Radiation Detector Having a Multiplicity of Individual Detecting Elements

The present application relates to radiation detectors and, more particularly, to a novel radiation detector having a multiplicity of individual detecting elements.

It is well known to use electromagnetic radiation, e.g. x-rays and the like, to examine an object. Typically, an x-ray examination system may utilize a single radiation source moved between each of a plurality of positions with respect to the object to be examined, with an array of radiation detectors fixedly positioned with respect to the source and moving about the object position in conjunction with source motion. It is highly desirable to have the system detection array remain stationary with respect to the object examination position, whereby the electrical leads from the detector elements need not be continually moved and flexed as the object is examined. It is also highly desirable to provide a detection system having a large multiplicity of individual detection elements, to increase the inspection system resolution. Hitherto, the reliability of a large detector has been reduced due to the possibility of breakage in the large number of associated flexible element lead wires. Thus, a radiation detector having an array of a multiplicity, typically on the order of several thousand, individual detecting elements and capable of providing high resolution detection of a source at various angular dispositions with respect to the detector, without movement of the detector, is highly desirable.

In accordance with the invention, a radiation detector has a chamber in which a number N of arrays, each of a multiplicity of coplanar individual detector collection elements, are arranged in parallel fashion. Each of the arrays has the multiplicity of elements thereof radially disposed with respect to an associated one of a plurality of locations to which a radiation source can be moved, while the radiation detector remains at a fixed position with respect to an object to be examined. The detector element arrays are formed of etched conductive material on a thin, flexible insulative substrate, having lead portions designed to extend through one surface of an enclosing housing.

In one presently preferred embodiment, the detection medium is a gas, such as xenon and the like, under high pressure in a housing cavity containing the detector arrays. The element leads are formed into groups, whereby short slots are formed through the housing at one side of the cavity, to provide a very stiff housing portion resisting the detection medium pressure. A three-part housing, having a stiffening member, is utilized.

Accordingly, it is an object of the present invention to provide a novel radiation detector having increased resolution due to a large number of individual detecting elements.

This and other objects of the present invention will become apparent upon consideration of the following detailed description, when read in conjunction with the drawings.

FIG. 1 is a side view of a radiation flaw-detection system in which the detection apparatus of the present invention may be utilized;

FIG. 2 is a perspective view of one of the arrays of a multiplicity of detector elements;

FIG. 3 is a section view of a detector in accordance with the principles of the present invention;

FIG. 4 is an exploded perspective view of a detector housing;

FIG. 4a is a sectional view of the top detector housing member, taken along lines 4a--4a of FIG. 4;

FIGS. 4b, 4c and 4d are sectional views of the middle detector housing member, taken along lines 4b--4b, 4c--4c and 4d--4d, respectively, of FIG. 4;

FIGS. 4e and 4f are sectional views of the lower detector housing member, taken along lines 4e--4e and 4f--4f, respectively of FIG. 4;

FIG. 5 is a partially sectioned perspective view of a completed detector assembly; and

FIG. 5a is a sectional top view of the detector assembly, taken along lines 5a--5a of FIG. 5.

Referring intially to FIG. 1, a radiation detection system 10 utilizes a radiation source 11, such as a source of x-rays and the like, which can be pivotally moved, in the direction of arrows A and B, to various positions with respect to an object 12 to be inspected. A radiation detector 14 is positioned upon the opposite side of object 12 from source 11, and receives the radiation differentially absorbed by object 12 for analysis thereof. Illustratively, source 11 can be positioned at one of three locations; at a first location, source 11a is substantially perpendicular to the plane of object 12; at a second location, source 11b has been moved in the direction of arrow A, by a predetermined rotation about a fixed center position to obliquely illuminate object 12 from a first side direction; and at a third location, source 11c has been moved in the direction of arrow B, in the opposite direction from source 11b and by substantially a like degree of rotation, to obliquely illuminate object 12 from another side, opposite to the side at which source 11b illuminates the object. The radiation emitted from the source forms a fan beam of angle .theta., illustratively on the order of 40.degree.. Object 12 can be moved, in step-wise or other fashion, in at least one of directions C and D, through the zone between source 11 and radiation detector 14. Each portion of object 12 is thus scanned three times, with the source respectively at zero, a first angle (e.g. 45.degree.) left orientation and the same first angle (e.g. 45.degree.) right orientation to the plane normal to the object surface.

The differentially-attenuated radiation is detected by apparatus 14. Apparatus 14 includes a pressure-tight housing 16 containing a detecting medium 17, such as xenon gas under high pressure and the like, in an electric field; a high voltage plate 18 is so positioned within detector assembly 14 as to provide a required field through the conversion medium, to move electrons or ions (resulting from radiation quanta collisions with molecules of the medium) to the applicable one of a plurality of detector element arrays 20. The number N of detector element arrays 20 is equal to the number N of positions, e.g. N=3, that radiation source 11 assumes during scanning of each location of object 12. One of detector element arrays 20 is assigned to each source location, and contains a multiplicity, typically between 20 and 10,000, of linear detector elements arrayed in the plane of source 11 rotation and radially disposed with respect to the source 11 location associated therewith. Thus, a first detector element array 20a is associated with source 11a at the perpendicular location; the elongated linear detector elements 22a thereof are coplanar positioned so as to converge toward the source 11a location. A second linear detector array 20b has a like multiplicity of coplanar, elongated linear detector elements 22b, so positioned as to converge toward the location of source 11b associated therewith. The third detector element array 20c also has a like multiplicity of coplanar, elongated linear detector elements 22c positioned to converge toward the position of the associated radiation source 11clocation. Each linear conductor element 22 of the detector element arrays 20a, 20b and 20c is individually available for connection to processing electronics (not shown). The electrical connection of the element of a particular array to the processing electronics is facilitated, by known means, dependent upon the source being at the source position associated with that particular array. The conversion of radiation quanta to an electronic signal in the high pressure xenon gas, and collection of the resulting electrons by the closest detector element 22, under influence of an electric field provided by high voltage plate 18, is itself known to the art.

Referring now to FIG. 2, each of the detector arrays, e.g. detector array 20a, utilizes a flexible substrate 23, formed of polyimide and the like materials. One surface 23a of the substrate has a conductive layer, as of copper and the like material, fabricated, as by photolithography and the like technique, into the array of detector collector elements 22, each having an integrally joined associated lead 24. A high-conductive coating, of gold and the like, may be used over each of the elements 22. Advantageously, each detector collector element 22 is a 2-milli-inch wide conductive line, with a 1-milli-inch average spacing between lines. Because detector collector elements 22 converge toward the substrate top edge 23b, the spacing increases as the lines progress from top edge 23b toward an imaginary line 23c, parallel to but spaced from edge 23b. The collector elements 22 are positioned with increasing symmetrical angulation about that detector line 22' at the center of array 20a. However, because the detector arrays 20b and 20c are associated with the source being positioned at an angle with respect to the plane normal to the frontal plane of the detector, all of the collector elements 22b and 22c of these arrays will be at some angle to the forward substrate edge 23b of the associated array substrate.

Each of the array substrates includes a plurality of slots 23d, e.g. five slots 23d-1 through 23d-5 illustrated, for a purpose which will beome apparent hereinbelow. The associated collector element leads 24 are so positioned as to pass around slots 23d, requiring that these connecting lines become somewhat narrower in areas defined at the end of slots 23d adjacent to line 23c.

Referring now to all of the Figures, the high pressure gas 17 and the plurality of detector collector element arrays 20, each with an associated high voltage plate 18, are enclosed in housing 16 (FIGS. 3, 4 and 5). The housing comprises a top or front housing member 16a, a middle housing member 16b and a bottom or rear housing member 16c. Front housing member 16a has a substantially rectangular cavity 26 formed therein through a bottom surface 16a-1; the cavity has substantially planar and substantially parallel side and end walls 26a and 26c, respectively, and a concave bottom 26b. The front surface 16a-2 of top member 16a has a portion 28 thereof fabricated with convex curvature, whereby a rectangular elongated portion 16a-2a of the top member is of substantially constant thickness and forms a radiation "window". Window portion 16a-2a is bowed outwardly to facilitate containment of the high pressure radiation-conversion medium, typically xenon gas, contained within detector 14 at a pressure on the order of 80 atmospheres. The relatively thick side and end portions 26a-3 and 26a-4, respectively, of member 16a have threaded apertures 30 tapped partially therethrough (FIGS. 3 and 4a) from bottom surface 16a-1.

Middle housing member 16b and lower housing member 16c are of the same substantially rectangular shape as top housing member 16a. Each of members 16b and 16c has a plurality of apertures 32 in the relatively thick side wall and end wall portions 16b-1, 16b-2, 16c-1 and 16c-2 thereof, of number and position located for passage of fastening means 34, such as a bolt and the like, therethrough and into tapped holes 30.

The elongated detector collector element arrays 20 extend along the length of the cavity 26 fabricated into top member 16a. The lead portion 24a of each flexible detector assembly board must be brought out of the high-pressure detector cavity 26 through member surface 16a-1 and middle member 16b. However, because of the magnitude of pressure contained within cavity 26, the least disruption of middle member 16b, by passage of lead portions 24a, is desired. A series of coplanar, separated thin slots 36 are fabricated through the thickness of middle housing member 16b, from the forward surface 16b-3 to the rear surface 16b-4 thereof (FIG. 4). A plurality of remaining longitudinal strips 38, in between the plane of each of the plurality of detector arrays, and a plurality of remaining cross-wise portions 40 thus form a stiffening web enhancing the resistance of the housing to the high-pressure gas contained within cavity 26; bottom member 16c further stiffens middle member 16b. A pressure gasket 42 is provided in a channel 44 fabricated into the upper surface 16b-3 of middle housing member 16b, about the area in which the plurality of elonged apertures 36 is contained. Groove 44, and sealing means 42 contained therein (FIG.-3), is so positioned as to be outward of the periphery of cavity 26, whereby seal means 42 can be compressed by the rear surface 16a-1 of the front housing member 16a. The lead portion 24a of each of the collector element arrays 20 pass through an associated line of slots 36, with array slots 23d being positioned to provide clearance at the location of web cross members 40. Advantageously, as shown in FIG. 3, slots 36 have a tapering cross section, being somewhat narrower at middle housing member rear surface 16b-4 than at middle housing member front surface 16b-3.

In a presently preferred embodiment, in which three detector arrays 20a-20c are utilized, a separate high voltage plate 18a-18c is associated with each array 20 (FIG. 3). The high voltage plate is attached to the flexible array substrate by suitable insulating means 45, such as nylon bolts, nuts and other hardware (FIG. 5a). A portion of the array substrate rear surface 23e (FIG. 2) has a conductive strip 48 fabricated thereon, of graphite and the like material, opposite only that portion of the substrate having detector collector lines 22, i.e. from top edge 23b to imaginary line 23c. The conductive strips are maintained at ground potential, to establish the detector electric field in conjunction with the associated one of voltage plates 18.

Each collector subassembly (of the relatively rigid voltage plate 18, insulatively fastened to and spaced from the detector-element-bearing surface 23a of a detector substrate 23, having a conductive strip 48 upon the opposite surface 23e thereof) is positioned within cavity 26 (FIG. 5a). The voltage plates 18 are fabricated of a length slightly less than the length of cavity 26; the voltage plate ends are fastened to the cavity end walls 26c by suitable insulative fastening means 49, such as deposits of insulative epoxy and the like, with the detector array 20 planes substantially parallel to one another and to cavity side walls 26a. The conductive backing members 48 are connected together and to the conductive cavity wall by leads 50 (FIG. 3). The voltage plates 18 of the plurality of detector subassemblies are connected together by leads 52; a voltage input lead 54 is extended from a plate, e.g. 18b, closest to one of cavity side walls 26a. Middle housing member 16b includes an aperture 56 (FIGS. 3 and 4c) having an upper entrance point 56a at upper surface 16b-3 which will be within cavity 26, and an exit point 56b at the side of middle housing member 16b. High voltage lead 54 is carried through middle housing member side wall 16b-1 in aperture 56, while the detector array lead portions 24a are carried through middle housing member slots 36. Once the high voltage lead 54 has been positioned in aperture 56 and lead portions 24 have been positioned in slots 36, an insulative material 58, such as an epoxy and the like, is forced into slots 36 and aperture 54 to backfill the openings through middle member 16b and provide a pressure-tight seal thereat.

The middle housing member bottom surface 16b-4 is provided with a set of relief portions 64, aligned with slots 36 and extending at right angles thereto, and leaving buttress portions 65 therebetween. Lower housing member 16c is provided with a set of grooves 66 in registration with an edge of relief portions 64 and slots 36, whereby the remaining array lead portions 24a-1 through 24a-6 can be bent and brought out through the sides of housing assembly 14, when lower housing member 16c is fastened to middle housing member 16b. Because lead portions 24a cannot be bent at an abrupt right angle, grooves 66 are provided to allow a sufficient bending radius to be utilized. Remaining lead portions 24a-1 through 24a-6 thus emerge from the side surfaces 14-1 and 14-2 of the detector assembly (FIG. 5). The forward surface of bottom member 16c abuts against the buttress portions of member 16b to provide additional mechanical strength thereto.

After assembling the detector collector arrays into cavity 26 and sealing array lead portions 24a and lead 54 in slots 36 and aperture 56, respectively, the middle member 16b is fastened against top member 16a by fastening means 34' passing through those apertures 32' located in recesses 64. Recessed clearance portions 67 allow the fasteners to be recessed to clear array lead portions 24a-1 and 24a-6, when the lead portions are bent over into recesses 64. The bottom member is now fastened to the remainder of the housing with the remainder of fastening means 34 (those passing through apertures 32 in the middle member buttress portions 65). A suitable pressurizing-media inlet means 68 is fabricated to one wall, e.g. end wall 16a-4, of the top housing member and operates to seal a medium-inlet aperture 69 formed through the wall of the member. After utilizing means 68 to introduce a pressurized testing medium through aperture 69, the pressure-tested assembly is evacuated and the xenon detection gas introduced to a pressure of about 1200 psi (80 atmospheres). Means 68 is thereafter operated to seal aperture 69 and retain the detection medium under pressure within the housing.

It will be seen that deflection of the detector housing 16 is greatly reduced by means of the stiffening action of lower housing member 16c and by the relatively short lengths of slots 36 in conjunction with the supporting web of portions 38 and 40 formed thereby.

While one presently preferred embodiment of our novel radiation detector is described herein, many modifications and variations will now become apparent to those skilled in the art. It is our intent, therefore, to be limited only by the scope of the appending claims and not by the particular details and instrumentalities presented by way of illustrative example herein.