Slotted X-Ray Collimator Assembly for Precise Septa Placement
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Solution Overview
Problem
Existing collimator manufacturing techniques for x-ray imaging systems, such as CT systems, are costly and require high precision in placing septa due to complex processes like casting lead or using thin tungsten plates, which increases production costs and complexity.
Innovation Solution
A collimator is formed from a laser-cut, foldable sheet of low x-ray attenuation material like aluminum, with slots for thin tungsten septa, allowing precise placement and integration into a detector assembly, reducing costs and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If casting lead in a mold with cores is used to manufacture collimators, then the septa can be formed with proper placement, but the resulting septa are relatively thick to maintain rigidity and the process is complex and costly
Solution Approach 1:
The collimator cover is divided into modular components (base plate and side plates) that can be separately manufactured and then assembled. The slots are pre-formed in these modular sections, allowing for precise septa placement without requiring complex full-cast molds and cores. This segmentation simplifies the manufacturing process while maintaining placement precision.
Solution Approach 2:
The slots for receiving septa are pre-formed in the collimator cover during the manufacturing process, before the actual assembly. This preliminary formation of reception structures ensures precise septa placement is achieved automatically when septa are inserted, eliminating the need for complex mold cores and manual placement procedures.
2Manufacturing precision
If thin tungsten plates are precisely placed at different angles in machine plates, then the collimator can be manufactured with proper septa alignment, but high precision placement is required and complex post-processing steps are involved which increase cost
Solution Approach 1:
The collimator cover acts as an intermediary structure that provides pre-formed slots as reception structures for the septa. These slots serve as guides and positioning features, allowing thin tungsten plates to be accurately positioned without requiring complex alignment procedures or post-processing steps. The intermediary cover simplifies the manufacturing process while ensuring proper septa alignment.
Solution Approach 2:
The reception structures (slots) are preliminarily formed in the collimator cover before septa installation. This preliminary action creates built-in positioning features that automatically guide septa into correct positions and orientations, eliminating the need for high-precision manual placement and complex post-processing operations.
3Reliability
If a collimator cover made from low radiation attenuation material is used, then x-ray beam direction and filtering can be improved, but the cover itself must provide structural integrity to support the septa
Solution Approach 1:
The collimator employs a composite structure combining a low radiation attenuation material cover (for optimal x-ray transmission and filtering) with separate high-strength septa components (typically tungsten or lead). This composite approach allows each material to perform its optimal function: the cover provides x-ray transparency and structural framework, while the dense septa provide the necessary radiation blocking with minimal thickness, collectively achieving both structural integrity and superior x-ray filtering performance.
Data Source
AI summary
A collimator includes a collimator cover formed from a material with low radiation attenuation, and a plurality of septa formed from a radiation attenuating material. The collimator cover includes a base plate, a first side plate extending from the base plate, and a second, opposing side plate extending from the base plate. The first side plate has a plurality of first slots defined therein and the second side plate has a plurality of second slots defined therein. Each septum includes a first end retained in one first slot of the plurality of first slots and a second end retained in one corresponding second slot of the plurality of second slots.