WO2000021096A9

WO2000021096A9 - Beam hardening filter for x-ray source

Info

Publication number: WO2000021096A9
Application number: PCT/US1999/022800
Authority: WO
Inventors: Edward G Solomon; Giovanni Pastrone
Original assignee: Cardiac Mariners Inc
Priority date: 1998-10-06
Filing date: 1999-09-30
Publication date: 2000-08-24
Also published as: JP2003517577A; IL142370A0; WO2000021096A1; AU6504699A; EP1119864A1

Abstract

An x-ray beam hardening filter (100) is disclosed. The X-ray beam hardening filter (100) comprises a support member (110) and a beam hardening sheet (120), the beam hardening sheet (120) having a multidimensional array of regularly spaced apertures (130). The apertures (130) are configured to have an x-ray transmissive quality. An actuator (300), engaging the support member (110), is capable of moving the multidimensional array of apertures (130) into or out of a path of an X-ray beam, thereby selectively introducing varying levels of X-ray energy filtration. In one embodiment, multiple layers of beam hardening sheets (610, 620) are added to the X-ray beam hardening filter (100) to create additional levels of X-ray energy filtration. Advantages of the X-ray beam hardening filter (100) include the relatively small distance the X-ray beam hardening filter (100) must move in order to absorb the incident X-ray beam, the ability to introduce varying levels of X-ray filtration, and the compact structure of the X-ray beam hardening filter (100).

Description

S P E C I F I C A T I O N

BEAM HARDENING FILTER FOR X-RAY SOURCE

BACKGROUND OF THE INVENTION

Field of the Invention

This invention pertains to the field of diagnostic x-ray imaging, and more specifically to x-ray beam hardening filters.

Background

X-ray sources used in medical imaging are typically polychromatic, that is, the x-ray source produces x-ray photons with varying energies. For example, an x-ray source capable of producing a 120 keV photon will typically produce an x-ray beam having a mean energy of only one-third to one-half of the peak energy. Given that the mean energy is roughly one- half to one- third of the peak energy, many of the photons that comprise an x-ray beam will be characterized by energy levels below the mean energy.

A problem with lower energy photons is that they do not contribute to the construction of the radiographic image. Many of the lower energy photons, for example those with energies less than 20 keV, may be absorbed in the object under investigation; these lower energy photons only contribute to harmful patient radiation. Therefore, it is desirable to filter the lower energy x-ray photons from the x-ray beam.

It is known to use filters to remove lower energy photons from the x-ray beam. One form of filtration is inherent filtration. Inherent filtration results from the absorption of x-ray photons as they pass through the x-ray tube and its housing. Such filtration varies with the composition, or lining of the x-ray tube and housing, as well as the length of the x-ray tube and housing. Inherent filtration, which is measured in aluminum equivalents, typically varies between 0.5 and 1.0 mm aluminum equivalent.

A second form of filtration is added filtration. Added filtration is achieved by placing an x-ray attenuator or filter in the path of the x-ray beam. Most materials have the property of attenuating the lower energy photons more strongly than higher energy photons. When lower energy x-ray beams strike the added filter they are absorbed. By adding a filter to the x-ray beam path, lower energy x-ray photons can be absorbed, thereby reducing the unnecessary radiation created by the lower energy x-ray photons. Because the lower energy x-ray photons are preferentially removed from the x-ray beam, the mean energy of the x-ray beam is increased. Increasing the mean energy of the x-ray beam is referred to as "hardening" of the x-ray beam.

Objects to be x-rayed vary in thickness and composition. Thus, it is desirable to control the amount of filtration that occurs. Some x-ray systems, having a relatively small diameter x-ray source, often use a filter consisting of a thin sheet of aluminum or aluminum and copper. The filter is placed in the path of the x-ray beam, either manually or by an electro-mechanical actuator. Because of the small diameter of the x-ray source, the filter and filter control mechanism can be made compact.

However, when a large-area x-ray source (e.g., having a diameter of approximately 25 cm or larger) is used in an x-ray imaging system and if added filtration is used, the beam hardening filter inserted into the path of the x-ray beam would be as large as the overall x-ray source in order to cover the entire source. Furthermore, the mechanical travel of the filter to insert it into the path of the x-ray beam would also be about the same as the size of the x-ray source (e.g., 25 cm) or the filter. Using a conventional x-ray hardening filter, for example one that slides in a parallel plane to the surface of the x-ray source, on a large-area x-ray source would involve a large mechanical actuator assembly and would add undesirable bulk to the x-ray imaging system.

Thus, an object of the invention is to provide an improved beam hardening filter for an x-ray source to address these problems with conventional beam hardening filters.

SUMMARY OF THE INVENTION The present invention comprises an x-ray beam hardening filter for use with a scanning beam x-ray source wherein the movement of the filter between a position in the x- ray beams to a position outside the x-ray beams is less than either the size of the filter or the x-ray source area. According to one aspect of the invention, the x-ray beam hardening filter comprises a beam hardening sheet and an actuator. The beam hardening sheet has a first x- ray absorption quality and comprises a plurality of areas, the plurality of areas having a second x-ray absorption quality. The actuator is configured to move the beam hardening sheet into or out of the path of the x-ray beams such that the beam hardening sheet absorbs x- ray radiation according to the first or the second x-ray absorption quality.

According to another embodiment, a highly adjustable x-ray beam hardening filter is provided comprising more than one beam hardening sheet. Each beam hardening sheet has an array of areas, the array of areas having different x-ray absorption qualities. In such an embodiment, multiple levels of x-ray absorption and beam hardening are possible.

According to another embodiment, a method for hardening an x-ray beam is disclosed. The method comprises the acts of intercepting an x-ray beam with an x-ray beam hardening filter, the x-ray beam hardening filter having a first x-ray absorption quality and an array of areas having a second x-ray absorption quality, and moving the x-ray beam hardening filter a minimal distance.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:

FIG. 1 depicts the x-ray beam hardening filter according to one embodiment of the present invention;

FIGS. 2A-B depict side and bottom views, respectively, of a motor used according to a preferred embodiment of the invention;

FIGS. 3A-C depict side and top views of the motor with a position sensor according to a preferred embodiment of the invention;

FIGS. 4A-B depict a top and a side view, respectively, of a cam bearing according to a preferred embodiment of the invention;

FIGS. 5A-C depict a bottom, top and side view, respectively, of a cam-filter control according to a preferred embodiment of the invention;

FIG. 6 depicts a cross-sectional view of a collimator and an x-ray beam hardening filter according to one embodiment of the invention;

FIG. 7 depicts a cross-sectional view of a collimator and an x-ray beam hardening filter with a support pin according to a preferred embodiment of the invention.

FIG. 8 depicts an x-ray beam hardening filter;

FIG. 9 depicts a support member for an x-ray beam hardening filter;

FIG. 10A is a detail schematic of a top portion of a support member; FIG. 1 OB is a detail schematic of a bottom portion of a support member; FIG. IOC is a detail schematic of a side portion of a support member; and FIG. 11 is cross-sectional view of a collimator assembly having an x-ray beam hardening filter according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 depicts a top view of a x-ray beam hardening filter 100 according to an embodiment of the present invention. (As used herein, "top" and "bottom" are used only for purposes of illustration.) The x-ray beam hardening filter 100 preferably comprises a support member 110, a beam hardening sheet 120, and an actuator.

The support member 110 is preferably a stainless steel structure that has a washer-like shape. The support member 110 comprises one or more direction guides 170. According to one embodiment, two direction guides 170 are carved or etched into support member 110 at opposing sides. Preferably, the direction guides 170 facilitate alignment of the x-ray beam hardening filter 100 over a collimator, as well as directing the movement of x-ray beam hardening filter 100 in a straight path. However, according to an alternative embodiment, the direction guides 170 can be replaced by a single pin from which the x-ray support member 110 can pivot as it is moved at an opposing end.

The beam hardening sheet 120 is attached to the support member 110. The beam hardening sheet 120 is preferably composed of copper (Cu) and beryllium (Be). The copper is configured to absorb lower energy x-ray radiation, whereas the beryllium is added to increase the structural rigidity of the x-ray beam hardening filter 100. The actual ratio of the elements of the beam hardening sheet 120 can vary between x-ray imaging applications and objects to be imaged.

The beam hardening sheet 120 contains a plurality of coterminously arranged areas of varying x-ray absorption. The areas of varying x-ray absoφtion are disposed about an active area of the beam hardening sheet, that is, they are arranged in the areas where an x-ray beam is likely to be dwelled. Some of the plurality of coterminously arranged areas are configured to absorb a significant energy level from a polychromatic x-ray beam, such as 10 keV, whereas others are configured to absorb little to no x-ray energy from the polychromatic x- ray beam. These higher and lower levels of x-ray absoφtion are arranged in regular intervals about a surface area of the beam hardening sheet 120. According to a preferred embodiment, an arrangement of varying levels of x-ray radiation is accomplished via a multidimensional array of apertures 130 which are disposed about the surface area of the beam hardening sheet 120. The array of apertures 130 are chemically etched into the surface of the beam hardening sheet 120 at regularly spaced intervals with a hole pitch of A_p. Each aperture 130 has a diameter A_d- Each aperture 130 is preferably no closer than to any other aperture than a distance approximately equal to diameter A The apertures 130 are configured to allow x-ray photons to freely pass through them, whereas other areas of the beam hardening sheet 120 (that is, without apertures 130) are configured to absorb some of the x-ray photons incident thereon.

The beam hardening sheet 120 is bonded to the support member 110 with a brazing paste after aligning the apertures 130 within the support member 110, the movement of the actuator, and the collimator.

The support member 110 comprises a receiver. According to one embodiment, the receiver is a rectangular aperture 160. Within rectangular aperture 160, a cam 140, having a diameter , is at least partially enclosed. The cam 140 rotates within rectangular aperture 160 based upon external control of a motor (not shown). The cam 140 is mounted to a cam shaft (not shown) at a rotation location 150. The rotation location 150 is offset from a center point of the rectangular aperture 160 a distance approximately equal to one-quarter of the aperture 130 pitch A_p. The rectangular aperture 160, it may be noted, has a major axis with a length of approximately twice the distance between the rotation location 150 and an outer most point on cam 140, and a minor axis approximately equal to the cam 140 diameter .

As engagement mechanism is moved by the actuator (cam 140 is rotated by the motor), pressure is applied to the edge of the receiver (e.g., rectangular aperture 160). As pressure is applied, the support member 110 moves, in a path defined by direction guides 170, in a straight line. Since the beam hardening sheet 120 is attached to the support member, it also moves, thereby causing the apertures 130 to be placed either into or out of the path of x-ray beams which are passing through collimator apertures (described in further detail with reference to FIG. 6.)

When the apertures 130 are aligned with collimator apertures, the x-ray beams pass through beam hardening filter 100 with little to no x-ray absoφtion. However, when the apertures are not in the path of the polychromatic x-ray beam, for example, when the areas between adjacent apertures 130 are aligned with the collimator apertures, then x-ray radiation is absorbed by the beam hardening sheet 120.

FIG. 2 A depicts a side view of an electrical motor 200 employed as a part of the actuator. Preferably, the motor comprises a winding (not shown), housed in a motor block 210, the winding centered about a cam shaft 220. Terminals 230 receive two power cables. FIG. 2B depicts a bottom view of the motor 200, which also shows the terminals 230. According to one embodiment, the motor 200 has the following electrical and mechanical characteristics: 4.5 V, 170 mA, 205 mW, rated torque 500 g cm, 40 φm, and a gear ratio of 1:298. A suitable motor meeting these characteristics is Copal Coφoration model no. LA12G-344, which can be obtained through distributor PEI Sales Assoc. of Cupertino, California.

FIGS. 3A-C depict an actuator 300. Referring to FIG. 3A, mounting block 360 supports the motor housing 210 and is used to attach the motor housing 210 to the collimator. Furthermore, a position plate 310 rests at a base portion of cam shaft 220 (described in further detail with reference to FIGS. 4A-B). The position plate 310 will be described in further detail below and with reference to FIGS. 5A-C. Power cables 320 are shown attached to electrical terminals 230. Attached at an end of power cables 320 is a two prong male connector 330.

FIG. 3B depicts a top view of the actuator 300. Rivets 350 are used to connect the mounting block 360 to the collimator.

Also shown in FIG. 3B and 3C are position sensors 340. The sensors 340 are preferably electro-optical sensors. As the cam shaft 220 rotates, so too does the position plate 310.

According to a preferred embodiment, the position plate 310 is configured to alternatively cover the two sensors 340. Because of the shape of the sense plate and the rotation of the cam shaft 220, the approximate position of the apertures 130 relative to the collimator apertures can be known. For example, when a the position plate 310 covers only a first sensor, the x-ray beam hardening filter 100 is set in absoφtion mode, however, when only a second sensor is covered by the position plate 310, then the x-ray beam hardening filter 100 is set in a non-absoφtion mode (or a less absorbing mode). When both sensors 340 are simultaneously covered or uncovered, then the x-ray beam hardening filter 100 is in an intermediate phase between an absorbing and a non-absorbing mode.

FIG. 4A depicts a top view of a cam bearing 400. The cam bearing 400 has an outer diameter (CBO_d) 402 and an inner diameter (CBId) 404. According to one embodiment, the outer diameter 402 is larger than the minor axis of the rectangular aperture 160, whereas the inner diameter 404 is smaller than the minor axis of the rectangular aperture 160.

FIG. 4B depicts a side view of the cam bearing 400. Viewed from the side, cam bearing 400 essentially comprises three washer-shaped body parts 410, 420 and 430. Part 410 has is relatively thin (e.g., 0.010 inches), whereas parts 420 and 430 are relatively thick (e.g., 0.040 inches). Part 420 is configured to be at least thick enough such that support member 110 can slide between parts 410 and 430. In such an embodiment, the rectangular aperture 160 is modified to have not only the rectangular aperture 160 described above, but also a bulbous end extending from one side, the bulbous end creating an opening at least sufficiently large to pass the outer diameter (CBO_d) 402 through it. The rectangular aperture 160 has a minor axis approximately equal to the diameter of part 420, but smaller than the diameter (CBO_d) 402. Accordingly, the support member 110 is capable of dropping over the cam bearing 400 so that the bulbous end surrounds the cam bearing 400. The support member 110 is then slid from the bulbous end and toward the rectangular aperture 160 until it comes to rest within the cavity created by parts 410, 420 and 430. Alignment of the support member 110 is finalized with direction guides 170.

FIGS. 5A-C depict a cam-filter control 500. The cam-filter control 500 comprises a cam 530 and a position plate 510. An inner diameter 520 of the cam-filter control 500 is configured to slide over the cam shaft 220. Furthermore, the cam 530 and the position plate 510 are attached together such that the outermost point 532 (relative to rotation location 150) on the cam 530 is aligned to a point approximately 10° clockwise of the midpoint of the outer diameter of the position plate 510. The position plate 510 is substantially similar to the position plate 310, described above, the primary difference being it is secured to the cam 530 to form the cam-filter control 500.

As the cam shaft 220 rotates, the cam-filter control 500 does too. As the cam-filter control 500 rotates, the position plate 510 rotates over sensors 340. Additionally, the cam 530, through cam bearing 400, applies a force to the support member 110, which in turn moves the x-ray beam hardening filter 100 such that the apertures 130 are moved into or out of the path of the polychromatic x-ray beam.

FIG. 6 depicts a cross-sectional view of the x-ray beam hardening filter 600, together with a collimator 660 and a cover 650. The collimator 660 and the cover 650 are tied o

together with posts 680.

The cover 650 preferably comprises an x-ray transmissive material. The collimator 660 comprises of a material that is not x-ray transmissive. The collimator 660 further comprises an array of collimator apertures 662 through which x-rays (e.g., 604) can pass. Areas of the collimator through which incident x-rays can pass are said to be illumination areas, whereas areas where an incident x-ray beam cannot pass are called non-illumination areas. In the broader spirit of the invention, the collimator and x-ray beam hardening filter are part of an x-ray target assembly.

Mounted to collimator 660 are motors 631 and 632. The motors 631 and 632 are attached to the collimator 660 via mounting blocks (e.g., mounting blocks 360). The cam bearings 641 and 642 slip over the cam-filter controls 646 and 647, respectively, and lock into place (e.g., with locking pins or rings). In one embodiment, the cover 650 comprises a cooling element.

The x-ray beam hardening filter 600 comprises two independent beam hardening sheets 610 and 620. However, according to another embodiment, the x-ray beam hardening filter 600 comprises multiple filters substantially similar to the x-ray beam hardening filter 100 as depicted in FIG. 1. The cam bearing 641 engages first beam hardening sheet 610. The cam bearing 641 is rotated by the motor 631. The cam bearing 642 engages second beam hardening sheet 620. The cam bearing 642 is rotated by the motor 632. Together, the motor, the cam shaft, the cam-filter control, the cam and, the cam bearing form an actuator. However, in other embodiments, more or less parts can comprise the actuator, so long as the actuator is still configured to move a portion of the x-ray beam hardening filter 600.

If n beam hardening sheets are used in the x-ray beam hardening filter 600, then one or more actuators are preferably capable of moving the beam hardening sheets (e.g., 610 and 620) in 2" different positions. For example, if four beam hardening sheets are employed, as many as four actuators can be used and 2⁴ (16) different positions of the four beam hardening sheets are possible. Different configurations of the actuators can accomplish such a positioning either by varying the cam shape or, simply by individually controlling each motor and cam.

Depending on the actuator configuration, as well as the collimator 660 configuration, notches and additional apertures may be cut into each successive layer of the x-ray beam hardening filter 600 so that movement of any layer is not physically constricted by another layer, or some other physical obstruction (e.g., a head of a rivet or bolt protruding through the top surface of collimator 660.)

Note that in FIG. 6, that beam hardening sheet 620 is slightly askew; that is, beam hardening sheet 620 is shifted to left in the figure relative to a fixed location, for example the collimator 660. When polychromatic x-ray beam 602 is incident upon beam hardening area 672, then a portion of the polychromatic x-ray beam 602 is absorbed by the beam hardening filter 620. The polychromatic x-ray beam passes through beam hardening sheet 620, then it passes through aperture 674 of beam hardening sheet 610, and finally it passes through the collimator aperture 662 — as filtered polychromatic x-ray beam 604.

If beam hardening sheet 620 is shift right and beam hardening sheet 610 is shifted left, then polychromatic x-ray beam 602 is instead received at aperture 670. As the x-ray beam 602 passes through beam hardening sheet 620, it is received by beam hardening sheet 610, which is operating in absoφtion mode, at beam hardening area 676. Beam hardening area 676 absorbs a portion of the polychromatic x-ray beam 602 and the resulting beam is passed through collimator aperture 662 and exits collimator 660 as filtered polychromatic x-ray beam 604.

Based upon the mode of the beam hardening sheets 610 and 620 (e.g., absorbing or non-absorbing) the x-ray beam hardening filter 600 can absorb varying amounts of x-ray radiation from the incident x-ray beam 602.

Accordingly, the apertures 130 are configured to have a low x-ray transmissivity such that most, if not all of the x-ray photons incident on the aperture 130 pass through it.

According to a preferred embodiment, beam hardening sheet 610 absorbs twice the x- ray energy of beam hardening sheet 620. Doubling the absoφtion quality of each successive beam hardening sheet added to the filter, while employing actuators capable of 2" positioning gives a high degree of control and selectivity of the x-ray beam hardening filter 600.

Alternatively, multiple beam hardening sheets employed in the x-ray beam filter can have the same x-ray absoφtion quality, which provides fewer distinct amounts of x-ray absoφtion of the overall x-ray beam hardening filter 600.

FIG. 7 depicts a cross-sectional view of a collimator assembly incoφorating an x-ray beam hardening filter 600. FIG. 7 depicts many of the same elements as FIG. 6, with like numerals referring to like elements. Added in FIG. 7 is detail pertaining to the collimator 660 and overall assembly of the x-ray beam hardening filter 600 with the collimator 660. Collimator 660 comprises a plurality of collimator sheets 740 stacked one on top of the other. The collimator sheets 740 build up to a divider sheet 745, which provides structural support for the plurality of collimator sheets 740. On top of the divider sheet 745 are a plurality of trimmed collimator sheets 730, which simply create a void for the actuator components (e.g., motor 631 and cam-filter control 646).

A support pin 700 ties the collimator 660 and the collimator cover 650 together. The support pin 700 is located outside of the outer edge of the support member (e.g., support member 110) so that it will not obstruct movement of the beam hardening sheets. According to one embodiment, the outer edge of the support member comprises notches which prevent the beam hardening filter and the support pin 700 from colliding. In a preferred embodiment of the present invention, the collimator utilizes more than one support pin 700.

The support pin 700 further comprises a spacer 710, which allows pressure to be applied to the outer surfaces of the collimator assembly without increasing the friction on the beam hardening sheets (e.g., beam hardening sheets 610 and 620).

A unique feature of the present invention is that a minimum amount of movement is required to cause the x-ray beam hardening filter to intercept a polychromatic x-ray beam. In an x-ray system having a large area x-ray source (e.g., 25 cm), the x-ray beam hardening filters disclosed in the description and accompanying drawings is highly advantageous; it minimizes space compared to traditional beam hardening filters while providing a high degree of flexibility in the amount of x-ray radiation the beam hardening filter absorbs. The x-ray beam hardening filter does not need to be moved a distance as great as the diameter of the x-ray source to fully enable the x-ray beam hardening filter. Rather, the x-ray beam hardening filter can be moved a distance substantially less than the diameter of the x-ray source and accomplish the same end.

METHOD OF MAKING X-RAY BEAM HARDENING FILTER AND ASSEMBLY FIG. 8 depicts a construction of an x-ray beam hardening filter 1100. The x-ray beam hardening filter 1100 comprises a filter plate or "support member" 1110, as it is referred to herein, and a sheet having a beam hardening quality. As used herein, the sheet having a beam hardening quality is referred to as a "beam hardening sheet" 1120. The beam hardening sheet 1120 preferably comprises a plurality of pits. The areas of the beam hardening sheet without pits are configured to cause certain energy levels of x-ray radiation from a polychromatic x- ray beam incident thereon to be absorbed (or filtered), whereas the plurality of pits are configured to not to filter the x-ray radiation. The x-ray beam hardening filter 1100 therefore is capable of shaping the energy spectrum envelope of the polychromatic x-ray beam such that certain energy levels of harmful radiation are selectively removed.

The support member 1110 is preferably manufactured from stainless steel. Furthermore, the support member 1110 is initially larger than washer-shaped article depicted in FIG. 8, for it includes an etching plate 1140, which can be removed after bonding a beam hardening sheet 1120 to the support member 1110, or, later still, after aligning the x-ray beam hardening filter 1100 to a collimator assembly.

The outer diameter of the relevant portion of the support member 1110 is approximately 10.27 inches, while the inner diameter of the support member 1110 is approximately 9.800 inches. The upper and lower portions of the support member 1110, that is bottom portion 1150 and top portion 1160, have a flattened edge 1112 extending inward from the outer diameter to a distance 4.512 inches from the x-centerline 1102. The side portion 1155 also has a flattened portion 1112 which extends inward from the outer diameter to a distance of 4.512 inches from the y-centerline 1104.

The outer edge of the support member 1110 is defined by a number of connector openings 1180 that permit unobstructed movement of the x-ray beam hardening filter 1100 within (or over) a collimator (described in greater detail below with reference to FIG. 10B). Both the top and bottom edges, 1160 and 1150, of the support member 1110 comprise direction guides 1192 which guide the motion of the support member in straight path. The direction guides 1192 have a width of 0.110 inches.

A receiver, or an "actuator aperture" 1194, as it is referred to herein, is formed on the top edge 1160 of the support member 1110. The actuator aperture 1194 surrounds an actuator (not shown) which provides a force to move that support member 1110 in the straight path defined by direction guides 1192. The bottom edge 1150 of the support member 1110 does not have an actuator aperture 1194. The bottom edge 1150 instead has a rectangular shaped opening 1152. Within the rectangular shaped opening 1152 is a break away alignment tab 1154. Two additional alignment tabs 1154 are also depicted in FIG. 8.

FIG. 9 depicts the support member 1110 without the beam hardening sheet 1120.

FIG. 10A depicts the top edge 1160 of the support member 1110, and FIG. 10B depicts the bottom edge 1150 of the same. Actuator aperture 1194 and alignment slot 1172 are depicted in the top edge 1160. Alignment slot 1172 is 0.110 (±0.002) circular mils. It is preferred that the alignment slot 1172 is within 0.002 inches of the true position of the apertures 1156 in the break away tabs 1154. The actuator aperture 1194 preferably has a generally rectangular shape with a height of approximately 0.220 inches, a width of approximately 0.695 inches, and rounded corners with a radius of approximately 0.046 inches. At approximately 0.520 inches from the left side of the rectangle (as depicted in FIG. 10A), near both the top and bottom edges of the rectangle, two circular extensions are carved from the actuator aperture 1194. The radius of the two circular extensions is 0.175 inches. The actuator aperture 1194 can vary in size and shape, however, it is important that it still allow for movement of an actuator therein, the actuator used to move the beam hardening filter 1100 into or out of the path of a polychromatic x-ray beam.

FIG. 10B depicts the bottom edge 1150 of the support member 1110. The rectangular ledge 1152 carved from the support member 1110 is begins approximately 0.338 inches from left of the y-centerline 1104 and down approximately 4.623 inches from the intersection of the x- and y-centerlines 1102 and 1104. An alignment tab 1154 connects to two sides of the ledge 1152. The alignment tab 1154 is configured to break away from the support member 1110. An alignment aperture 1156, measuring 0.047 circular mils, is located on the alignment tab 1154. Similar alignment apertures 1156 are located on the left and right side of the support member 1110 on the x- and y-centerlines 1102 and 1104.

FIG. 10C depicts a break away tab 1154 and alignment aperture 1156 which is located on the right side 1155 of the support member 1110. The break away tab 1154 has a radius of 0.100 inches, which is the same as the radius of the alignment tab 1154 depicted with reference to FIG. 10B. Again, an alignment aperture 1156 is located at the center point of the alignment tab 1154.

Returning again to FIG. 8, according to an embodiment, a method for making the x- ray beam hardening filter comprises the steps described below. First, a plurality of areas having a different x-ray absoφtion quality than the beam hardening sheet 1120 are chemically etched into the surface of the beryllium (Be) and copper (Cu) beam hardening sheet 1120. The result of the etching is a plurality of pits 1130 that are regularly spaced about the surface area of the beam hardening sheet 1120.

The pits 1130 are preferably 0.036 (±0.002) circular mils, and are spaced and shaped according to the parameters defined in Table 1. Furthermore, the pits 1130 are symmetrical with the x- and y- centerlines 1102 and 1104 respectively, with a center of a single pit placed at the intersection of the centerlines 1102 and 1104. Thus, according to a preferred embodiment, the plurality of pits form a multidimensional array of uniformly sized and spaced pits in the surface area of the beam hardening sheet 1120.

Table 1: Beam Hardening Filter Pit Spacing (inches & circular mils)

An advantage of the present invention is that when uniformly spaced and sized pits 1130 are employed, and they are spaced according to Table 1 above, then the movement of the beam hardening sheet need only be a distance approximately equal to one-half the hole pitch, or the spacing between two adjacent pits in the beam hardening sheet. In other embodiments, movement of the beam hardening sheet 1120 may follow a curved path and the movement can be restricted to approximately three times the distance between two adjacent areas of equal x-ray absoφtion. This unique feature allows for a minimal amount of movement of the beam hardening sheet 1120 to vary the x-ray absoφtion quality of the beam hardening filter 1100.

In the next step, the support member 1110 and the beam hardening sheet 1120 are aligned. The alignment is accomplished with the aid of one or more alignment elements. In a preferred embodiment, the beam hardening sheet 1120 is first placed on a surface (e.g., a jig) and support member 1110 is placed over it. The beam hardening sheet 1120 and the support member are aligned to a reference position, namely the alignment slots 1170 (having a diameter of 0.125 inches) which are formed into the etching blank 1140 and the beam hardening sheet 1120.

Once the beam hardening sheet 1120 and the support member 1110 are aligned, they are bonded together. The bonding step comprises applying a 95% tin and a 5% silver brazing paste between the top of the beam hardening sheet 1120 and the bottom of the support member 1110, followed by heating the brazing paste to approximately 480 F in a hydrogen atmosphere. Preferably, none of the solder overlaps any of the pits 1130. To accomplish this, the brazing paste may be blown from the active area of the sheet before the step of heating with a fan. Furthermore, the beam hardening sheet 1120 and support member 1110 are clamped together to prevent movement which may cause misalignment before the step of bonding.

It is important not to overheat the brazing paste, and consequently the x-ray beam hardening filter, because there is a chance it will waφ. Furthermore, the heating step is preferably performed in a furnace.

According to one embodiment, the x-ray beam hardening filter 1100 components (e.g., beam hardening sheet 1120 and support member 1110) are electroplated before the step of bonding.

Now that the beam hardening sheet 120 has been bonded to the support member 1110, another alignment step is performed. Referring to FIG. 11, the x-ray beam hardening filter 1100 is placed over a collimator 1404 such that the pits 1130 align with collimator apertures 1436 in the collimator 1404. The alignment is facilitated again by alignment slots 1170, which can be placed over a jig or alignment pins, alignment slots 1172, through which an alignment pin 1408 can pass, as well as with the aid of alignment apertures 1156 in alignment tabs 1154.

Once the pits 1130 are aligned, the direction guides 1192 are reamed to their preferred size. A final inspection is made of the alignment of the pits 1130 with the collimator apertures 1436. If alignment is confirmed, then the alignment slots 1172 are machined and the etching blank 1140 and alignment tabs 1154 are removed from the support member 1110.

The x-ray beam hardening filter 1100 can then be removed from the collimator 1404. Burs are preferably ground from the edges of the support member 1110. A lubricant is applied to the surfaces of the finished x-ray beam hardening filter 1100. According to one embodiment, a dry film lubricant is used. A presently preferred dry film lubricant is Dicronite® made by Dricronite® Dry Lube Northwest, and which is available from CLS, Inc, in Santa Clara, California.

Turning again to FIG. 11, one or more x-ray beam hardening filters 1416 are placed within a collimator assembly 1400. Mounting pins 1412 tie the collimator 1404 to the collimator cover 1432. Spacers, e.g., spacer 1428, create a void between the collimator 1404 and the collimator cover 1432 in which the one or more beam hardening filters 1416 can move, aided by an actuator 1420 having a cam bearing 1424, while pressure is maintained around the collimator cover 1432 and collimator 1404. In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will be evident, however, that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative, rather than a restrictive sense.

Claims

loCLAIMSWhat is claimed is:

1. An x-ray beam hardening filter comprising: a beam hardening sheet, said beam hardening sheet having a first x-ray absoφtion quality, said beam hardening sheet comprising a plurality of areas having a second x-ray absoφtion quality, said beam hardening sheet have a thickness and a smallest additional dimension wherein said smallest additional dimension is not said thickness; and an actuator configured to move said beam hardening sheet a distance no greater than said smallest additional dimension of said beam hardening sheet.

2. The x-ray beam hardening filter of claim 1 wherein said plurality of areas having said second x-ray absoφtion quality comprises an array of areas.

3. The x-ray beam hardening filter of Claim 2 comprising two or more of said array of areas, said two or more array of said areas forming a multidimensional array of areas having said second x-ray absoφtion quality.

4. The x-ray beam hardening filter of Claim 2, wherein movement of said array of areas relative to a fixed location is not greater than a distance of approximately three times a greatest spacing between two adjacent areas of said array.

5. The x-ray beam hardening filter of Claim 1 , wherein said plurality of areas having said second x-ray absoφtion quality comprises a plurality of apertures.

6. The x-ray beam hardening filter of Claim 1 , wherein said plurality of areas having said second x-ray absoφtion quality are evenly distributed about an active area of said beam hardening sheet, and wherein any two adjacent areas of said plurality of areas having said second x-ray absoφtion quality are separated by a distance not less than the distance across any single area of said plurality of areas having said second x-ray absoφtion quality.

7. The x-ray beam hardening filter of Claim 1, further comprising at least one more beam hardening sheet, said at least one more beam hardening sheet formed of a material having a third x-ray absoφtion quality, said at least one more beam hardening sheet comprising a second plurality of areas, said second plurality of areas of said one more beam hardening sheet having a fourth x-ray absoφtion quality.

8. The x-ray beam hardening filter of Claim 7, in which said at least one more beam hardening sheet is adjacent to said beam hardening sheet.

9. The x-ray beam hardening filter of Claim 8, in which said beam hardening sheet is in a first position, said at least one more beam hardening sheet may be either in said first or in a second position.

10. The x-ray beam hardening filter of claim 1 in which said actuator comprises an engagement mechanism, said engagement mechanism engaging said beam hardening sheet such that when said actuator is actuated, said engagement mechanism moves said beam hardening sheet between a first position and a second position.

11. The x-ray beam hardening filter of Claim 10, in which said beam hardening sheet further comprises a support member, said support member surrounding an active area, and wherein said engagement mechanism engages said support member.

12. The x-ray beam hardening filter of Claim 10 further comprising a position sensor, said position sensor configured to output signals indicative of whether said beam hardening sheet is in said first position or said second position.

13. The x-ray beam hardening filter of claim 1 further comprising: a collimator, said collimator comprising a plurality of x-ray transmissive areas, said x- ray transmissive areas disposed about said collimator in a first arrangement; said actuator configured to move said beam hardening sheet between a first position and a second position, wherein said plurality of areas are arranged with said plurality of x-ray transmissive areas.

14. The x-ray beam hardening filter of Claim 13 in which said beam hardening sheet comprises a receiver, said receiver having a substantially rectangular shape; and said actuator comprises a cam shaft and a cam bearing attached to said cam shaft at a rotation location, said rotation location offset from a center point of said cam bearing by a distance approximately equal to one-quarter a dimension between two adjacent areas of said plurality of areas.

15. The x-ray beam hardening filter of Claim 13, wherein said x-ray transmissiveness and said plurality of areas are substantially aligned.

16. A method for hardening an x-ray beam comprising: intercepting an x-ray beam with an x-ray beam hardening filter, said x-ray beam hardening filter having a first x-ray absoφtion quality and an array of areas having a second x-ray absoφtion quality; and moving said x-ray beam hardening filter along a path no greater than three times a greatest distance between two adjacent areas in said array of areas.

17. The method of Claim 16, further comprising: inteφosing at least one more beam hardening sheet into said x-ray beam.

18. The method of Claim 16, further comprising: sensing a position of said x-ray beam hardening filter; returning a signal indicative of the position of said x-ray beam hardening filter; and in response to said act of returning said signal indicative of the position, modifying the position of said x-ray beam hardening filter.