Scintillator Panel Production via Segmented Protective Coating
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Solution Overview
Problem
Existing methods for producing scintillator panels face challenges in achieving high production efficiency and low cost while maintaining a large effective image area, particularly for small-sized devices with diverse forms, due to issues with phosphor layer durability and protective layer application.
Innovation Solution
A method involving dividing a first scintillator panel into multiple smaller panels, using an adsorbing member to attach them to a second support, and forming a protective layer on all surfaces except where the adsorbing member contacts, allowing for efficient production of scintillator panels of various sizes with a large effective image area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional protective layer methods are used (covering only upper portion and lateral face), then the phosphor layer is protected from deterioration, but the production efficiency is low and the effective image area is reduced
Solution Approach 1:
The patent divides the protective layer formation process into multiple stages: first forming a protective layer on the phosphor layer, then dividing the panel into multiple regions, and finally forming additional protective layers on specific regions (upper portion, lateral face, and outer peripheral portion) separately. This segmented approach allows comprehensive protection while maintaining production efficiency.
Solution Approach 2:
The patent applies preliminary protective coating to the phosphor layer before division, and then performs additional protective layer formation on specific regions after division. This preliminary action ensures the phosphor layer is protected from the start, while subsequent regional protection addresses specific vulnerability areas without requiring complete re-coating.
2Reliability
If the phosphor layer is completely covered with protective material, then the phosphor layer durability is improved, but the production cost increases and production efficiency decreases
Solution Approach 1:
The patent applies different protective layer configurations to different regions of the scintillator panel. The outer peripheral portion receives protective coating on all surfaces (upper, lateral, and bottom), while the central imaging region receives protection only on the phosphor layer surface. This local quality approach provides enhanced protection where needed while maintaining production efficiency.
Solution Approach 2:
The patent uses a support structure as an intermediary to facilitate the protective layer formation process. The support structure allows for precise application of protective materials to specific regions and enables easy removal after coating, improving overall production efficiency while ensuring comprehensive protection.
3Adaptability or versatility
If the scintillator panel is divided into smaller panels, then the adaptability for various applications is improved, but the production complexity increases
Solution Approach 1:
The patent divides a large scintillator panel into multiple smaller panels after forming the protective layers. This segmentation allows the same production process to generate multiple product sizes and configurations, enhancing adaptability for different applications (medical imaging, industrial inspection, etc.) without requiring separate production lines for each size.
Solution Approach 2:
The patent performs protective layer formation on the entire panel before division into smaller units. This preliminary action simplifies the production process by performing coating operations once rather than repeatedly on each individual small panel, thereby reducing production complexity while still achieving comprehensive protection on all resulting panels.
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 production of scintillator panels with high efficiency and low cost, ensuring a high production yield and minimizing damage during the peeling process, thereby addressing the limitations of conventional techniques.
Implementation Method 1
providing an adsorbing member between a side of the first support of each of the plurality of the second scintillator panels and a side of a second support; and allowing to adsorb the plurality of the second scintillator panels onto the second support
Data Source
AI summary
The steps of the method to make the scintillator panel are providing a first support having thereon a phosphor layer; dividing the first support the phosphor layer into a plurality of scintillator panel sections each having a first support section and a phosphor layer section thereon; providing an adhesive member between a side of the first support section of each of the plurality of the scintillator panel sections and a side of a second support; adhering the plurality of the scintillator panel sections onto the second support; forming a protective layer on a whole surface of the plurality of the scintillator panel sections except a portion of the scintillator panel sections which is contacted with the adhesive member; and separating the scintillator panel sections with their protective layer thereon from the second support. The separated scintillator panel sections with their protective layer are then adhered to light receiving element to form the flat panel detector.