Radiation Detector Substrate Reinforcement for Defect-Free Peeling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing radiographic imaging apparatuses face defects in the substrate of radiation detectors due to deflection of flexible base materials, leading to peeling issues and poor connection of cables, which are not adequately addressed by existing techniques.
Innovation Solution
A method of manufacturing radiation detectors involving a flexible base material with a peeling layer, a conversion layer, and reinforcing substrates to prevent substrate defects and improve peeling properties during reworking, including specific steps for substrate formation, conversion layer formation, and reinforcing substrate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a flexible base material is used for the substrate, then the weight of the radiographic imaging apparatus is reduced and imaging is easier, but the substrate may deflect during manufacturing causing defects such as peeling of the conversion layer or damage to pixels
Solution Approach 1:
The substrate system is segmented into multiple functional layers: a flexible base material layer, a peeling layer, and a reinforcing substrate layer. This segmentation allows the flexible base material to maintain its weight-reducing advantage while the reinforcing substrate provides the necessary structural support to prevent deflection and manufacturing defects. The peeling layer further segments the system to enable selective removal of the reinforcing substrate after manufacturing.
Solution Approach 2:
The solution introduces a dimensional change by adding a reinforcing substrate layer in the structural support dimension, while maintaining the flexibility dimension through the base material. This multi-dimensional approach allows simultaneous achievement of light weight and manufacturing precision by operating in different functional dimensions.
2Manufacturing precision
If a reinforcing substrate is provided on the conversion layer side to prevent substrate defects, then manufacturing precision is improved, but the reinforcing substrate becomes an obstacle during cable reworking and deteriorates peeling property
Solution Approach 1:
The peeling layer is introduced as a preliminary action during manufacturing to enable future reworking operations. This layer is applied before cable connection, allowing the reinforcing substrate to be selectively peeled off later without damaging the base material or conversion layer, thus facilitating cable reworking after the initial manufacturing benefit is achieved.
Solution Approach 2:
The peeling layer acts as an intermediary between the reinforcing substrate and the base material with conversion layer. This intermediary layer enables the reinforcing substrate to be easily separated when needed for reworking, resolving the conflict between needing structural support during manufacturing and needing ease of repair later.
3Adaptability or versatility
If the base material is deflected during manufacturing, then flexibility is maintained, but defects occur such as peeling of conversion layer or damage to pixels
Solution Approach 1:
The reinforcing substrate acts as a counterweight to the flexibility of the base material during manufacturing. It provides opposing structural support that counteracts the deflection tendency of the flexible base material, preventing conversion layer peeling and pixel damage while allowing the base material to retain its inherent flexibility for the final application.
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 method effectively suppresses substrate defects and enhances peeling properties during reworking, ensuring reliable operation of radiation detectors.
Implementation Method 1
forming a substrate in which a flexible base material is provided via a peeling layer on a support body
Implementation Method 2
a conversion layer, such as a scintillator, which converts radiation into light
Implementation Method 3
a plurality of pixels, which accumulate electric charges generated in response to light converted in the conversion layer
Data Source
AI summary
A method of manufacturing a radiation detector includes: forming a substrate in which a flexible base material is provided via a peeling layer on a support body and plural pixels that accumulate electric charges generated in response to light converted from radiation are provided in a pixel region of the base material; forming a conversion layer for converting the radiation into light on a surface of the base material; providing a first reinforcing substrate on a surface of the conversion layer opposite to a surface on the substrate side; peeling the substrate provided with the conversion layer and the first reinforcing substrate from the support body; providing a second reinforcing substrate on a surface of the substrate peeled from the support body; and peeling the first reinforcing substrate from the substrate provided with the conversion layer after providing the second reinforcing substrate.