Deformable X-ray Phase Contrast Grating Mold
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Solution Overview
Problem
Existing x-ray phase contrast gratings are not optimally tailored to the local radiation direction, leading to suboptimal image contrast in x-ray imaging, particularly in medical applications, due to the fixed orientation of lamellae in the grating.
Innovation Solution
A method involving a deformable silicon mold with x-ray absorbing material is used, where the mold is heated and formed into a final contour with precise specifications, allowing the lamellae to be aligned at angles optimal for the radiation direction, thereby improving the grating's microstructure and image contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etching methods in silicon wafers with fixed orientation lamellae are used, then manufacturing precision of microstructure is improved, but adaptability to local radiation direction is worsened
Solution Approach 1:
The patent applies the dynamics principle by making the mold deformable about a bending axis, allowing the rigid silicon substrate with etched cutouts to be dynamically bent into a final contour that angles the lamellae relative to each other. This enables the microstructure to adapt to radial radiation directions while maintaining manufacturing precision through the deformable mold approach.
Solution Approach 2:
The patent changes the physical state and geometric parameters of the mold by heating it to a working temperature above room temperature but below the melting temperature of the filler material. This temperature parameter change enables the mold to be deformed into the final contour with angled lamellae, resolving the contradiction between precision and adaptability.
2Adaptability or versatility
If mold is heated to working temperature for deformation, then adaptability of grating contour is improved, but energy consumption increases
Solution Approach 1:
The patent utilizes phase transitions by heating the mold to a working temperature that changes its mechanical properties, enabling deformation into the final contour. The temperature is controlled to remain below the melting temperature of the filler material, achieving the necessary phase change for adaptability while minimizing energy consumption through controlled thermal processing.
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 enables the production of x-ray phase contrast gratings with improved alignment and precision, enhancing image contrast and radiation absorption, leading to more effective x-ray imaging.
Implementation Method 1
The mold into which the material is poured is heated up to a working temperature value lying above room temperature and below a melting temperature value of the filler material
Implementation Method 2
subsequently formed into a final contour as per specifications
Data Source
AI summary
In a method for producing a microstructure component, which is used in particular as an x-ray phase contrast grating in an x-ray device, a material absorbing x-rays is poured into a mold able at least to be deformed about one bending axis, which is formed by a silicon substrate and which has a plurality of cutouts running in a direction of the thickness of the silicon substrate with dimensions in the micrometer range. The mold into which the material is poured is heated up to a working temperature value lying above the room temperature and below a melting temperature value of the material which is poured into it and is formed into a final contour as per specifications.