Melt-Extruded Storage Phosphor Panels for X-Ray Imaging

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Solution Overview

Problem

There is a need for inorganic storage phosphor panels with improved image quality comparable to traditional solvent-coated screens of equivalent x-ray absorbance, particularly in melt-extruded, injection-molded, or hot-pressed forms, which also offer enhanced mechanical and environmental robustness.

Innovation Solution

The development of melt-extruded or injection-molded inorganic storage phosphor panels comprising a thermoplastic polymer and inorganic storage phosphor material, with a copper phthalocyanine-based blue dye, that are processed to achieve a coefficient of variation in linearized pixel values of less than or equal to 0.4, allowing for effective x-ray absorption and stimulation for digital image generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional solvent-coated screens are used, then image quality can be achieved, but mechanical and environmental robustness deteriorates

Engineering Contradiction:

Improvemechanical and environmental robustnessVSAvoidimage quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the physical and chemical parameters of the phosphor layer by transitioning from solvent-coated to melt-extruded processing. This involves modifying the polymer matrix composition, processing temperature, and cooling rates to achieve a robust structure while maintaining image quality through controlled crystallization and phase separation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials consisting of phosphor particles embedded in a thermoplastic polymer matrix. This composite structure provides both the imaging functionality of the phosphor and the mechanical robustness of the polymer, while the melt-extrusion process ensures homogeneous distribution and strong interfacial bonding.

Inventive Principle:

Principle #40Composite materials

2Strength

If melt extrusion or injection molding is used, then mechanical robustness improves, but image quality may deteriorate

Engineering Contradiction:

Improvemechanical robustnessVSAvoidimage quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-blending the phosphor particles with the polymer matrix before extrusion. This pre-mixing ensures homogeneous distribution of phosphor particles, which prevents image quality deterioration while maintaining the mechanical advantages of the melt-extruded structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses an intermediary polymer matrix that mediates between the phosphor particles and the extrusion process. The polymer acts as a carrier that protects phosphor particles during processing while enabling the formation of a mechanically robust structure with controlled morphology that preserves image quality.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If inorganic storage phosphor material is processed by melt extrusion, then manufacturing efficiency improves, but manufacturing precision may worsen

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidimage quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the traditional mechanical solvent-coating system with a thermal melt-extrusion system. This substitution eliminates solvent evaporation steps and enables continuous processing, significantly improving manufacturing efficiency while the controlled thermal processing maintains manufacturing precision through consistent phosphor particle distribution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 resulting panels demonstrate image quality comparable to traditional solvent-coated screens, with improved mechanical and environmental robustness, enabling efficient x-ray absorption and digital image processing, and are recyclable.

Implementation Method 1

absorb X-rays and emit light to expose the film

Methodology Applied

Scientific EffectX-ray absorption: Absorption (EM radiation)

Implementation Method 2

emission of the energy stored in the phosphor particles as stimulated luminescence

Methodology Applied

Scientific EffectStimulated luminescence: Photoluminescence

Implementation Method 3

copper phthalocyanine-based blue dye

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 4

melt extrudable and/or injection moldable

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 5

melt extruded or injection molded or hot pressed

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP3391382B1Radiation sensing thermoplastic composite panels

Publication Date: 2021.08.25 CARESTREAM DENTAL TECH TOPCO LTD

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 noise. 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.