Scintillator Dual Array Bonding via Intermediate Resin Layer

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Solution Overview

Problem

Existing methods for producing scintillator dual arrays lack efficiency and precision in manufacturing, particularly in the alignment and bonding of scintillator bars with different sensitivity distributions for X-ray energy detection.

Innovation Solution

A method involving the bonding of first and second scintillator bar arrays via an intermediate resin layer, followed by cutting and coating to form a dual array assembly, ensuring precise alignment and efficient production of scintillator dual arrays with the same pitch for high-energy X-ray detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If scintillator bars are bonded individually with epoxy adhesive and photodiodes are bonded separately, then assembly flexibility is maintained, but production time and complexity increase significantly

Engineering Contradiction:

Improveproduction efficiencyVSAvoidnumber of production steps

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate bonding operations into a single integrated process. Scintillator bars and photodiodes are bonded simultaneously using a single adhesive application, eliminating the need for separate bonding steps. This merging of operations directly increases productivity while reducing the overall complexity of the production process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs preliminary positioning structures (such as recesses and protrusions) that are prepared in advance on the scintillator bars and photodiodes. These pre-formed positioning features ensure automatic alignment during the bonding process, eliminating the need for complex alignment procedures and reducing production time without sacrificing precision.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If multiple bonding steps are used for scintillator and photodiode assembly, then alignment precision can be controlled, but manufacturing time and process complexity increase

Engineering Contradiction:

Improvealignment precisionVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Positioning recesses and protrusions are pre-formed on the scintillator bars and photodiodes respectively. These preliminary positioning structures ensure precise alignment is achieved automatically during the single bonding step, maintaining high manufacturing precision while eliminating the time required for multiple alignment and bonding operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning recesses and protrusions act as intermediary alignment features that mediate between the scintillator bars and photodiodes. These intermediary structures ensure precise relative positioning without requiring complex external alignment equipment or multiple bonding steps, thus reducing production time while maintaining precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If ceramic and single-crystal scintillators are bonded separately with adhesive, then material selection flexibility is maintained, but the number of production steps increases

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidproduction process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges the bonding of different scintillator materials (ceramic and single-crystal) into a single adhesive bonding operation. This approach maintains the flexibility to use different materials while simplifying the production process by eliminating separate bonding steps for each material type, thereby improving ease of manufacture.

Inventive Principle:

Principle #5Merging (Combining)

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 method enables the efficient and precise production of scintillator dual arrays, enhancing the accuracy and reliability of radiation detectors used in medical and security CT apparatuses.

Implementation Method 1

a hardened reflecting resin filling the grooves

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

bonding a first scintillator bar array comprising pluralities of first scintillator bars arranged via parallel grooves and a hardened reflecting resin filling the grooves, to a second scintillator bar array comprising pluralities of second scintillator bars arranged via parallel grooves and a hardened reflecting resin filling the grooves, via an intermediate resin layer

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 3

first scintillator bars arranged via parallel grooves... second scintillator bars... having different sensitivity distributions of X-ray energy detection

Methodology Applied

Scientific EffectScintillation: Scintillation

Data Source

PatentUS9899113B2Production method of scintillator dual array

Publication Date: 2018.02.20 PROTERIAL LTD

AI summary

A method for producing a scintillator dual array comprising the steps of bonding first and second scintillator bar arrays having different sensitivity distributions of X-ray energy detection and pluralities of parallel grooves with equal gaps, via an intermediate resin layer, such that both scintillator bars are aligned in a lamination direction, cutting the integrally bonded bar array in a direction crossing the scintillator bars, and coating one cut surface of each bonded bar array piece with a resin.