Flat Panel Detector Manufacturing via Scintillator Trimming
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Solution Overview
Problem
Existing methods for manufacturing flat panel detectors face challenges in reducing non-imaging regions, achieving miniaturization, and maintaining image quality, particularly due to issues with substrate size, phosphor layer formation, and moisture protection, which affect the sensitivity and sharpness of X-ray images.
Innovation Solution
A method involving the production of a scintillator panel with a phosphor layer formed on a substrate larger than the light-receiving element, followed by cutting to match the element's size, and the application of a protective layer before cutting to prevent damage, using techniques like blade dicing or laser cutting, and employing materials like poly paraxylylene or hot-melt resins for adhesion and moisture protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a substrate with size corresponding to the FPD is used to form a phosphor layer, then the phosphor layer can be formed completely, but a non-imaging region occurs in the peripheral edge portion due to unevenness at evaporation
Solution Approach 1:
The invention divides the phosphor layer formation into two stages: first forming a phosphor layer on a large substrate, then cutting out the required portion. This segmentation allows the evaporation process to work on a larger area where uniformity can be achieved, while the final image formation area is obtained through precise cutting, eliminating the non-imaging region problem.
Solution Approach 2:
The invention performs preliminary actions by forming the phosphor layer on a larger substrate before cutting. This preliminary formation allows the evaporation process to deposit phosphor uniformly across the entire substrate surface, and subsequent cutting removes only the necessary portion, ensuring the final product has no non-imaging regions.
2Length of moving object
If the FPD is made thinner and smaller, then the detector can be inserted in mouth for panoramic photography, but the area for image formation is reduced due to peripheral non-imaging regions
Solution Approach 1:
The invention segments the manufacturing process into forming a phosphor layer on a large substrate, then cutting to the required size. This allows the detector to be made thin and small for mouth insertion while ensuring the entire usable area can be used for image formation, as the cutting process removes only the peripheral portions that would otherwise be non-imaging regions.
3Reliability
If a protective layer is formed on the phosphor layer before cutting, then crystal cracks can be prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The invention forms a protective layer on the phosphor layer before cutting as a preliminary action. This protective layer prevents crystal cracks during the cutting process, and since it is applied before cutting, it integrates smoothly into the manufacturing flow without requiring additional complex steps after the main fabrication processes.
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 results in a flat panel detector with minimal non-imaging regions, improved productivity, and maintained image quality, enabling smaller, thinner detectors with reduced peripheral defects and enhanced moisture protection.
Implementation Method 1
a scintillator panel including a phosphor layer containing a phosphor is used to convert once X rays into visible light
Implementation Method 2
the visible light is converted into electrical charge signals by a flat light receiving element including photodiode
Implementation Method 3
a flat radiation image sensing device provided with a scintillator panel having a phosphor layer fanned by gas phase methods, such as evaporation
Data Source
AI summary
Disclosed is a method of manufacturing a flat panel detector such that the surface on the side of a fluorescent body layer of a scintillator panel which has the fluorescent body layer comprising a column crystal on the supporting body, is coupled to the planar light receiving element surface of a light-receiving element, comprising: a step of manufacturing the scintillator panel which has a larger area than that of the planar light receiving element surface; a step of trimming the edges of the scintillator panel, obtained by the step of manufacturing the scintillator panel, to correspond to the area of the planar light receiving element surface; and a step of coupling the edge-trimmed scintillator panel to the planar light receiving element surface, thus providing a flat panel detector which has an excellent productivity and that can be made small in size without non-image area.