Laser Processing Resin Frame for Radiation Detector
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Solution Overview
Problem
The existing process for producing radiation detectors with a scintillator layer and resin frame is inefficient due to the need for skilled cutting techniques, which hinders the reduction of device size and effective area, and increases production costs.
Innovation Solution
A radiation detector design where the protection film on the resin frame is processed using a laser beam, allowing for accurate cutting without requiring proficient techniques, enabling a smaller resin frame and increased effective area of the scintillator layer while minimizing adverse effects on the scintillator and bonding pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the resin frame is made smaller and positioned closer to the scintillator layer to maximize effective area, then the device size is reduced and effective area increases, but the cutting process becomes more difficult and requires higher proficiency
Solution Approach 1:
The patent replaces the mechanical cutter-based cutting process with a laser beam processing system. The laser beam precisely processes the protection film and resin frame without requiring manual skill or proficiency, thereby resolving the contradiction between maximizing effective area (smaller resin frame) and ease of manufacture (cutting difficulty).
2Area of stationary object
If the resin frame is made smaller to reduce device size, then the effective area of the scintillator layer increases, but productivity decreases due to the need for skilled manual cutting
Solution Approach 1:
The patent replaces manual mechanical cutting with automated laser beam processing, eliminating the need for skilled workers and significantly improving productivity. This allows the resin frame to be made smaller without compromising production efficiency.
Solution Approach 2:
The patent changes the processing method from mechanical cutting to laser processing, fundamentally altering the parameters of the manufacturing process. This enables precise processing of smaller resin frames with consistent quality, thereby improving productivity.
3Area of stationary object
If the resin frame is positioned closer to the scintillator layer to maximize effective area, then device size is reduced, but the risk of laser beam affecting the scintillator layer increases
Solution Approach 1:
The patent performs preliminary processing of the protection film with the laser beam before processing the resin frame. This preliminary action creates a buffer zone and allows for controlled energy dissipation, preventing the laser beam from adversely affecting the scintillator layer while still enabling the resin frame to be positioned close to maximize effective area.
4Manufacturing precision
If manual cutting with a cutter is used to process the protection film, then the process requires high proficiency and precision, but productivity is reduced and production cost increases
Solution Approach 1:
The patent replaces manual mechanical cutting with automated laser beam processing, which inherently provides high precision without requiring skilled operators. This substitution simultaneously improves manufacturing precision and increases productivity while reducing production costs.
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 reduces the size of the radiation detector, increases the effective area of the scintillator layer, and improves productivity by simplifying the cutting process and reducing production costs.
Implementation Method 1
the outer edge of the protection film and a corresponding region of the resin frame corresponding to the outer edge of the protection film are in a processed state with a laser beam
Implementation Method 2
a scintillator layer stacked on the photoelectric conversion element array so as to cover the light receiving unit and configured to convert radiation into light
Data Source
AI summary
A radiation detector has a photoelectric conversion element array having a light receiving unit and a plurality of bonding pads; a scintillator layer stacked on the photoelectric conversion element array; a resin frame formed on the photoelectric conversion element array so as to pass between the scintillator layer and the bonding pads away from the scintillator layer and the bonding pads and so as to surround the scintillator layer; and a protection film covering the scintillator layer and having an outer edge located on the resin frame; a first distance between an inner edge of the resin frame and an outer edge of the scintillator layer is shorter than a second distance between an outer edge of the resin frame and an outer edge of the photoelectric conversion element array; the outer edge and a groove are processed with a laser beam.