Scattered Beam Collimator Lithographic Fabrication
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Solution Overview
Problem
Existing methods for producing scattered beam collimators, used in X-ray devices to filter out unwanted scattered radiation, are inefficient as they rely on stacking metal sheets which can be cumbersome and lack precision in creating fine structures necessary for effective X-ray absorption and pass-through channels.
Innovation Solution
A method utilizing a lithographic process to form X-ray absorbing partitions with precise pass-through channels, where the partitions are built up in layers using a photoresist mixed with X-ray absorbing material, allowing for the creation of fine structures and efficient channel alignment, such as parallel or converging channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal sheets are stacked to produce scattered beam collimators, then the structure can be assembled, but the manufacturing precision and fine structure creation are insufficient
Solution Approach 1:
The scattered beam collimator is divided into multiple layers, each layer being formed by a separate lithographic process. This segmentation allows precise control of pass-through channels in each layer while maintaining overall manufacturing feasibility through modular layer-by-layer construction.
Solution Approach 2:
The invention transitions from traditional 2D metal sheet stacking to 3D layered structure formation using lithographic processes. This dimensional approach enables precise control of channel geometry, depth, and alignment across multiple layers, achieving fine structure creation that is impossible with flat metal sheets.
2Manufacturing precision
If traditional stacking methods are used, then assembly is possible, but the alignment of pass-through channels is imprecise
Solution Approach 1:
Multiple functional layers are merged into a single integrated lithographic structure. The pass-through channels across different layers are formed and aligned as part of a unified process, eliminating the need for separate assembly operations and ensuring precise channel alignment throughout the collimator.
Solution Approach 2:
The mechanical stacking and alignment process is replaced with a lithographic formation process. Instead of physically assembling metal sheets and manually aligning channels, the channels are precisely formed and aligned through photolithographic patterning across multiple layers, achieving superior alignment precision.
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 enables the production of scattered beam collimators with precise, thin partitions and aligned channels, enhancing the filtering of scattered X-rays while maintaining transparency for unscattered radiation, thereby improving the imaging quality in X-ray devices.
Implementation Method 1
forming the number of X-ray absorbing partitions of the scattered beam collimator, using a lithographic process, from a photoresist into which an X-ray absorbing material is mixed
Data Source
AI summary
A method is for producing a scattered beam collimator starting from a lower side and extending in a build-up direction as far as an upper side, and having a large number of X-ray absorbing partitions, and in which pass-through channels for unscattered X-ray radiation are embodied between the partitions. A lithographic process is used, by which the partitions of the scattered beam collimator are formed from a photoresist into which an X-ray absorbing material is mixed.