Scintillator Module Moisture-Proof Welding Layer

Solution Overview

Problem

The manufacturing process for scintillator modules with fiber optic plates is complicated and costly due to the need for sophisticated vacuum deposition for reflective layers and moisture-proof coatings, which are also prone to scratches and have low moisture-proof properties.

Innovation Solution

A scintillator module with a butyl-rubber moisture-proof welding layer extending to the side surfaces of a fiber optic plate, covered by a thermoplastic resin case, which is pressed and heated to form a sealed and robust moisture-proof structure, eliminating the need for vacuum deposition and enhancing mechanical impact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vacuum deposition is used to form reflective layers and moisture-proof coatings, then the scintillator module achieves basic moisture-proof properties, but the manufacturing process becomes complicated and production cost increases

Engineering Contradiction:

Improvemoisture-proof propertyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the moisture-proof coating formation process from the vacuum deposition system and replaces it with a separate resin material application process. The moisture-proof resin is applied directly to the scintillator layer without requiring vacuum deposition equipment, thereby eliminating the need for sophisticated vacuum deposition apparatus while maintaining moisture-proof properties.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a cost-effective resin material instead of expensive vacuum-deposited metal layers for moisture protection. This resin material can be applied using simple coating methods and provides sufficient moisture-proof performance without the high equipment and material costs associated with vacuum deposition.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If vacuum deposition is used to form reflective layers and moisture-proof coatings, then the scintillator module achieves basic moisture-proof properties, but production cost increases

Engineering Contradiction:

Improvemoisture-proof propertyVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective resin material instead of expensive vacuum-deposited metal layers for moisture protection. This resin material can be applied using simple coating methods and provides sufficient moisture-proof performance without the high equipment and material costs associated with vacuum deposition.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts the moisture-proof coating formation process from the vacuum deposition system and replaces it with a separate resin material application process. This eliminates the need for sophisticated vacuum deposition equipment and reduces production costs while maintaining moisture-proof properties.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If a thin moisture-proof coating is used, then the manufacturing process is simplified, but the coating becomes vulnerable to external impact causing scratches and peel-off

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical impact resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent creates a composite protective structure where a resin material is applied over the scintillator layer. This resin layer serves as a robust protective coating that resists mechanical impact, scratches, and peel-off, while the underlying scintillator layer maintains its functional properties. The composite structure combines the advantages of both materials for enhanced durability.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If a thin moisture-proof coating is used, then the manufacturing process is simplified, but moisture-proof property deteriorates significantly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmoisture-proof property

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite protective structure where a resin material is applied over the scintillator layer. This resin layer serves as a robust protective coating that resists mechanical impact, scratches, and peel-off, while the underlying scintillator layer maintains its functional properties. The composite structure combines the advantages of both materials for enhanced durability.

Inventive Principle:

Principle #40Composite materials

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 simplifies the manufacturing process, reduces production costs, and significantly improves the moisture-proof properties of the scintillator module, making it more robust against mechanical impacts and maintaining high moisture resistance.

Implementation Method 1

a moisture-proof welding layer formed of a butyl-rubber welding material

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

applying pressure to the resin case toward the fiber optic plate while heating the resin case and the sheet with a mold

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

a scintillator layer formed on one surface of the fiber optic plate

Methodology Applied

Scientific EffectScintillation: Scintillation

Data Source

PatentUS10871581B2Scintillator module, scintillator sensor unit, and scintillator module production method

Publication Date: 2020.12.22 YMIT CO LTD

AI summary

According to an embodiment, a scintillator module includes a moisture-proof welding layer and a resin case. The moisture-proof welding layer is formed of a material having a welding property and a moisture-proof property, and extends to a side surface of a fiber optic plate to cover, in a sealed state, a scintillator layer and a visible-light reflective layer laminated on the fiber optic plate. The resin case covers the moisture-proof welding layer while being pressed against the side surface of the fiber optic plate.