Modular CT Detector Segmentation for Cost Reduction
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Solution Overview
Problem
Computed tomography (CT) imaging systems face high fabrication and testing costs due to complex detector module designs, which are expensive and yield-intensive, limiting accessibility to imaging technologies, especially in markets requiring lower-end scanning capabilities.
Innovation Solution
A modular CT system design where detector modules are directly attached to the gantry, allowing for standalone fabrication and testing, reducing complexity and cost by using a single design for multiple slice configurations, such as 8-slice and 16-slice setups, with common components and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If detector modules are designed with high complexity to achieve precise alignment and micrometer-level positioning accuracy, then measurement precision is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The detector array is divided into multiple independently fabricable modules, each module being a complete functional unit that can be manufactured separately and then assembled into the full detector array. This segmentation allows each module to be optimized for standard manufacturing processes while maintaining precise alignment through modular interfaces.
Solution Approach 2:
A single detector module design serves multiple slice configurations (8-slice, 16-slice, and potentially other configurations), eliminating the need for different module designs for different applications. This universal module can be arranged in various configurations to meet different z-coverage requirements, reducing overall system complexity.
2Adaptability or versatility
If separate detector module designs are created for different slice configurations (8-slice, 16-slice, 64-slice, etc.), then adaptability to different market needs is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The detector module is designed as a universal, configurable unit that can be arranged in different slice configurations (8-slice, 16-slice, 64-slice, etc.) without requiring different module designs. The same basic module architecture serves multiple market segments, from cost-sensitive applications to high-end imaging, by varying the number and arrangement of modules rather than the module design itself.
Solution Approach 2:
The system allows dynamic configuration of slice coverage by adjusting the number and arrangement of identical modules rather than requiring fixed, dedicated designs for each slice count. This enables the detector array to be adapted to different market needs through flexible assembly configurations.
3Manufacturing precision
If detector modules are fabricated and tested as stand-alone units with high precision requirements, then measurement precision is improved, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The detector array is segmented into modular units that can be fabricated using standard, high-volume manufacturing processes rather than custom, low-volume processes. Each module is designed to be manufactured independently with standard precision requirements, then assembled into the complete detector array, significantly improving fabrication efficiency while maintaining necessary precision through modular interfaces.
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 approach reduces system fabrication costs while maintaining image quality, enabling more affordable CT systems with flexible slice configurations and improved manufacturing efficiency, making advanced imaging technologies more accessible.
Implementation Method 1
a scintillator for converting x-rays to light energy adjacent the collimator
Implementation Method 2
photodiodes for receiving the light energy from the adjacent scintillator and producing electrical signals therefrom
Data Source
AI summary
A CT system includes a rotatable gantry having an opening to receive an object to be scanned, the rotatable gantry having a detector mounting surface, an x-ray source attached to the gantry and configured to project an x-ray beam toward the object, a plurality of detector modules each mounted within one field-of-view (FOV) and mounted directly to the detector mounting surface of the rotatable gantry, a data acquisition system (DAS) configured to receive outputs from at least one of the plurality of detector modules, and a computer programmed to acquire projections of imaging data of the object from the DAS, and generate an image of the object using the imaging data.