Method for fabricating pixelated scintillators

Abstract

In a method of making pixelated scintillators, an amorphous scintillator material in a molten state is pressed into a plurality of cavities defined by a plurality of walls of a mesh array. The molten scintillator material in the plurality of cavities is cooled to form a pixelated scintillator array. An x-ray imager including a pixelated scintillator is also described.

1 . A method of making pixelated scintillators, comprising:
 providing a mesh array including a plurality of walls defining a plurality of cavities;   providing an amorphous scintillator material in a molten state;   introducing the amorphous scintillator material in the molten state into the plurality of cavities of the mesh array; and   cooling the amorphous scintillator material in the mesh array to form a pixelated scintillator array.   
     
     
         2 . The method of  claim 1 , wherein the introducing step comprises pouring the amorphous scintillator material in the molten state over the mesh array to allow it to flow into the plurality of cavities. 
     
     
         3 . The method of  claim 1 , wherein the introducing step comprises placing the amorphous scintillator material in the molten state over the mesh array and pressing it into the plurality of cavities. 
     
     
         4 . The method of  claim 1 , wherein the mesh array is constructed from a material having a thermal expansion coefficient substantially same as or smaller than a thermal expansion coefficient of the scintillator material. 
     
     
         5 . The method of  claim 4 , wherein the mesh array is constructed from a material having a melting temperature higher than a melting temperature of the scintillator material. 
     
     
         6 . The method of  claim 5 , wherein the mesh array is constructed from a material comprising a metal or metal alloy selected from the group consisting of cupronickel, Hastalloy C, Inconel, iridium, iron, Monel, molybdenum, steel, steel-carbon alloy, tantalum, thorium, titanium, tungsten, vanadium, and zirconium. 
     
     
         7 . The method of  claim 5 , wherein the mesh array is constructed from a material comprising a ceramic selected from the group consisting of HfB 2 , HfC, NfN, ZrB 2 , ZrC, ZrN, TiB 2 , TiC, TiN, TaB 2 , TaC, TaN, and SiC. 
     
     
         8 . The method of  claim 5 , wherein the mesh array is constructed from a material selected from the group consisting of graphite, silicon carbide, and boron nitride. 
     
     
         9 . The method of  claim 1 , wherein the plurality of walls of the mesh array are coated with a reflective layer. 
     
     
         10 . The method of  claim 9 , wherein the reflective layer has a color substantially matches a color of light emitted by the scintillator material. 
     
     
         11 - 19 . (canceled) 
     
     
         20 . A method of fabricating pixelated scintillators, comprising:
 forming a plurality of scintillator pixels from an amorphous scintillator material in a molten state;   applying a reflective layer on each of the plurality of scintillator pixels formed; and   assembling the plurality of scintillator pixels applied with the reflective layer to form a pixelated scintillator array.   
     
     
         21 . The method of  claim 20 , wherein the plurality of scintillator pixels are assembled by inserting them into a mesh array including a plurality of walls defining a plurality of cavities configured to receive the plurality of scintillator pixels. 
     
     
         22 . The method of  claim 21 , further comprising fixing the plurality of scintillator pixels in the mesh array using an adhesive in the plurality of cavities. 
     
     
         23 . The method of  claim 20 , wherein the plurality of scintillator pixels are assembled by binding them to each other using an adhesive. 
     
     
         24 . The method of  claim 20 , wherein each of the plurality of scintillator pixels has a first end portion and a second end portion, and the plurality of scintillator pixels are assembled through attachments to the first end portions of the plurality of scintillator pixels. 
     
     
         25 . The method of  claim 20 , wherein the plurality of scintillator pixels are formed from the amorphous scintillator material by a drawing technique. 
     
     
         26 . The method of  claim 20 , further comprising fire polishing the plurality of the scintillator pixels formed. 
     
     
         27 . The method of  claim 20 , wherein each of the plurality of scintillator pixels has a shape of a cylinder, a rectangular prism, or a square prism. 
     
     
         28 - 30 . (canceled) 
     
     
         31 . The method of  claim 20 , wherein the reflective layer has a color substantially matches a color of light emitted by the scintillator material. 
     
     
         32 . (canceled) 
     
     
         33 . The method of  claim 20 , wherein the plurality of scintillator pixels are assembled in plural rows and plural columns. 
     
     
         34 . The method of  claim 33 , wherein scintillator pixels in adjacent rows and/or columns are arranged staggered. 
     
     
         35 - 52 . (canceled) 
     
     
         53 - 58 . (canceled)