Structured surface part for a radiation capturing device, method for producing such a part, and X-ray detector

Abstract

In conventional radiation capturing devices such as X-ray devices or CT scanners, structured surface parts (e.g. scintillator arrays) manufactured by mechanical processing (e.g. by cutting and grinding) are used. In order to modify the scintillation properties of the scintillating material, additional manufacturing steps such as high temperature cycles like sintering are performed in order to restore or at least improve the scintillation properties. The present application proposes the use of additive manufacturing using a photosensitive mixture to form a layer-by-layer structure to form a structured surface part with a particle structure in a binder containing scintillators or other radiation-related particles. Thus, subsequent manufacturing steps such as sintering can be omitted. The structured surface part is bendable.

Description

Technical Field

[0001] The present invention relates to a structured surface part which can be used in a radiation capturing device in security or medical applications, such as an X-ray device or a CT scanner. The invention also relates to an associated method of manufacturing such a surface part and an X-ray detector comprising the surface part in question. Background Art

[0002] In radiation capture devices such as X-ray devices or CT scanners, there are several applications for structured surface parts. For example, X-ray devices usually have a scintillator, which is irradiated by X-rays and converts the X-ray radiation into visible light, which is then converted into electric charge by a photodiode. However, there are also such applications, in which, for example, a collimator is used to modulate a series of X-rays by allowing only, for example, parallel X-rays to pass. As a further application, a filter that removes part of the X-ray spectrum can be arranged in the beam path. What these traditional structured surface parts have in common is that they are manufactured by mechanical processing (for example by cutting and grinding). For example, in the case of scintillators, this has the disadvantage that cutting and grinding must be performed on relatively hard materials, which leads to relatively slow production and corresponding high production costs. However, alternative manufacturing processes such as injecting scintillating materials into molds also have disadvantages, for example, in terms of the accuracy of the surface structure that can be achieved.

[0003] US 2007 / 0138409 discloses a method of forming an X-ray conversion screen. The method uses a mold that injection molds a scintillating material layer including a cavity into a scintillating material layer. By repeated injection molding, a phosphor layer is built up. The cavity can be filled with a pixel unit separation material or coated with a reflective material such as sputtered metal to optically isolate each pixel.

[0004] WO 2015 / 118533 discloses a process for making a three-dimensional scintillator material. A pattern of a scintillator formulation is formed on a surface area, wherein the formulation includes at least one prepolymer that can be polymerized into a polymer and at least one photoinitiator. Polymerization of the at least one prepolymer forming the pattern is then affected. Then, a further pattern is formed on the polymerized pattern. These steps are repeated to provide a three-dimensional structure.

[0005] US 2009 / 0039562 A1 discloses a method for producing an anti-scatter grid or collimator for a radiation type, the anti-scatter grid or collimator being formed by at least one substrate having a predictable geometry with a transmission channel or slit for the primary radiation of the radiation type extending between two opposite surfaces of the substrate. The substrate is formed from a structural material that strongly absorbs the radiation type using injection molding techniques or by means of stereolithography techniques.

[0006] WO 2010 / 047494 A2 describes a flexible X-ray image sensor that can be flexibly bent during imaging of a surface of a structure. The flexible X-ray image sensor comprises a flexible polymer plate, a flexible light detection device and a flexible scintillator panel.

[0007] US 2013 / 058452 A1 describes a scintillator element comprising an uncured scintillator material and being formed and optically cured to produce a cured scintillator element. The uncured scintillator material suitably combines at least a scintillator material powder with an uncured polymeric host. In a reel-to-reel process, a flexible array of optical detectors is transferred from a source reel to a take-up reel, and the uncured scintillator material is disposed on the flexible array and optically cured during said transfer. Summary of the invention

[0008] Therefore, the object of the present invention is to overcome the above mentioned disadvantages and to provide an improved surface part applicable for radiation capturing devices which can ideally be manufactured with less effort.The object of the present invention is solved by the subject matter of the attached independent claims, wherein further embodiments are contained in the dependent claims.

[0009] According to a first aspect, a structured surface part is provided which is applicable in a radiation capturing device, in particular a structured surface part to be irradiated in such a device, for example in an X-ray device or a CT scanner.

[0010] In the present description, a "structured surface feature" may in particular be understood as a feature having, for example, a grid-like surface, a pixelated surface, etc. It may also have radiation spectrum filtering or radiation shielding properties.

[0011] The structured surface part comprises:

[0012] An arrangement area which defines at least one surface area of ​​the structured surface element.

[0013] In this specification, a layout area may be a virtual or physical area, which may be flat or curved.

[0014] - a plurality of protrusions arranged on the arrangement area, preferably in the surface area, wherein the protrusions comprise a photosensitive material mixture comprising at least particles having radiation-related properties, a binder and a curing photosensitive component.

[0015] In this specification, particles with "radiation-dependent properties" may be understood in particular as particles that can be activated by radiation and react accordingly (or shield or absorb radiation). In the following, such particles may also be referred to as radiation-dependent particles.

[0016] These particles and / or cured photosensitive components can be initially dispersed in a binder (e.g., before or at the beginning of manufacturing a structured surface feature), wherein the particle structure in the binder is formed and, ideally, at least largely retained in the current structured surface feature.

[0017] The protrusions can be arranged in a grid, wherein the protrusions can be connected to each other, or can form an array, for example, of pixels, wherein the protrusions are arranged individually, preferably with a uniform distance to each other. The height dimension of the protrusions can vary depending on the application, wherein, for example, in scintillator applications, a height of 0.1 to 10 mm, preferably 0.1 to 5 mm, more preferably 0.1 to 2 mm has proven to be particularly advantageous. In the case of, for example, radiation shielding applications, the height dimension can be adapted to the type of radiation, wherein a height of 0.5 to 100 mm is advantageous.

[0018] - In addition, the protrusions may also comprise several layers, one on top of another, in a direction pointing away from the surface area or perpendicular to the surface area (eg oriented at an angle). All or at least most of these layers may contain at least part of the cured photosensitive composition.

[0019] Ideally, the individual layers are uniform, but individual layers may be slightly smaller or larger in area than other layers.

[0020] The structured surface part is bendable and / or flexible. This is achieved by adding non-polymerizable materials to polymerizable materials. These combinations of materials can be dispersed in an adhesive, or a combination of these materials can form an adhesive. Alternatively or additionally, the arrangement area can have material properties that allow the structured surface part to be bendable and / or flexible. The bending can be performed selectively, that is, it can be bent back and forth at different bending angles, and can be repeated many times to make the structured surface part suitable for various imaging tasks. Therefore, under the bendability and flexibility, it can be understood that the shape of the structured surface part can be changed several times depending on the corresponding imaging task.

[0021] The advantageous effect of the surface part is that additive manufacturing processes such as 3D printing (e.g., stereolithography) can be used, which allow the immediate use of the structured surface part in radiation capture devices for security or medical applications. In particular, since the particles can be present in a particle structure in a binder and a layer-by-layer arrangement of protrusions is formed by using a photosensitive component, no further heat treatment or high temperature cycle such as sintering is required, as is necessary in previous mechanical manufacturing processes to remove the bonding material and / or restore or improve the initial properties of these particles after applying the radiation-related particles. Therefore, the radiation-related properties of the particles in the particle structure in the binder do not change during the formation of the structure, especially in the case where a subsequent heat treatment will be applied. Therefore, at least one of the above-mentioned disadvantages can be overcome. In addition, before the surface part manufacturing process itself, the properties of the starting material mixture can be formulated and customized for each specific irradiation application. In addition, in the case of individually arranged protrusions and compared to previous casting processes, the gaps between individual protrusions can be made particularly small. This is particularly advantageous when using a structured surface part as a scintillator, because this has a particularly high efficiency. Thus, for example, relatively small gaps of 0.04 to 0.4 mm between individual protrusions may be achieved.

[0022] In an embodiment, the photosensitive component is selected from or combined with: acrylate monomers, oligomers and modified acrylates.

[0023] These starting materials are particularly suitable for photopolymerization, which is also known as stereolithography. The component can be dispersed in the starting material mixture or in a portion thereof and due to its curing properties is suitable for easy curing by light such as a UV laser beam as a light source controlled by a microcontroller or other computing unit.

[0024] Optionally, the adhesive is an organic adhesive and may be selected from or combined among, inter alia: acrylates, epoxies, polyurethanes and silicones.

[0025] At least some of the components of the material mixture may initially be in powder form, which may then be dispersed in a binder or mixed with a binder, thereby creating an organic-inorganic system that can be photopolymerized, for example in the form of a paste, suspension, etc. In particular, the radiation-related particles may initially be dispersed in a binder and may additionally also be retained in the binder in a particle structure during use of the structured surface part.

[0026] In an embodiment, the binder material and the photosensitive component material may be the same.

[0027] This simplifies the preparation and supply of the starting material mixture. In this case, the binder material can have photopolymerization properties and can still be suitable for building a particle structure in the binder with radiation-related particles. Optionally, the photosensitive material mixture contains at least one scintillating material and / or the above preferably organic binder material, preferably dispersed in the binder in powder form or mixed with the binder, in the initial state.

[0028] The starting scintillating material may have been annealed, sintered or otherwise treated under suitable conditions. Due to the dispersion of the material, the protrusions also have scintillation properties caused by the dispersed scintillating material. In this case, the structured surface part can be applied to an X-ray device as a structured scintillator, which generates light when irradiated with radiation. In addition, before the manufacturing process of the structured surface element, the properties of the starting scintillator material can be formulated and customized for each specific imaging application. This is advantageous for providing, for example, a large area scintillator with a high modulation transfer function (MTF) and especially a low afterglow effect, thereby providing a fast scintillator.

[0029] For example, good results have been achieved using, for example, GdO2S2:Pr.

[0030] In other applications where high light output is desired, GdO2S2:Tb may be used.

[0031] In an embodiment, a first layer of a corresponding protrusion may contain a first scintillating material, while a second layer of the same protrusion may contain a second scintillating material having a different composition and, therefore, different properties than the first material.

[0032] As a possible consequence, the first and second layers having different scintillation properties may generate first and second radiations also having different properties.Thus, it may be distinguished whether radiation has been generated in a respective upper or lower part of the scintillator.

[0033] Optionally, the structured surface feature is a scintillator array, wherein the protrusions are individual pixels each having scintillation properties.

[0034] The pixels of the individual arrangements may preferably be spaced apart at equal intervals within the same surface area as defined in particular by the arrangement area.

[0035] This provides a pixelated scintillator with a particularly small gap between the individual pixels, which effects a high efficiency as well as a high light sensitivity. Due to the pixelated structure, for example the spatial resolution of a scintillator or an X-ray device can be improved.

[0036] Additionally, optionally, the substrate physically defines the arrangement area of ​​the structured surface features and the at least one surface region.

[0037] For example, the substrate may be a homogenous material such as a plastic (e.g. carbon, polyimide) provided as a foil or sheet, a metal (e.g. aluminum) provided as a foil or sheet, or paper. The substrate has mechanical properties that enable the structured part to be flexible and / or bendable.

[0038] In an embodiment, the single protrusion is at least partially covered by the reflector, ideally completely covered by the reflector.

[0039] Reflectors have properties that allow at least partial reflection of radiation. Thus, by applying reflectors, for example, the radiation absorption of structured surface parts can be improved. In addition, the relative light output of such structures used as scintillators can be improved compared to protrusions without reflectors or left empty. And, compared to empty protrusions, the MTF can be optimized.

[0040] Optionally, the reflector comprises at least one top reflector layer arranged on at least the outermost layer or as a plurality of outer layers of the respective pixel and facing away from the substrate or a surface area thereof.

[0041] The top reflector layer prevents leakage of radiation in the direction of the top layer. Advantageously, this results in any generated light protruding away from the photosensitive array to which the scintillator may be attached being reflected back towards the photosensitive array. The application of the top reflector layer may be performed after application of several layers on the substrate and thus forms the uppermost layer. However, it differs in its reflective properties from the photosensitive material mixture of the other layers of the protrusion.

[0042] In an embodiment, the reflector may comprise at least one inter-pixel reflector layer arranged in the gap between two individual pixels.

[0043] Inter-pixel reflectors can further increase efficiency by also directing radiation between pixels in a preferred direction and steer the light beam towards the pixels. This can result in an even more improved light output and optimized MTF.

[0044] In other words, preferably reflectors may be arranged between individual protrusions or pixels, except for one on top of a pixel.Thereby, the light output of the surface part may be further improved.

[0045] Optionally, the reflector may be provided as reflective particles, preferably in an organic binder.

[0046] These reflective particles can be selected or combined from: TiO2, ZrO2, Al2O3, etc., dispersed, mixed or dissolved in an organic binder material such as epoxy or silicone. Therefore, the properties of the reflector can be formulated and customized for each specific imaging application. In addition, the reflector can be applied by the same manufacturing method as the protrusions or pixels.

[0047] Optionally, the reflector member may be a reflective film or sheet. By using a reflective sheet, a light absorbing layer may be applied for further optimizing the MTF. For example, a suitable reflective sheet is available as so-called Vicuity tape provided by 3M.

[0048] For the actual use of the structured surface part, as explained above, a reflector can be applied on top of the pixel. Then, the substrate explained above to which the pixel on the opposite side of the top reflector is applied is removed. This can be done by grinding, for example.

[0049] Optionally, the above-mentioned substrate can be selected to have reflective properties, for example, by using white paper or aluminum. Thus, the substrate itself can form a reflector, in particular in a continuous manner, thereby forming the top side of the protrusion or scintillator pixel. In more detail, the protrusion or scintillator pixel can be formed directly on top of the paper or aluminum substrate, in particular 3D printed on top of the paper or aluminum substrate, wherein the substrate simultaneously forms the reflector.

[0050] Optionally, the reflector has a strength of less than 10000 N / mm 2 or an elastic modulus of 10 GPa, preferably less than 3000 N / mm 2 Or an elastic modulus of 3GPa.

[0051] This advantageously results in the structured surface part being more flexible or bendable within mechanical limits.Thus, the structured surface part can be used as a flexible scintillator for applications in medicine such as dentistry, or in security X-ray devices.

[0052] As an alternative to using structured surface parts as scintillators, the photosensitive material mixture may contain a radiation shielding material dispersed or mixed in the material mixture (ie in the photosensitive component and / or the binder), wherein the radiation shielding material is suitable for shielding, for example, X-rays or gamma rays.

[0053] Thus, the structured surface part can also be used in radiation shielding applications, wherein the protrusions have radiation shielding properties and can be connected to each other instead of the above-mentioned spaced arrangement. For example, such a structured surface part can be used in, for example, X-ray shielding applications, such as collimators or grids. The radiation shielding material can be applied as metal particles, such as Mo, Pb, Ta or W.

[0054] According to a second aspect, an X-ray detector is provided, which comprises a structured surface part of one or more of the embodiments explained above. The X-ray detector comprises:

[0055] - Structured surface features, such as pixelated scintillator arrays, have a plurality of pixels individually arranged on a substrate.

[0056] The substrate can be, for example, a homogenous material, such as plastic (e.g. carbon, polyimide), metal (e.g. aluminum) or paper. Optionally, the top reflector explained above can simultaneously form the substrate. The substrate has material properties that allow flexible and / or bendable structured surface parts.

[0057] - An optical detector arranged in optical communication with the structured surface feature. The optical detector may have a structure and / or material properties allowing flexibility and / or bendability, so that the shape of the optical detector may be adapted to the structured surface feature and to various imaging tasks.

[0058] - In addition, a single pixel comprises several layers one above the other in a direction pointing away from or perpendicular to the surface area of ​​the substrate.

[0059] - In addition, a single pixel comprises a photosensitive material mixture comprising at least a scintillation material, a binder and a cured photosensitive component.

[0060] Since the scintillating material, which is preferably present in particles, ideally has a particle-in-binder structure, the X-ray device can be manufactured with less effort. In particular, the binder does not have to be removed compared to previous manufacturing methods. More precisely, a heat treatment, such as sintering, can be omitted at the end of the manufacturing process of the scintillator. Therefore, the scintillation properties of the scintillating material are not changed by the heat treatment, and therefore, the scintillation properties of the starting scintillator are preserved. This results in improved X-ray absorption, relative light output and MTF.

[0061] According to a third aspect of the present invention, a method for manufacturing a structured surface part is provided. The method comprises the following steps:

[0062] - Providing a substrate defining a surface area. The substrate may be bendable and / or flexible.

[0063] - providing a photosensitive material mixture comprising at least particles having radiation-dependent properties, a binder and a curing photosensitive component.

[0064] - applying the photosensitive material mixture to the surface area layer by layer, one layer above the other, in such a way that a protuberance comprising several layers is formed.

[0065] - In addition, between the applications of the respective layers, the photosensitive material is cured with the aid of a light source.

[0066] In addition, the adhesive and / or the photosensitive component is retained in the protrusions so as to still be present in the use of the structured surface element.

[0067] Since the scintillating material preferably present in the particles ideally has a particle-in-binder structure, the binder does not have to be removed by a heat treatment such as sintering after the protrusions are formed. Therefore, the radiation-related properties are not changed by the heat treatment, thereby enabling better performance of the structured surface part.

[0068] - In addition, it is provided that the structured surface element is bendable.

[0069] - Additionally, the bendability properties are adjusted by combining a non-polymerizable material with the photosensitive component.

[0070] In an embodiment, the layer-by-layer application of the photosensitive material mixture can be performed on a substrate, which is selected to be reflective, such as white paper or aluminum. Thus, the substrate itself can form a continuous reflector on top of the protrusions. This provides a particularly efficient pixelated scintillator having pixels (i.e., protrusions) on which reflectors are arranged.

[0071] Alternatively, the reflector may be applied on top of the protrusions (ie, scintillator pixels) formed layer by layer, and the substrate on which the pixels are formed removed, for example by grinding.

[0072] It will be appreciated that a preferred embodiment of the invention can also be any combination of the dependent claims with the respective independent claim.These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] Exemplary embodiments of the present invention will be described in the following drawings. In the following drawings:

[0074] Figure 1 An embodiment of an X-ray detector according to the second aspect comprising a structured surface part according to the first aspect is shown schematically and exemplarily.

[0075] Figure 2A A side view of an embodiment of a third structured surface feature according to the first aspect is schematically and exemplarily shown.

[0076] Figure 2B A side view of an embodiment of a fourth structured surface part according to the first aspect is schematically and exemplarily shown.

[0077] Figure 3 Parts of further embodiments of the structured surface part according to the first aspect are shown schematically and exemplarily.

[0078] Figure 4An embodiment is shown which exemplarily illustrates a production method according to the third aspect for producing a structured surface part according to the first aspect.

[0079] Reference numerals list

[0080] 100 X-ray detectors

[0081] 110 X-ray radiation source

[0082] 120 Collimator

[0083] 130 Radiation Beam

[0084] 140 first structured surface component (eg, collimator)

[0085] 141 layout area (eg, substrate)

[0086] 142 Multiple protrusions

[0087] 143 multiple layers

[0088] 150 second structured surface part (eg, filter)

[0089] 151 layout area (eg, substrate)

[0090] 152 Multiple protrusions

[0091] 153 multiple layers

[0092] 160 objects

[0093] 170 Detection Equipment

[0094] 180 Third structured surface part (e.g., anti-scattering grid)

[0095] 181 layout area (eg, substrate)

[0096] 182 Multiple protrusions

[0097] 183 multiple layers

[0098] 190 Fourth structured surface component (eg, scintillator array)

[0099] 191 layout area (e.g., substrate)

[0100] 192 protrusions / pixel

[0101] 193 multiple layers

[0102] 194 Top reflector

[0103] 195 Inter-Pixel Reflector

[0104] 196 First Floor

[0105] 197 Second Floor

[0106] 198 First Radiation

[0107] 199 Second Radiation

[0108] 200 Optical detectors

[0109] 201 First Detection Unit

[0110] 202 Second detection unit

[0111] 210 Electronic converter

[0112] 220 Monitor

[0113] D Distance

[0114] H Height

[0115] W Width

[0116] S1 Method Step 1

[0117] S2 Method Step 2

[0118] S3 Method Step 3

[0119] S4 Method Step 4

[0120] S5 Method Step 5 DETAILED DESCRIPTION

[0121] Figure 1 An embodiment of an X-ray detector 100 as an example of a radiation capture device or an object imaging device is schematically and exemplarily shown. The X-ray detector 100 comprises an X-ray radiation source 110 capable of generating X-ray radiation, a collimator 120 arranged adjacent to the radiation source 110 and adapted to narrow the spatial extension of a radiation beam 130, in particular an X-ray beam, generated by the radiation source 110. For this purpose, the collimator 120 comprises a first structured surface part 140 which will be described in more detail below. In this embodiment, a second structured surface part 150 in the form of a filter capable of modifying the X-ray spectrum emitted by the radiation beam 130 is arranged in the beam path. The second structured surface part 150 will also be described in more detail below.

[0122] The radiation beam 130 is here focused on an object 160 to be examined, which is penetrated by the radiation beam 130 when the radiation source 110 is activated.

[0123] On the side opposite to the radiation source 110 of the object 160, a detection device 170 of the X-ray detector 100 is arranged. This comprises a third structured surface part 180, in particular an anti-scatter grid, arranged in the beam path of the radiation beam 130 to reduce its scattered radiation for downstream components, and this will be described in more detail below.

[0124] The detection device 170 of this embodiment also includes a fourth structured surface part 190 arranged downstream of the third structured surface part 180 in the direction of the beam path. The function of the fourth structured surface part 190 is different from that of the structured surface parts 140, 150 and 180 mentioned above, because the fourth structured surface part 190 is a scintillator capable of converting the incident X-ray radiation beam 130 into visible light. The fourth structured surface part 190 will also be described in more detail below.

[0125] The detection device 170 further comprises an optical detector 200 in the form of a photodiode array, which is arranged in optical communication with the fourth structured surface part 190 (i.e., the scintillator) and is capable of converting the visible light of the second structured surface part 190 into electric charge. An electronic converter 210 (e.g., an A / D converter) is suitable for converting the electric charge so that a corresponding image of the object 160 is displayed on the monitor 220.

[0126] In the following, four structured surface parts 140, 150, 180 and 190 are described in more detail. Accordingly, these have in common that they each have a (in some embodiments, only virtual) arrangement area 141, 151, 181, 191 defining a two-dimensional surface area of ​​the respective structured surface part 140, 150, 180 and 190. On the respective surface area or within the respective arrangement area 141, 151, 181, 191, a respective plurality of protrusions 142, 152, 182 and 192 are arranged, wherein their arrangement and orientation depends on which of the above-mentioned applications within the X-ray detector 100 the respective surface part 140, 150, 180, 190 is provided to. In addition, the structured surface parts 140, 150, 180 and 190 have in common that their protrusions 142, 152, 182, 192 are each formed layer by layer from a photosensitive material mixture containing at least specific particles having radiation-related properties suitable for the respective purpose. The specific particles are combined with a binder and a curing photosensitive component, wherein the binder is an organic binder, such as acrylate, epoxy resin, polyurethane or silicone. The photosensitive component is made of, for example, acrylate monomers, oligomers and modified acrylates, and is cured by photopolymerization, as will be described in more detail below. Note that the specific particles are present in the particle structure in the binder.

[0127] In addition, it is noted that in order to avoid repetition, only two exemplary embodiments of the four structured surface parts 140, 150, 180, 190 are described below, namely, a third structured surface part 180 in which the particles have radiation shielding properties (i.e., an anti-scatter grid) and a fourth structured surface part 190 in which the particles are suitable for having scintillation properties (i.e., a scintillator).

[0128] Therefore and refer to Figure 2A , the third structured surface part 180 of the detection device 170, i.e. the anti-scatter grid, will now be described in more detail by way of example. In this embodiment, the arrangement area 181 of the third structured surface part 180 is a physical substrate having a two-dimensional surface defining the surface area of ​​the first structured surface part 140. On the surface of the substrate or in the surface area, a plurality of protrusions 182 are arranged in a grid-like manner and oriented along an angle (not shown) at which the X-ray radiation of the radiation beam 130 should reach the fourth structured surface part 190, i.e. the scintillator, arranged downstream thereof. The protrusions 182 are formed of the above-mentioned photosensitive material mixture containing at least metal particles having radiation-related properties, which are suitable for the purpose of being suitable for the anti-scatter grid, i.e. for partially shielding the X-ray radiation of the radiation beam 130. In this embodiment, for radiation shielding purposes, Pb-particles are used, wherein other metal particles having radiation shielding properties, such as Mo, Ta or W, are also suitable. The metal particles are combined with the above-mentioned binder and a curable photosensitive component, wherein the binder is an organic binder, such as acrylate, epoxy resin, polyurethane or silicone. The photosensitive component is made of, for example, acrylate monomers, oligomers and modified acrylates and is cured by photopolymerization, as will be described in more detail below. As already mentioned above, in the third structured surface part 180, the metal particles, i.e., here Pb particles, are present in the particle structure of the binder. As in Figure 2A As schematically indicated in the leftmost protrusion 182 in FIG. 1 , the protrusions 182 each comprise a plurality of layers 183 arranged one above the other. Due to the shielding properties of the protrusions 182, only the radiating portion of the radiation beam 130 may pass through the third structured surface part 180 properly aligned with the protrusions 182.

[0129] refer to Figure 2B, the fourth structured surface part 190 of the detection device 170 will now be described in more detail by way of example. Instead of providing radiation shielding, the fourth structured surface part 190 is used as a scintillator. Therefore, the arrangement area 191 of the fourth structured surface part 190 is a homogeneous substrate with a two-dimensional surface having a limited surface area, such as a plastic such as carbon or polyimide. As described in more detail below, in some embodiments, the substrate can be removed. On the surface of the substrate, a plurality of protrusions 192 are arranged in an array, each of the protrusions 192 being formed by the above-mentioned photosensitive material mixture containing at least particles having radiation-related properties suitable for the purpose of the scintillator (i.e., having scintillation properties). In this embodiment, GdOS:Pr or GdO2S2:Pr particles are used, wherein GdO2S2:Tb and the like are also suitable for this purpose, depending on the precise application of the X-ray device 100. Due to the use as a scintillator, the protrusions 192 of the fourth structured surface part 190 can be referred to as pixels forming a pixelated scintillator array.

[0130] The scintillating particles are combined with the above-mentioned adhesive and the cured photosensitive component, wherein the adhesive is an organic adhesive, such as acrylate, epoxy, polyurethane or silicone. The photosensitive component is made of, for example, acrylate monomers, oligomers and modified acrylates, and is cured by photopolymerization, which will be described in more detail below. Note that the scintillating particles form a particle structure in the adhesive, which is why the adhesive and the cured photosensitive component are actually present in the protrusion 192. As shown in FIG. Figure 2B As schematically indicated in the leftmost protrusion 192 , the protrusions 192 each include a plurality of layers 193 , arranged one layer above another.

[0131] In addition, if you can Figure 2B As can be seen in FIG. 1 , the pixels or protrusions 192 are arranged with gaps therebetween. Typically, the distance D or gap between individual pixels or protrusions 192 is 0.04 mm to 0.4 mm. The height H of the protrusions 192 is preferably between 0.1 mm and 10 mm, more preferably between 0.1 mm and 1 mm. The width W and / or length L are between 0.4 mm and 4 mm.

[0132] Note that relatively small gaps between pixels or protrusions 192 are possible due to the combination of the above mentioned particle structure in the (scintillating) adhesive and the manufacturing method of photopolymerization of the photosensitive component.

[0133] In addition, the protrusions 192 are covered by a continuous top reflector 194 arranged on the top layer of the layer 193 of each protrusion 192. Moreover, inter-pixel reflectors 195 are arranged between the individually arranged pixels or protrusions 192. In this regard, it is noted that for better illustration, Figure 2BThe reflectors 194, 195 in FIG. 1 are only spaced apart from the corresponding surfaces of the pixels or protrusions 192. In practice, the corresponding reflectors 194, 195 are in direct contact with the corresponding outer surfaces.

[0134] In this embodiment, both the top reflector 194 and the inter-pixel reflector 195 are formed as a layer covering the corresponding protrusion 192 or its outermost layer. They are exemplarily provided as reflective particles in an organic binder, such as TiO2 or ZrO2 or Al2O3. Here, the reflectors 194, 195 are provided with a pressure of less than 10000 N / mm 2 The elastic modulus is preferably provided to be less than 3000 N / mm 2 The elastic modulus is thus obtained, thereby obtaining a flexible fourth structured surface part 190 that can be used, for example, in a dental X-ray detector.

[0135] In addition, embodiments not shown have a top reflector provided as a reflective film or sheet.Other embodiments have a substrate formed of a reflective material such as aluminum or (white) paper, which simultaneously serves as a top reflector, in particular as top reflector 194.

[0136] Figure 3 A portion of a further embodiment of a pixel or protrusion 192 of a fourth structured surface part 190 (i.e., a scintillator) is shown, which pixel or protrusion comprises at least a first layer 196 and a second layer 197 with different scintillating material compositions, i.e., a respective first scintillating material and a respective second scintillating material are dispersed in a photosensitive material mixture. However, what both layers 196, 197 have in common is that they also have the particle structure in the binder described above.

[0137] When irradiated with X-rays, the different layers 196, 197 are suitable for generating a first radiation 198 and a second radiation 199 with different wavelengths. The optical detector 200 comprises a first detection unit 201 for generating a first detection value depending on the first radiation 196 and a second detection unit 202 for generating a second detection value depending on the second radiation 199, respectively, wherein, in this exemplary embodiment, the first detection unit 201 and the second detection unit 202 are arranged one above the other, and wherein the upper one is sensitive to a first wavelength range of the first radiation 198 and transparent to a second wavelength range of the second radiation 199, and wherein the lower one is sensitive to the second wavelength range.

[0138] For the sake of completeness, it is noted that the protrusions 142 , 152 of the first and second structured surface features also comprise several layers 143 , 153 , since the basic principle of these structured surface features 140 , 150 is the same as that of the structured surface features 180 , 190 .

[0139] refer to Figure 4 , which shows a flow chart, and an embodiment of a manufacturing method for manufacturing a fourth structured surface part 190 will be exemplarily described below. Of course, the method can also be at least basically applied to manufacturing the first structured surface part 140, the second structured surface part 150 and the third structured surface part 180.

[0140] In step S1, a homogenous substrate is provided, which represents the arrangement area 191 and is made of, for example, a plastic such as carbon, polyimide. The substrate has a two-dimensional surface defining a surface area.

[0141] In step S2 , a photosensitive material mixture is provided, which at least contains particles having scintillation properties, a binder and a curing photosensitive component.

[0142] In step S3, a layer-by-layer application of the photosensitive material mixture to the surface area is performed in such a way that the pixels or protrusions 192 comprising several layers are formed and arranged individually, one layer above the other. When applying a single layer, the photosensitive composition is cured in each case between the layer applications, wherein a light source such as a UV laser beam (not shown) is used.

[0143] In step S4, the binder and / or the photosensitive component are retained in the protrusions 192 so as to still be present in the use of the structured surface part 190. Therefore, the particles having scintillating properties are present in the particle structure in the binder without requiring subsequent heat treatment such as sintering. Therefore, the entire manufacturing process step can be omitted and the scintillating properties of the particles are not adversely changed.

[0144] However, for some of the other structured surface features, an optional further step S5 (not shown) of removing the substrate by, for example, grinding is performed.

[0145] It should be noted that embodiments of the present invention are described with reference to different subject matters. Specifically, some embodiments are described with reference to method type claims, while other embodiments are described with reference to device type claims. However, a person skilled in the art will gather from the following and following descriptions that, in addition to any combination of features belonging to one type of subject matter, other combinations between features relating to different subject matters are also considered to be disclosed by the present application, unless otherwise notified.

[0146] All features may be combined to provide synergistic effects that are more than the simple sum of the features.

[0147] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. The invention is not limited to the disclosed embodiments.

[0148] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

[0149] In the claims, the word "comprising" does not exclude other elements or steps, and the word "a" or "an" does not exclude a plurality. A single unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. A structured surface part to be irradiated for a radiation capturing device, include: an arrangement area which defines a surface area of ​​the structured surface part, a plurality of protrusions arranged in the arrangement area, wherein the protrusions include a photosensitive material mixture containing at least particles having radiation-related properties, a binder, a non-polymerizable material, and a curable photosensitive component, wherein, in a direction pointing away from or perpendicular to the surface area, the photosensitive material mixture of the protrusion comprises several layers, one layer on top of another, wherein the structured surface element is bendable, and The bendability property is adjusted by combining the non-polymerizable material with the photosensitive component.

2. The structured surface part according to claim 1, in, The particles having radiation-related properties include at least one scintillating material dispersed in or mixed with the photoactive component and / or the binder.

3. The structured surface part according to claim 2, in, The first layer of the corresponding protrusion contains a first scintillating material and the second layer of the same protrusion contains a second scintillating material.

4. The structured surface part according to any one of claims 1 to 3, in, A substrate defines the arrangement area or the surface area of ​​the structured surface features.

5. The structured surface part according to any one of claims 1 to 3, in, The structured surface feature is a scintillator array, wherein the protrusions are individual pixels each having scintillation properties, and wherein the pixels are at least partially covered by a reflector.

6. The structured surface part according to claim 5, in, The reflector comprises at least one top reflector layer arranged on at least the outermost layer of the respective pixel and facing away from the substrate.

7. The structured surface part according to claim 5, in, The reflector comprises at least one inter-pixel reflector layer arranged in the gap between two individual pixels.

8. The structured surface part according to claim 5, in, The reflector comprises reflective particles in an organic binder.

9. The structured surface part according to claim 5, in, The reflector is a reflective film or a reflective sheet.

10. The structured surface part according to claim 5, in, The reflector is formed by a substrate made of a material having reflective properties.

11. The structured surface part according to claim 5, in, The reflector is bendable.

12. The structured surface part according to claim 5, in, The reflector has a strength of less than 10000 N / mm 2 The elastic modulus is preferably less than 3000 N / mm 2 The elastic modulus.

13. The structured surface part according to any one of claims 1 to 3, in, Said particles comprising radiation related properties comprise particles which partially or fully absorb at least a portion of X-rays or gamma rays or their respective spectra.

14. An X-ray detector, include: The structured surface part according to any one of claims 1 to 13, and An optical detector is arranged in optical communication with the structured surface feature.

15. A method of manufacturing a structured surface part to be irradiated for a radiation capturing device, The following steps are involved: providing a substrate defining a surface area, providing a photosensitive material mixture comprising at least particles having radiation-related properties, a binder, a non-polymerizable material, and a curable photosensitive component, and applying the photosensitive material mixture to the surface area layer by layer, one layer above the other, in such a way that a protrusion comprising several layers is formed, wherein the light-sensitive component is cured by means of a light source between the application of the respective layers, wherein the adhesive and / or the photosensitive component is retained in the protrusions so as to still be present during use of the structured surface element, wherein the structured surface element is provided to be bendable, and The bendability property is adjusted by combining the non-polymerizable material with the photosensitive component.

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