2D Collimator Assembly for CT Imaging Air Gap Elimination
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Solution Overview
Problem
Current CT imaging systems face challenges in achieving precise alignment between collimator plates and scintillator arrays, leading to air gaps and limitations in x-ray collimation, resulting in noise and anomalies in reconstructed images.
Innovation Solution
A two-dimensional reflector and collimator assembly with a honeycomb structure, where a mixed metal-binder material forms a wall structure with a two-dimensional array of channels, integrating scintillator cells within the channels to eliminate air gaps and provide effective collimation in both dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a continuous collimator is used to span the entire detector length, then collimation coverage is improved, but alignment precision deteriorates due to air gaps between collimator plates and scintillator cells
Solution Approach 1:
The collimator is divided into multiple individual collimator cells, each corresponding to a specific scintillator cell. This segmentation eliminates the need for a continuous collimator structure and allows each cell to be precisely positioned and aligned with its corresponding scintillator element, thereby eliminating air gaps while maintaining full coverage.
Solution Approach 2:
The collimator cells are integrated within the scintillator array structure, with each collimator cell positioned in direct contact with or nested around its corresponding scintillator cell. This nesting approach ensures precise alignment and eliminates air gaps between the collimator and scintillator surfaces.
2Ease of manufacture
If traditional collimator assembly methods are used, then ease of manufacture is improved, but device complexity increases due to the need for exact mechanical alignment and tight tolerancing
Solution Approach 1:
By segmenting the collimator into individual cells that can be independently manufactured and then assembled, the system eliminates the need for complex continuous collimator fabrication and alignment procedures. Each cell can be manufactured separately with standard tolerances and then positioned precisely during assembly.
Solution Approach 2:
The collimator cells are designed to self-align with the scintillator cells through their geometric configuration and integration method, eliminating the need for complex external alignment tools and procedures. The structure itself provides the alignment mechanism.
3Reliability
If collimator plates are arranged in a continuous pattern, then collimation effectiveness is improved, but loss of substance increases due to waste of parts and material from discarded components
Solution Approach 1:
Segmenting the collimator into individual cells allows for modular manufacturing where only the specific number of cells needed for the detector array are produced. This eliminates material waste associated with manufacturing large continuous collimators that may need to be discarded due to alignment issues or defects.
Solution Approach 2:
The modular cell structure allows for easy replacement of individual defective cells without discarding entire collimator assemblies. Defective cells can be identified and replaced individually, recovering and reusing the majority of the collimator structure and minimizing material waste.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables precise alignment, reduces noise, and enhances image quality by preventing cross-talk between scintillator cells and allowing for higher spatial resolution in CT images.
Implementation Method 1
The second portion of the wall structure includes a reflective material coated on the wall structure in each of the channels
Implementation Method 2
a powder material having a density and atomic number that is sufficient to substantially absorb x-rays
Implementation Method 3
a scintillator for converting x-rays to light energy adjacent the collimator
Data Source
AI summary
A two dimensional collimator assembly and method of manufacturing thereof is disclosed. The collimator assembly includes a wall structure constructed to form a two dimensional array of channels to collimate x-rays. The wall structure further includes a first portion positioned proximate the object to be scanned and configured to absorb scattered x-rays and a second portion formed integrally with the first portion and extending out from the first portion away from the object to be scanned. The first portion of the wall structure has a height greater than a height of the second portion of the wall structure. The second portion of the wall structure includes a reflective material coated thereon in each of the channels forming the two dimensional array of channels.