (51), the truncated cone angle (51) is a tapering angle of an outer surface of the truncated cone shape and the truncated cone angle (51) is at least 0.2° and not more than 5°. [9] Method according to claim 1, wherein the power supply housing (11) comprises side walls (11w) at edges of a base (11b) having an internal angle (61) between the base (11b) and the side walls (11w), and the internal angle (61) is ≥ 90.2° and ≤ 100°. [10] Method according to claim 1, wherein: the power supply housing (11) comprises side walls (11w) at edges of a base (11b); the side walls (11w) comprise an end wall (11e) and two sides (11s); the two sides (11s) are opposite each other; the end wall (11e) adjoins the X-ray tube housing (12) and the two sides (11s); and an interior angle (71) between the end wall (11e) and each of the two sides (11s) is ≥ 90.2° and ≤ 100°.

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