Scintillating Fiber Bundle Manufacturing via Pressure Infusion
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Solution Overview
Problem
Current coherent bundles of scintillating fibers used in x-ray detectors have limitations in achieving high resolution images, with feature sizes of scintillators correlating to maximum imaging resolution, necessitating the development of fibers with smaller diameters to enhance image clarity in medical, scientific, and engineering applications.
Innovation Solution
A method of manufacturing coherent bundles of scintillating fibers involves using a collimated glass preform with capillaries, where a transparent scintillating polymer or polymer matrix with nanoparticles is infused into the capillaries under controlled pressure, employing a pressure vessel to apply pressure and back pressure to prevent bundle failure, thereby increasing the resolution of x-ray images to the single-digit micron range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied to force polymer into capillaries, then manufacturing precision is improved, but the collimated bundle may fail due to excessive tension
Solution Approach 1:
The patent applies back pressure to the collimated bundle to counterbalance the forward pressure applied to force the polymer into the capillaries. This counterweight approach prevents excessive tension that would cause bundle failure while maintaining sufficient pressure to achieve complete capillary filling and uniform fiber diameters.
Solution Approach 2:
The patent controls and adjusts pressure parameters during the manufacturing process, applying both forward pressure to drive polymer into capillaries and back pressure to prevent bundle failure. By optimizing these pressure parameters, the process achieves complete capillary filling while maintaining bundle integrity.
2Manufacturing precision
If scintillating polymer is infused into capillaries under pressure, then manufacturing precision is improved, but device complexity increases due to pressure vessel requirements
Solution Approach 1:
The patent employs a pressure vessel system using pneumatic or hydraulic pressure to infuse the scintillating polymer into the capillaries. This approach simplifies the manufacturing process by using fluid pressure to achieve complete capillary filling and uniform polymer distribution, replacing more complex mechanical infusion methods.
3Measurement precision
If smaller diameter scintillating fibers are used, then measurement precision is improved, but manufacturing precision becomes more difficult to achieve
Solution Approach 1:
The patent controls the diameter of scintillating fibers by precisely controlling the capillary dimensions and the pressure parameters during polymer infusion. By adjusting pressure, temperature, and infusion rate parameters, the process achieves uniform fiber diameters in the single-digit micron range, enabling high-resolution imaging while maintaining manufacturing feasibility.
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 significantly improves image resolution to the micron range, surpassing existing CAT and digital x-ray detector resolutions, enabling more accurate imaging in medical, engineering, and scientific fields, as well as domestic security and non-destructive testing applications.
Implementation Method 1
Incident x-rays activate the scintillators in individual fibers, which then emit visible light to the camera
Implementation Method 2
the scintillating light in the fiber (caused by x-rays), reflects the light down to the sensor: Total Internal Reflection
Implementation Method 3
Pressure is applied to the polymer matrix, driving it into the capillaries while a back pressure is applied to the collimated bundle thereby reducing the risk of failure of the collimated bundle
Data Source
AI summary
A method and apparatus to manufacture a coherent bundle of scintillating fibers is disclosed. A method includes providing a collimated bundle having a glass preform with capillaries therethrough known in the industry as a glass capillary array, and infusing the glass capillary array with a scintillating polymer or a polymer matrix containing scintillating nanoparticles.