3D Printed Tungsten Collimator to Scintillator Array
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Solution Overview
Problem
Current manufacturing processes for CT imaging systems require precise and uniform alignment of scintillator and collimator components, which is time-consuming, costly, and prone to errors, leading to high waste and rework as detectors grow in size, necessitating a method for precise alignment without excessive mechanical assembly challenges.
Innovation Solution
An integrated scintillator and collimator assembly is created by applying a transition material layer to the scintillator array using optical measurement analysis, followed by the application of collimator material, forming a combined structure with precise alignment, reducing the need for manual assembly and minimizing alignment errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical assembly methods are used to align collimator and scintillator components, then assembly precision can be achieved, but assembly time and cost increase significantly
Solution Approach 1:
The patent combines the collimator and scintillator array into a single integrated assembly where the collimator is directly attached to the scintillator substrate. This merging eliminates the need for separate alignment and assembly operations, thereby reducing assembly time while maintaining alignment precision through direct integration rather than mechanical assembly.
Solution Approach 2:
The patent replaces traditional mechanical alignment and assembly methods with a direct attachment process where the collimator is bonded or integrated to the scintillator array. This substitution eliminates complex mechanical adjustment procedures and tight tolerancing requirements, significantly reducing assembly time while maintaining the necessary alignment precision through the integration process itself.
2Manufacturing precision
If tight mechanical tolerances are maintained during manual assembly, then alignment precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
By merging the collimator and scintillator into an integrated assembly, the patent eliminates the need for separate components that require tight mechanical tolerances during assembly. The integration process inherently ensures alignment precision without requiring complex manual adjustment procedures or tight tolerancing specifications for individual components.
Solution Approach 2:
The patent substitutes traditional mechanical assembly systems requiring tight tolerances with a direct integration approach. This replacement eliminates the need for precision mechanical adjustments, specialized tooling, and highly skilled operators, thereby simplifying manufacturing while maintaining alignment precision through the integrated design.
3Adaptability or versatility
If traditional separate assembly of collimator and scintillator is used, then component flexibility is maintained, but alignment precision and yield decrease
Solution Approach 1:
The patent merges the collimator and scintillator into an integrated assembly that is produced as a unified structure. This integration ensures precise alignment between components by design, eliminating alignment errors that occur in separate assemblies. The integrated approach maintains adaptability through modular detector array configurations while ensuring consistent alignment precision across all components.
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 precise alignment of collimator structures relative to scintillator pixels, reducing assembly time and costs, and improving image quality by eliminating the need for tight mechanical tolerances, thus enhancing the efficiency and yield of detector assembly.
Implementation Method 1
a transition material layer bonded to the pixels and a plurality of collimator plates bonded to the transition material layer
Implementation Method 2
a scintillator for converting x-rays to light energy adjacent the collimator
Data Source
AI summary
In the present invention, an integrated scintillator and collimator array for a detector utilized in a CT imaging system is provided. The integrated scintillator and collimator assembly is are fabricated from a manufacturing process or technique in which a scintillator array including a number of scintillation pixels is optically measured to determine the precise position of each pixel on the array. A transition material is applied to the array in a 3D printing method using the position data from the optical measurement and in subsequently bonded thereto in a sintering process to form a transition material layer. A collimator material is then 3D printed onto the transition material layer using the optical measurement data to form collimator plates on the array in alignment with the pixels thereby forming a unitary scintillator/collimator assembly for use in a detector for a CT imaging system.