Lead free barium sulfate electrical insulator and method of manufacture

Abstract

A high voltage insulator and radiation shield made of barium sulfate composite having a polymer matrix and barium sulfate therein. The device may be made by casting. By means of use of various combinations of barium sulfate, other radiologically resistant materials, polymers, and third components, the physical, radiological and electrical properties of the finished products may be tailored to achieve desired properties. In addition, the invention teaches that radiation shielding, insulators, and combined radiation shield/insulators may be fashioned from the composite. A wide range of production methods may be employed, including but not limited to liquid resin casting.

1. A high voltage insulating radiation enclosure comprising:
 a first truncated cone section and a second truncated cone section;   the two truncated cone sections secured together at their respective bases by an overlap joint;   an interior space defined by the two truncated cones sections;   the first and second truncated cone sections having walls, the walls made of a material comprising:
 a) a polymer matrix and 
 b) barium sulfate within the polymer matrix in an approximate amount of at least 10% by volume; 
   a first emission port passing through at least one wall;   a second electrical port passing through at least one walls.   
     
     
       2. The high voltage insulating radiation enclosure of  claim 1 , further comprising an X-ray tube disposed within the hollow body. 
     
     
       3. The high voltage insulating radiation enclosure of  claim 1 , further comprising at least one oil port passing through the walls. 
     
     
       4. The high voltage insulating radiation enclosure of  claim 1 , wherein the polymer matrix comprises at least one member selected from the following group: epoxy, polyester, polyurethane, silicone rubber, bismaleimides, polyimides, vinylesters, urethane hybrids, polyurea elastomer, phenolics, cyanates, cellulose, flouro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyetherimide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene flouride, acrylic, homopolymers, acetates, copolymers, acrlonitrile-butadiene-stryene, flouropolymers, ionimers, polyamides, polyamide-imides, polyacrylates, polyether ketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, stryrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, allyls, aminos, polyphenylene oxide, and combinations thereof. 
     
     
       5. The high voltage insulating radiation enclosure of  claim 1 , wherein the polymer matrix comprises epoxy resin is an approximate amount of 50% to 70% by volume. 
     
     
       6. The high voltage insulating radiation enclosure of  claim 1 , further comprising:
 c) a third material.   
     
     
       7. The high voltage insulating radiation enclosure of  claim 6 , wherein the third material comprises at least one member selected from the following group: electrically insulating materials, binders, high density materials and combinations thereof. 
     
     
       8. The high voltage insulating radiation enclosure of  claim 6 , wherein the third material comprises at least one member selected from the following group: tungsten, lead, platinum, gold, silver, tantalum, calcium carbonate, hydrated alumina, tabular alumina, silica, glass beads, glass fibers, magnesium oxide/sulfate, wollastonite, stainless steel fibers, copper, carbonyl iron, iron, molybdenum, nickel and combinations thereof. 
     
     
       9. An electrical insulator for an ion source, the insulator comprising:
 a generally annular body having a diameter of at least 6 inches; 
 the body having at least one vacuum sealing surface dimensioned and configured to provide a tight seal; 
 at least one alignment pin projecting from the vacuum sealing surface of the insulator; 
 at least one metal insert secured to the body; 
 the body made of a material comprising:
 a. a polymer matrix and 
 b. barium sulfate within the polymer matrix in an approximate amount of at least 35% by volume. 
 
 
     
     
       10. The electrical insulator of claim 9, further comprising at least one element selected from alignment pins projecting from the vacuum sealing surface of the insulator, metal inserts secured to the body, and combinations thereof. 
     
     
       11. The electrical insulator of claim 9, further comprising a third material selected from the group consisting of electrically insulating materials, binders, high density materials, and combinations thereof. 
     
     
       12. The electrical insulator of claim 11, wherein the third material comprises at least one member selected from the group of tungsten, lead, platinum, gold, silver, tantalum, calcium carbonate, hydrated alumina, tabular alumina, silica, glass beads, glass fibers, magnesium oxide/sulfate, wollastonite, stainless steel fibers, copper, carbonyl iron, iron, molybdenum, nickel and combinations thereof. 
     
     
       13. The electrical insulator of claim 9, wherein the polymer matrix comprises at least one member selected from the following group: epoxy, polyester, polyurethane, silicone rubber, bismaleimides, polyimides, vinylesters, urethane hybrids, polyurea elastomer, phenolics, cyanates, cellulose, flouro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyetherimide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene flouride, acrylic, homopolymers, acetates, copolymers, acrylonitrile-butadiene-styrene, flouropolymers, ionimers, polyamides, polyamide-imides, polyacrylates, polyether ketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, stryrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, allyls, aminos, polyphenylene oxide, and combinations thereof. 
     
     
       14. The electrical insulator of claim 9, wherein the polymer matrix comprises epoxy resin in an approximate amount between about 50% and about 70% by volume. 
     
     
       15. A high voltage insulating radiation enclosure comprising:
 a first truncated cone section and a second truncated cone section;   the two truncated cone sections secured together at their respective bases by an overlap joint;   an interior space defined by the two truncated cone sections;   the first and second truncated cone sections having walls, the walls made of a material comprising:   a) a polymer matrix; and   b) barium sulfate within the polymer matrix in an approximate amount of at least 10% by volume;   a first emission port passing through at least one wall; and   a second electrical port passing through at least one wall.   
     
     
       16. The high voltage insulating radiation enclosure of claim 15, further comprising an X-ray tube disposed within the hollow body. 
     
     
       17. The high voltage insulating radiation enclosure of claim 15, further comprising at least one oil port passing through at least one wall. 
     
     
       18. The high voltage insulating radiation enclosure of claim 15, wherein the polymer matrix comprises at least one member selected from the following group: epoxy, polyester, polyurethane, silicone rubber, bismaleimides, polyimides, vinylesters, urethane hybrids, polyurea elastomer, phenolics, cyanates, cellulose, flouro-polymer, ethylene inter-polymer alloy elastomer, ethylene vinyl acetate, nylon, polyetherimide, polyester elastomer, polyester sulfone, polyphenyl amide, polypropylene, polyvinylidene flouride, acrylic, homopolymers, acetates, copolymers, acrlonitrile-butadiene-styrene, flouropolymers, ionimers, polyamides, polyamide-imides, polyacrylates, polyether ketones, polyaryl-sulfones, polybenzimidazoles, polycarbonates, polybutylene, terephthalates, polyether sulfones, thermoplastic polyimides, thermoplastic polyurethanes, polyphenylene sulfides, polyethylene, polypropylene, polysulfones, polyvinylchlorides, stryrene acrylonitriles, polystyrenes, polyphenylene, ether blends, styrene maleic anhydrides, allyls, aminos, polyphenylene oxide, and combinations thereof. 
     
     
       19. The high voltage insulating radiation enclosure of claim 15, wherein the polymer matrix comprises epoxy resin is an approximate amount of 50% to 70% by volume. 
     
     
       20. The high voltage insulating radiation enclosure of claim 15, further comprising:
 c) a third material.   
     
     
       21. The high voltage insulating radiation enclosure of claim 20, wherein the third material comprises at least one member selected from the following group: electrically insulating materials, binders, high density materials and combinations thereof. 
     
     
       22. The high voltage insulating radiation enclosure of claim 20, wherein the third material comprises at least one member selected from the following group: tungsten, lead, platinum, gold, silver, tantalum, calcium carbonate, hydrated alumina, tabular alumina, silica, glass beads, glass fibers, magnesium oxide/sulfate, wollastonite, stainless steel fibers, copper, carbonyl iron, molybdenum, nickel and combinations thereof.