Selective Laser Sintered X-ray Grid with Pore-Filled Composite
Solution Overview
Problem
Current grids for selective transmission of electromagnetic radiation, particularly in medical imaging devices, face challenges in mechanical stability and radiation-absorbing properties, and the manufacturing process is complex and costly.
Innovation Solution
A method involving selective laser sintering of particles to form a structural element with pores, followed by filling these pores with a liquid second material that is then solidified, enhancing both mechanical stability and radiation-absorbing properties, and allowing for larger particle sizes to simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If selective laser sintering is used to manufacture grids with complex three-dimensional structures, then design freedom and structural complexity are improved, but mechanical stability and radiation-absorbing properties deteriorate due to porous sintered structures
Solution Approach 1:
The patent combines sintered particles with a binding matrix material to create a composite structure. The sintered particles provide the complex three-dimensional geometry and radiation-absorbing properties, while the binding matrix fills the pores between particles to enhance mechanical stability and structural integrity, resolving the contradiction between design freedom and mechanical strength.
Solution Approach 2:
The patent utilizes the inherent porosity of sintered structures but transforms it from a weakness into a feature by filling the pores with binding material. The controlled porous structure allows for maintaining design freedom while the pore-filling process improves mechanical stability, addressing the contradiction between structural complexity and strength.
2Adaptability or versatility
If selective laser sintering is used to manufacture grids with complex three-dimensional structures, then design freedom is improved, but radiation-absorbing properties deteriorate due to scattered radiation through pores
Solution Approach 1:
The composite structure combines radiation-absorbing sintered particles with a binding matrix that also contributes to radiation absorption. This combination ensures that both the complex geometry and the pore-filling materials work together to improve overall radiation-absorbing properties while maintaining design freedom.
Solution Approach 2:
The patent converts the harmful effect of pores (which allow scattered radiation to pass through) into a benefit by filling them with binding material that absorbs radiation. The pores that initially represented a weakness are transformed into opportunities for enhancing radiation absorption through the binding matrix.
3Ease of manufacture
If conventional molding or milling techniques are used to manufacture grids, then manufacturing simplicity is improved, but ability to create complex three-dimensional structures deteriorates
Solution Approach 1:
The patent replaces conventional mechanical molding or milling techniques with selective laser sintering, which uses thermal energy and material deposition to create complex structures. This substitution enables the manufacturing of highly complex three-dimensional grid structures that would be impossible to achieve with traditional mechanical methods, while still maintaining manufacturing efficiency.
4Strength
If pores are filled with binding material to improve mechanical stability, then manufacturing complexity increases
Solution Approach 1:
The binding matrix material automatically fills the pores between sintered particles through its own flow and solidification properties during the manufacturing process. This self-service mechanism eliminates the need for additional complex steps to fill pores, as the binding material naturally occupies the void spaces and provides structural consolidation.
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 method improves the mechanical stability and radiation-absorbing efficiency of the grid, simplifies the manufacturing process, and enables the production of high-quality anti-scatter grids with complex structures, reducing production costs and time.
Implementation Method 1
a method for manufacturing a grid comprises the step of growing at least a structural element by means of selective laser sintering from a powder material
Implementation Method 2
selective laser sintering allows for a large design freedom
Implementation Method 3
inserting a liquid second material into the pores
Implementation Method 4
solidifying the second material
Implementation Method 5
The radiation reduction is usually being realized by means of radiation absorption
Data Source
AI summary
A grid (1) for selective transmission of electromagnetic radiation and a method for manufacturing such grid is proposed. Therein, the grid (1) comprises a structural element with walls (3) comprising a plurality of particles (19) of a radiation-absorbing material wherein the particles (19) are sintered together such that pores (21) are present between neighboring particles (19). The pores (21) are at least partially filled with a second solid material. The filling of the pores (21) can be done by inserting the second material in a liquid, preferably molten form into the pores. The second material can be itself radiation-absorbing as well and may help to both, increase the mechanical stability of the grid and to enhance the radiation-absorbing properties.