X-ray Source Voltage Shield with Liquid Potting Insulation
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Solution Overview
Problem
Existing x-ray sources face challenges in achieving high power while maintaining small size and light weight, are costly due to complex manufacturing processes, and suffer from stray x-ray emission and electromagnetic interference issues.
Innovation Solution
The development of shielded power supplies and x-ray sources that incorporate a shield wrapping around the x-ray tube or voltage multiplier with a gap, filled with a liquid potting compound that cures into a solid insulative material, reducing size, weight, and electromagnetic interference, and enhancing electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power is increased, then x-ray source power increases, but size and weight must be increased due to increased electrical insulation needed for voltage isolation
Solution Approach 1:
The patent changes the physical state of the insulation material from solid to liquid, allowing it to be injected into and fill the gaps between high-voltage components. This liquid-to-solid transformation enables the insulation material to adapt to complex geometries and completely fill void spaces, achieving superior electrical insulation with reduced material volume and weight compared to traditional solid insulation structures.
Solution Approach 2:
The patent employs liquid insulation material that can be injected and pumped into the x-ray source assembly, utilizing fluid dynamics principles to deliver the material through narrow passages and ensure complete filling of gaps between components. This hydraulic approach enables precise placement of insulation material without requiring heavy mechanical assembly processes.
2Power
If high power is increased, then x-ray source power increases, but device complexity increases due to increased electrical insulation needed for voltage isolation
Solution Approach 1:
The patent merges multiple functions into the liquid insulation material: electrical insulation, structural support, thermal management, and gap filling. By combining these functions into a single material system, the patent eliminates the need for separate insulation components, brackets, and assembly procedures, thereby reducing device complexity while maintaining high power capability.
Solution Approach 2:
The patent utilizes composite material properties by combining the insulating characteristics of dielectric materials with the fluidity and adaptability of liquids. The liquid insulation material can be formulated with specific dielectric strength, viscosity, and curing properties to simultaneously provide electrical isolation and structural integrity, reducing the need for additional protective components.
3Ease of manufacture
If manufacturing process is simplified, then cost decreases, but manufacturing precision may be compromised
Solution Approach 1:
The patent performs preliminary preparation by formulating the insulation material in a liquid state with optimized rheological properties before injection. This pre-preparation ensures that the material flows easily into all gaps and voids during the injection process, achieving complete and uniform insulation coverage without requiring complex assembly fixtures or multi-step procedures, thus maintaining both simplicity and precision.
Solution Approach 2:
The patent exploits the phase transition of the insulation material from liquid to solid after injection. The material is injected in liquid form to ensure complete filling of gaps, then cures or solidifies in place to provide permanent structural and electrical insulation. This phase change ensures high manufacturing precision while keeping the process simple, as the material self-sets without requiring additional bonding or fastening steps.
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 approach results in smaller, lighter, and more cost-effective x-ray sources with reduced arcing failures and electromagnetic interference, improving manufacturing efficiency and safety by blocking stray x-rays and optimizing electrical insulation.
Implementation Method 1
inserting a liquid x-ray tube potting compound into the gap
Implementation Method 2
curing the x-ray tube potting compound into a solid electrically insulative material
Implementation Method 3
inserting a liquid power supply potting compound into the gap
Implementation Method 4
curing the power supply potting compound into solid power supply insulation
Implementation Method 5
Blocking x-rays
Implementation Method 6
curing the x-ray tube potting compound into a solid electrically insulative material
Implementation Method 7
reducing unwanted electromagnetic interference
Data Source
AI summary
A shield around an x-ray tube, a voltage multiplier, or both can improve the manufacturing process by allowing testing earlier in the process and by providing a holder for liquid potting material. The shield can also improve voltage standoff. A shielded x-ray tube can be electrically coupled to a shielded power supply.