Mammography Image Detector Substrate Cutting for Edge Detection
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Solution Overview
Problem
Conventional two-dimensional image detecting apparatuses with a mold structure are challenging to apply in mammography due to the inherent design, which results in parts of the subject being outside the image detection area, leading to incomplete image capture.
Innovation Solution
A manufacturing method that involves forming a conversion layer on a substrate with an image detection area and a non-detection area, using a spacer material to create a mold structure, cutting the substrate and counter substrate to bring the image detection area closer to the outer edge, and sealing the cut surfaces to prevent moisture and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mold structure is used to protect the conversion layer and upper electrode, then reliability is improved, but the image detection area cannot extend to the outer edge of the apparatus
Solution Approach 1:
The patent divides the substrate into an image detection area and a non-detection area, and further segments the non-detection area into regions for mold structure and regions for cutting. This segmentation allows the mold structure to be positioned only in areas where it is needed for protection, while allowing the image detection area to extend closer to the outer edge of the apparatus.
Solution Approach 2:
The patent extracts the mold structure from covering the entire substrate and repositions it only in the non-detection area. By taking out the mold structure from areas where it would block the image detection, the patent allows the image detection area to extend to the outer edge while maintaining protection where needed.
2Measurement precision
If the image detection area is extended to the outer edge for complete subject capture, then measurement precision is improved, but the conversion layer becomes exposed to moisture and contamination
Solution Approach 1:
The patent introduces a sealing member as an intermediary element that covers the cut surfaces of the substrate, conversion layer, and upper electrode. This sealing member acts as a barrier between the conversion layer and harmful external factors such as moisture and contamination, allowing the image detection area to extend to the edge while maintaining protection.
3Area of stationary object
If the substrate is cut to bring the image detection area closer to the outer edge, then area coverage is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs the cutting operation after forming the mold structure in the non-detection area. By doing the cutting as a preliminary action before final assembly and sealing, the patent simplifies the manufacturing process. The cutting is done when the mold structure is already in place to define the boundaries, making the subsequent sealing and assembly steps more straightforward.
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 allows for the detection of the entire subject in mammography by ensuring the image detection area is closer to the outer edge of the apparatus, enhancing image capture quality and reliability while protecting the conversion layer from moisture and electrical discharge.
Implementation Method 1
a conversion layer (element) which converts X-rays into electrical signals
Data Source
AI summary
The present invention provides a two-dimensional image detecting apparatus including a mold structure which apparatus can be applied to mammography, and a manufacturing method thereof. The manufacturing method includes: a conversion layer formation step of forming a conversion layer (3) on an active matrix substrate (2); a counter substrate formation step of disposing a spacer material (5) and disposing the counter substrate (6) so as to be opposite to the active matrix substrate (2) via the spacer material (5); a mold resin layer formation step of forming a mold structure layer (8) in a space surrounded by the conversion layer (3), the spacer material (5), and the counter substrate (6); and a cutting step of cutting at least the active matrix substrate (2) so that cut surfaces of the constituent members are flush with each other; and a sealing step of securing a sealing material (7) to the cut surface.