Additive Manufactured X-ray Tube Casing with Integral Heat Exchanger

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Solution Overview

Problem

Conventional x-ray tube casings require external cooling circuits, which increase weight, size, and cost, and limit oblique imaging angles due to the need for separate heat exchanger components.

Innovation Solution

An x-ray tube casing formed through additive manufacturing with integral metal walls and internal cooling channels, eliminating the need for external cooling circuits and incorporating a manifold for efficient coolant distribution and a deformable bladder for pressure accommodation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If external cooling circuits and separate heat exchanger components are used, then cooling function is provided, but weight and size increase

Engineering Contradiction:

Improvecooling functionVSAvoidcasing weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The heat exchanger channels are integrated directly into the casing structure, merging the cooling function with the structural component. This eliminates separate external cooling circuits and reduces overall weight while maintaining effective heat dissipation from the x-ray tube insert.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The casing serves multiple functions: it provides structural support, shields against x-rays, and acts as an integral heat exchanger for cooling. By combining these functions into a single component, the design reduces weight and complexity compared to using separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If external cooling circuits and separate heat exchanger components are used, then cooling function is provided, but device size increases

Engineering Contradiction:

Improvecooling functionVSAvoidcasing size

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The heat exchanger channels are integrated directly into the casing structure, merging the cooling function with the structural component. This eliminates separate external cooling circuits and reduces overall size while maintaining effective heat dissipation from the x-ray tube insert.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If external cooling circuits and separate heat exchanger components are used, then cooling function is provided, but manufacturing cost increases

Engineering Contradiction:

Improvecooling functionVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat exchanger channels are integrated directly into the casing structure, merging the cooling function with the structural component. This eliminates separate external cooling circuits and reduces overall manufacturing cost while maintaining effective heat dissipation from the x-ray tube insert.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention employs additive manufacturing technology to create complex internal cooling channels within the casing. This manufacturing approach reduces costs by eliminating the need for separate heat exchanger components and their associated assembly, while enabling intricate channel geometries that optimize cooling efficiency.

Inventive Principle:

Principle #35Parameter changes

4Temperature

If external cooling circuits and separate heat exchanger components are used, then cooling function is provided, but imaging angle flexibility is limited

Engineering Contradiction:

Improvecooling functionVSAvoidimaging angle flexibility

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The heat exchanger channels are integrated directly into the casing structure, merging the cooling function with the structural component. This eliminates separate external cooling circuits and reduces overall size while maintaining effective heat dissipation from the x-ray tube insert.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design reduces weight and size while enhancing cooling efficiency, allowing for improved imaging angles and reduced costs by integrating cooling functions within the casing and accommodating thermal expansion.

Implementation Method 1

The cooling fluid is directed into the passages to remove heat from the x-ray tube insert

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The bellows is deformable in response to pressure changes within the casing to accommodate expansion of the cooling fluid

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10806014B2X-ray tube casing with integral heat exchanger

Publication Date: 2020.10.13 GE PRECISION HEALTHCARE LLC

AI summary

An x-ray tube casing is provided which includes a housing having a heat exchanger integrally formed thereon in an additive manufacturing process. The additive manufacturing process allows for tight tolerances with regard to the structure for the casing and the internal passages of the heat exchanger to significantly reduce the size and weight of the casing. The casing additionally includes a fluid distribution manifold that effectively distributes the cooling fluid within the casing to more efficiently provide cooling to the x-ray tube insert disposed within the casing.