Portable X-ray Backscatter System

Abstract

The present invention is entitled "Portable X-ray Backscatter System". A method, system and apparatus for making and using a nondestructive inspection device are disclosed, wherein the nondestructive inspection device comprises a portable X-ray backscatter detection device having a predetermined electromagnetic radiation elimination feature in the form of a deflection coil communicating with a photomultiplier tube to improve imaging contrast for nondestructive inspection of a target substrate in situ and in real time.

Description

Technical Field

[0001] The present disclosure relates generally to the field of nondestructive testing and nondestructive inspection of subsurface areas of target structures and substrates. More specifically, the present disclosure relates to the field of using small angle X-ray backscattering techniques to nondestructively inspect interlayer properties, including, for example, the bond strength of composite material layers. Background Art

[0002] Currently, regulatory guidelines covering the inspection of composite materials in certain industries mandate the use of testing techniques that destructively test the material. This incurs significant costs because large structures containing composite parts, such as aircraft and other vehicles, must be taken out of service, destructively inspected, and then reworked before the aircraft can be returned to service.

[0003] Nondestructive inspection systems for evaluating substrates have found utility in industry where, for example, access to a wide variety of components and substrate materials requiring routine maintenance and inspection may be difficult to achieve without expending considerable labor or partially or completely destroying the component or substrate material. For a nondestructive testing method or system to replace the currently used mandatory destructive methods, the nondestructive testing method must ensure a consistently reliable and repeatable analysis of the surface or subsurface of the object being inspected that at least equals or exceeds the physically determined values ​​obtained during destructive testing.

[0004] X-rays are a form of electromagnetic radiation that typically has a wavelength in the range of 0.01 to 10 nanometers, corresponding to frequencies between 30 pHZ and 30 Hz (3 × 10 16 Hz to 3×10 19 Hz) and energies in the range of 100eV to 100KeV. An X-ray backscatter system is a type of X-ray imaging system that uses indirect detection of X-rays to examine a target object. An X-ray backscatter system typically includes an X-ray tube, a collimator, and a detector. The X-ray tube generates and emits X-rays. The collimator filters the X-rays to form an X-ray beam, which uses a portion of the X-rays that travels substantially parallel to a specified direction.

[0005] When an X-ray beam encounters a target object, some or all of the X-rays in the X-ray beam are scattered by the target object in multiple directions. Specifically, the X-rays can be scattered from the surface of the target object and / or from the sub-surface of the target object. The scattered X-rays are called backscatter. When the backscatter strikes a detector, the detected X-ray backscatter can be used to generate image data of the target object under investigation. For example, when the X-ray beam is directed to a specific location on or inside a specific target object, the detected backscatter can be used to generate pixel intensity values ​​in an image corresponding to the specific location on or inside the target object. The use of X-rays for non-destructive material evaluation allows inspections to be performed without destroying the inspected parts, components, substrates, etc.

[0006] Due at least to the weight and configuration of the various components, typical X-ray backscatter systems are generally large, bulky, and use a fixed detector with a fixed focal spot, which is generally planar in shape, to collect X-ray backscatter from an object. Summary of the invention

[0007] According to the present aspect, an X-ray backscatter detection device is disclosed, which includes a housing configured to enclose components including at least a plurality of electronic circuits and an integrated high voltage power supply. The device further includes at least one photomultiplier tube configured to generate an electromagnetic field, and the photomultiplier tube is oriented by the exterior of the housing, and the at least one photomultiplier tube is further oriented near the housing; and at least one deflection coil, the deflection coil is positioned near the photomultiplier tube.

[0008] According to a further aspect, the deflection coil is configured to generate a predetermined cancelling electromagnetic field configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube.

[0009] On the other hand, the photomultiplier tube has an integrated deflection coil.

[0010] In another aspect, a photomultiplier tube includes a plurality of deflection coils, wherein the plurality of deflection coils are coupled to the photomultiplier tube.

[0011] In a further aspect, the presence of the deflection coil eliminates the need for multiple components, including one or more of the following: a cooling device; a high voltage cable; a commutation cable, a control unit; a cable management device; or a combination thereof.

[0012] In another aspect, the deflection coil is configured to generate a cancelling electromagnetic field having a predetermined strength and value.

[0013] In another aspect, the X-ray backscatter detection device has a footprint sufficient to implement a portable X-ray backscatter detection device footprint for use with the X-ray backscatter detection device of the present disclosure.

[0014] On the other hand, a method for manufacturing an X-ray backscatter detection device is disclosed, wherein the method includes integrating a plurality of X-ray backscatter detection components into a housing, which may be an integral housing, the housing including a housing exterior, and the plurality of X-ray backscatter detection components include: a high voltage power supply, a plurality of electronic circuits, and an X-ray generating source. The method further includes orienting at least one scintillator detector proximate to the housing exterior, orienting at least one photomultiplier tube proximate to the scintillator detector, and orienting at least one deflection coil proximate to the photomultiplier tube. The terms "scintillator" and "scintillator detector" are used herein generally and equivalently and interchangeably when specifically referring to the enumerated part 26.

[0015] In another aspect, a method of manufacturing an X-ray backscatter detection device is disclosed, wherein the method includes integrating a plurality of X-ray backscatter detection components into a housing, the housing including a housing exterior, and the plurality of X-ray backscatter detection components include: a high voltage power supply; a plurality of electronic circuits; and an X-ray generating source. The method further includes orienting at least one scintillator detector proximate to the housing exterior, orienting at least one photomultiplier tube (18) proximate to the scintillator detector; and orienting at least one deflection coil (20) proximate to the photomultiplier tube.

[0016] On the other hand, the method further includes coupling at least one deflection coil to the photomultiplier tube, and wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field, wherein the cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube; and generating a predetermined cancelling electromagnetic field, wherein the predetermined cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube.

[0017] In another aspect, the method further includes coupling a plurality of deflection coils to the photomultiplier tubes.

[0018] In another aspect, the method further includes coupling a plurality of deflection coils to the plurality of photomultiplier tubes.

[0019] In another aspect, a method for nondestructively inspecting a substrate is disclosed, wherein the method includes orienting an X-ray backscatter detection device proximate to the substrate, the integrated X-ray backscatter detection device including: an integrated X-ray source, an integrated collimator, an integrated high voltage power supply, at least one scintillator detector, at least one photomultiplier tube, wherein the photomultiplier tube is configured to generate an electromagnetic field, and at least one deflection coil oriented proximate to the photomultiplier tube, wherein the deflection coil is configured to generate a predetermined canceling electromagnetic field; and delivering an X-ray beam to the substrate. The method further includes collecting a certain amount of X-ray backscatter at the scintillator detector, generating an image signal, and sending the image signal to a reader.

[0020] The features, functions, and advantages that have been discussed can be achieved independently in various aspects or may be combined in still other aspects, further details of which can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Having thus described variations of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0022] Figure 1 is a non-limiting diagram of a portable X-ray backscatter detection device according to the present invention.

[0023] Figure 2 is a non-limiting diagram of a portable X-ray backscatter detection device according to the present invention;

[0024] Figure 3 is a non-limiting illustration of a vehicle in the form of an aircraft according to the present invention;

[0025] Figure 4 is a non-limiting illustration of an interior portion of a vehicle in the form of a fuselage interior according to the present invention;

[0026] Figure 5 is a non-limiting flow chart outlining a method according to the present invention;

[0027] Figure 6 is a non-limiting flow chart outlining a method according to the present invention;

[0028] Figure 7 is a non-limiting flow chart outlining a method according to the present invention; and

[0029] Figure 8 is a non-limiting flow chart outlining a method according to the present invention. DETAILED DESCRIPTION

[0030] X-ray backscatter analysis is a type of X-ray imaging that allows an assessor to indirectly inspect an object using X-rays by directing an X-ray beam at the object and indirectly collecting the X-ray backscatter as a reading on a detection device because the X-rays are scattered from the target object as "backscatter." When the signal generated by the collected X-ray backscatter is interpreted by appropriate software, the X-ray backscatter technique can produce a visual image of the target object area, for example, to detect defects or otherwise characterize the target object area, such as the target object surface and / or the target object sub-surface.

[0031] Depending on the shape of the target object, the X-ray backscatter system may not include sufficient resolution to determine the characteristics of the target object. For example, the image produced by the signal generated from the X-ray detector and sent to the X-ray imaging system may not provide the desired contrast (e.g., the image may not be sharp or clear enough) to enable one to reliably detect anomalies of a certain size that may cause the target object to be uninspectable. Further, typical X-ray backscatter systems are generally large, bulky and use a fixed detector with a fixed focus that has a generally planar shape to collect X-ray backscatter from the object.

[0032] In a typical X-ray backscatter protocol and system, an X-ray beam may be moved relative to a target object in a selected pattern (e.g., a raster pattern) so that image data may be generated for different locations on or within the target object. The image data may then form one or more images that may be interpreted using computing software and hardware to determine whether there are inconsistencies, anomalies, defects, etc., in a locale of the target object being inspected by the X-ray backscatter system.

[0033] The typical size or "footprint" of an X-ray backscatter detector can limit the practicality of an X-ray backscatter inspection scheme. In some cases, a typical X-ray backscatter detection system can weigh 1,000 pounds or more, and typically requires fixed testing at the instrument site. That is, in-situ nondestructive inspection of large structures is often complicated by the footprint (equivalently referred to herein as "physical footprint") and size of the inspection instruments (e.g., devices), methods, and systems. In addition, if the target object surface has a complex geometry, or the target surface is located in a difficult-to-access location, it may be difficult to employ an X-ray backscatter detector.

[0034] Further, typical designs for X-ray backscatter systems require a large number of components that are used to generate the required amount and intensity of emitted electromagnetic radiation (EMR) in the form of X-rays. For example, the large power supplies required to operate the 160,000 volt X-ray tubes typically required for operating X-ray backscatter detectors are typically integrated into the instrument. In addition, components such as cooling devices, high voltage cables, communication cables, control units, cable management devices, etc. are typically further integrated into the X-ray backscatter detector, which further increases the complexity, weight and overall size or "footprint" of the system. In addition, when these components are powered on, they generate electronic signatures that can contribute to system "noise" that can interfere with the recording and reading of the scintillator detector(s) that detect the backscatter.

[0035] According to the present aspect, an improved X-ray backscatter detection device is disclosed, which contains certain components within a housing and moves further components to a location outside the housing. In addition, aspects of the present invention provide noise cancellation for certain integrated components by providing and orienting a deflection coil proximate to a photomultiplier tube associated with a scintillator detector (one or more). The deflection coil is designed to provide an expected and predetermined cancellation effect for the EMR signal and provide noise cancellation, which produces an improved scintillator reading, thereby producing an improved resolution of the readout image by improving, for example, image contrast, etc. During operation of the X-ray backscatter detection device, one or more electromagnetic fields generated by the powered components of the X-ray backscatter detection device are achieved by manufacturing, changing, modifying the deflection coil, etc. (for example, by providing a predetermined amount of wire wrapped around the deflection coil (or providing a predetermined amount of other material to the deflection coil, the material provided to the deflection coil is configured to produce a predetermined electromagnetic field that can be a customizable electromagnetic field) or other material for producing the expected and predetermined electromagnetic field cancellation or cancellation effect (one or more)). The predetermined electromagnetic field cancellation effect, which can be at least a predetermined partial electromagnetic field cancellation effect, is achieved. For the present purpose, the terms "predetermined electromagnetic cancellation effect", "electromagnetic cancellation effect" and "electromagnetic cancellation effect" are equivalent terms and are intended to be used interchangeably when describing a predetermined electromagnetic field and a predetermined counteracting electromagnetic field. As currently considered in this article, the electromagnetic field and the counteracting electromagnetic field have an electromagnetic field value and a counteracting electromagnetic field value, both of which can be predetermined values.

[0036] In addition, the orientation of components inside and outside the housing eliminates the need for multiple components, including at least the elimination of previously required cooling devices, high voltage cables, communication cables, control units, cable management devices, etc. By eliminating such components from the X-ray backscatter detector system, the overall complexity of the system is reduced, the system is significantly simplified, and the total weight and "space volume" of the system are significantly reduced to a total weight in the range of about 200 to 300 pounds. This weight reduction allows the X-ray backscatter system of the present disclosure to be operated, for example, by a load-bearing robot or other mechanical positioning device, so that the X-ray backscatter detector of the present disclosure is classified as a "portable" system. That is, according to this aspect, the term "portable" as used in this application refers to a non-destructive X-ray backscatter system and / or device (e.g., including a system and / or device used in the method of the present disclosure) that weighs from about 200 pounds to about 300 pounds.

[0037] In addition, by eliminating many electronic and other electrically powered components from the X-ray backscatter system, significantly improved X-ray backscatter imaging is achieved. Further, with the reduced number of electrically powered components, EMR that may interfere with the scintillator detector can be determined, accounted for, and eliminated by positioning deflection coils positioned near or in conjunction with the photomultiplier tubes.

[0038] The scintillator detectors disclosed herein may be those used in conjunction with the currently disclosed X-ray backscattering methods, systems, and apparatus, and include a scintillator layer comprising a scintillator material deposited on or otherwise incorporated into the X-ray backscatter detector. The scintillator material absorbs backscattered X-rays and converts the X-ray radiation into visible light. A photodetector sensitive to visible light present in the detector converts the light from the scintillator into an electrical signal that is interpreted as a visible image. The scintillator coating may be, for example, at least one continuous thin layer or layer of a scintillator material.

[0039] The X-ray backscatter detector substrate of the present invention is made of materials and can be customized in size so that the X-ray backscatter detector can be highly flexible, so that the X-ray backscatter detector substrate includes such a scintillating material layer that can be oriented and otherwise formed into a desired non-planar geometry that (e.g., a complement) closely approximates and / or substantially matches the geometry of a target substrate (equivalently referred to herein as a "target object"), which geometry includes but is not limited to the geometry of the target substrate surface. The geometry of the target substrate may include a planar geometry, or the target substrate geometry may include a non-planar geometry, including, for example, one or more of a concave geometry, a convex geometry, one or more irregular geometries, a complex non-planar geometry, and combinations thereof.

[0040] According to the present aspect, in situations where a reduced overall X-ray backscatter system weight is desired, the presently disclosed X-ray backscatter detection apparatus, system, and method may further benefit from the use of a very thin detector substrate comprising a continuous thin layer of scintillating material, wherein the scintillating material substantially covers at least one surface of the flexible detector substrate. The presently disclosed X-ray backscatter detector comprising the detector substrate and the scintillating material layer may be selected and manufactured to have an overall thickness of the flexible detector preferably in the range of about 50 μm to about 100 μm, although thicker scintillating material layers may be used if desired.

[0041] According to the present aspect, by using deflection coils configured to effectively cancel or "cancel" a predetermined amount of EMR emitted from multiple sources in the system, the X-ray backscatter technology that can be achieved by using the presently disclosed X-ray backscatter methods, devices and systems, as well as the resolution and contrast of X-ray backscatter imaging are significantly improved.

[0042] Thus, the presently disclosed non-destructive X-ray backscatter detection devices, systems and methods provide improved inspection imaging signals and resulting images by measuring or otherwise determining and taking into account existing electromagnetic radiation introduced into the devices and systems through various device components. Once the level or amount of potentially interfering electromagnetic radiation is determined, the deflection coils can be customized to produce a canceling level of electromagnetic radiation to "cancel" or otherwise neutralize the external system "noise" caused by the presence of interfering electromagnetic radiation introduced into such systems and devices.

[0043] According to a further aspect of the present invention, the customized deflection coil is constructed of materials and is configured to provide the necessary orientation to counteract the forces of electromagnetic radiation, such as by providing a certain amount or degree of metal or other material "wrap". Another aspect of the present invention further functions to mitigate the presence of interfering electromagnetic radiation by orienting various system components (capable of emitting specific levels of electromagnetic radiation) within the housing. The device housing may include a shielding layer or other one or more layers of material to reduce external electromagnetic radiation that might otherwise interfere with the scintillator or interfere with the signal sent by the scintillator - which signal will be interpreted by the computing functions of the device, and otherwise contribute to "noise" - which reduces contrast or otherwise adversely affects the resolution of the imaging signal viewable at the system or device viewing output.

[0044] Further, the orientation of certain system and device components within or outside the housing, together with the canceling effect of the deflection coils being oriented proximate to the photomultiplier tubes outside the housing, eliminates the need for various system and device components, including, for example, cooling devices; high voltage cables; switching cables, control units; cable management devices, etc.; or combinations thereof. The resolution and contrast of the imaging signals and visible images produced by the present system are further improved by eliminating the presence of at least the aforementioned components, which otherwise would have generated interfering electromagnetic radiation if such components reduced the amount of canceling EMR that must be generated.

[0045] The methods, systems, and apparatus disclosed herein greatly improve nondestructive X-ray inspection techniques, including indirect nondestructive X-ray backscattering techniques for evaluating and inspecting target surfaces, including target surfaces that are non-planar or target surfaces that include non-planar target geometries. As used herein, in the context of a "non-planar" surface, the term "non-planar" is defined as a surface having at least one such area that is not completely located or cannot be confined within a single plane. According to this aspect, such non-planar targets and target surfaces further include the following geometries in a non-limiting manner: concave geometries, convex geometries, irregular geometries, geometries including contours including complex contours, other complex geometries, and combinations thereof.

[0046] According to the present aspect, the X-ray backscatter detector substrate may be made of a material (eg, a material containing organic carbon) including, for example, polyethylene naphthalate, poly-4-vinylphenol, and combinations thereof.

[0047] According to this aspect, a scintillating material can be deposited onto an X-ray backscatter detector substrate (which can be a flexible substrate) to achieve a scintillating material layer on the scintillator having an average thickness in the range of about 200 nm to about 50 μm. Furthermore, for example, the scintillating material layer can be deposited on a thin, flexible X-ray backscatter detector substrate by an additive manufacturing method for depositing thin films, including, for example, an inkjet printing method. When inkjet printing technology is used to deposit the scintillating material onto a flexible substrate, the scintillating material is provided to the inkjet printer in the form of a scintillating inkjet printing ink. Any scintillating material that can be formulated into an inkjet printing ink can be used to make the scintillating layer. A specifically preferred scintillating material layer may include, for example, gadolinium oxide based on europium doping (Gd2O3:Eu 3+ ); gadolinium oxysulfate (GdOS); cesium iodide (CsI) and calcium tungstate (CaWO4) inkjet printer deposited or "printed" formulations.

[0048] This non-limiting aspect is Figure 1 As shown in the figure. Figure 1As shown, the portable non-destructive X-ray backscatter inspection system 10 includes a housing 12 having a housing exterior 12a, wherein the housing 12 is configured to encapsulate system components, including: electronic circuits 14, a high voltage power supply 16, and an X-ray radiation source 22 and a filament 23 (wherein the filament 23 and the X-ray radiation source 22 together constitute an X-ray radiation source). Although not shown, the X-ray radiation source is further understood to include an X-ray radiation tube located within a collimator, wherein the collimator has an aperture. In operation, when X-rays 24 are emitted from the X-ray radiation source 22 (which may be, for example, an X-ray tube or a portion of an X-ray tube), the collimator may be rotated so that the aperture changes position and directs the emitted X-rays 24 to different locations on a target substrate 28. As shown Figure 1 As shown, the target substrate includes a target substrate surface 28a and a target substrate subsurface 28b. The terms "X-ray source" and "X-ray radiation source" and "X-ray generating source" are used herein generally and equivalently when referring to the "part" enumerated as "22".

[0049] According to this aspect, Figure 1 Further shown are a plurality of system components oriented from outside the housing 12 and proximate to the housing exterior 12a, wherein the components oriented from outside the housing 12 and proximate to the housing exterior 12a include: a plurality of photomultiplier tubes 18 and a plurality of deflection coils 20 shown oriented proximate to the photomultiplier tubes 18, and the photomultiplier tubes oriented proximate to the scintillator 26.

[0050] Figure 2 is a diagram further illustrating in a non-limiting manner an X-ray backscatter system 30 according to a further aspect of the present invention. Figure 2 As shown, the X-ray backscatter system 30, which may be a portable X-ray backscatter system 30, includes a portable X-ray backscatter detector 32, which may be configured to receive X-rays from an X-ray source 22 (eg, Figure 1 etc., but not in Figure 2 X-ray radiation in the form of an X-ray beam 33 (shown explicitly in FIG. 1 ) is directed toward a target substrate 34. Figure 2As further shown, the reflected X-ray beam 36 is directed to a scintillator 35 as backscatter from a target substrate 34. Signals generated at and / or by the scintillator are then sent from the portable X-ray backscatter detector 32 to a computer 38, which includes interpretation software / hardware that may be configured to interpret the signals so received and convert the signals received from the scintillator into imaging signals 39. The imaging signals 39 are then directed to a visual reader 40, which may be in the form of, for example, a computer monitor, handheld device, etc. from which visual images may be viewed, recorded, etc. The visual reader may be located proximate to the system 30, or may be located at a greater distance from the system and communicate with the system via wireless technology, such as Wi-Fi, Bluetooth, etc.

[0051] Using the currently disclosed system and apparatus, the target substrate for nondestructive inspection according to the currently disclosed method can be made of any material. For example, the portable X-ray backscattering system can nondestructively inspect metallic materials, non-metallic materials, and combinations thereof. Non-limiting examples of non-metallic materials include, for example, composite materials, materials, and material layers present between metals and / or non-metallic materials, including, for example, adhesive layers present in or adjacent to the composite material (e.g., adhesive materials that can be cured, and adhesive materials that can, for example, be present in the form of material bond lines, etc.), including composite laminates. That is, according to this aspect, the portable X-ray backscattering method, system, and apparatus can be configured to perform in-situ, real-time nondestructive inspection of bond lines in the target substrate material, including bond lines in the composite material, or bond lines between the composite material (or other non-metallic material) and the metallic material.

[0052] The target substrate may include discrete components (equivalently referred to herein as "parts"), as well as components incorporated into larger assemblies, subassemblies, etc., which may be nondestructively inspected in situ and in real time according to the present aspects. A non-exhaustive list of objects that benefit from the presently disclosed nondestructive inspection methods, systems, and apparatus include, for example, metal and non-metal parts used in the manufacture of fixed structures, including buildings, bridges, trusses, pipe systems, tubes, pipelines, ducts, etc., including pipes, pipe systems, and pipelines used in connection with pipelines of petroleum products or other chemical products (including, for example, water); and vehicles, such as manned and unmanned aircraft, manned and unmanned spacecraft, manned and unmanned rotorcraft, manned and unmanned ground vehicles, manned and unmanned surface water vehicles, manned and unmanned underwater water vehicles, satellites, etc.

[0053] Figure 3 is a non-limiting illustration of a vehicle 50 in the form of an aircraft, wherein the vehicle / aircraft includes a fuselage 52. According to the present aspect, Figure 4A non-limiting illustration of a fuselage interior 92a of fuselage 52 is shown, illustrating frames 94 and stringers 96. According to the present aspect, surface and sub-surface areas of frames and stringers, as well as the fuselage itself, may be targeted surfaces for non-destructive inspection. Figure 3 and / or Figure 4 The target surface in the example can be used Figure 1 and Figure 2 Any of the illustrated portable X-ray backscatter systems can be used for non-destructive inspection.

[0054] Figure 5 is a flow chart outlining a non-limiting method for non-destructively inspecting a target surface according to the present invention, which illustrates the use of Figure 1 , 2 , 3 and 4 any one of the portable X-ray backscatter system. Figure 5 As shown, a method 100 is summarized according to the present aspect, the method includes integrating 102 a plurality of X-ray backscatter detection components into a housing 12, the housing including a housing exterior 12a, the plurality of X-ray backscatter detection components including: a high voltage power supply 16; a plurality of electronic circuits 14; and an X-ray generating source 22. The method further includes: orienting 104 at least one scintillator 26 proximate to the housing exterior 12a, orienting 106 at least one photomultiplier tube 18 proximate to the scintillator 26, and orienting 108 at least one deflection coil 20 proximate to the photomultiplier tube 18.

[0055] Figure 6 is a flow chart outlining a non-limiting method for non-destructively inspecting a target surface according to the present invention, the method illustrating the use of Figure 1 , 2 , 3 and 4 of any of the portable X-ray backscatter system and the incorporation of Figure 5 As outlined in Figure 6 As shown, a method 200 is summarized according to the present aspect, the method includes integrating 102 a plurality of X-ray backscatter detection components into a housing 12, the housing including a housing exterior 12a, the plurality of X-ray backscatter detection components including: a high voltage power supply 16; a plurality of electronic circuits 14; and an X-ray generating source 22. The method further includes: orienting 104 at least one scintillator 26 proximate to the housing exterior; orienting 106 at least one photomultiplier tube 18 proximate to the scintillator 26; and orienting 108 at least one deflection coil 20 proximate to the photomultiplier tube 18. Figure 6The illustrated method 200 further includes: coupling 210 at least one deflection coil to the photomultiplier tube, wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field, wherein the cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube. The method further includes generating 212 a predetermined cancelling electromagnetic field, wherein the predetermined cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube; and at least partially cancelling 214 the electromagnetic field generated by the photomultiplier tube.

[0056] Figure 7 is a flow chart outlining a non-limiting method for non-destructively inspecting a target surface according to the present invention, the method using Figure 1 , 2 , 3, 4, any of the portable X-ray backscatter system and the incorporation Figure 5 and 6 Any of the methods outlined in Figure 7 As shown, a method 300 is summarized according to the present aspect, the method includes integrating 102 a plurality of X-ray backscatter detection components into a housing 12, wherein the housing includes a housing exterior 12a, and the plurality of X-ray backscatter detection components include: a high voltage power supply 16; a plurality of electronic circuits 14; and an X-ray generating source 22. The method further includes: orienting 104 at least one scintillator 26 proximate to the housing exterior, orienting 106 at least one photomultiplier tube 18 proximate to the scintillator, and orienting 108 at least one deflection coil 20 proximate to the photomultiplier tube. Figure 7 The illustrated method 200 further comprises: coupling 210 at least one deflection coil to the photomultiplier tube, wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field, the cancelling electromagnetic field being configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube; generating 212 a predetermined cancelling electromagnetic field, the predetermined cancelling electromagnetic field being configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube; and at least partially cancelling 214 the electromagnetic field generated by the photomultiplier tube. Figure 7 As shown, the method outlined further includes optionally coupling 312 a plurality of deflection coils to the photomultiplier tube. When the present method, system and apparatus employ a plurality of photomultiplier tubes, Figure 7 The method outlined in may further optionally include coupling 314 a plurality of deflection coils to a plurality of photomultiplier tubes.

[0057] Figure 8 is a flow chart outlining a non-limiting method for non-destructively inspecting a target surface according to the present invention, the method using Figure 1 , 2 , 3 and 4 any of the portable X-ray backscatter system and the incorporation of Figure 5 , 6 and 7. Figure 8 As shown, according to the present aspect, a method 400 is summarized, which includes: orienting 402 an X-ray backscatter detection device near a substrate, wherein the X-ray backscatter detection device includes a shell, the shell includes an exterior of the shell, and the X-ray backscatter detection device includes a variety of components within the shell, including: an integrated X-ray source; an integrated collimator; and an integrated high-voltage power supply. The method 400 further includes: orienting 404 at least one photomultiplier tube outside the shell exterior, wherein the photomultiplier tube is configured to generate an electromagnetic field; orienting at least one deflection coil near the photomultiplier tube, and the deflection coil is configured to generate a predetermined canceling electromagnetic field having a predetermined value; and at least one scintillator detector. According to the present aspect, as Figure 8 The method 400 shown in further includes: generating 406 a predetermined electromagnetic field; generating 408 a predetermined counteracting electromagnetic field, which can be an at least partially counteracting electromagnetic field; and delivering 410 an X-ray beam to a substrate; collecting 412 a certain amount of X-ray backscatter at a scintillator detector; generating 414 an image signal; and sending 416 the image signal to a reader.

[0058] According to further aspects of the present invention, when the detector collects and records photon energy and generates image data in the form of image data signals, the currently disclosed portable X-ray backscatter detection system and the currently disclosed portable X-ray backscatter detection device generate and send image data signals to a computer imaging system (such as those commercially available) or a computer imaging system that can be further modified.

[0059] According to further non-limiting aspects, depositing the scintillating material layer onto the scintillator(s) may be accomplished by any method capable of depositing a substantially uniform scintillating material layer having an average thickness in the range of about 200 nm to about 50 μm. According to one present aspect, inkjet printing of the scintillating material may be accomplished by using, for example, a Dimitrix Materials Printer (DMP 2831 (Fujifilm Dimatrix, Inc.). In a preferred aspect, the inkjet printer may have a 16-nozzle piezoelectric print head with a drop volume of about 10 pL and a spacing of about 250 μm between nozzles. Printing may be performed at a maximum jetting frequency of about 5 kHz.

[0060] According to a further non-limiting aspect, a useful polymer-based scintillating ink may be europium-doped gadolinium oxide (Gd2O2:Eu 3+) as the scintillating material. The scintillating material can be combined with a thermoplastic elastomer copolymer as the polymer matrix to produce a flexible scintillating ink having the necessary adhesive properties to adhere to a flexible detector substrate. One useful thermoplastic elastomer copolymer includes, for example, styrene-ethylene / butylene-styrene (SEBS) Calprene CH-6120 (Dynasol, Houston, Texas), which has an average molecular weight of 245.33 g / mol and is present in a ratio of ethylene-butylene:styrene of 68:32.

[0061] According to this aspect, when the disclosed methods and systems orient the currently disclosed portable X-ray backscatter detector close to a target. The target may have a target surface geometry, and the portable X-ray backscatter detector may include an X-ray radiation source configured to emit X-rays, a collimator communicating with the X-ray radiation source, and the collimator is configured to form an X-ray beam using at least a portion of the X-ray radiation emitted from the X-ray radiation source. The portable X-ray backscatter detector is configured to detect X-ray backscatter formed in response to the X-ray beam encountering a target substrate. The portable X-ray backscatter detector includes: an X-ray scintillator substrate, which is preferably a continuous X-ray scintillator substrate; and at least one layer of X-ray scintillating material, which is configured to substantially cover the X-ray scintillator substrate (for example, it may be a flexible X-ray scintillator substrate).

[0062] The presently disclosed methods, systems, and apparatus provide enhanced nondestructive inspection techniques for targets such as components and parts that are difficult to inspect and may otherwise be difficult to access. Such objects may include components and parts in vehicles, as well as components and parts in stationary objects and systems, including, for example, but not limited to, pipes used in pipelines, oil storage tanks, structural supports in buildings, bridges, railways, trusses, etc. Nondestructive inspection of vehicles and components in vehicles may include, but is not limited to, for example, components and assemblies incorporated into manned and unmanned aircraft, manned and unmanned spacecraft, manned and unmanned rotorcraft, manned and unmanned ground vehicles, manned and unmanned non-ground vehicles, manned and unmanned surface water vehicles, and manned and unmanned underwater water vehicles, and combinations thereof.

[0063] Further, the present disclosure includes implementations according to the following clauses:

[0064] Clause 1. An X-ray backscatter detection device (10), comprising:

[0065] A housing (12) comprising a housing exterior (12a), the housing being configured to enclose components including: at least a plurality of electronic circuits (14); an X-ray source (22); and an integrated high voltage power supply (16);

[0066] a photomultiplier tube (18), the photomultiplier tube being configured to generate an electromagnetic field, and the at least one photomultiplier tube being oriented outside the housing (12), and the at least one photomultiplier tube being oriented proximate to the housing exterior (12a);

[0067] a scintillator detector (26) oriented proximate the exterior of the housing; and

[0068] At least one deflection coil (20) is oriented proximate to the photomultiplier tube (18) and the at least one deflection coil is oriented proximate to the housing exterior (12a).

[0069] Clause 2. The X-ray backscatter detection device of Clause 1, wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field, wherein the predetermined cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube.

[0070] Clause 3. The X-ray backscatter detection device of Clause 1, wherein the photomultiplier tube is integrated with a deflection coil.

[0071] Clause 4. The X-ray backscatter detection device of Clause 1, wherein the photomultiplier tube comprises a plurality of deflection coils coupled to the photomultiplier tube.

[0072] Clause 5. The X-ray backscatter detection device of Clause 1, wherein the deflection coil eliminates multiple components, the multiple components including one or more of the following: a cooling device; a high-voltage cable; a switching cable, a control unit; a cable management device; or a combination thereof.

[0073] Clause 6. The X-ray backscatter detection device of Clause 1, wherein the X-ray backscatter detection device comprises a physical volume, the physical volume further comprising a portable volume, and wherein the X-ray backscatter detection device is portable.

[0074] Clause 7. The X-ray backscatter detection apparatus of Clause 1, wherein the deflection coil comprises a predetermined amount of wire wound around the deflection coil.

[0075] Clause 8. The X-ray backscatter detection device of Clause 1, wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field having a predetermined cancelling electromagnetic field value.

[0076] Clause 9. The X-ray backscatter detection device of Clause 1, wherein the integrated X-ray source; and the integrated high-voltage power supply are integrated within a housing, the housing including a housing exterior.

[0077] Clause 10. A method (100)(200)(300) of manufacturing an X-ray backscatter detection device, the method comprising:

[0078] Integrating (102) a plurality of X-ray backscatter detection components into a housing (12), the housing including a housing exterior (12a), the plurality of X-ray backscatter detection components including: a high voltage power supply (16); a plurality of electronic circuits (14); and an X-ray generating source (22);

[0079] orienting the scintillator (26) proximate the exterior of the housing (104);

[0080] orienting a photomultiplier tube (18) proximate to a scintillator (106); and

[0081] At least one deflection coil (20) is oriented (108) proximate to the photomultiplier tube.

[0082] Clause 11. The method of clause 10 further comprises:

[0083] coupling (210) at least one deflection coil to the photomultiplier tube; and

[0084] wherein the deflection coil is configured to generate a predetermined cancelling electromagnetic field, the predetermined cancelling electromagnetic field being configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube;

[0085] generating (212) a predetermined cancelling electromagnetic field configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube; and

[0086] The electromagnetic field generated by the photomultiplier tube is at least partially canceled (214).

[0087] Clause 12. The method of clause 10 further comprises:

[0088] A plurality of deflection coils are coupled (312) to the photomultiplier tubes.

[0089] Clause 13. The method of clause 10 further comprises:

[0090] A plurality of deflection coils are coupled (314) to the plurality of photomultiplier tubes.

[0091] Clause 14. A method (400) of non-destructively inspecting a substrate, the method comprising:

[0092] An X-ray backscatter detection device is positioned near a substrate (402), the X-ray backscatter detection device comprising a housing, the housing comprising a housing exterior, the X-ray backscatter detection device further comprising within the housing:

[0093] X-ray source;

[0094] High voltage power supply;

[0095] Oriented outside the shell (404):

[0096] a photomultiplier tube configured to generate an electromagnetic field;

[0097] a deflection coil positioned proximate the photomultiplier tube, the deflection coil configured to generate a predetermined canceling electromagnetic field;

[0098] Scintillator detectors;

[0099] generating (406) a predetermined electromagnetic field;

[0100] generating (408) a predetermined at least partially cancelling electromagnetic field;

[0101] delivering (410) an X-ray beam to a substrate;

[0102] collecting (412) an amount of X-ray backscatter at a scintillator detector;

[0103] generating (414) an image signal; and

[0104] The image signal is sent (416) to a reader.

[0105] Clause 15. The method of clause 14, wherein the X-ray source and the high voltage power supply are oriented within a housing, the housing comprising a housing exterior.

[0106] Clause 16. The method of clause 14, wherein the scintillator detector, the photomultiplier tube, and the deflection coil are oriented proximate to an exterior of the housing and further oriented outside of the housing.

[0107] Clause 17. The method of clause 14, further comprising:

[0108] At least one deflection coil is coupled (418) to the photomultiplier tube.

[0109] Clause 18. The method of clause 14 further comprises:

[0110] A plurality of deflection coils are coupled (420) to the photomultiplier tubes.

[0111] Clause 19. The method of clause 14, further comprising:

[0112] A plurality of deflection coils are coupled (422) to the plurality of photomultiplier tubes.

[0113] Clause 20. The method of Clause 14, wherein the X-ray backscatter detection device is a portable X-ray backscatter detection device.

[0114] Of course, without departing from the essential characteristics of the presently disclosed aspects, the presently disclosed aspects may be implemented in ways other than those specifically set forth herein. The present aspects should be considered in all respects to be illustrative and not restrictive, and all changes falling within the meaning and equivalent range of the appended claims are intended to be included therein.

Claims

1. An X-ray backscatter detection device (10), comprising: A housing (12) comprising a housing exterior (12a), the housing being configured to enclose components including: at least a plurality of electronic circuits (14); an X-ray source (22); and an integrated high voltage power supply (16); photomultiplier tubes (18), the photomultiplier tubes being configured to generate an electromagnetic field, and at least one of the photomultiplier tubes being oriented outside of the housing (12), and the at least one of the photomultiplier tubes being oriented proximate to the housing exterior (12a); a scintillator detector (26) oriented proximate the exterior of the housing; and at least one deflection coil (20), the at least one deflection coil being oriented proximate to the photomultiplier tube (18), and the at least one deflection coil being oriented proximate to the housing exterior (12a), The deflection coil is configured to generate a predetermined cancelling electromagnetic field, and the predetermined cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube.

2. The X-ray backscatter detection device according to claim 1, wherein the photomultiplier tube is integrated with the deflection coil.

3. The X-ray backscatter detection device of claim 1, wherein the photomultiplier tube comprises a plurality of deflection coils coupled to the photomultiplier tube.

4. The X-ray backscatter detection device of claim 1, wherein the deflection coil eliminates multiple components, and the multiple components include one or more of the following: a cooling device; a high-voltage cable; a switching cable; a control unit; a cable management device; or a combination thereof.

5. The X-ray backscatter detection device of claim 1, wherein the X-ray backscatter detection device comprises a physical volume, the physical volume further comprising a portable volume, and wherein the X-ray backscatter detection device is portable.

6. The X-ray backscatter detection apparatus of claim 1, wherein the deflection coil comprises a predetermined amount of metal wire wound around the deflection coil.

7. The X-ray backscatter detection device of claim 1, wherein the offset electromagnetic field has a predetermined offset electromagnetic field value.

8. The X-ray backscatter detection device of any one of claims 1 to 7, wherein the integrated X-ray source; and the integrated high-voltage power supply are integrated within the housing, and the housing includes a housing exterior.

9. A method (100)(200)(300) for manufacturing an X-ray backscatter detection device, the method comprising: Integrating a plurality of X-ray backscatter detection components into a housing (12) (102), the housing including a housing exterior (12a), the plurality of X-ray backscatter detection components including: a high voltage power supply (16); a plurality of electronic circuits (14); and an X-ray generating source (22); orienting (104) a scintillator detector (26) proximate the exterior of the housing; orienting (106) a photomultiplier tube (18) proximate to the scintillator detector; and orienting (108) at least one deflection coil (20) proximate to the photomultiplier tube, The at least one deflection coil is configured to generate a predetermined cancelling electromagnetic field, wherein the predetermined cancelling electromagnetic field is configured to at least partially cancel the electromagnetic field generated by the photomultiplier tube.

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