Scintillator Panel Edge Alignment for Uniform Phosphor Deposition
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Solution Overview
Problem
Conventional scintillator panels have a reduced effective image area due to non-uniform phosphor layer formation at the peripheral edges, limiting the expansion of the imaging area in radiation imaging applications like mammography.
Innovation Solution
A scintillator panel design where at least one edge of the substrate and one edge of the phosphor layer are arranged on the same plane, allowing for uniform phosphor layer formation and expanded effective imaging area, achieved through manufacturing methods that include cutting the substrate and phosphor layer to align their edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the substrate is held by the substrate holder at the circumference portion during phosphor layer formation by vacuum evaporation, then the phosphor layer can be formed on the substrate, but a non-image forming area is created at the peripheral portion reducing the effective image area
Solution Approach 1:
The invention divides the substrate into two functional zones: a central imaging area where the phosphor layer is uniformly formed, and a peripheral non-imaging area where the substrate holder contacts the substrate. This segmentation allows the phosphor layer formation process to focus on the central area while accepting that the periphery will not contribute to imaging, thereby resolving the contradiction between manufacturing precision and effective image area.
Solution Approach 2:
The substrate holder is positioned and secured to the substrate circumference before the phosphor layer formation process begins. This preliminary action ensures that during vacuum evaporation, the phosphor material is deposited only on the central imaging area while the peripheral area remains protected by the substrate holder structure, preventing non-uniform formation and defining the effective image area boundaries in advance.
2Area of stationary object
If the effective image area is expanded to include peripheral regions, then more imaging coverage is achieved, but non-uniform phosphor layer formation occurs at the edges
Solution Approach 1:
The invention applies different functional qualities to different regions of the substrate: the central region is designed to receive and uniformly form the phosphor layer for high-quality imaging, while the peripheral region is designated as a non-imaging support zone. This local differentiation allows the system to maximize effective image area within the constraints of uniform phosphor formation by clearly defining where imaging-quality phosphor should and should not be deposited.
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 design enhances the effective image area by preventing non-uniformity and enabling radiation detection across the entire panel, particularly at the peripheral regions, thereby improving the overall imaging performance.
Implementation Method 1
a phosphor layer provided on the substrate, the phosphor layer emitting light when irradiated with a radiation
Data Source
AI summary
A scintillator panel comprising: a radiation-transparent substrate; and a phosphor layer provided on the substrate, the phosphor layer emitting light when irradiated with a radiation, wherein at least one edge of the substrate and at least one edge of the phosphor layer are arranged on a same plane.