Extruded Storage Phosphor Panels for Medical Imaging
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Solution Overview
Problem
There is a need for improved storage phosphor panels that offer image quality comparable to traditional solvent-coated screens with equivalent x-ray absorbance, while being melt extrudable, injection moldable, or hot pressable, and capable of repeated use in medical and non-destructive imaging applications.
Innovation Solution
The development of freestanding inorganic storage phosphor panels comprising a melt extruded, injection molded, or hot pressed layer made from a thermoplastic polymer and inorganic storage phosphor material, which can be recycled and reused, with enhanced mechanical and environmental robustness, and improved x-ray absorbance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solvent-coated phosphor screens are used, then x-ray absorbance can be achieved, but mechanical strength and environmental robustness are poor
Solution Approach 1:
The patent uses composite materials by combining thermoplastic polymer matrix with inorganic storage phosphor particles to create a mechanically robust yet functionally effective phosphor screen. The thermoplastic binder provides mechanical strength and environmental stability while the inorganic phosphor particles maintain x-ray absorbance properties, resolving the contradiction between strength and manufacturing ease.
Solution Approach 2:
The patent changes the physical state parameter of the binder from solvent-based to thermoplastic melt-state, enabling the phosphor screen to be formed through extrusion or molding processes. This parameter change improves mechanical strength and environmental robustness while maintaining manufacturability through established plastic processing techniques.
2Reliability
If melt extrusion process is used, then mechanical robustness and recyclability improve, but image quality may deteriorate
Solution Approach 1:
The patent applies local quality by optimizing the distribution and concentration of inorganic phosphor particles within the thermoplastic matrix to ensure uniform x-ray absorbance and image quality. The controlled dispersion of phosphor particles during extrusion maintains manufacturing precision while enabling recyclability through the thermoplastic nature of the binder.
Solution Approach 2:
The patent controls processing parameters such as extrusion temperature, cooling rate, and phosphor particle size to maintain image quality while achieving recyclability. By optimizing these parameters, the thermoplastic matrix can be re-melted and re-formed without degrading the phosphor particles or image quality.
3Productivity
If inorganic storage phosphor material is embedded in thermoplastic polymer, then recyclability and reusability improve, but manufacturing process complexity increases
Solution Approach 1:
The patent leverages the parameter change of thermoplastic polymers from solid to melt state and back, enabling simple extrusion or injection molding processes to embed inorganic phosphor particles. This phase transition approach simplifies the manufacturing process despite the composite nature, as standard plastic processing equipment can be used without major modifications.
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 solution provides storage phosphor panels with image quality comparable to traditional solvent-coated screens, improved mechanical strength, and the ability to be recycled, making them suitable for various imaging applications with enhanced x-ray absorbance and handling capabilities.
Implementation Method 1
the inorganic phosphor layer is generally a crystalline material that responds to X-rays in an image-wise fashion
Implementation Method 2
the storage phosphor panel is subjected to longer wave length radiation, such as visible or infrared light (e.g., stimulating light), resulting in the emission of the energy stored in the phosphor particles as stimulated luminescence
Implementation Method 3
melt extrudable and/or injection moldable and/or hot-melt pressable composites of inorganic storage phosphor materials and thermoplastic and/or thermoset polymers
Data Source
Figure 1A~1C
AI summary
A storage phosphor panel can include an extruded inorganic storage phosphor layer including a thermoplastic polymer and an inorganic storage phosphor material, where the extruded inorganic storage phosphor panel has an image quality comparable to that of a traditional solvent coated inorganic storage phosphor screen. Further disclosed are certain exemplary method and/or apparatus embodiments that can provide inorganic storage phosphor panels including reduced tearing or grinding resistance. Further disclosed are certain exemplary method and/or apparatus embodiments that can include inorganic storage phosphor layer including at least one polymer, an inorganic storage phosphor material, and a copper phthalocyanine based blue dye.