Scintillator Arrays with Silicate Smoothing Layer

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Solution Overview

Problem

Conventional x-ray detector scintillator arrays suffer from surface roughness issues due to the cutting and coating processes, leading to increased scattering and reduced performance.

Innovation Solution

A scintillator array with a smoothing layer made of organically modified silicate and an optical reflector layer is applied over the scintillator substrate, reducing surface roughness and improving light output by minimizing cracking during the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional cutting and coating processes are used to manufacture pixelated scintillator structures, then the scintillator array can be produced, but surface roughness increases causing additional scattering and reduced performance

Engineering Contradiction:

Improvemanufacturability of pixelated scintillator structureVSAvoidsurface roughness of scintillator pixels

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies a smoothing layer of organically modified silicate to the scintillator pixel surfaces before final assembly. This preliminary smoothing action addresses the surface roughness issue created by cutting processes, reducing light scattering and improving detector performance while maintaining the manufacturability of pixelated structures.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a smoothing layer of organically modified silicate is applied to reduce surface roughness, then light output and sensitivity are enhanced, but the device complexity increases

Engineering Contradiction:

Improvelight output and sensitivity of scintillator arrayVSAvoidstructural complexity of scintillator array

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses organically modified silicate as a composite smoothing layer material that combines organic and inorganic properties. This material provides effective surface smoothing to reduce light scattering and improve light output, while its unique properties allow it to be applied as a relatively simple coating process rather than a complex multi-step procedure.

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

The solution effectively reduces surface roughness by up to a factor of 6.5, enhancing the light output and sensitivity of the scintillator array, particularly in x-ray Computed Tomography (CT) imaging systems.

Implementation Method 1

a smoothing layer overlaying a surface of the scintillator substrate within the gaps... effectively reduces surface roughness by up to a factor of 6.5

Methodology Applied

Scientific EffectSurface smoothing:

Implementation Method 2

each scintillator of the scintillator array converts x-rays to light energy, which each scintillator then discharges to an adjacent photodiode

Methodology Applied

Scientific EffectScintillation: Scintillation

Implementation Method 3

an optical reflector layer overlaying a surface of the smoothing layer within the gaps

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS8981306B2Scintillator arrays and methods of making scintillator arrays

Publication Date: 2015.03.17 GE PRECISION HEALTHCARE LLC

AI summary

Scintillator arrays and methods of making scintillator arrays are provided. One scintillator array includes a scintillator substrate having a plurality of scintillators spaced apart by gaps within the scintillator substrate and a smoothing layer overlaying a surface of the scintillator substrate within the gaps. The smoothing layer includes an organically modified silicate. The scintillator array also includes an optical reflector layer overlaying a surface of the smoothing layer within the gaps.