Plastic X-ray Detector Housing with Conductive Coating
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Solution Overview
Problem
Conventional x-ray detectors with metal housings are heavy and costly, and they pose challenges in terms of electromagnetic interference (EMI) shielding and ingress protection.
Innovation Solution
The use of a plastic housing with a conductive coating and a flexible two-dimensional sensor array, along with a front plate and a printed circuit board mounted at specific points, forms an enclosure that provides EMI shielding and improved ingress protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal housings are used for x-ray detectors, then structural strength and rigidity are improved, but weight and cost increase
Solution Approach 1:
The patent changes the material parameter from metal to plastic, specifically using plastic housings with integrated rigid support structures. This parameter change reduces weight while maintaining structural strength through design optimization rather than material substitution alone.
Solution Approach 2:
The patent employs composite construction by integrating rigid support structures within the plastic housing. The combination of plastic material and embedded rigid supports creates a composite structure that achieves both weight reduction and structural strength requirements.
2Strength
If metal housings are used for x-ray detectors, then structural strength and rigidity are improved, but cost increases
Solution Approach 1:
The patent changes the material parameter from metal to plastic, which reduces manufacturing cost while maintaining structural strength through design optimization. Plastic materials are generally less expensive and easier to manufacture than metal housings.
Solution Approach 2:
The patent employs composite construction by integrating rigid support structures within the plastic housing. This approach achieves structural strength requirements while utilizing cost-effective plastic materials, reducing overall manufacturing cost.
3Weight of moving object
If plastic housing is used, then weight and cost are reduced, but EMI shielding capability deteriorates
Solution Approach 1:
The patent introduces a conductive coating as an intermediary layer on the plastic housing. This conductive coating serves as a mediator that provides EMI shielding capability to the otherwise non-conductive plastic material, allowing the housing to block electromagnetic interference while maintaining the weight advantages of plastic construction.
4Weight of moving object
If plastic housing is used, then weight and cost are reduced, but ability to resist physical loads deteriorates
Solution Approach 1:
The patent employs composite construction by integrating rigid support structures within the plastic housing. These rigid supports are strategically positioned to bear physical loads, allowing the plastic housing to maintain its weight advantage while the embedded rigid structures provide the necessary load-bearing capacity.
Solution Approach 2:
The patent divides the housing structure into functional segments: the outer plastic housing for weight reduction and the integrated rigid support structures for load bearing. This segmentation allows each component to perform its optimized function, with the plastic providing weight reduction and the rigid supports providing load resistance.
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 configuration reduces the weight and cost of the x-ray detector while effectively shielding against electromagnetic interference and enhancing the detector's ability to withstand physical loads and environmental ingress.
Implementation Method 1
a conductive coating... the conductive coating and the front plate form at least part of an electromagnetic interference shield around the two-dimensional sensor array
Data Source
AI summary
Some embodiments include an x-ray detector, the x-ray detector including a plastic housing, a two-dimensional sensor array disposed in a within the plastic housing and configured to generate image data in response to incident x-rays, a front plate connected to the plastic housing, the front plate and the plastic housing forming an enclosure surrounding the two-dimensional sensor array, and a printed circuit board mounted to the plastic housing at a plurality of mount points. In some examples a centroid of the printed circuit board is closer to a center of the plastic housing than a centroid of the mount points.