X-ray detector metal barrier on polymeric substrate
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Solution Overview
Problem
Polymeric substrates used in X-ray detectors are prone to moisture and oxygen diffusion, leading to performance degradation and chemical attacks, which existing technologies have not adequately addressed.
Innovation Solution
A metal barrier is applied around the X-ray detector and polymeric substrate, extending over the upper surface, peripherally-extending edges, and lower surface, providing a hermetic seal to prevent moisture, oxygen, and chemical exposure, using methods like physical vapor deposition or metal foils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a polymeric substrate is used for flexibility, then the device can be made flexible, but moisture and oxygen diffuse rapidly through the substrate causing performance degradation
Solution Approach 1:
The barrier protection is segmented into multiple discrete metal layers (first metal barrier layer and second metal barrier layer) positioned at different locations - one on the substrate and one surrounding the electro-optical device - rather than using a single continuous barrier. This segmentation allows the polymeric substrate to maintain flexibility while providing targeted protection against moisture and oxygen diffusion at critical interfaces.
Solution Approach 2:
Metal barrier layers are introduced as intermediary elements between the polymeric substrate and the electro-optical device components. These metal layers act as mediators that block the harmful diffusion of moisture and oxygen from the substrate and environment to the sensitive electronic components, thereby protecting device performance while allowing the flexible substrate to function.
2Adaptability or versatility
If a polymeric substrate is used, then the device can be made flexible, but the substrate is subject to attack by chemicals used during processing
Solution Approach 1:
Thin metal barrier films are applied to the polymeric substrate and device components. These thin film barriers provide chemical resistance during processing while maintaining the overall flexibility of the polymeric substrate structure. The metal films act as protective shells that prevent direct contact between harsh processing chemicals and the vulnerable polymeric and electronic components.
3Reliability
If glass or silicon substrate is used, then the substrate provides good barrier properties, but the device becomes rigid
Solution Approach 1:
The invention creates a composite structure combining a flexible polymeric substrate with metal barrier layers. This composite material system integrates the flexibility advantage of polymers with the barrier performance advantage of metals, achieving both flexible form factor and effective protection against moisture and oxygen diffusion without requiring rigid glass or silicon substrates.
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 metal barrier significantly enhances the reliability of X-ray detectors by preventing exposure to moisture, oxygen, and chemicals, thereby improving their performance and longevity.
Implementation Method 1
The metal barrier may be formed by known deposition techniques, for example, physical vapor deposition (PVD), chemical vapor deposition (CVD), atomic layer deposition (ALD), or any other suitable deposition technique.
Implementation Method 2
a scintillator disposed on the organic photodiode
Data Source
AI summary
An X-ray detector assembly includes a polymeric substrate having a lower surface and an upper surface, and an X-ray detector disposed on the upper surface of the substrate. The X-ray detector includes a thin-film-transistor array disposed on the substrate, an organic photodiode disposed on the thin-film-transistor array, and a scintillator disposed on the organic photodiode. A metal barrier extends substantially over an upper surface of the scintillator, substantially over peripherally-extending edges of the scintillator, the organic photodiode, and the thin-film-transistor array, and substantially over the lower surface of the substrate.