X-ray Tube Thrust Flange Cooling Channels
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Solution Overview
Problem
X-ray tube bearings face challenges with thermal deformation and fluid leakage due to the use of low thermal conductivity materials like steel, which are prone to thermal gradients and expansion, leading to non-uniform bearing deflections and reduced lifespan.
Innovation Solution
A liquid metal or spiral groove bearing structure with a journal bearing shaft and a radially protruding thrust bearing flange, incorporating a cooling fluid passage and channels within the thrust flange to enhance heat transfer, allowing the use of lower thermal conductivity materials like steel while maintaining effective cooling and reducing thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steel is used for the bearing shaft and thrust flange, then manufacturing cost is reduced and ease of manufacture is improved, but thermal conductivity is insufficient leading to thermal deformation and fluid leakage
Solution Approach 1:
The patent employs a composite material structure where a steel bearing shaft and thrust flange are coated with a corrosion-resistant material layer (such as nickel, chromium, or ceramic coating). This composite approach combines the manufacturing advantages of steel with the thermal and corrosion resistance properties of specialized materials, thereby maintaining reliability while improving ease of manufacture.
Solution Approach 2:
The patent modifies the surface properties of the steel components through thermal treatment, surface hardening, or coating applications. These parameter changes enhance the thermal conductivity and corrosion resistance of the steel surfaces without changing the base material, thus maintaining manufacturing ease while improving reliability against thermal deformation and fluid leakage.
2Reliability
If refractory materials like molybdenum or tungsten are used, then resistance to corrosion and high temperatures is improved, but difficulty of machining increases and manufacturing precision deteriorates
Solution Approach 1:
The patent divides the bearing assembly into two functional segments: the bearing shaft and thrust flange are made of machinable steel, while a separate corrosion-resistant coating or lining is applied to the surfaces contacting the liquid metal. This segmentation allows each component to be optimized independently - the steel for manufacturing precision and the coating for corrosion resistance.
Solution Approach 2:
The patent introduces an intermediary layer (coating or lining) between the steel bearing components and the liquid metal bearing material. This intermediary layer provides the corrosion and high-temperature resistance normally associated with refractory materials, while the underlying steel structure maintains manufacturing precision and ease of fabrication.
3Ease of manufacture
If steel is used for the bearing structure, then ease of manufacture is improved, but thermal gradients cause non-uniform bearing deflections reducing reliability
Solution Approach 1:
The patent applies thermal management techniques such as controlled cooling channels, thermal barriers, or surface treatments to steel bearing components. These parameter changes reduce thermal gradients within the steel structure, preventing non-uniform thermal expansion and maintaining stable bearing deflections while preserving the manufacturing advantages of steel.
Solution Approach 2:
The patent uses composite material construction where steel components are combined with materials having different thermal expansion coefficients or superior thermal conductivity. This composite structure compensates for thermal gradients in the steel, maintaining dimensional stability and uniform bearing deflections while retaining the ease of steel manufacturing.
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 improves heat transfer and reduces thermal deformation, extending the lifespan of the bearing assembly by minimizing fluid leakage and focal spot movement, while enabling the use of cost-effective materials.
Implementation Method 1
incorporating a cooling fluid passage and channels within the thrust flange to enhance heat transfer
Implementation Method 2
directing a flow of coolant through the channel within the thrust flange
Data Source
AI summary
A bearing structure for an X-ray tube is provided that includes a journal bearing shaft with a radially protruding thrust bearing flange encased within a bearing housing or sleeve. The sleeve includes a thrust seal that is engaged with the sleeve in a manner to maintain coaxiality for the rotating liquid metal seal formed in the sleeve about the shaft. The shaft includes a central bore containing a cooling tube that directs coolant within the bore to maximize the heat transfer from the shaft to the coolant, allowing materials with lower thermal conductivities, such as steel, to be used to form the bearing shaft. The thrust flange on the shaft is formed with channel(s) therein that enable the coolant and/or the liquid metal to effect greater heat transfer on the components of the sleeve through the thrust flange, thereby reducing thermal deformation of the bearing components.