Radiation Detector Frame Groove for Safe Protective Film Cutting
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Solution Overview
Problem
Existing radiation detector manufacturing methods face issues with productivity due to the potential for damage to the photodetection panel during laser beam cutting of the protective film and resin frame, which can lead to defective products, and inconsistent cutting results due to varying heights and energy levels of the laser beam.
Innovation Solution
A radiation detector design with a resin frame and scintillator protective film that includes a groove with overlapping end portions to control the depth of laser beam penetration, preventing damage to the panel and ensuring reliable cutting of the protective film, accompanied by a coating resin to secure the film edge and reduce peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the energy of the laser beam is increased to reliably cut the protective film, then the cutting reliability is improved, but the resin frame and photodetection panel may be damaged
Solution Approach 1:
The resin frame is segmented into multiple parts: the main body and a protruding portion that extends toward the protective film. This protruding portion acts as a dedicated cutting target that can be reliably cut by the laser beam without requiring high energy that would damage the photodetection panel. The segmentation allows the laser to cut the protective film through the protruding portion while the main body of the resin frame remains protected.
Solution Approach 2:
The protruding portion of the resin frame serves as an intermediary element between the protective film and the photodetection panel. It absorbs the laser beam energy intended for cutting the protective film, preventing the beam from directly interacting with and potentially damaging the photodetection panel. This intermediary structure enables reliable cutting while protecting sensitive components.
2Ease of manufacture
If constant laser beam energy is used, then the manufacturing process is simplified, but cutting quality becomes inconsistent due to varying heights of protective film and resin frame
Solution Approach 1:
The resin frame is designed with non-uniform structure: the protruding portion has a different height and position compared to the main body. This local variation in structure creates a consistent reference point for laser cutting. The protruding portion's specific geometry ensures that the laser beam always interacts with the same relative features, maintaining cutting quality consistency even with constant laser energy.
Solution Approach 2:
The protruding portion is pre-formed on the resin frame before the laser cutting process. This preliminary structural feature establishes a predetermined cutting location and depth reference, eliminating the need for real-time laser energy adjustment. The pre-existing protrusion guides the laser beam to the correct position, ensuring consistent cutting results throughout manufacturing.
3Reliability
If deep grooves are formed in the resin frame by laser beam, then the protective film is thoroughly cut, but unintended damage may occur to the photodetection panel
Solution Approach 1:
The solution moves the cutting interaction to a different spatial dimension by creating a protruding portion that extends vertically toward the protective film. Instead of cutting horizontally through the resin frame body, the laser beam cuts vertically through the protruding portion and the protective film above it. This dimensional change allows deep cutting of the protective film while the laser beam's path is limited by the protrusion's geometry, preventing damage to the photodetection panel below.
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 design enhances productivity by minimizing defective products and maintaining panel integrity, allowing for precise laser cutting without damaging the photodetection panel, while also reducing the size of the detector.
Implementation Method 1
The protective film on the resin frame is cut by irradiation with a laser beam so that the protective film is cut
Implementation Method 2
a scintillator layer converting radiation into light
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A radiation detector 1 includes a photoelectric conversion element array 7, a scintillator layer 8 converting radiation into light, a resin frame 9 formed on the photoelectric conversion element array 7, and a protective film 13 covering the scintillator layer 8. The resin frame 9 has a groove 30 continuous with an outer edge 13a of the protective film 13. The groove 30 has an overlapping region 31 including a first groove end portion 32 and a second groove end portion 33 partially overlapping in a direction intersecting with an extension direction of the groove 30.