Scintillator and Photodiode Stack for Spectral CT Detection
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Solution Overview
Problem
Existing radiation detectors for high-energy radiation, such as X-ray photons, have limitations in sensitivity and manufacturing complexity, particularly for applications in Spectral CT scanners, where direct conversion of radiation by photodiode arrays is inefficient and requires additional substrates that increase detection area loss.
Innovation Solution
A radiation detector design featuring a stack of scintillator elements and photodiode arrays with electrical leads extending into a border volume, filled with a material like epoxy resin, minimizing additional carrier requirements and optimizing lead thickness and arrangement for enhanced sensitivity and spatial resolution, allowing for efficient detection and manufacturing scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photodiode arrays directly convert high-energy radiation, then detection capability is provided, but sensitivity is insufficient and additional substrates are required which increase detection area loss
Solution Approach 1:
The patent introduces scintillator elements as an intermediary substance between the high-energy radiation and the photodiode arrays. The scintillators convert high-energy photons into visible light photons, which the photodiodes then efficiently detect. This mediator enables indirect conversion with superior sensitivity compared to direct photodiode conversion, resolving the contradiction between detection capability and sensitivity.
2Stability of the object's composition
If additional substrates are used to mount scintillator crystals and connectors, then structural support is provided, but manufacturing complexity increases and detection area is reduced
Solution Approach 1:
The patent merges the substrate function directly into the PDA structure by extending the PDA with electrical leads that form an integrated body. This eliminates the need for separate substrates to mount scintillator crystals and connectors, as the extended PDA body serves as both the mounting platform and the electrical connection structure, thereby reducing manufacturing complexity and preserving detection area.
Solution Approach 2:
The extended PDA body serves multiple functions simultaneously: it provides structural support for stacking, acts as the mounting platform for scintillator elements, provides electrical connections through integrated leads, and maintains mechanical stability. This multi-functional design eliminates the need for separate specialized components, reducing overall device complexity.
3Ease of manufacture
If connectors are attached to substrates in lateral volume and components are combined into a stack, then assembly is achieved, but the lateral volume requires filling with epoxy resin increasing manufacturing steps
Solution Approach 1:
The patent combines the electrical connection function and the structural mounting function into a single integrated PDA body with extended leads. This eliminates the need for separate connectors and substrate assemblies, allowing direct stacking of scintillator elements between PDA bodies without requiring lateral volume filling or additional assembly steps, thereby reducing manufacturing complexity.
4Area of stationary object
If lead thickness is reduced to minimize detection area loss, then detection area is maximized, but electrical connection reliability may be compromised
Solution Approach 1:
The patent implements a hierarchical lead structure where thin lead extensions from individual photodiodes nest within and connect to thicker redistribution leads, which in turn connect to even thicker external connection leads. This nested architecture allows the detection area to be maximized with thin leads while maintaining electrical reliability through progressively thicker supporting leads at each connection level.
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
The design achieves high sensitivity and reduced detection area loss, enabling efficient detection of high-energy radiation with improved spatial and energy resolution, suitable for Spectral CT applications, and simplifies manufacturing by eliminating the need for additional substrates.
Implementation Method 1
The scintillator elements have a cuboid shape and are made of a scintillation material that converts incident high energy radiation (e.g. X-rays) into photons of lower energy, particularly photons of the visible spectrum
Implementation Method 2
Said photons can then be detected by photodiodes in the PDAs, i.e. they are converted into electrical signals
Data Source
AI summary
The invention relates to a radiation detector and a method for producing such a detector, wherein the detector comprises a stack of the scintillator elements and photodiode arrays. The PDAs extend with electrical leads into a rigid body filling a border volume lateral of the scintillator elements, wherein said leads end in a contact surface of the border volume. Moreover, a redistribution layer is disposed on the contact surface, wherein electrical lines of the redistribution layer contact the leads of the PDAs.