Pixelated Scintillator Array Fabrication via Jig Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for fabricating pixelated scintillator arrays are labor-intensive and costly, with significant material loss due to slicing and re-assembling, which hinders the production of large area arrays with high spatial resolution.
Innovation Solution
A method using foundation and alignment jigs to precisely arrange and bond scintillator pixels with a reflective layer, forming a pixelated array with minimal material loss and improved spatial resolution, where each pixel is separated by a reflective layer, and the pixels can be made of amorphous or crystalline materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conventional slice and dice approach is used to fabricate pixelated scintillator arrays, then spatial resolution can be improved by limiting lateral spread of light photons, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the scintillator material into discrete pixel elements using a mold with multiple cavities. Each cavity forms a separate scintillator pixel with integrated reflective septa, allowing parallel fabrication of multiple pixels simultaneously. This segmented approach maintains the spatial resolution benefits of pixelated structures while enabling efficient batch production that reduces manufacturing cost and labor intensity compared to conventional sequential slice and dice methods.
Solution Approach 2:
The patent implements preliminary action by pre-forming the reflective septa structures within the mold cavities before scintillator material is introduced. The reflective layers are already in place on the mold surfaces, so when scintillator material is deposited and cured, the pixels are automatically formed with integrated reflective boundaries. This preliminary preparation of reflective structures eliminates the need for subsequent assembly steps, significantly reducing manufacturing complexity and cost while maintaining precise pixel geometry for high spatial resolution.
2Manufacturing precision
If the slice and dice method is used to create pixelated scintillators, then pixelated structure with reflective septa can be formed, but material loss becomes significant when pitch is very small
Solution Approach 1:
The patent applies parameter changes by transitioning from mechanical cutting processes to a casting/forming process using mold cavities. The key parameter change is in the fabrication method itself - instead of removing material through slicing and dicing, the scintillator material is deposited into pre-formed mold cavities and cured in place. This parameter change in the manufacturing process eliminates material loss associated with small pitch cutting operations, as the material is directly formed into the final pixel geometry without waste generation.
Solution Approach 2:
The patent implements copying by using mold cavities as templates that replicate the desired pixel geometry. The mold contains multiple cavities that are exact copies of the target pixel structure, including the reflective septa configurations. When scintillator material is deposited into these cavities and cured, each pixel is a precise copy of the mold cavity geometry. This copying approach eliminates material loss because the material is formed to match the mold cavity dimensions exactly, with no material removed or wasted during the process.
3Manufacturing precision
If conventional slicing and re-assembling processes are used, then pixelated scintillator arrays can be fabricated, but productivity decreases due to labor intensive operations
Solution Approach 1:
The patent applies merging by combining multiple fabrication steps into a single integrated casting process. The reflective septa structures, pixel boundaries, and scintillator material formation are all accomplished in one operation within the mold assembly. The mold cavities simultaneously define multiple pixel geometries, allowing parallel fabrication of numerous pixels. This merging of operations eliminates the sequential slicing, coating, and re-assembly steps, dramatically improving productivity while maintaining precise pixelated array fabrication through the mold's built-in geometric constraints.
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 material loss and fabrication costs while maintaining high spatial resolution, enabling the efficient production of large area pixelated scintillator arrays for improved x-ray imaging.
Implementation Method 1
An adhesive layer is applied on the N protrusions of the N scintillator pixels
Implementation Method 2
a reflective layer is placed over the N protrusions of the N scintillator pixels... forming a first row of a scintillator array comprising the N scintillator pixels and the at least portion of the reflective layer
Implementation Method 3
The scintillator layer absorbs incident x-ray radiation indicative of the structure of an object imaged and converts the absorbed radiation into light photons
Data Source
AI summary
A method of making pixelated scintillator arrays employs a first jig comprising a plurality of recesses and a second jig comprising a plurality of recesses. A plurality of or N scintillator pixels are placed in a plurality of or N recesses of the first jig. The N scintillator pixels have a shape such that a portion of each of the N scintillator pixels is conformably received in one of the N recesses of the first jig, e.g. a portion of each of the N scintillator pixels is received in and conforms to the shape of one of the N recesses. The remaining portion of each of the N scintillator pixels protrudes out from the recess, forming N protrusions substantially conforming to the shape of the recesses of the second jig. An adhesive layer is applied on the N protrusions of the N scintillator pixels. A reflective layer is placed over the N protrusions of the N scintillator pixels. The recesses of the second jig are aligned with the N protrusions of the N scintillator pixels and the reflective layer is pressed with the second jig such that at least a portion of the reflective layer conforms to the N protrusions of the N scintillator pixels, forming a first row of a scintillator array comprising the N scintillator pixels and the at least portion of the reflective layer.