Irregular X-ray Sensor Mosaic for Dental Imaging

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Solution Overview

Problem

Existing digital X-ray imaging devices face challenges in manufacturing large sensor areas with flexible, irregular shapes required for different imaging modes, such as dental extraoral X-ray imaging, which often necessitate using multiple sensors or large rectangular sensors, leading to increased costs and reduced compactness.

Innovation Solution

A digital X-ray sensor with an irregularly shaped active area, constructed from separate semiconductor pixel detectors mounted in a mosaic pattern with a finite physical gap between them, allowing for optimized beam coverage and efficient production, particularly suitable for semiconductor-CMOS technology.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If separate semiconductor pixel detectors are mounted side by side in a mosaic pattern to form large sensor areas, then the active imaging area can be increased and irregular shapes can be achieved, but dead space or blind regions appear between the separate detector elements

Engineering Contradiction:

Improveactive imaging areaVSAvoiduniformity of X-ray images

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The large sensor area is divided into multiple separate semiconductor pixel detectors mounted in a mosaic pattern. Each detector element is independently manufactured and then assembled together to form the complete imaging sensor, allowing flexible configuration of irregular shapes while managing the complexity of large area fabrication

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A light-tight housing or mounting structure serves as an intermediary between separate detector elements, providing mechanical support and electrical connections while minimizing the gaps between elements. This intermediary structure allows the detectors to be positioned as close as possible without direct physical contact, reducing dead space while maintaining manufacturing feasibility

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If detector elements are mounted in physical contact to eliminate dead space, then uniform X-ray images can be achieved, but manufacturing complexity and risk of damage to fragile semiconductor crystals increase

Engineering Contradiction:

Improveuniformity of X-ray imagesVSAvoidassembly feasibility

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mounting structure is designed with built-in tolerance and cushioning features that accommodate minor misalignments and prevent direct contact between fragile semiconductor crystals. This prior cushioning approach protects the delicate detector elements during assembly and operation while maintaining sufficient proximity to minimize dead space

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Adaptability or versatility

If large rectangular sensors are used to cover both fan beam and cone beam imaging modes, then both imaging modes can be supported, but cost and device compactness are reduced

Engineering Contradiction:

Improveimaging mode coverageVSAvoidsensor area

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

Instead of using a large rectangular sensor that covers both imaging modes, the patent employs an asymmetric irregular shape formed by mounting detector elements in a mosaic pattern. This asymmetric configuration optimizes the active imaging area to match the specific requirements of dental extraoral imaging, reducing unnecessary sensor area while maintaining versatility for both fan beam panoramic scan and cone beam 3D imaging modes

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The modular mosaic construction of separate detector elements provides universal applicability for multiple imaging modes. The same sensor array can be configured to support both fan beam panoramic scanning and cone beam 3D imaging by utilizing different regions of the irregularly shaped active area, eliminating the need for separate sensors for each imaging mode

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables efficient beam coverage for both fan beam and cone beam imaging modes with a single sensor, reducing material costs and improving production yield by avoiding physical contact between fragile semiconductor crystals, thus enhancing durability and readout speed.

Implementation Method 1

semiconductor pixel detectors defining an active area responsive to x-rays

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentUS8295432B2Radiation imaging device with irregular rectangular shape and extraoral dental imaging system therefrom

Publication Date: 2012.10.23 OY VAREX IMAGING FINLAND LTD

AI summary

A radiation imaging device includes plural individual detectors defining an irregular rectangular active area responsive to x-rays and with different widths along a length of the active area. The individual detectors may be of different rectangular shapes and mounted on a motherboard. The motherboard may be formed of a first module mounting a first of two individual detectors and a second module detachable connected to the first module and mounting a second of two individual detectors.