Curved X-Ray Detector Bonding to Minimize Image Distortion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional X-ray detectors are not designed to accommodate the curved structure of the human body, leading to distorted radiographic images due to the use of a flat radiation source, and their manufacturing process is complex and costly.
Innovation Solution
A method to manufacture a curved-surface detector by slimming a sensor substrate to a predetermined thickness, curving it using a jig, and joining a flexible scintillator substrate with a heat-melted junction layer to maintain the curvature, ensuring the detector's accuracy and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat detector is used to capture radiation from a dot source, then the manufacturing process is simple, but the captured radiographic image is enlarged and distorted
Solution Approach 1:
The detector is designed with a curved surface that matches the curvature of the human body, replacing the conventional flat detector structure. This curvature allows the detector to capture radiographic images without enlargement or distortion, improving image accuracy while adapting to the anatomical shape of the patient
2Shape
If the sensor substrate is slimmed to enable curving, then the detector can be shaped to match body curvature, but the photoelectric devices may be damaged by the slimming medium
Solution Approach 1:
The photoelectric devices are sealed before the slimming process is performed on the sensor substrate. This preliminary sealing action protects the sensitive photoelectric devices from exposure to the slimming medium, preventing damage while allowing the substrate to be thinned for subsequent curving operations
3Stability of the object's composition
If the scintillator substrate is joined to the curved sensor substrate, then the curvature can be maintained, but separation or deformation may occur at the junction portion
Solution Approach 1:
The junction layer undergoes a phase change from liquid to solid state through heating and cooling processes. The liquid junction layer is applied to the curved sensor substrate, then heated to melt and flow into the curvature, and finally cooled to solidify, maintaining the curved shape while creating a strong bond that prevents separation or deformation at the junction portion
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
The method allows for the production of a curved-surface detector that minimizes image distortion, is easy to manufacture, and reduces manufacturing costs while providing vivid radiographic images by maintaining the curvature and minimizing refraction.
Implementation Method 1
a scintillator that converts into fluorescence radiation emitted by way of a subject
Implementation Method 2
a photodetecting unit provided on a radiation entrance side of the scintillator; and the photodetecting unit includes a thin film portion that detects the fluorescence as an electric signal
Implementation Method 3
the scintillator substrate is joined to the sensor substrate via a junction layer in the state of being curved at curvature identical to curvature of the sensor substrate
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The present invention relates to a curved-surface detector that is bent to have a curved surface so as to capture a radiographic image. A method for manufacturing a curved-surface detector according to an embodiment of the present invention provides a method for manufacturing a curved-surface detector in which a detector for converting radiation into an electrical signal so as to obtain a radiographic image is bent in such a manner as to have a curved surface. The method comprises the steps of: slimming a sensor substrate having photoelectric elements arranged thereon so as to achieve a predetermined thickness; bending the sensor substrate that is slimmed to the predetermined thickness to have a curved-surface by placing the same in a jig that is curved in such a manner as to have a curved surface; and bonding a flexible scintillator substrate that is struck by the radiation and illuminated to an upper surface of the sensor substrate so that the sensor substrate that is bent to have a curved-surface by means of the jig to maintain its curved surface, wherein the scintillator substrate is bonded to a bonded layer while being curved with the same curvature as the curvature of the sensor substrate, and maintains the curvature of the sensor substrate in order to prevent detachment or deformation of a bonded part between the scintillator substrate and the sensor substrate. As a result, a radiographic image in which distortion is minimised can be obtained by manufacturing the curved-surface detector that is bent to have a curved surface.