Lightweight X-ray Detector Using Composite Panel Support
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Solution Overview
Problem
Conventional x-ray detectors are heavy and thick due to rigid metal panel supports and enclosures, making them unsuitable for portable designs that require a lightweight yet durable and mechanically stiff structure to withstand dynamic and static loads.
Innovation Solution
An x-ray detector design featuring a 2D flat panel substrate bonded to a low density core over a support layer, forming an integrated panel support that is lightweight yet mechanically stiff, using composite materials like carbon fiber reinforced plastic with a foam core for improved energy absorption and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy machined metal panel supports and enclosures are used, then mechanical protection and structural rigidity are improved, but weight and thickness increase
Solution Approach 1:
The patent applies composite materials by bonding carbon fiber reinforced plastic (CFRP) panels to a foam core structure. The CFRP provides high strength-to-weight ratio and mechanical rigidity, while the foam core provides structural support and impact absorption. This composite construction achieves the required mechanical protection without the excessive weight of solid metal enclosures.
Solution Approach 2:
The patent utilizes foam core material with porous structure as the central element of the panel support. The foam provides mechanical support, impact absorption, and energy dissipation while being significantly lighter than solid metal. The porous structure allows for weight reduction while maintaining adequate structural integrity for portable detector applications.
2Reliability
If thick rigid metal enclosures are used, then protection against impacts and loads is improved, but portability and ease of handling deteriorate
Solution Approach 1:
The composite construction of CFRP panels bonded to foam core creates a structure that is both protective and lightweight. The CFRP provides impact resistance and structural rigidity, while the foam core absorbs impact energy. Together they create a protective enclosure that is light enough for portable applications, enabling easy handling and mobility.
Solution Approach 2:
The foam core acts as a pre-installed cushioning element between the imaging panel and the external environment. It provides impact absorption and shock mitigation before impacts occur, protecting sensitive components during portable use when the detector may be dropped or subjected to accidental impacts.
3Weight of moving object
If low density composite materials are used, then weight is reduced, but structural stiffness and rigidity may deteriorate
Solution Approach 1:
The patent uses carbon fiber reinforced plastic (CFRP) which is a high-performance composite material with exceptional strength-to-weight ratio and stiffness-to-weight ratio. The carbon fiber reinforcement provides the necessary structural stiffness and rigidity, while the plastic matrix binds the fibers together. This allows the enclosure to be both lightweight and structurally rigid, overcoming the typical trade-off between weight and stiffness.
Solution Approach 2:
The patent applies different materials with different properties to different parts of the structure: CFRP panels are used where high stiffness and strength are needed (outer surfaces), while foam core is used in the interior where impact absorption and weight reduction are priorities. This local differentiation of material properties optimizes both weight and structural stiffness throughout the enclosure.
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 integrated panel support design results in a portable x-ray detector that is lightweight, rugged, and capable of withstanding impacts and patient loads, while maintaining mechanical stiffness and reducing the overall weight and cost of the detector.
Implementation Method 1
using composite materials like carbon fiber reinforced plastic with a foam core for improved energy absorption and reduced weight
Implementation Method 2
using composite materials like carbon fiber reinforced plastic with a foam core for improved energy absorption and reduced weight
Data Source
AI summary
An x-ray detector is provided for use in imaging systems. The x-ray detector includes a detector subsystem configured to output electrical signals in response to reception of x-rays. The detector subsystem includes an imaging panel, a support layer and a low density core disposed between the imaging panel and the support layer.