X-ray detector with a plastic housing

Abstract

Some embodiments include an x-ray detector comprising: a plastic housing; a two-dimensional sensor array disposed within the plastic housing and configured to generate image data in response to incident x-rays; a front plate connected to the plastic housing, the front plate and the plastic housing forming an enclosure that encloses the two-dimensional sensor array; and a printed circuit board mounted to the plastic housing at a plurality of mounting points. Wherein a centroid of the printed circuit board is closer to a center of the plastic housing than a centroid of the mounting points.

Description

[0001] X-ray detectors are typically formed from a metal housing. The metal housing provides rigidity to the detector to withstand loads experienced during use, such as the weight of the patient during imaging operations. Because the antenna cannot communicate through the walls of the metal housing, an access panel or door can be formed above the antenna inside the metal housing. Attached Figure Description

[0002] Figure 1 This is a block diagram of an X-ray detector with a plastic casing according to some implementation schemes.

[0003] Figure 2 This is a block diagram of an X-ray detector with a coated plastic housing according to some implementation schemes.

[0004] Figure 3 This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having multiple electrical connections for electromagnetic interference shielding.

[0005] Figure 4 This is a block diagram of an X-ray detector having a plastic housing with a conductive, elastic, deformable material, according to some implementation schemes.

[0006] Figure 5 This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having multiple electrical connections to electromagnetic interference shielding and a conductive, elastic, deformable material.

[0007] Figures 6A to 6B This is a block diagram of an X-ray detector with a plastic housing and conductive gaskets according to some implementation schemes.

[0008] Figures 7A to 7B This is a block diagram of an X-ray detector with a plastic housing and an antenna, according to some implementation schemes.

[0009] Figure 8 This is a block diagram of an X-ray detector with a plastic casing and a battery, according to some implementation schemes.

[0010] Figures 9A to 9C It is a block diagram of an X-ray detector having a plastic housing with at least one rigid component, according to some embodiments.

[0011] Figures 10A to 10C This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having at least one rigid component with a conductive material.

[0012] Figures 11A to 11C This is a block diagram of an X-ray detector with a plastic housing and corner buffer, according to some implementation schemes.

[0013] Figure 12 This is a block diagram of an X-ray detector with a plastic housing and a printed circuit board, according to some implementation schemes.

[0014] Figure 13 This is a block diagram of an X-ray detector with a plastic housing and an oriented printed circuit board, according to some implementation schemes.

[0015] Figure 14 This is a block diagram of an X-ray detector with a plastic housing and multiple printed circuit boards according to some implementation schemes.

[0016] Figures 15A to 15C This is a block diagram of an X-ray detector with a plastic housing and modular adapter, according to some implementation schemes.

[0017] Figures 16A to 16C This is a block diagram of an X-ray detector with a plastic housing and another modular adapter, according to some implementation schemes.

[0018] Figure 17 This is a block diagram of an X-ray detector with a plastic housing and multiple modular adapters, according to some implementation schemes.

[0019] Figure 18A and Figure 18B This is a block diagram of a portion of an X-ray detector with a plastic housing and a user interface, according to some implementation schemes.

[0020] Figure 19 This is a block diagram of an X-ray detector with a plastic housing extending beyond the front panel, according to some implementation schemes.

[0021] Figures 20A to 20C This is a block diagram of an X-ray detector with a plastic housing having an insulating front panel, according to some implementation schemes.

[0022] Figure 21 This is a block diagram of a portion of an X-ray detector having a plastic housing with metal fasteners, according to some implementation schemes.

[0023] Figure 22 This is a block diagram of a 2D x-ray imaging system based on some implementation schemes. Detailed Implementation

[0024] Some implementations involve X-ray detectors with plastic housings. Plastic housings can reduce the weight and / or cost of X-ray detectors. Various modifications to X-ray detectors with plastic housings can improve electromagnetic interference performance, invasiveness performance, physical load specifications, etc.

[0025] Figure 1This is a block diagram of an X-ray detector with a plastic housing according to some embodiments. In some embodiments, the X-ray detector 100a includes a plastic housing 102, a front panel 104, a two-dimensional sensor array 108, and a conductive coating 110.

[0026] A two-dimensional sensor array 108 is housed within a plastic housing 102. The two-dimensional sensor array 108 is configured to generate image data in response to incident x-rays 101. For example, the two-dimensional sensor array 108 may include sensors such as direct conversion sensors, indirect conversion sensors, amorphous silicon (a-Si) based imaging arrays, complementary metal-oxide-semiconductor (CMOS) based imaging arrays, photon counting imaging arrays, etc. The two-dimensional sensor array 108 may include scintillators or x-ray conversion materials such as gadolinium oxysulfide (Gd₂O₂S; GOS; Gadox), terbium-doped gadolinium oxysulfide (Gd₂O₂S:Tb), cesium iodide (CsI), etc. Direct conversion sensors may include x-ray conversion materials and / or semiconductor materials such as cadmium telluride (CdTe). While some materials have been used as examples, the materials may differ in other embodiments. The two-dimensional sensor array 108 may include electronic circuitry such as readout circuitry, communication circuitry, processing circuitry, etc.

[0027] The plastic housing 102 is a structure formed from materials such as impact-resistant plastics, non-impact-resistant plastics, polycarbonate, acrylic, etc. Plastics encompass a wide range of synthetic or semi-synthetic materials using polymers as the primary component. The plastic housing 102 is configured to support various other components, such as the front panel 104, the two-dimensional sensor array 108, antennas, batteries, etc. These components and / or other parts may be part of the x-ray detector 100a.

[0028] The plastic housing 102 may include internal structural features such as ribs, recesses, grooves, pillars, etc., to provide rigid and semi-rigid support to the housing. The plastic housing 102 can be formed in various ways (e.g., molding, welding, gluing, etc. of various components). In a specific example, the plastic housing 102 is formed by injection molding. The plastic housing 102 may include sidewalls 102a and a base 102b.

[0029] In some implementations, the two-dimensional sensor array 108 is supported within a plastic housing 102. For example, a bracket, structure, or other feature of the plastic housing 102 can support the two-dimensional sensor array 108 within the plastic housing 102.

[0030] The front panel 104 is attached to the plastic housing 102. The front panel 104 and the plastic housing 102 form a housing that surrounds the two-dimensional sensor array 108. As will be described in more detail below, once the front panel 104 is attached to the plastic housing 102, the housing can be completely sealed. In other embodiments, other structures such as screws with seals, electrical connectors or contacts, eccentric cams, plastic hinges, cantilever snaps, hinge and pin connections, pressure-sensitive adhesives, etc., may be included in the completely sealed housing.

[0031] The front panel 104 may include conductive surfaces, layers, coatings, materials, etc. For example, the front panel 104 may include carbon fiber sheets, materials such as impact-resistant plastics, non-impact-resistant plastics, polycarbonate, acrylic, etc. Conductive materials such as aluminum may be embedded within the carbon fiber sheets, attached to one side of the structure (such as the inner side), etc. Thus, the conductive surfaces may extend across the main plane of the front panel 104.

[0032] The plastic housing 102 includes a conductive coating 110. The conductive coating 110 is electrically connected to the front panel 104 and forms at least a portion of the electromagnetic interference shielding surrounding the two-dimensional sensor array 108. In some embodiments, the conductive coating may include conductive paints such as copper (Cu) paints, silver (Ag) paints, nickel (Ni) paints, alloy conductive paints, hybrid paints, etc. In some embodiments, the conductive coating may be a sprayable conductive coating that can be applied in aerosol form. In some embodiments, the conductive coating may include a mild solvent compatible with solvent-sensitive materials (such as polycarbonate) or polycarbonate materials. In some embodiments, the conductive coating may include an alcohol-based coating, such as ethanol. In a particular example, the conductive paint may include silver-plated copper. In some embodiments, the conductive coating may be less than 12 mils (12 / 1000 inch or 300 micrometers [μm]), 8 mils (200 μm), 4 mils (100 μm), 2 mils (50 μm), 1 mil (25 μm), or 0.5 mils (12 μm).

[0033] Using a plastic housing 102 instead of a metal housing may increase the likelihood of electromagnetic interference (EMI) affecting circuitry such as the two-dimensional sensor array 108. EMI can be particularly problematic for the x-ray detector 100a. For example, the x-ray detector 100a, and especially the two-dimensional sensor array 108, can be highly sensitive to EMI. Voltage differences on the order of millivolts (mV) can introduce artifacts into the image generated by the x-ray detector 100a. If artifacts are introduced, the patient may need to be exposed to x-rays again to generate another image, thus increasing the dose delivered to the patient. The conductive coating 110 provides effective shielding against EMI. In some embodiments, the conductive coating may have a sheet resistance of less than 0.1 ohms / square (Ω / □), 0.05 Ω / □, 0.025 Ω / □, 0.015 Ω / □, or 0.007 Ω / □ per 25 μm or 1.0 mil. While the sheet resistance is provided based on a 25 μm thickness, the sheet resistance can be lower with a thicker coating and higher with a thinner coating. In some implementations, the resistivity (ρ) of the conductive coating can be less than 5.0 x 10⁻⁶ at 20°C. -7 Ohmmeter (Ωm), 3.75 x 10 -7 Ωm, 1.1x10 -7 Ωm, 5.0x10 -8 Ωm or 3.0x10 -8 Ωm.

[0034] Using a plastic housing 102 instead of a metal housing reduces the weight of the x-ray detector 100a. In some embodiments, the x-ray detector 100a may be a mobile device, such as a portable flat panel detector. The x-ray detector 100a can be moved from one location to another, inserted into a filter, or otherwise operated by a user. The weight reduction reduces the stress on the user.

[0035] In some embodiments, the conductive coating 110 may have a thickness within a certain range. For example, the thickness range may be from about 100 micrometers (μm) to about 300 μm. The actual thickness may vary based on manufacturing tolerances, structural features, etc., of the plastic housing 102. In some embodiments, the thickness is about 100 μm. In some embodiments, the thickness of the material is determined by the desired level of EMI protection. For some EMI protection requirements, a thickness of 25 μm may be too thin, such as the EMI shielding level used for the two-dimensional sensor array 108. Additionally, a coating that is too thick (e.g., greater than 300 μm) may cause peeling. In some embodiments, depositing a conductive coating layer of about 200 μm can reduce or eliminate peeling while still providing a sufficient level of EMI protection for the two-dimensional sensor array 108.

[0036] In some embodiments, the conductive coating 110 extends across all or substantially all of the inner surfaces of the plastic housing 102. In other embodiments, the conductive coating 110 may have sufficiently small gaps so that EMI is still adequately reduced. In other embodiments, gaps may be present in the conductive coating 110 on various features of the plastic housing 102 for attaching structural components, connectors, contacts, interfaces, etc. As will be described in more detail below, conductive materials such as copper strips (e.g., copper foil shielding strips) may be applied over such features to cover the gaps.

[0037] Figure 2 This is a block diagram of an X-ray detector with a coated plastic housing according to some embodiments. In some embodiments, X-ray detector 100b may be similar to X-ray detector 100a, etc. However, coating 116 may be deposited on at least a portion of conductive coating 110. Coating 116 reduces the likelihood that conductive coating 110 may peel off. Therefore, the use of coating 116 maintains the EMI shielding performance of conductive coating 110. Coating 116 may not be present over certain areas of conductive coating 110, where contact with conductive coating 110 is formed. Coating 116 may include a varnish coating, including polyurethane, acrylic, etc. In some embodiments, coating 116 may be translucent or opaque.

[0038] Figure 3 This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having multiple electrical connections for electromagnetic interference shielding. In some embodiments, X-ray detector 100c may be similar to X-ray detectors 100a-100b, etc. However, conductive strips 120 can electrically connect conductive coating 110 to two-dimensional sensor array 108. For example, various grounding terminals, contacts, etc. on two-dimensional sensor array 108 can be electrically connected to conductive coating 110 and / or front panel 104 via conductive strips 120. Although four conductive strips 120 are used as an example, in other embodiments, two, three, five, or more conductive strips 120 can electrically connect two-dimensional sensor array 108 to conductive coating. The number of conductive strips 120 can be based on the desired grounding degree of two-dimensional sensor array 108.

[0039] Additionally, while different connection locations of the conductive strip 120 have been used as examples, the locations may differ in other embodiments. For example, connections may be made to the threaded terminals of the plastic housing 102 coated with the conductive coating 110. The conductive strip 120 may be electrically connected to various areas of the conductive coating 110 on the plastic housing, such as the sidewall 102a and the base 102b.

[0040] The conductive strip 120 can take many forms. For example, the conductive strip 120 may include copper strip, wire, braided conductor, etc. In some embodiments, the conductive strip 120 may be electrically connected to one or more of the conductive coating 110, the two-dimensional sensor array 108, and / or the front panel 104 using a conductive adhesive such as conductive epoxy resin or conductive acrylic adhesive.

[0041] Figure 4 This is a block diagram of an X-ray detector having a plastic housing with a conductive elastic deformable material, according to some embodiments. In some embodiments, the X-ray detector 100d may be similar to X-ray detectors 100a-100c, etc. However, the conductive elastic deformable material 122 is electrically connected between the two-dimensional sensor array 108 and at least one of the conductive coating and the front panel. As shown, the conductive elastic deformable material 122 is disposed between the two-dimensional sensor array 108 and the base 102b of the plastic housing 102. The conductive elastic deformable material 122 can be compressed during installation to contact both the conductive coating 110 and the conductive contacts of the two-dimensional sensor array 108.

[0042] In some embodiments, when coating 116 is present, gap 116a may be present in coating 116 to allow the conductive elastic deformable material 122 to make electrical contact with the conductive coating 110.

[0043] The conductive elastic deformable material 122 can take many forms. For example, the conductive elastic deformable material 122 may include an open-cell foam with metal-coated fibers. In another example, the conductive elastic deformable material 122 may include anisotropic conductive films, isotropic conductive adhesives, etc.

[0044] Figure 5 This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having multiple electrical connections to an electromagnetic interference shield and a conductive elastic deformable material. In some embodiments, the X-ray detector 100e may be similar to X-ray detectors 100a-100d, etc. However, both the conductive strip 120 and the conductive elastic deformable material 122 can be used to electrically connect the two-dimensional sensor array 108 to the EMI shield. Multiple contact points distribute the grounding load across the conductive coating 110. Therefore, the lower thickness of the conductive coating 110 reduces the impact on performance compared to a metal housing.

[0045] Figures 6A to 6B This is a block diagram of an X-ray detector with a plastic housing and conductive gaskets according to some implementation schemes. Figure 6A This is an unfolded view of the interface between the side wall 102a and the front panel 104. Figure 6B This is a top view of the plastic housing 102 without the front panel 104. See also... Figure 6A and Figure 6BIn some embodiments, the x-ray detector 100f may be similar to x-ray detectors 100a-100e, etc. However, the conductive gasket 132 is disposed between the front panel 104 and the plastic housing 102, and is electrically connected to the front panel 104 and the conductive coating 110, and seals the interface between the front panel 104 and the plastic housing 102.

[0046] Here, the sidewall 102a of the plastic housing has a continuous groove 102c surrounding the periphery of the plastic housing 102. The conductive coating 110 extends into the groove. A conductive washer 132 is disposed in the groove 102c such that when the front plate 104 is attached to the plastic housing 102, the conductive washer 132 is compressed and contacts both the front plate 104 and the conductive coating 110.

[0047] While recess 132 has been used as an example, in other embodiments, conductive gasket 132 may take different forms. For example, conductive gasket 132 may comprise a conductive sheet formed to match the shape of the sidewall 102a of the plastic housing. In any case, conductive gasket 132 may form an electrical connection with front panel 104 around the periphery of plastic housing 102. This connection may maintain EMI shielding during the transition from conductive coating 110 to front panel 104.

[0048] The conductive gasket 132 can be formed from a variety of materials. In some embodiments, the conductive gasket 132 is formed from nickel, graphite, and silicon. In some embodiments, the conductive gasket 132 may include a conductive elastomer. For example, the conductive gasket 132 may use a fluorosilicone adhesive.

[0049] Figures 7A to 7B This is a block diagram of an X-ray detector with a plastic housing and antenna, according to some implementation schemes. See also... Figure 7A In some implementations, the x-ray detector 100g may be similar to x-ray detectors 100a-100f, etc. However, the x-ray detector 100g includes an antenna 124 electrically connected to the two-dimensional sensor array 108. The antenna 124 allows wireless communication between the x-ray detector 100g and an external computer. For example, the antenna 124 may be an antenna for WiFi (i.e., IEEE 802.11-2020 or earlier), Bluetooth (e.g., IEEE 802.15.1 or Bluetooth 5.2 or earlier), or other wireless communication standards.

[0050] However, in order for antenna 124 to transmit wireless signals, antenna 124 should be outside the EMI shield. Therefore, conductive coating 110, conductive tape, metal casing, etc., can surround antenna 124 on the housing 106 side of antenna 124. Although conductive coating 110 is shown as being disposed on antenna 124, the conductive material forming the EMI shield in the area surrounding antenna 124 can be formed by a combination of conductive structures as described above. Therefore, the EMI shield may be continuous, allowing antenna 124 to be outside the EMI shield.

[0051] In some embodiments, the antenna 124 is housed within the housing 106 such that the wall of the plastic housing 102 is positioned between the antenna 124 and the external region 126 of the housing 106. In this example, both the sidewall 102a and the base 102b are positioned between the antenna 124 and the external region 126. Specifically, the antenna 124 is within the plastic housing 102. In some embodiments, there is no access to the antenna 124. That is, there are no openings, doors, hatches, etc., through which the antenna 124 can be accessed via a localized area of ​​the plastic housing 102. This inaccessibility may contribute to sealing the housing 106, as will be described in more detail below.

[0052] In some embodiments, the use of a plastic housing 102 allows for easier placement of the antenna 124. In some embodiments, the antenna 124 may be positioned along the edge of the plastic housing 102. However, the absence of access to the antenna 124 or the lack of a separate structure for sealing the antenna 124 (such as a plastic cover on a metal housing) allows the antenna 124 to be moved to any desired location, regardless of where such pathways might be needed within the plastic housing 102, since the plastic housing does not obstruct radio or wireless transmissions.

[0053] See Figure 7A and Figure 7B In some embodiments, the antenna 124 can be attached to the housing in different ways. In the X-ray detector 100g, the antenna 124 can be attached to the plastic housing 102 using adhesives, fasteners that do not completely penetrate the plastic housing 102, etc. The passage for attaching the antenna 124 can be entirely within the plastic housing 102.

[0054] In other embodiments, in the x-ray detector 100h, the antenna 124 can be attached to the plastic housing 102 using fasteners 128 such as screws or bolts. In some embodiments, a seal 130 can be disposed between the fastener 128 and the plastic housing 102.

[0055] In some implementations, the various features described above can contribute to better performance regarding entry. See back for further details. Figure 1 , Figure 6A and Figure 6B In some embodiments, the plastic housing 102 is a continuous structure with only a first opening configured to receive the front panel 104. For example, the plastic housing 102 may have only one opening sealed by the gasket 132 and the front panel 104.

[0056] In other embodiments, the plastic housing 102 described herein may have additional openings. However, the number and characteristics of these openings may reduce the likelihood of ingress of dust, water, etc. Conventional X-ray detectors may be able to meet an entry protection code level of IP56, which provides some protection against dust (e.g., limiting dust ingress) and water jets (e.g., water sprayed from a 12.5 mm nozzle from any direction). An entry protection code level refers to the protection against solid ingress indicated by the first digit (e.g., 5 in IP56) and the protection against liquid ingress indicated by the second digit (e.g., 6 in IP56). However, X-ray detectors with IP56 cannot be immersed in liquids (such as water). The x-ray detector 100 described herein meets or exceeds the entry protection code level of conventional x-ray detectors, having the following entry protection levels: IP57 (where 7 means immersion in 1 meter of water for 30 minutes), IP67 (where 6 means dustproof, with no dust ingress for 2 to 8 hours), or IP68, wherein the x-ray detector 100 is dustproof and can be submerged in or immersed in 1 meter or deeper of water for at least 60 minutes.

[0057] See Figure 7A When the antenna 124 is completely within the plastic housing 102, the entry point is eliminated. That is, conventional X-ray detectors may have doors, panels, etc., made of plastic that cover the antenna within the metal housing. This door is necessary because the metal housing would otherwise obstruct the antenna's wireless transmission. Conversely, with the antenna 124 completely within the plastic housing 102, no cover is needed to allow the antenna 124 to communicate wirelessly. See also... Figure 7B Even when the fastener 128 is accessible from the outside of the plastic housing 102, sealing the interface with the seal 130 is much easier than covering the antenna with an irregular, curved, or other complex door or hatch. Furthermore, the difficulty of sealing the interface with a metal housing is exacerbated because such a door or hatch must be relatively thin.

[0058] Figure 8This is a block diagram of an x-ray detector with a plastic housing and a battery according to some embodiments. In some embodiments, the x-ray detector 100i may be similar to x-ray detectors 100a-100h, etc. However, the externally accessible battery 112 may be part of the x-ray detector 100i. The battery 112 may be connected to a two-dimensional sensor array 108 via contacts 114. Contacts 114 may penetrate the plastic housing 102. In some embodiments, a battery door 112a may conceal the battery 112 within the x-ray detector 100i.

[0059] In some embodiments, the plastic housing 102 may be a continuous structure having a first opening configured to receive the front panel 104 as described above. The only other opening in the plastic housing 102 may include an opening in which contacts 114 for forming an electrical connection between the battery 112 and the two-dimensional sensor array 108 are disposed. For example, the battery contacts 114 may include spring pins in a plug or other structure. This structure may be sealed to the plastic housing 102 at this opening. For example, U.S. Patent Application No. 16 / 730,953 (“'935 application”), filed December 30, 2019, entitled “Removable Battery Connector Adapter,” provides an example of battery contacts 114 sealed together with a metal housing, which may also be used with the plastic housing 102. This U.S. patent application is incorporated herein by reference in its entirety.

[0060] While battery contact 114 has been described as an example of an electrical connection penetrating the plastic housing 102, other electrical connections may penetrate in other embodiments. For example, a service port, a universal serial bus port, a power connector, etc., may be present. Each of these connectors, ports, etc., may be formed to create a seal in a corresponding opening in the plastic housing 102. However, the number of seals, potential locations for dust and / or water ingress, etc., can be reduced. Furthermore, the geometry of this penetration of the plastic housing 102 and the seal may be less complex, thereby reducing the likelihood of seal failure. Gaps as small as 1 μm may allow water or dust to enter. A simplified geometry of the interface increases the likelihood of such gaps not occurring. In some embodiments, battery 112 may be sealed to plastic housing 102. U.S. Patent No. 9,269,935 (“'935 Patent”), entitled “Battery Pack with IntegralSeal Member and Electronic Device Including the Same”, issued February 23, 2016, provides an example of a battery 112 sealed to a metal housing, which may also be used with plastic housing 102. The entire contents of the U.S. Patent are incorporated herein by reference.

[0061] Figures 9A to 9C This is a block diagram of an X-ray detector having a plastic housing with at least one rigid component, according to some embodiments. See also Figure 9A In some embodiments, the x-ray detector 100j-1 may be similar to the various x-ray detectors 100a-100i described above. However, in the x-ray detector 100j-1, at least one rigid component 134 is attached to the plastic housing 102. The rigid component 134 may include various forms, such as a rod, beam, bar, plate, etc.

[0062] In some embodiments, there may be multiple rigid components 134. Nine rigid components 134 are used here as an example. However, in other embodiments, the number and placement of the rigid components 134 may differ.

[0063] The rigid component 134 can be formed of a material with higher mechanical strength than plastic. For example, the rigid component 134 can be formed of carbon fiber, metal, etc.

[0064] In some embodiments, ribs 135 or other similar structures may be formed as part of the plastic housing 102. That is, strips or other shaped plastics may extend from the base 102b in various locations. While ribs 135 may increase the rigidity of the plastic housing 102, this increase may not be sufficient to achieve the desired rigidity. In some embodiments, rigid members 134 may be added in conjunction with ribs 135 to further increase rigidity.

[0065] In some implementations, the use of rigid component 134 can increase the static load that the x-ray detector 100j-1 can handle. For example, the increase may be about 50% or more. In a particular example, a conventional x-ray detector may have a point static load limit of about 100 kg and a distributed static load limit of 150 kg. Adding rigid component 134 can increase the static load limits to 200 kg and 300 kg, respectively.

[0066] In some embodiments, the rigid members 134 may be distributed on the plastic housing 102 such that the rigid members 134 are uniformly or consistently spaced apart. Therefore, the load transmitted to the rigid members 134 can be distributed substantially uniformly. However, in other embodiments, the rigid members 134 may be irregularly spaced apart to accommodate other internal structures, etc.

[0067] See Figure 9BIn some embodiments, the X-ray detector 100j-2 may include a plate 134' as a rigid component 134. The plate 134' may cover an area of ​​the base 102b of the plastic housing 102, which is greater than 50% of the area of ​​the base 102b. Although the plate 134' is shown as a single component in a specific location and having a specific shape, in other embodiments, the plate 134' may be multiple plates, which may have different shapes and may be in different locations or orientations.

[0068] In some embodiments, board 134' may be positioned on base 102b in an area overlapping with printed circuit board 1202, as will be described in more detail below.

[0069] In some embodiments, the thickness of plate 134' may be less than the thickness of base 102b. For example, base 102b may have a thickness of about 1 millimeter (mm), about 1 mm to 2 mm, etc. Plate 134' may have a thickness of at least about 0.3 mm, about 0.3 mm to about 1 mm, etc. Examples of such a thinner plate 134' may include carbon fiber plates.

[0070] See Figure 9C In some embodiments, plate 134' may be thicker than base 102b. For example, plate 134' may comprise a plastic material. Plate 134' may be 2, 3, 4, or more times thicker than base 102b. In some embodiments, plate 134' may have a thickness that results in a substantially the same height as the adjacent structure of base 102b. For example, base 102b may include a portion 137 configured to receive a battery. Plate 134' may be positioned adjacent to portion 137 and have a thickness such that plate 134' and the corresponding portion 137 configured to receive the battery are at substantially the same level. Therefore, the ridge between plate 134' and the portion 137 configured to receive the battery can be reduced or eliminated, thereby reducing or eliminating point loads on other components (such as the two-dimensional sensor array 108) from such a structure. Using a plate such as plate 134' can reduce the cost of plastic housing 102, as forming plastic housing 102 with varying thicknesses can be more expensive.

[0071] In some embodiments, the area of ​​the base 102b without the plate 134', portion 137, etc., may include foam or other elastic material at substantially the same height. Therefore, the two-dimensional sensor array 108 can be adjacent to or in contact with a substantially flat surface, thereby reducing the likelihood of damage due to point loads.

[0072] Figures 10A to 10C This is a block diagram of an X-ray detector with a plastic housing according to some embodiments, the plastic housing having at least one rigid component with a conductive material. Although Figures 10A to 10CThe rigid member 134 shown has a rectangular cross-section, but the rigid member can have any type of cross-section, such as elliptical, circular, triangular, polygonal, I-beam, etc. See also Figure 10A In some embodiments, the rigid member 134 may be directly attached to the plastic housing 102. Here, the rigid member 134 is attached to the base 102b of the plastic housing 102 by an adhesive 138.

[0073] In some embodiments, the rigid member 134 may be non-conductive. Additionally, by attaching the rigid member 134 directly to the plastic housing 102, the non-conductive rigid member 134 can create gaps in the EMI shielding. Therefore, a conductive material 136 can be disposed on the rigid member 134 to cover it. The conductive material 136 may be electrically connected to the conductive coating 110. For example, the conductive material 136 may include conductive tape covering the rigid member 134. In other embodiments, the rigid member 134 may be covered with conductive epoxy resin. In other embodiments, the rigid member 134 may be covered by the conductive coating 110 itself.

[0074] In some embodiments, conductive material covers all rigid components 134. In other embodiments, conductive material 136 covers a sufficient amount of rigid components 134 to maintain the desired level of EMI shielding.

[0075] See Figure 10B In some embodiments, the rigid member 134 may be attached to the conductive coating 110. Here, the rigid member 134 is attached to the conductive coating 110 using an adhesive 138.

[0076] See Figure 10C In some embodiments, the rigid member 134 may be embedded within a recess 102c or other structure of the plastic housing 102. The recess 102c may be similar to or different from the rib 135 described above. An adhesive 138 may be used to attach the rigid member 134 to the recess 102c. The rigid member 134, the recess 102c, etc., may be covered by a conductive material 136, which is conductive and... Figure 10A The conductive materials described in the text are similar.

[0077] In the various embodiments described above, the rigid component 134 may be covered to maintain at least part of the EMI shielding formed by the conductive coating 110 and the front panel 104.

[0078] Figures 11A to 11C This is a block diagram of an X-ray detector with a plastic housing and corner buffer, according to some implementation schemes. See also Figure 11AIn some embodiments, the x-ray detector 100k may be similar to other x-ray detectors 100a-100j described herein. However, the x-ray detector 100k includes at least one corner buffer 140. The corner buffer 140 is attached to a plastic housing 102. The corner buffer 140 includes a tip 142 and a body 144. The tip 142 is formed of a first material. The body 144 is formed of a second material different from the first material. When mounted on the plastic housing 102, the tip 142 may be positioned at the distal end of the corner buffer 140.

[0079] In some implementations, the corner buffer 140 may be removably attached to the plastic housing 102. For example, a fastener (not shown) may attach the corner buffer 140 to the plastic housing 102. Therefore, if the corner buffer 140 is damaged during an impact, the corner buffer 140 can be replaced.

[0080] In some embodiments, the first material may include a flexible material that can deform or disperse under load. In some embodiments, the first material may include an elastic plastic. In some embodiments, the first material of the tip 142 includes rubber. The first material may include an elastic material.

[0081] The second material may be more rigid than the first material. For example, the second material may include an impact-resistant plastic. The second material is less likely to elastically deform under load and is more likely to crack or break. In some embodiments, the second material may be similar to or the same as the material of the plastic housing 102. In some embodiments, both the second material and the plastic housing 102 may include impact-resistant plastics. However, in other embodiments, the second material may include impact-resistant plastic, while the plastic housing 102 may include non-impact-resistant plastic.

[0082] The tip 142 and the body 144 can be integrally formed. For example, the body 144 can be molded onto the tip 142 using an overmolding process. Thus, chemical bonds can be formed between the two to transfer impact between the two materials.

[0083] In some embodiments, the body 144 may include sufficient material to mount the corner buffer 140 to the plastic housing 102 and to accommodate the tip 142 upon deformation. The combination of the first and second materials improves the impact resistance of the X-ray detector 100k. Specifically, if an elastic material is used alone, it may deform excessively. Hard plastic may shatter and bounce upon impact. The combination of both may result in some bounce, but the body 144 accommodates the tip 142 and limits deformation. Thus, deformation of the tip 142 can mitigate impact, but it can also be restrained so that its deformation is insufficient to damage the front panel 104. For example, excessive deformation of the tip 142 may contact the front panel 104 and cause delamination. By limiting deformation, the possibility of such delamination can be reduced or eliminated.

[0084] See Figure 11B In some embodiments, the x-ray detector 100I is similar to the x-ray detector 100k. However, the corner buffer 140 does not extend beyond a rectangle coinciding with each side of the outer perimeter of the plastic housing 102 in a plan view. That is, the corner buffer 146 is slightly recessed into the plastic housing 102. Therefore, when the x-ray detector 100I is placed in the filter during use, the corner buffer 140 does not interfere with insertion. In other words, the installation in the filter can be controlled by the size of the x-ray detector 100I rather than by the size of the corner buffer 140.

[0085] In some embodiments, the corner buffer 140 is positioned only at the corner of the x-ray detector 100. However, in other embodiments, other similar structures may be formed on the side of the x-ray detector 100, whether continuous along the side, continuous with the corner buffer 140, periodically spaced apart, etc.

[0086] See Figure 11C In some embodiments, the x-ray detector 100m may be similar to the x-ray detector 100k or 100l. The x-ray detector 100m has a generally rectangular plastic housing 102. Corner buffers 140 may be disposed in the four corners of the plastic housing 102.

[0087] Figure 12 This is a block diagram of an X-ray detector having a plastic housing and a printed circuit board according to some embodiments. The X-ray detector 100n may be similar to the X-ray detectors 100a-100m described above, including a plastic housing 102 and a two-dimensional sensor array 108. However, the X-ray detector 100n includes a printed circuit board (PCB) 1202.

[0088] PCB 1202 may include various circuits, such as readout circuits, amplifiers, analog-to-digital converters, processors, application-specific integrated circuits (ASICs), etc. The circuits may be configured to perform various operations on the data received from the two-dimensional sensor array 108, to control the two-dimensional sensor array 108, to control other functions of the x-ray detector 100n, etc.

[0089] PCB 1202 includes multiple mounting points 1204. Mounting points 1204 are locations on PCB 1202 where PCB 1202 is mounted to the plastic housing 102. Corresponding receiving points for mounting points 1204 on PCB 1202 are located on the plastic housing 102. PCB 1202 can be mounted to the corresponding receiving points on the plastic housing 102 at mounting points 1204 using fasteners, brackets, pins, clips, rivets, solder joints, etc.

[0090] The centroid 1202a of PCB 1202 is closer to the center 102d of the plastic housing 102 than the centroid 1204a of mounting point 1204. The centroid 1202a of PCB 1202 can be determined by determining the centroid of PCB 1202. The centroid can be determined while assuming that PCB 1202 has a uniform density. Alternatively, the centroid 1202a of PCB 1202 can be determined by determining the region center of the main plane of PCB 1202 or the projection of PCB 1202 onto the main plane. The centroid 1204a of mounting point 1204 can be determined similarly. For example, the centroid 1204a of mounting point 1204 can be determined by averaging the center positions of mounting point 1204. In another example, the size of mounting point 1204 can be incorporated. The centroid 1204a of mounting point 1204 can also be based on the projection of mounting point 1204 onto the main plane of PCB 1202. Therefore, mounting point 1204 as a whole is further away from the center 102d of plastic housing 102 than PCB 1202 itself.

[0091] In some embodiments, the plastic housing 102 has the ability to flex. The plastic housing 102 can subsequently return to its original shape. The design of the plastic housing 102 may intentionally allow flexure. For example, the plastic housing 102 may include fewer or no internal structural features that would otherwise provide rigid or semi-rigid support, such as ribs, recesses, grooves, pillars, etc. Similarly, the plastic housing 102 may include fewer or no rigid components, such as rigid component 134 as described above. Flexibility can increase the survivability of the x-ray detector 100n from drops from greater heights compared to a more rigid housing. Increased or enhanced survivability can indicate less or no damage under equivalent or similar conditions, such as drops.

[0092] The use of mounting point 1204 and its position relative to PCB 1202 allows PCB 1202 to accommodate increased deflection of the plastic housing 102. For example, the amount of deflection can decrease as it moves away from the center 102d of the plastic housing. Because the centroid 1204a of mounting point 1204 is farther from the center 102d of the plastic housing 102 than the centroid 1202a of PCB 1202, the amount of deflection experienced by PCB 1202 and the strain and / or stress on the fasteners of mounting point 1204 will be less compared to the case where mounting points 1204 are uniformly distributed on PCB 1202 or distributed closer to the center 102d. The reduced deflection of PCB 1202 increases the likelihood that components, traces, vias, layers, etc., of PCB 1202 will not be disconnected, delaminated, or otherwise altered in a manner that affects the operation of PCB 1202.

[0093] Therefore, the X-ray detector 100n can tolerate greater deflection while remaining operable after deflection. For example, the X-ray detector 100n may experience this increased deflection when inserting or removing it from behind a more severely injured patient.

[0094] Fragmentation-induced damage can be a significant failure mode for X-ray detectors. Even with increased structural rigidity, the protection provided may not be sufficient to prevent damage to components such as the 2D array 108 and PCB 1202. Instead, X-ray detector 102n utilizes the flexibility of the plastic housing 102 to absorb at least some of the energy that would cause X-ray detector 100n to flex. PCB 1202 can be mounted in a flexural manner.

[0095] In some embodiments, the two-dimensional sensor array 108 includes a flexible substrate. For example, the flexible substrate of the two-dimensional sensor array 108 may include polyamide, polyester, or polyethylene terephthalate (PET) film, etc. Therefore, the two-dimensional sensor array 108 can adapt to the flexural deformation of the plastic housing 102.

[0096] In some embodiments, a first number of mounting points 1204 are positioned along an edge 1202b of the PCB 1202, which is furthest from the center 102d of the plastic housing 102. In this example, the "edge" in "along an edge" for a given mounting point 1204 refers to the edge closest to that mounting point 1204. A second number of mounting points 1204 are positioned along an edge 1202c of the PCB 1202, which is closest to the center 102d of the plastic housing 102. The first number is greater than the second number. In this example, five mounting points 1204 are positioned along edge 1202b, while two mounting points 1204 are positioned along edge 1202c; however, in other embodiments, the number of mounting points along either edge 1202b or 1202c may differ. Therefore, the number of mounting points 1204 experiencing a greater amount of deflection of the plastic housing 102 may be less than the number of mounting points 1204 experiencing a lesser amount of deflection.

[0097] In some embodiments, PCB 1202 is positioned along the edge 102e of the plastic housing 102. In some embodiments, "along the edge" means that PCB 1202 is immediately adjacent to the edge 102e, with only a mechanical tolerance gap to accommodate the plastic housing 102, PCB 1202, etc. In other embodiments, "along the edge" means that the centroid 1202a of PCB 1202 is closer to the edge 102e than the center 102d of the plastic housing 102. Therefore, PCB 1202 may experience less flexing compared to positioning PCB 1202 closer to the center 102d.

[0098] In some implementations, the use of a plastic housing 102 and a two-dimensional sensor array 108 with a flexible substrate can increase the point and distributed static load limits to 500 kg and 1000 kg, respectively.

[0099] Figure 13 This is a block diagram of an X-ray detector having a plastic housing and an oriented printed circuit board according to some embodiments. In some embodiments, X-ray detector 100o may be similar to X-ray detector 100n. A first dimension D1 of PCB 1202 along an axis including the center 102d of the plastic housing 102 is smaller than a second dimension D2 of PCB 1202 along its long axis 1202d. Here, the long axis 102f of the plastic housing 102 is used as an example; however, in other embodiments, this axis may be a short axis. Therefore, more surface area of ​​PCB 1202 may be further away from the center 102d compared to the case where PCB 1202 is rotated 90 degrees. In some embodiments, the long axis 1202d of PCB 1202 may be perpendicular to the long axis 102f.

[0100] In some embodiments, PCB 1202 may also be disposed outside the central region 102m of the plastic housing. The central region 102m is the midpoint of the width of the plastic housing 102 along both the X and Y axes. That is, the central region 102m begins at one-quarter of the distance along the X and Y axes within the outer perimeter of the plastic housing 102. PCB 1202 may be disposed within a region of the plastic housing 102 that is within the first or fourth quarter of the plastic housing 102 along both the X and Y axes.

[0101] Figure 14 This is a block diagram of an x-ray detector having a plastic housing and multiple printed circuit boards according to some embodiments. The x-ray detector 100p may be similar to x-ray detectors 100n-100o. However, the x-ray detector 100p includes multiple PCBs 1202. Here, as an example, two PCBs 1202-1 and 1202-2 are used on the same side of the x-ray detector 100p; however, in other embodiments, any number of PCBs 1202 may be included in the x-ray detector 100p. Additionally, while the two PCBs 1202-1 and 1202-2 are arranged along one side of the plastic housing 102, in other embodiments, the PCBs 1202 may be arranged along different sides, such as on opposite sides, orthogonal sides, or other sides of the x-ray detector 100p, or at different locations.

[0102] In some implementations, some or all of PCB 1202 are related to the above regarding Figure 12 and Figure 13One or more of the described PCBs 1202 are similar. That is, the mounting points 1204, orientation, location, etc. of PCB 1202 can be similar to those described above. For example, even if PCB 1202-2 is closer to the center 102d than PCB 1202-1, PCB 1202-2 may still experience less flexing due to the mounting points 1204, orientation, location, etc. Furthermore, using multiple PCBs 1202 can also reduce the potential effects of flexing. For example, a PCB 1202 spanning the locations of PCBs 1202-1 and 1202-2 will experience greater distortion than any single PCB 1202-1 or PCB 1202-2.

[0103] Figures 15A to 15C This is a block diagram of an X-ray detector with a plastic housing and modular adapter, according to some implementation schemes. See also... Figures 15A to 15C In some embodiments, the x-ray detector 100q may be similar to x-ray detectors 100a-100p. The x-ray detector 100q includes a modular adapter 1502 having a first mechanical interface 1502a and a second mechanical interface 1502b. The modular adapter 1502 may be removable from the plastic housing 102. The plastic housing 102 includes a container 1504 configured to receive the modular adapter 1502. The container 1504 includes a third mechanical interface 1504a configured to mate with the first mechanical interface 1502a of the modular adapter 1502. In some embodiments, the mating of the first mechanical interface 1502a and the third mechanical interface 1504a may be purely mechanical. In other embodiments, the first mechanical interface 1502a and the third mechanical interface 1504a may include electrical connections similar to those disclosed in U.S. Provisional Patent Application No. 63 / 220,941, filed July 12, 2021, entitled “X-RAY SYSTEMS INCLUDING AN ADAPTER”, and U.S. Patent Application No. 17 / 711,743, filed April 1, 2022, entitled “X-RAY SYSTEMS INCLUDING AN ADAPTER”, the contents of each of which are incorporated herein by reference in their entirety.

[0104] Mechanical interfaces 1502a and 1504a may include complementary features that allow the modular adapter 1502 to be attached to the plastic housing 102. For example, mechanical interfaces 1502a and 1504a may include protrusions and mating recesses, screws and mating threaded portions, posts and mating openings, etc.

[0105] Modular adapter 1502 may include a structure that produces a desired form when combined with plastic housing 102. For example, container 1506 (such as a filter) for x-ray detector 100q may have a specific form intended to receive x-ray detector 100q having a matching complementary form. In this example, container 1506 includes mechanical interface 1506a configured to mate with mechanical interface 1502b of modular adapter 1502. Mechanical interfaces 1502b and 1506a may have similar features to mechanical interfaces 1502a and 1504a; however, the type, number, configuration, etc., may be the same as or different from mechanical interfaces 1502a and 1504a.

[0106] Figures 16A to 16C This is a block diagram of an X-ray detector with a plastic housing and another modular adapter, according to some implementation schemes. See also Figures 16A to 16C In some embodiments, the x-ray detector 100r may be similar to the x-ray detector 100q. Specifically, the plastic housing 102 including the container 1504 may be identical between the x-ray detectors 100q and 100r. However, different modular adapters 1508 with mechanical interfaces 1508a and 1508b are attached to the container 1504. Therefore, the x-ray detector 100r can be configured to be placed within a container 1510 having a mechanical interface 1510a configured to mate with mechanical interface 1508b.

[0107] Modular adapter 1508 includes a mechanical interface 1508a configured to mate with mechanical interface 1504a. While mechanical interface 1508a may mate with mechanical interface 1504a in the same manner as mechanical interface 1502a, in other embodiments, mechanical interface 1508a may mate with mechanical interface 1504a in a different manner. For example, mechanical interface 1508a may have fewer fastener locations, occupy a smaller structure that does not occupy the entire container 1504, etc. However, the container's mechanical interface 1504a is configured to mate with both mechanical interfaces 1502a and 1508a.

[0108] Therefore, the same plastic housing 102 and other components can be reconfigured into x-ray detectors 100q or 100r, depending on which modular adapter 1502 or 1508 is attached to the container 1504. This allows the use of the same underlying components to form x-ray detectors that conform to a variety of different form factors.

[0109] In some implementations, container 1504 is part of the access protection boundary of x-ray detector 100q / 100r. Attaching or removing modular adapters 1502, 1508, or other components may not impair the seals at the access protection boundary.

[0110] Figure 17 This is a block diagram of an X-ray detector with a plastic housing and multiple modular adapters according to some embodiments. The X-ray detector 100s may be similar to X-ray detectors 100q and 100r. However, the X-ray detector 100s includes multiple modular adapters 1512. In this example, the X-ray detector 100s includes two modular adapters 1512-1 and 1512-2; however, in other embodiments, the number may be greater. The modular adapters 1512 may be identical or different, and two or more of the modular adapters 1512 may be identical, while one or more other modular adapters 1512 may be different.

[0111] In some implementations, different form factors may correspond to different x-ray systems. Additionally, the plastic housing 102, without any modular adapters such as modular adapters 1502, 1508, 1512, may have a geometrically intersecting form that represents all shapes of the x-ray detector. Adding one or more modular adapters, such as modular adapters 1502, 1508, etc., can be used to configure the x-ray detector 100s for a specific application.

[0112] Although modular adapters such as modular adapters 1502, 1508 and 1512 have been shown as single components directly attached to the plastic housing 102, in some embodiments, modular adapters can be formed by combining multiple structures, multiple modular adapters, etc.

[0113] Figure 18A and Figure 18B This is a block diagram of a portion of an X-ray detector with a plastic housing and user interface, according to some implementation schemes. See also... Figure 18A In some embodiments, the x-ray detector 100t may be similar to x-ray detectors 100a-100r. However, the x-ray detector 100t includes a user interface 1802 housed within a plastic housing 102. A portion of the x-ray detector 100t is shown, illustrating the relationship between the user interface 1802, the plastic housing 102, and the access protection boundary 102g.

[0114] User interface 1802 may include various input and output devices. For example, the user interface may include output devices such as a display, lamps, light-emitting diodes, and speakers. User interface 1802 may also include input devices such as buttons and touch screens. User interface 1802 may be electrically connected to circuit 1804.

[0115] As described above, the plastic housing 102 and the front panel 104 may form at least a portion of the entry into the protective boundary 102g. The user interface 1802 is exposed through the plastic housing 102 without penetrating the entry into the protective boundary 102g, wherein exposure means that the user can access or see it, and thus the user interface 1802, which serves as an input or output device, can be accessed by the user. In this example, the plastic housing 102 includes a portion 102h that allows access to the user interface 1802.

[0116] In some embodiments, portion 102h of the plastic housing 102 may be thin or partially translucent. Therefore, displays, touchscreens, status lights, etc., may be visible and / or accessible through portion 102h. However, entry into the protective boundary 102g may not be impaired. In a particular example, because the plastic housing 102 is non-conductive, capacitive touch buttons or sensors may be placed within the plastic housing 102 but still accessible to the user from the outside, without any physical breaks or holes in the plastic housing 102. While portion 102h has been described as being different in some way from the rest of the plastic housing 102, in other embodiments, portion 102h of the plastic housing 102 may be identical as long as the user interface 1802 is accessible.

[0117] See Figure 18B In some embodiments, the x-ray detector 100u may be similar to x-ray detectors 100a-100r. However, the x-ray detector 100u includes a user interface 1802 disposed outside the plastic housing 102. The user interface 1802 can be electrically connected to circuitry 1804 within the plastic housing 102 via an electrical interface 1806. For example, the electrical interface may include wires extending through grommets, potting material, connectors, etc., that maintain access to the protective boundary 102g. The electrical interface 1806 may be any structure that both allows electrical signals and / or power to be transmitted through the plastic housing 102 and maintains access to the protective boundary 102g formed by the plastic housing 102 and the front panel 104.

[0118] Figure 19This is a block diagram of an x-ray detector having a plastic housing extending beyond a front panel, according to some embodiments. In some embodiments, the x-ray detector 100v may be similar to x-ray detectors 100a-100u. However, the x-ray detector 100v includes a plastic housing 102 extending beyond a front panel 104. Specifically, the front panel 104 includes an outer surface 104a facing the exterior 10 of the x-ray detector 100v. The plastic housing 102 includes a wall 102i extending from the x-ray detector 100v along an axis 102j perpendicular to the outer surface 104a of the front panel 104, beyond the outer surface 104a of the front panel 104. In this example, the extension 102k of the wall 102i extends a distance D3 beyond the outer surface 104a of the front panel 104. In some embodiments, the distance D3 may be from about 0.2 mm to about 0.3 mm. In other embodiments, the distance D3 may be based on the thickness of the plastic housing 102, such as about 10% to about 30% of the thickness of the plastic housing 102.

[0119] The wall 102i may extend this distance around the entire perimeter of the x-ray detector 100v. Therefore, the extension 102k of the wall 102i prevents contact with the side 104b of the front panel 104, the bottom 104c of the front panel 104, or components attached to the bottom 104c. In particular, it prevents the user from contacting conductive surfaces, as leakage or static electricity is better contained within the x-ray detector 100v. Even if the side 104b of the front panel 104 does not contact the wall 102i, the extension 102k may make contact with the side 104b or structures further inside the plastic housing 102 more difficult or impossible. Therefore, conductive paths that could result in electric shock to the user are reduced or eliminated.

[0120] Figures 20A to 20C This is a block diagram of an X-ray detector with a plastic housing and an insulating front panel, according to some embodiments. As used herein, "insulated" and "insulating" refer to "electrically insulated" and "electrically insulating," respectively. As used herein, "conducting" means electrically conductive. See also Figure 20A In some embodiments, the x-ray detector 100w may be similar to the x-ray detector 100v. However, the x-ray detector 100w includes a conductive support 2002 configured to support the front panel 104. The conductive support 2002 may include a metal support, a portion of the plastic housing 102 covered by a conductive surface, etc.

[0121] X-ray detector 100w includes a conductive sheet 2004 electrically connected to a conductive support 2002. The conductive sheet 2004 may comprise a conductive material that is substantially X-ray transparent. Substantially X-ray transparentness includes a transmittance coefficient that results in the efficiency of the X-ray detector 100w given the performance of other components. For example, the conductive sheet 2004 may comprise an aluminum sheet with a thickness that results in a transmittance coefficient greater than 0.88, 0.9, etc. In some embodiments, the conductive sheet 2004 may have a transmittance coefficient of about 0.95 to about 0.99.

[0122] The X-ray detector 100w includes an insulating sheet 2006 disposed between a conductive sheet 2004 and a front panel 104, thereby insulating the front panel 104 from the conductive sheet 2004. The insulating sheet 2006 may include glass fiber, non-conductive epoxy resin, polyamide, plastic (including PET plastic), etc.

[0123] In some embodiments, the plastic housing 102 includes a conductive coating 110 as described above. The conductive coating 110 is electrically connected to the conductive support 2002. The conductive support 2002 is electrically connected to the conductive sheet 2004. Thus, the conductive coating 110, the conductive support 2002, and the conductive sheet 2004 form at least a portion of the electromagnetic interference shielding surrounding the two-dimensional sensor array 108.

[0124] See Figure 20B In some embodiments, the X-ray detector 100x may be similar to the X-ray detector 100w. The X-ray detector 100w includes a conductive washer 2008 disposed between a conductive sheet 2004 and a conductive support 2002. The conductive washer 2008 may be configured to electrically connect the conductive sheet 2004 and the conductive support 2002. The conductive washer 2008 may be configured to seal the interface between the conductive sheet 2004 and the conductive support 2002. The conductive washer 2008 may be similar to conductive washer 132 and may help establish or improve the entry protection code level.

[0125] See Figure 20C In some embodiments, the x-ray detector 100y may be similar to x-ray detectors 100w-100x. The x-ray detector 100y is shown to have a structure similar to that of the x-ray detector 100w, but in other embodiments, it may include a conductive pad 132 similar to that of the x-ray detector 100x. As described above, the front panel 104 may be formed of an insulating material such as impact-resistant plastic, non-impact-resistant plastic, polycarbonate, acrylic, etc. Therefore, the insulating sheet 2006 can be omitted, as the front panel 104 itself may be an insulating structure. The insulating front panel 104 may be outside of an EMI shield, such as an EMI shield including the conductive sheet 2004, conductive support 2002, and conductive coating 110.

[0126] In some implementations, the configuration of the insulating sheet 1206, the insulating front plate 104, and / or other components reduces or eliminates the path a user may take when contacting the internal conductive surfaces and components of the x-ray detector 100. Therefore, the probability of the user potentially suffering an electric shock can be reduced or eliminated.

[0127] Figure 21 This is a block diagram of a portion of an X-ray detector having a plastic housing using metal fasteners, according to some embodiments. X-ray detector 100z may be similar to X-ray detectors 100a-100x. However, the plastic housing 102 includes mounting points 2102. Here, a bracket or post is used as an example of mounting point 2102; however, different types of mounting points 2102 may be used in other embodiments. A PCB 1202 may be mounted to the plastic housing 102 at mounting point 2102. Fasteners 2104, such as screws, bolts, nuts, clips, etc., may interface with mounting point 2102 to attach the PCB 1202 to the plastic housing 102. The PCB 1202 is used as an example of something that can be attached to the plastic housing 102. In another example, an external handle (not shown) may be attached to the plastic housing 102 in this manner using metal fasteners.

[0128] Each of a plurality of metal fasteners may be used in such a manner that it mates with a non-metallic component. In this example, fastener 2104 may be a metal screw. The metal screw may mate with a threaded portion of mounting point 2102. This threaded portion may be plastic, as it may be a molded portion of the plastic housing 102. Depending on the configuration of fastener 2104, mounting point 2102 may not have threads. In another example, a metal insert (such as a helical insert) may be inserted into mounting point 2102. Fastener 2104 in this example may be a non-metallic fastener, such as a plastic screw.

[0129] In both examples, the interface between the fasteners is a metal-to-nonmetal interface. This interface reduces or eliminates the formation of metal particles. Such metal particles can cause malfunctions in the X-ray detector 100z. Reducing or eliminating metal particles reduces or eliminates such malfunctions.

[0130] Figure 22This is a block diagram of a 2D x-ray imaging system according to some embodiments. The 2D x-ray imaging system 2200 includes an x-ray source 2202 and a detector 2210. The detector 2210 may include an x-ray detector 100 as described above. The x-ray source 2202 is positioned relative to the detector 2210 such that x-rays 2220 can be generated to pass through a specimen 2222 and be detected by the detector 2210. In some embodiments, the detector 2210 is part of a medical imaging system. In other embodiments, the 2D x-ray imaging system 2200 may include a portable vehicle scanning system as part of a cargo scanning system.

[0131] As used herein, x-ray detector 100 refers to any one of the x-ray detectors 100a-100y described above.

[0132] An X-ray detector includes: a plastic housing 102 including a conductive coating 110; a two-dimensional sensor array 108 disposed within the plastic housing 102 and configured to generate image data in response to incident X-rays; and a front panel 104 connected to the plastic housing, the front panel 104 and the plastic housing 102 forming a housing surrounding the two-dimensional sensor array 108; wherein the conductive coating 110 and the front panel 104 form at least a portion of electromagnetic interference shielding surrounding the two-dimensional sensor array 108.

[0133] In some implementations, the enclosure meets or exceeds the entry protection code IP67.

[0134] In some embodiments, the plastic housing 102 is a continuous structure with only a first opening configured to receive the front panel 104.

[0135] In some embodiments, the X-ray detector also includes a battery contact 114; wherein: the plastic housing 102 is a continuous structure having only a first opening and a second opening configured to receive the front panel 104; and the battery contact 114 is disposed in the second opening.

[0136] In some embodiments, the conductive coating 110 includes a conductive coating.

[0137] In some embodiments, the X-ray detector also includes a coating 116 disposed on a conductive coating.

[0138] In some embodiments, the conductive coating includes copper coating, silver coating, nickel coating, or alloy coating, or a mixture of copper, silver, or nickel.

[0139] In some embodiments, the thickness of the conductive coating 110 is between about 100 micrometers (μm) and 300 μm.

[0140] In some embodiments, the X-ray detector also includes a conductive strip 120 that electrically connects the conductive coating 110 to the two-dimensional sensor array 108.

[0141] In some embodiments, the X-ray detector further includes a conductive elastic deformable material 122 electrically connected between the two-dimensional sensor array 108 and at least one of the conductive coating 110 and the front panel 104.

[0142] In some implementations, the two-dimensional sensor array 108 is electrically connected to the electromagnetic interference shield via at least two electrical connections.

[0143] In some embodiments, the X-ray detector further includes an antenna 124 electrically connected to a two-dimensional sensor array 108; wherein the antenna 124 is housed within a housing such that the wall of the plastic housing 102 is positioned between the antenna 124 and the area outside the housing.

[0144] In some embodiments, the X-ray detector further includes a conductive washer 132 disposed between the front panel 104 and the plastic housing 102, and electrically connected to the front panel 104 and the conductive coating 110, and sealing the interface between the front panel 104 and the plastic housing 102.

[0145] In some embodiments, the X-ray detector also includes at least one rigid component 134 attached to the plastic housing 102.

[0146] In some embodiments, the X-ray detector also includes conductive materials 110 and 136, which cover at least one rigid component 134 and are electrically connected to the conductive coating 110.

[0147] In some embodiments, at least one rigid component 134 is attached to the plastic housing 102 by an adhesive 138.

[0148] In some embodiments, the X-ray detector further includes at least one corner buffer 140, each corner buffer 140 including: a tip 142 formed of a first material; and a body 144 formed of a second material different from the first material.

[0149] In some implementations, the first material is rubber, while the second material is impact-resistant plastic.

[0150] In some implementations, for each corner buffer 140: the corner buffer 140 is integrally formed.

[0151] In some implementations, for each corner buffer 140: the corner buffer 140 is removably attached to the plastic housing 102.

[0152] In some implementations, for each corner buffer 140: in a plan view, the corner buffer 140 is entirely within a rectangle that coincides with each side of the outer perimeter of the plastic housing 102.

[0153] Some embodiments include a method of forming an X-ray detector, comprising: providing a plastic housing 102; applying a conductive coating 110 to the plastic housing 102; attaching a two-dimensional sensor array 108 configured to generate image data in response to X-rays incident on the plastic housing 102; forming a housing surrounding the two-dimensional sensor array 108 using the plastic housing 102 and a front panel 104; and electrically connecting the two-dimensional sensor array 108 to the conductive coating 110.

[0154] Some embodiments include an X-ray detector comprising: a plastic housing 102 including at least one rigid component attached to the plastic housing 102; a two-dimensional sensor array 108 disposed within the plastic housing 102 and configured to generate image data in response to incident X-rays; and a front panel 104 connected to the housing, the front panel 104 and the plastic housing 102 forming a shell surrounding the two-dimensional sensor array 108.

[0155] Some embodiments include an x-ray detector comprising: means for generating image data in response to x-rays; a non-conductive means for supporting the means for generating image data in response to x-rays; means for forming a housing together with the non-conductive means for supporting the means; and a conductive means compliantly disposed on the non-conductive means for shielding the means for generating image data in response to x-rays within the housing from electromagnetic interference.

[0156] Examples of devices for generating image data in response to x-rays include a two-dimensional sensor array 108.

[0157] Examples of non-conductive devices used to support a means for generating image data in response to x-rays include a plastic housing 102.

[0158] Examples of devices used to form a housing together with non-conductive devices for support include front plate 104.

[0159] Examples of conductive devices that are compliantly mounted on non-conductive devices to shield devices for generating image data in response to x-rays within the housing from electromagnetic interference include conductive coating 110 and conductive material 136.

[0160] In some embodiments, the X-ray detector also includes means for conductively coating a non-conductive device used for support. Examples of means for conductively coating a non-conductive device used for support include conductive coatings.

[0161] Some implementations include an X-ray detector comprising: a plastic housing 102; a two-dimensional sensor array 108 disposed within the plastic housing 102 and configured to generate image data in response to incident X-rays; a front panel 104 connected to the plastic housing 102, the front panel 104 and the plastic housing 102 forming a housing surrounding the two-dimensional sensor array 108; and a printed circuit board 1202 mounted to the plastic housing 102 at a plurality of mounting points 1204; wherein the centroid of the printed circuit board 1202 is closer to the center of the plastic housing 102 than the centroid of the mounting points 1204.

[0162] In some implementations, the two-dimensional sensor array 108 includes a flexible substrate.

[0163] In some embodiments, a first number of mounting points 1204 are arranged along the edge of the printed circuit board 1202 furthest from the center of the plastic housing 102; a second number of mounting points 1204 are arranged along the edge of the printed circuit board 1202 closest to the center of the plastic housing 102; and the first number is greater than the second number.

[0164] In some embodiments, the printed circuit board 1202 is disposed along the edge of the plastic housing 102, wherein the centroid of the printed circuit board 1202 is closer to the edge than the center of the plastic housing 102.

[0165] In some embodiments, the first dimension of the printed circuit board 1202 along the axis including the center of the plastic housing 102 is smaller than the second dimension of the printed circuit board 1202 along the long axis of the printed circuit board 1202.

[0166] In some implementations, the long axis of the printed circuit board 1202 is substantially perpendicular to the long axis of the plastic housing 102.

[0167] In some embodiments, the X-ray detector further includes: modular adapters 1502, 1508, 1512, the modular adapters having a first mechanical interface and a second mechanical interface; wherein the plastic housing 102 includes a container configured to receive the modular adapters 1502, 1508, 1512, and the container includes a third mechanical interface configured to mate with the first mechanical interface.

[0168] In some embodiments, the X-ray detector further includes a user interface 1802 housed within a plastic housing 102; wherein the plastic housing 102 and the front panel 104 form at least a portion of the access protection boundary; and the user interface 1802 can be accessed through the plastic housing 102 without penetrating the access protection boundary.

[0169] In some embodiments, the X-ray detector further includes: a user interface 1802 disposed outside the plastic housing 102; and an electrical interface that electrically connects the user interface 1802 to circuitry within the plastic housing 102; wherein the plastic housing 102, the electrical interface, and the front panel 104 form at least a portion of the entry into the protective boundary.

[0170] In some embodiments, the front panel 104 includes an outer surface facing the outside of the x-ray detector; and the plastic housing 102 includes a wall extending from the x-ray detector along an axis perpendicular to the outer surface of the front panel 104 beyond the outer surface of the front panel 104.

[0171] In some embodiments, the X-ray detector further includes: a conductive sheet 2004; and an insulating sheet 2006 disposed between the conductive sheet 2004 and the front panel 104, such that the front panel 104 is insulated from the conductive sheet 2004; wherein: the plastic housing 102 includes a conductive coating 110 electrically connected to the conductive sheet 2004.

[0172] In some embodiments, the X-ray detector further includes: a conductive support 2002 configured to support a front panel 104; a conductive sheet 2004 coupled to the conductive support 2002; and an electromagnetic interference shield surrounding a two-dimensional sensor array 108; wherein the conductive support 2002 and the conductive sheet 2004 are at least a portion of the electromagnetic interference shield.

[0173] In some embodiments, the X-ray detector further includes a conductive washer 2008 disposed between the conductive sheet 2004 and the conductive support 2002, electrically connected to the conductive sheet 2004 and the conductive support 2002, and configured to seal the interface between the conductive sheet 2004 and the conductive support 2002.

[0174] In some embodiments, the X-ray detector further includes a plurality of metal fasteners 2104 configured to attach the plastic housing 102 together to at least one of the two-dimensional sensor array 108, the front panel 104, and the printed circuit board 1202; wherein each of the metal fasteners 2104 is arranged such that the metal fastener engages with a non-metallic component.

[0175] In some embodiments, the X-ray detector further includes at least one rigid component attached to the plastic housing 102; wherein the at least one rigid component comprises a plate.

[0176] In some embodiments, the X-ray detector further includes an electromagnetic interference shield surrounding a two-dimensional sensor array 108; wherein the front panel 104 includes an insulating material outside the electromagnetic interference shield.

[0177] Some implementations include a method of forming an x-ray detector, comprising: providing a plastic housing 102; attaching a two-dimensional sensor array 108 configured to generate image data in response to x-rays incident on the plastic housing 102; attaching a printed circuit board 1202 to the plastic housing 102 at a plurality of mounting points 1204, wherein the centroid of the printed circuit board 1202 is closer to the center of the plastic housing 102 than the centroid of the mounting points 1204; and using the plastic housing 102 and a front panel 104 to form a housing surrounding the two-dimensional sensor array 108.

[0178] In some embodiments, the method further includes attaching at least one modular adapter 1502, 1508, 1512 to a corresponding container in the plastic housing 102.

[0179] In some embodiments, the method further includes electrically isolating the front panel 104 of the x-ray detector from the electromagnetic interference shielding surrounding the two-dimensional sensor array 108.

[0180] In some embodiments, attaching the printed circuit board 1202 to the plastic housing 102 and forming a housing surrounding the two-dimensional sensor array 108 using the plastic housing 102 and the front panel 104 includes attaching metal fasteners to non-metallic components.

[0181] In some embodiments, the method further includes mounting the user interface 1802 to the plastic housing 102 such that the user interface 1802 can be accessed through the plastic housing 102.

[0182] Some embodiments include an X-ray detector comprising: a plastic housing 102 including a conductive coating 110; a flexible two-dimensional sensor array 108 disposed within the plastic housing 102 and configured to generate image data in response to incident X-rays; a front panel 104 connected to the plastic housing 102, the front panel 104 and the plastic housing 102 forming a housing surrounding the two-dimensional sensor array 108; and an electromagnetic interference shield surrounding the two-dimensional sensor array 108; wherein the conductive coating 110 and the front panel 104 are at least a portion of the electromagnetic interference shield.

[0183] Although structures, apparatus, methods, and systems have been described according to specific embodiments, those skilled in the art will readily recognize that many variations of the specific embodiments are possible, and therefore any variations should be considered within the spirit and scope of the disclosure herein. Consequently, many modifications can be made by those skilled in the art without departing from the spirit and scope of the appended claims.

[0184] The claims following this written disclosure are hereby expressly incorporated into this written disclosure, wherein each claim is an independent embodiment. This disclosure includes all permutations of the independent claims and their dependent claims. Furthermore, additional embodiments that can be derived from the appended independent and dependent claims are also expressly incorporated into this written description. These additional embodiments are determined by replacing the dependency relationship of a given dependent claim with the phrase “any one of the claims that begins with claim [x] and ends with the claim immediately preceding said claim,” where the term “[x]” in parentheses is replaced with the number of the most recently cited independent claim. For example, for a first set of claims beginning with independent claim 1, claim 4 may be dependent on either claim 1 or claim 3, wherein these individual dependencies produce two different embodiments; claim 5 may be dependent on any one of claim 1, claim 3, or claim 4, wherein these individual dependencies produce three different embodiments; claim 6 may be dependent on any one of claim 1, claim 3, claim 4, or claim 5, wherein these individual dependencies produce four different embodiments; and so on.

[0185] The use of the term "first" in the claims regarding a feature or element does not necessarily imply the presence of a second or additional such feature or element. Elements specifically described in the device plus function format (if any) are intended, according to 35 U.S.SC §112(f), to cover the corresponding structure, material, or behavior described herein, and its equivalents. Embodiments of the invention claiming exclusive attributes or privileges are defined as follows.

Claims

1. An x-ray detector, the x-ray detector comprising: Plastic casing; A two-dimensional sensor array, which is housed within the plastic housing and configured to generate image data in response to incident X-rays; A front panel, which is connected to the plastic housing, and the front panel and the plastic housing form a housing surrounding the two-dimensional sensor array; as well as A printed circuit board, which is mounted to the plastic housing at multiple mounting points; The centroid of the printed circuit board is closer to the center of the plastic housing than the centroid of the mounting point.

2. The x-ray detector as claimed in claim 1, wherein: The two-dimensional sensor array includes a flexible substrate.

3. The x-ray detector as claimed in claim 1, wherein: The printed circuit board is positioned along the edge of the plastic housing, wherein the centroid of the printed circuit board is closer to the edge than the center of the plastic housing.

4. The x-ray detector of claim 1, further comprising: At least one rigid component is attached to the plastic housing; The at least one rigid component mentioned above includes a plate.

5. The x-ray detector of claim 1, further comprising: Electromagnetic interference shielding, wherein the electromagnetic interference shielding surrounds the two-dimensional sensor array; The front panel includes an insulating material outside the electromagnetic interference shield.

6. The x-ray detector of claim 1, further comprising: Multiple metal fasteners are configured to attach the plastic housing together to at least one of the two-dimensional sensor array, the front panel, and the printed circuit board; Each of the metal fasteners is arranged such that the metal fastener mates with a non-metallic component.

7. The x-ray detector as claimed in claim 1, wherein: The first number of mounting points are positioned along the edge of the printed circuit board furthest from the center of the plastic housing; A second number of mounting points are positioned along the edge of the printed circuit board closest to the center of the plastic housing; and The first quantity is greater than the second quantity.

8. The x-ray detector as claimed in any one of claims 1 to 7, wherein: The first dimension of the printed circuit board along the axis of the center including the plastic housing is smaller than the second dimension of the printed circuit board along the long axis of the printed circuit board.

9. The x-ray detector according to any one of claims 1 to 7, wherein the x-ray detector further comprises: A modular adapter, the modular adapter having a first mechanical interface and a second mechanical interface; The plastic housing includes a container configured to receive the modular adapter, and the container includes a third mechanical interface configured to mate with the first mechanical interface.

10. The x-ray detector according to any one of claims 1 to 7, wherein the x-ray detector further comprises: User interface, which is housed within the plastic housing; in: The plastic housing and the front panel form at least a portion of the boundary entering the protective area; and The user interface can be accessed through the plastic housing without penetrating the access protection boundary.

11. The x-ray detector of any one of claims 1 to 7, wherein the x-ray detector further comprises: User interface, which is located outside the plastic housing; as well as An electrical interface that electrically connects the user interface to the circuitry within the plastic housing; in: The plastic housing, the electrical interface, and the front panel form at least a portion of the entry into the protective boundary.

12. The x-ray detector according to any one of claims 1 to 7, wherein: The front panel includes an outer surface facing the exterior of the x-ray detector; and The plastic housing includes a wall that extends from the X-ray detector along an axis perpendicular to the outer surface of the front panel, beyond the outer surface of the front panel.

13. The x-ray detector of any one of claims 1 to 7, wherein the x-ray detector further comprises: Conductive thin film; as well as An insulating sheet is disposed between the conductive sheet and the front plate, such that the front plate is insulated from the conductive sheet; in: The plastic housing includes a conductive coating electrically connected to the conductive sheet.

14. The x-ray detector according to any one of claims 1 to 7, wherein the x-ray detector further comprises: A conductive support member configured to support the front panel; A conductive sheet, the conductive sheet being electrically connected to the conductive support; as well as Electromagnetic interference shielding, wherein the electromagnetic interference shielding surrounds the two-dimensional sensor array; in: The conductive support and the conductive sheet are at least part of the electromagnetic interference shielding.

15. The x-ray detector of claim 14, further comprising: A conductive washer is disposed between the conductive sheet and the conductive support, electrically connected to the conductive sheet and the conductive support, and configured to seal the interface between the conductive sheet and the conductive support.

16. A method of forming an X-ray detector, the method comprising: Plastic casing provided; A two-dimensional sensor array is attached, which is configured to generate image data in response to X-rays incident on the plastic housing; A printed circuit board is attached to the plastic housing at multiple mounting points, wherein the centroid of the printed circuit board is closer to the center of the plastic housing than the centroid of the mounting points; and The plastic housing and front panel are used to form a shell that surrounds the two-dimensional sensor array.

17. The method of claim 16, further comprising at least one of the following: Attach at least one modular adapter to the corresponding container within the plastic housing; and The front plate of the X-ray detector is electrically insulated from the electromagnetic interference shield surrounding the two-dimensional sensor array.

18. The method of any one of claims 16 to 17, wherein: Attaching the printed circuit board to the plastic housing and forming a housing surrounding the two-dimensional sensor array using the plastic housing and the front panel at least one of these includes attaching metal fasteners to non-metallic components.

19. The method of any one of claims 16 to 17, further comprising: The user interface is mounted to the plastic housing so that it can be accessed through the plastic housing.

20. An x-ray detector, the x-ray detector comprising: A plastic housing, the plastic housing including a conductive coating; A flexible two-dimensional sensor array, which is housed within the plastic housing and configured to generate image data in response to incident X-rays; A front panel, which is connected to the plastic housing, and the front panel and the plastic housing form a housing surrounding the two-dimensional sensor array; as well as Electromagnetic interference shielding, wherein the electromagnetic interference shielding surrounds the two-dimensional sensor array; as well as A printed circuit board, which is mounted to the plastic housing at multiple mounting points; in: The conductive coating and the front panel are at least a part of the electromagnetic interference shielding; The first number of mounting points are arranged along the edge of the printed circuit board furthest from the center of the plastic housing; The second number of mounting points are positioned along the edge of the printed circuit board closest to the center of the plastic housing; and The first quantity is greater than the second quantity.

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