WO2015068686A1 - 立体構造物の製造方法、シンチレータパネルの製造方法、立体構造物及びシンチレータパネル - Google Patents
立体構造物の製造方法、シンチレータパネルの製造方法、立体構造物及びシンチレータパネル Download PDFInfo
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- WO2015068686A1 WO2015068686A1 PCT/JP2014/079217 JP2014079217W WO2015068686A1 WO 2015068686 A1 WO2015068686 A1 WO 2015068686A1 JP 2014079217 W JP2014079217 W JP 2014079217W WO 2015068686 A1 WO2015068686 A1 WO 2015068686A1
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- dimensional structure
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- glass powder
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01T—MEASUREMENT OF NUCLEAR OR X-RADIATION
- G01T1/00—Measuring X-radiation, gamma radiation, corpuscular radiation, or cosmic radiation
- G01T1/16—Measuring radiation intensity
- G01T1/20—Measuring radiation intensity with scintillation detectors
- G01T1/2002—Optical details, e.g. reflecting or diffusing layers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01T—MEASUREMENT OF NUCLEAR OR X-RADIATION
- G01T1/00—Measuring X-radiation, gamma radiation, corpuscular radiation, or cosmic radiation
- G01T1/16—Measuring radiation intensity
- G01T1/20—Measuring radiation intensity with scintillation detectors
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/001—General methods for coating; Devices therefor
- C03C17/002—General methods for coating; Devices therefor for flat glass, e.g. float glass
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/02—Surface treatment of glass, not in the form of fibres or filaments, by coating with glass
- C03C17/04—Surface treatment of glass, not in the form of fibres or filaments, by coating with glass by fritting glass powder
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
- C03C8/16—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions with vehicle or suspending agents, e.g. slip
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- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21K—TECHNIQUES FOR HANDLING PARTICLES OR IONISING RADIATION NOT OTHERWISE PROVIDED FOR; IRRADIATION DEVICES; GAMMA RAY OR X-RAY MICROSCOPES
- G21K4/00—Conversion screens for the conversion of the spatial distribution of X-rays or particle radiation into visible images, e.g. fluoroscopic screens
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- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21K—TECHNIQUES FOR HANDLING PARTICLES OR IONISING RADIATION NOT OTHERWISE PROVIDED FOR; IRRADIATION DEVICES; GAMMA RAY OR X-RAY MICROSCOPES
- G21K4/00—Conversion screens for the conversion of the spatial distribution of X-rays or particle radiation into visible images, e.g. fluoroscopic screens
- G21K2004/06—Conversion screens for the conversion of the spatial distribution of X-rays or particle radiation into visible images, e.g. fluoroscopic screens with a phosphor layer
Definitions
- the present invention relates to a method for manufacturing a three-dimensional structure, a method for manufacturing a scintillator panel, a three-dimensional structure, and a scintillator panel.
- X-ray images using films have been widely used in medical practice.
- digital radiation detection such as a computed radiography (CR) or a flat panel X-ray detector (flat panel detector: FPD) is used.
- Equipment has been developed.
- a scintillator panel is used to convert radiation into visible light.
- the scintillator panel includes an X-ray phosphor such as cesium iodide (CsI), and the X-ray phosphor emits visible light in response to the irradiated X-ray, and the light emission is emitted from a TFT (thin film transistor).
- X-ray information is converted into digital image information by converting it into an electrical signal using a CCD (charge-coupled device).
- CCD charge-coupled device
- FPD has a problem that the S / N ratio is low. This is because visible light is scattered by the phosphor itself when the X-ray phosphor emits light. In order to reduce the influence of this light scattering, a method of filling a phosphor in a cell partitioned by a partition has been proposed (Patent Documents 1 to 4).
- the conventional method for manufacturing a scintillator panel using a glass powder-containing paste forms a pattern made of a glass powder-containing paste on a substrate, and then sinters the glass powder by baking to form partition walls. It was necessary to select a highly heat-resistant substrate that does not burn out or undergo large deformation in the process. Furthermore, it is necessary to ensure the strength of the substrate in order to suppress the warpage of the substrate during firing, and it is necessary to use a thick substrate in order to increase the strength.
- the substrate having high heat resistance and high strength include a substrate mainly made of an inorganic material, such as a glass substrate or a ceramic substrate.
- the present invention provides a method for manufacturing a three-dimensional structure, a three-dimensional structure, and a method for manufacturing a scintillator panel, which can arbitrarily select the type and thickness of a substrate of the scintillator panel using the three-dimensional structure.
- An object is to provide a scintillator panel.
- a method for producing a three-dimensional structure comprising: a separation step of separating the post-baking pattern from the substrate to obtain a three-dimensional structure.
- a method for producing a three-dimensional structure comprising: a peeling step of peeling the post-fired pattern and the non-sintered layer from the substrate to obtain a three-dimensional structure.
- a method for producing a three-dimensional structure comprising: a peeling step in which the post-baking pattern, the reinforcing layer, and the non-sintered layer are peeled from the substrate to obtain a three-dimensional structure.
- a method for manufacturing a scintillator panel comprising: a mounting step of mounting a three-dimensional structure on a substrate manufactured by the method for manufacturing a three-dimensional structure according to any one of (1) to (8).
- (11) The method for manufacturing a scintillator panel according to (9) or (10), wherein the reflectance of the substrate is 90% or more.
- a substrate, a partition mainly composed of glass, and a non-sintered layer are provided, The scintillator panel, wherein the non-sintered layer is located between the substrate and the partition wall.
- a narrow partition can be placed on a large area with high accuracy on an arbitrary substrate. Therefore, an appropriate substrate can be selected without being restricted by heat resistance and strength, and a narrow partition can be placed there. That is, it is possible to provide a scintillator panel manufacturing method and a scintillator panel capable of realizing higher brightness and clear photographing.
- FIG. 1 is a cross-sectional view schematically showing a configuration of a radiation detection apparatus including a scintillator panel manufactured by the method for manufacturing a scintillator panel of the present invention.
- FIG. 2 is a perspective view schematically showing the configuration of the scintillator panel manufactured by the method of manufacturing a scintillator panel of the present invention.
- the radiation detection apparatus 1 includes a scintillator panel 2, an output substrate 3, and a power supply unit 12.
- the scintillator panel 2 includes a scintillator layer 7 made of a phosphor, absorbs the energy of incident radiation such as X-rays, and absorbs electromagnetic waves having a wavelength in the range of 300 to 800 nm, that is, ultraviolet light centered on visible light. Radiates electromagnetic waves (light) in the range from to infrared.
- the scintillator panel 2 includes a flat substrate 4, a partition wall 6 formed thereon, that is, a partition wall 6 for forming a cell, and a scintillator layer 7 made of a phosphor filled in the space formed by the partition wall 6. Is composed of. Further, by further forming the adhesive layer 5 between the substrate 4 and the partition wall 6, the partition wall 6 can be stably fixed, that is, fixed to the substrate 4. Further, it is preferable that the reflective film 13 is formed on the surface of the partition wall 6. Further, it is preferable to have a non-sintered layer 14 and a reinforcing layer 15 between the partition wall 6 and the substrate 4.
- the output substrate 3 has a photoelectric conversion layer 9 and an output layer 10 in which pixels composed of photosensors and TFTs are two-dimensionally formed on a substrate 11.
- the radiation detection apparatus 1 is obtained by adhering or adhering the light output surface of the scintillator panel 2 and the photoelectric conversion layer 9 of the output substrate 3 via the diaphragm layer 8 made of polyimide resin or the like.
- the photoelectric conversion layer 9 When the light emitted from the scintillator layer 7 reaches the photoelectric conversion layer 9, photoelectric conversion is performed in the photoelectric conversion layer 9 and an electric signal is output through the output layer 10.
- each cell is partitioned by a partition wall. Therefore, by making the size and pitch of the pixels of the photoelectric conversion element coincide with the size and pitch of the cells of the scintillator panel, photoelectric conversion is performed.
- Each pixel of the element can be associated with each cell of the scintillator panel.
- the method for producing a three-dimensional structure according to the first aspect of the present invention is characterized in that after the glass pattern is formed on the substrate, the glass pattern is peeled off from the substrate. That is, according to the method for producing a three-dimensional structure of the present invention, an independent three-dimensional structure is obtained by peeling from the base material. If this three-dimensional structure is a narrow partition, the narrow partition can be placed on a large area with high accuracy on an arbitrary substrate. Therefore, an appropriate substrate can be selected without being restricted by heat resistance and strength, and a narrow partition can be placed there. That is, it is possible to provide a scintillator panel manufacturing method and a scintillator panel capable of realizing higher brightness and clear photographing. It is preferable that the glass pattern formed on a base material has glass as a main component. The glass pattern is preferably a sintered body obtained by sintering glass powder.
- the surface of the base material is coated with the glass powder-containing paste A to obtain the coating film A, and the coating film A is processed.
- the substrate is preferably used through a coating process, a pattern formation process, and a baking process.
- Base materials include ceramic plates such as alumina, aluminum nitride, mullite, steatite, silicon nitride or silicon carbide, glass ceramic plates obtained by mixing and sintering ceramic powder and glass powder, silicon, germanium, gallium arsenide
- a semiconductor plate made of a semiconductor such as gallium phosphide or gallium nitrogen, a metal sheet such as an aluminum sheet, an iron sheet or a copper sheet, a glass plate made of glass such as quartz, borosilicate glass or chemically tempered glass can be used. .
- the substrate is preferably highly heat resistant.
- the high heat-resistant base material means a base material that does not burn out in the firing step and has a volume change rate of 20% or less at room temperature before and after the firing step.
- of the difference between ⁇ s and ⁇ g is preferably 200 ⁇ 10 ⁇ 7 (K ⁇ 1 ) or less, and is preferably 50 ⁇ 10 ⁇ 7 (K ⁇ 1 ) or less. More preferred.
- the three-dimensional structure manufactured by the manufacturing method of the present invention is preferably substantially made of an inorganic material in order to increase its strength and heat resistance.
- the inorganic substance refers to a compound composed of a simple part of a carbon compound (carbon allotrope such as graphite or diamond, metal carbide or metal carbonate) and elements other than carbon. Note that “actually composed of an inorganic substance” does not exclude the existence of components other than inorganic substances in a strict sense, but does not exclude impurities contained in the raw material itself or residuals in the process of manufacturing a three-dimensional structure. The presence of components other than inorganic substances having a degree of impurities is acceptable.
- the three-dimensional structure manufactured by the manufacturing method of the present invention preferably contains glass as a main component. Since the three-dimensional structure mainly composed of glass has high strength, the shape does not change even if the three-dimensional structure is peeled from the substrate in the peeling step. In addition, since glass can be fired at a relatively low temperature compared to ceramics and the like, it is easy to manufacture a three-dimensional structure. In order to produce a three-dimensional structure mainly composed of glass in the second aspect of the present invention, the glass powder-containing paste A used in the coating step needs to have glass powder as the main component in the inorganic component.
- glass as the main component means that 50 to 100% by volume of the material constituting the three-dimensional structure is glass
- glass powder as the main component in the inorganic component means that the glass powder-containing paste A is It means that 50 to 100% by volume of the inorganic component contained is glass powder.
- the glass powder contained in the glass powder-containing paste A is preferably glass that softens at the firing temperature, and more preferably low-softening point glass having a softening temperature of 700 ° C. or lower.
- the firing temperature can be lowered, and the range of selection of the substrate is widened.
- the softening temperature is determined by calculating the endothermic end temperature at the endothermic peak from the DTA curve obtained by measuring the sample using a differential thermal analyzer (eg, differential type differential thermal balance TG8120; manufactured by Rigaku Corporation) by the tangent method. It can be obtained by inserting. More specifically, first, using a differential thermal analyzer, using alumina powder as a standard sample, the temperature is raised from room temperature at 20 ° C./min to measure the inorganic powder serving as a measurement sample to obtain a DTA curve. Then, from the obtained DTA curve, the softening point Ts obtained by extrapolating the endothermic end temperature at the endothermic peak by the tangent method can be used as the softening temperature.
- a differential thermal analyzer eg, differential type differential thermal balance TG8120; manufactured by Rigaku Corporation
- a metal oxide selected from the group consisting of lead oxide, bismuth oxide, zinc oxide and alkali metal oxides, which is an effective compound for lowering the softening point of glass is used.
- the softening temperature of the glass is adjusted using an alkali metal oxide.
- the alkali metal refers to a metal selected from the group consisting of lithium, sodium and potassium.
- the proportion of the alkali metal oxide in the low softening point glass is preferably 2 to 20% by mass.
- the ratio of the alkali metal oxide is less than 2% by mass, the softening temperature becomes high, and the firing process needs to be performed at a high temperature, and the three-dimensional structure is likely to be defective.
- the ratio of the alkali metal oxide exceeds 20% by mass, the viscosity of the glass is excessively lowered in the baking step, and the shape of the obtained pattern after baking is likely to be distorted.
- the low softening point glass preferably contains 3 to 10% by mass of zinc oxide in order to optimize the viscosity at high temperature.
- the proportion of zinc oxide in the low softening point glass is less than 3% by mass, the viscosity at high temperature increases.
- the content of zinc oxide exceeds 10% by mass, the production cost of the low softening point glass increases.
- the low softening point glass is a metal selected from the group consisting of oxides of silicon oxide, boron oxide, aluminum oxide and alkaline earth metal for the purpose of adjusting stability, crystallinity, transparency, refractive index or thermal expansion characteristics. It is preferable to contain an oxide.
- the alkaline earth metal refers to a metal selected from the group consisting of magnesium, calcium, barium and strontium.
- the low softening point glass may contain titanium oxide, zirconium oxide, bismuth oxide, or the like. On the other hand, since there is a concern of causing environmental pollution, it is preferable that substantially no lead oxide is contained.
- composition range of a preferred low softening point glass is shown below.
- Alkali metal oxide 2 to 20% by mass
- Zinc oxide 3-10% by mass
- Silicon oxide 20-40% by mass
- Boron oxide 25-40% by mass
- Aluminum oxide 10-30% by mass
- Alkaline earth metal oxide 5 to 15% by mass
- the particle diameter of the inorganic powder containing glass powder can be measured using a particle size distribution measuring device (for example, MT3300; manufactured by Nikkiso Co., Ltd.). More specifically, the measurement can be performed after the inorganic powder is introduced into the sample chamber of the particle size distribution measuring apparatus filled with water and subjected to ultrasonic treatment for 300 seconds.
- the 50% volume average particle diameter (hereinafter referred to as “D50”) of the low softening point glass powder is preferably 1.0 to 4.0 ⁇ m.
- D50 volume average particle diameter
- the glass powder is aggregated, and uniform dispersibility cannot be obtained, and the flow stability of the paste is lowered.
- D50 exceeds 4.0 ⁇ m, the surface unevenness of the post-baking pattern obtained in the baking process becomes large, and the three-dimensional structure tends to be crushed afterwards.
- Glass powder-containing paste A is a glass that does not soften at the firing temperature, in addition to the glass that softens at the firing temperature, in order to control the shrinkage rate of the pattern in the firing step and to maintain the shape of the finally obtained three-dimensional structure, or Ceramic particles such as silicon oxide, aluminum oxide, titanium oxide or zirconium oxide may be contained as a filler.
- the proportion of the filler in the entire inorganic component is preferably 50% by volume or less in order to prevent a reduction in strength of the three-dimensional structure due to inhibition of sintering of the glass powder that is softened at the firing temperature.
- the filler D50 is preferably the same as that of the low softening point glass powder.
- the coating step provided in the method for producing a three-dimensional structure of the present invention is a step of obtaining a coating film by coating the glass powder-containing paste A entirely or partially on the surface of the substrate directly or via another layer.
- Examples of the method for applying the glass powder-containing paste A include a screen printing method, a bar coater, a roll coater, a die coater, and a blade coater.
- the thickness of the obtained coating film A can be appropriately adjusted depending on the paste composition and process conditions.
- the coating film A may be composed of a plurality of layers.
- the multi-layer coating film A is obtained by repeating the coating process a plurality of times.
- the composition of each layer may be the same or different from each other.
- the pattern forming step included in the method for producing a three-dimensional structure of the present invention is a step of processing the coating film obtained in the coating step to obtain a pattern before firing.
- the method for processing the coating film include a photosensitive paste method, that is, photolithography, a sand blast method, an imprint method, and a machining method, but since a pre-baking pattern can be manufactured in a large area with a high yield, it is photosensitive.
- the paste method is preferred.
- the structure of the pattern before firing formed in the pattern forming step is any one of a stripe shape, a lattice shape, and a honeycomb shape (hexagonal shape)
- the stripe shape, the lattice shape, or the honeycomb shape corresponding to each after firing.
- a three-dimensional structure having the following structure is obtained.
- Such a three-dimensional structure having a stripe, lattice, or honeycomb structure can be used as a partition that is a constituent element of a scintillator panel.
- the pattern formation process by photolithography includes, for example, an exposure process in which the coating film A is exposed through a photomask having a predetermined opening in the coating process, and a part soluble in the developer in the coating film A after the exposure. And a developing step for dissolving and removing the slag.
- a necessary part of the coating film A is photocured by exposure, or an unnecessary part of the coating film A is photodecomposed to make any part of the coating film A soluble in the developer. It is a process.
- the development step a part that is soluble in the developing solution in the coating film A after exposure is dissolved and removed with the developing solution, and a pre-baking pattern in which only a necessary part remains is obtained.
- an arbitrary pattern may be directly drawn with a laser beam or the like without using a photomask.
- the exposure apparatus include a proximity exposure machine or a laser exposure machine.
- the actinic rays irradiated in the exposure step include near infrared rays, visible rays, and ultraviolet rays, and ultraviolet rays are preferable.
- the light source include a low pressure mercury lamp, a high pressure mercury lamp, an ultra high pressure mercury lamp, a halogen lamp, and a germicidal lamp, and an ultra high pressure mercury lamp is preferable.
- exposure conditions vary depending on the coating thickness, exposure is usually performed for 0.01 to 30 minutes using an ultrahigh pressure mercury lamp with an output of 1 to 100 mW / cm 2 .
- Examples of the development method in the development process include an immersion method, a spray method, and a brush method.
- a solvent capable of dissolving unnecessary portions in the coating film A after exposure may be appropriately selected, but an aqueous solution containing water as a main component is preferable.
- an alkaline aqueous solution can be selected as the developer.
- the alkaline aqueous solution examples include an inorganic alkaline aqueous solution such as sodium hydroxide, sodium carbonate or calcium hydroxide, or an organic alkaline aqueous solution such as tetramethylammonium hydroxide, trimethylbenzylammonium hydroxide, monoethanolamine or diethanolamine.
- An organic alkali aqueous solution is preferable because it can be easily removed in the firing step.
- the concentration of the alkaline aqueous solution is preferably 0.05 to 5% by mass, and more preferably 0.1 to 2% by mass. If the alkali concentration is excessively low, unnecessary portions in the coating film A after exposure are not sufficiently removed. On the other hand, if the alkali concentration is excessively high, the pattern before baking may be peeled off or corroded.
- the development temperature is preferably 20 to 50 ° C. to facilitate process control.
- the glass powder-containing paste A applied in the coating process needs to be photosensitive. That is, the glass powder-containing paste A needs to contain a photosensitive organic component.
- the proportion of the organic component in the photosensitive glass powder-containing paste A is preferably 30 to 80% by mass, and more preferably 40 to 70% by mass.
- the organic component is less than 30% by mass, the dispersibility of the inorganic component in the paste is lowered, and not only is the defect easily generated in the baking process, but the paste viscosity is increased and the applicability is lowered. Stability is also reduced.
- the organic component exceeds 80% by mass, the shrinkage rate of the pattern in the baking process is increased, and defects are likely to occur.
- the glass powder contained in the photosensitive glass powder-containing paste A has a softening temperature of 480 ° C. or higher in order to remove organic components almost completely in the firing step and ensure the strength of the finally obtained three-dimensional structure. It is preferable.
- the softening temperature is less than 480 ° C.
- the glass powder is softened before the organic components are sufficiently removed in the firing step, and the carbon component (hereinafter referred to as “carbon residue”) left unburned in the sintered glass. )) Remains and induces coloring of the three-dimensional structure, and when the three-dimensional structure is a partition for the scintillator panel, there is a concern that the brightness of the scintillator panel is lowered.
- the refractive index n1 of the glass powder and the refractive index n2 of the organic component are ⁇ 0.1.
- ⁇ N1-n2 ⁇ 0.1 is preferably satisfied, more preferably ⁇ 0.01 ⁇ n1-n2 ⁇ 0.01, ⁇ 0.005 ⁇ n1-n2 ⁇ 0.005 More preferably, the relationship is satisfied.
- the refractive index of glass powder can be suitably adjusted with the composition of the metal oxide which glass powder contains.
- the refractive index of glass powder can be measured by the Becke line detection method. Moreover, the refractive index of an organic component can be calculated
- Examples of the photosensitive organic component contained in the photosensitive glass powder-containing paste A include a photosensitive monomer, a photosensitive oligomer, and a photosensitive polymer.
- the photosensitive monomer, photosensitive oligomer or photosensitive polymer refers to a monomer, oligomer or polymer whose chemical structure is changed by a reaction such as photocrosslinking or photopolymerization upon irradiation with actinic rays.
- a compound having an active carbon-carbon unsaturated double bond is preferable.
- examples of such a compound include a compound having a vinyl group, an acryloyl group, a methacryloyl group, or an acrylamide group.
- Functional methacrylate compounds are preferred.
- the photosensitive oligomer or photosensitive polymer is preferably an oligomer or polymer having an active carbon-carbon unsaturated double bond and a carboxyl group.
- oligomers or polymers include, for example, acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid, vinyl acetic acid or their anhydrides, carboxyl group-containing monomers, methacrylic acid esters, acrylic acid esters , Styrene, acrylonitrile, vinyl acetate or 2-hydroxyacrylate.
- Examples of a method for introducing an active carbon-carbon unsaturated double bond into an oligomer or polymer include acrylic acid chloride, methacrylic acid chloride, or a mercapto group, amino group, hydroxyl group or carboxyl group of the oligomer or polymer.
- Examples thereof include a method of reacting an allylic chloride, an ethylenically unsaturated compound having a glycidyl group or an isocyanate group, or a carboxylic acid such as maleic acid.
- the photosensitive glass powder-containing paste A may contain a photopolymerization initiator as necessary.
- the photopolymerization initiator refers to a compound that generates radicals upon irradiation with actinic rays.
- the photopolymerization initiator include benzophenone, methyl o-benzoylbenzoate, 4,4-bis (dimethylamino) benzophenone, 4,4-bis (diethylamino) benzophenone, 4,4-dichlorobenzophenone, 4-benzoyl- 4-methyldiphenyl ketone, dibenzyl ketone, fluorenone, 2,2-dimethoxy-2-phenylacetophenone, 2-hydroxy-2-methylpropiophenone, thioxanthone, 2-methylthioxanthone, 2-chlorothioxanthone, 2-isopropylthioxanthone , Diethylthioxanthone, benzyl, benzylmethoxye
- the solubility in an alkaline aqueous solution during development is improved.
- the acid value of the polymer having a carboxyl group is preferably 50 to 150 mgKOH / g.
- the acid value is 150 mgKOH / g or less, the development margin becomes wide.
- the acid value is 50 mgKOH / g or more, the solubility in an alkaline aqueous solution is not lowered, and a high-definition pattern can be obtained.
- the photosensitive glass powder-containing paste A can be obtained by preparing various components so as to have a predetermined composition and then uniformly mixing and dispersing them with a three-roller or a kneader.
- the viscosity of the photosensitive glass powder-containing paste A can be appropriately adjusted depending on the addition ratio of inorganic powder, thickener, organic solvent, polymerization inhibitor, plasticizer, anti-settling agent, etc., but the range is from 2 to 200 Pa ⁇ s is preferable.
- a viscosity of 2 to 5 Pa ⁇ s is preferable, and when applied to a substrate by a blade coater method or a die coater method.
- a viscosity of 10 to 50 Pa ⁇ s is preferred.
- the photosensitive glass powder-containing paste A is applied by a single screen printing method to obtain a coating film having a thickness of 10 to 20 ⁇ m, a viscosity of 50 to 200 Pa ⁇ s is preferable.
- the firing step included in the method for producing a three-dimensional structure of the present invention comprises firing the pre-fired pattern obtained in the pattern forming step, decomposing and removing the organic components contained in the glass powder-containing paste A, softening the glass powder, and Sintering to obtain a post-firing pattern.
- the firing conditions vary depending on the composition of the glass powder-containing paste A and the type of substrate, but can be fired in a firing furnace in an air, nitrogen or hydrogen atmosphere, for example. Examples of the firing furnace include a batch-type firing furnace or a belt-type continuous firing furnace.
- the firing temperature (maximum temperature in the firing profile) is preferably 500 to 1000 ° C, more preferably 500 to 800 ° C, and even more preferably 500 to 700 ° C.
- the firing temperature is less than 500 ° C., decomposition and removal of organic components may be insufficient.
- the firing temperature exceeds 1000 ° C.
- the base material that can be used as a high heat-resistant base material is limited to a ceramic plate or the like.
- the firing time is preferably 10 to 60 minutes.
- the peeling step included in the method for producing a three-dimensional structure of the present invention is a step of obtaining a three-dimensional structure by peeling the post-baking pattern obtained in the baking step from the substrate.
- a first application step for obtaining a peeling auxiliary layer by applying a non-sintered paste to the surface of the substrate, and a surface of the peeling auxiliary layer are provided.
- the manufacturing method of the three-dimensional structure according to the present invention in this aspect is the same as the manufacturing method of the three-dimensional structure according to the second aspect of the present invention by applying a non-sintered paste to the surface of the base material.
- a first coating step for obtaining a layer is added.
- the coating process in the second aspect corresponds to the second coating process in the third aspect.
- the substrate is preferably used through the first coating step, the second coating step, the pattern forming step, and the baking step.
- the first coating step by forming a peeling auxiliary layer on the surface of the substrate, it becomes easy to peel the post-baking pattern from the substrate in the subsequent peeling step. Compared with the method of removing etc., it does not cost and is preferable.
- the peeling auxiliary layer is obtained by applying a non-sintered paste.
- the non-sintered paste refers to a paste containing an inorganic powder that is not sintered in the firing step (hereinafter, “non-sintered inorganic powder”) as a main component in the inorganic component.
- non-sintered inorganic powder as a main component in the inorganic component means that 50 to 100% by volume of the inorganic component contained in the non-sintered paste is the non-sintered inorganic powder.
- the peeling assist layer can suppress the fusion between the pattern and the substrate in the firing process, and the post-firing pattern and non-sintered Peeling of the layer becomes easy.
- the proportion of the non-sintered inorganic powder in the inorganic component contained in the non-sintered paste is preferably 70 to 100% by volume, more preferably 90 to 100% by volume.
- non-sintered inorganic powder examples include glass powder or ceramic powder whose softening temperature is higher than the firing temperature, but the softening temperature is 50 ° C. higher than the firing temperature in order to prevent fusion with the substrate in the firing process. It is preferable that the height is higher. More specifically, ceramic particles such as silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, barium titanate, cobalt oxide or nickel oxide, or high softening point glass powder is preferable.
- the D50 of the non-sintered inorganic powder is preferably 0.01 to 20 ⁇ m, and more preferably 0.05 to 3.0 ⁇ m.
- D50 is less than 0.01 ⁇ m, it is difficult to peel the three-dimensional structure from the base material after the firing step.
- D50 exceeds 20 ⁇ m, it becomes easy to peel excessively, and the pattern may be partially peeled during firing.
- Examples of the shape of the non-sintered inorganic powder include an indefinite shape, a spherical shape, a flat shape, and a rod shape.
- Non-sintered paste is required to contain 50% by volume or more of non-sintered inorganic powder with respect to all inorganic components, but glass powder that is sintered at a firing temperature within a range that does not impair the properties of the auxiliary peeling layer. May be included. By containing an appropriate amount of such glass powder, turning and warping of the pattern end during firing may be suppressed.
- the non-sintered paste is composed of an inorganic component containing non-sintered inorganic powder remaining after the firing step and an organic component thermally decomposed during the firing step.
- the organic component contained in the non-sintered paste is preferably 20 to 80% by mass. When the organic component is less than 20% by mass, the dispersibility of the inorganic component in the paste is lowered, and defects are likely to occur in the firing step. On the other hand, when the organic component exceeds 80% by mass, shrinkage in the firing process increases, and defects such as cracks are likely to occur.
- the organic component contained in the non-sintered paste is preferably a binder resin, a curable monomer, a polymerization initiator, a dispersant, or an organic solvent.
- binder resin examples include polyvinyl butyral, polyvinyl acetate, polyvinyl alcohol, ethyl cellulose, methyl cellulose, polyethylene, polystyrene, butadiene / styrene copolymer, polystyrene, polyvinyl pyrrolidone, polyamide, high molecular weight polyether, ethylene oxide and propylene oxide
- binder resin examples include coalescence, polyacrylamide or acrylic resin.
- the photosensitive oligomer or photosensitive polymer used for the photosensitive glass powder containing paste can also be used suitably.
- silicone resin such as polymethylsiloxane or polymethylphenylsiloxane may be contained, since the silicone resin tends to increase the carbon residue after firing, its content is 50% by mass or less in the binder resin. Preferably there is.
- Examples of the method for applying the non-sintered paste include a screen printing method, a bar coater, a roll coater, a die coater, and a blade coater. After applying by these methods, the peeling auxiliary layer is obtained by drying.
- the peeling auxiliary layer may be composed of a plurality of layers.
- a plurality of peeling assist layers can be obtained by repeating the first coating step a plurality of times.
- the composition of each layer may be the same or different from each other.
- the curable monomer a monomer having a carbon-carbon unsaturated double bond or a monomer having a hydroxyl group or an isocyanate group is preferable because a reaction such as crosslinking or polymerization is caused by light or heat.
- a reaction such as cross-linking or polymerization
- the solvent resistance and scratch resistance of the peeling auxiliary layer are improved, so that when the paste is applied to the surface of the peeling auxiliary layer, the peeling auxiliary layer is unlikely to swell or peel off. Become.
- the thickness of the peeling assist layer is preferably from 0.1 to 100 ⁇ m, more preferably from 0.2 to 50 ⁇ m, and even more preferably from 1 to 10 ⁇ m.
- the thickness of the peeling assist layer is less than 0.2 ⁇ m, it is difficult to peel the three-dimensional structure from the substrate after the firing step.
- the thickness exceeds 50 ⁇ m it becomes easy to peel excessively, and the pattern may be partially peeled off during the firing step.
- a non-sintered layer is obtained by firing the peeling assist layer.
- a non-sintered layer means the layer which contains a non-sintered inorganic powder as a main component in an inorganic component. Since the non-sintered layer after firing is usually attached to both the base material and the three-dimensional structure, the non-sintered layer is separated from the base material side and the three-dimensional structure with the separation of the three-dimensional structure from the base material. Separated from the object side.
- the thickness of the non-sintered layer remaining on the three-dimensional structure side after peeling is preferably 0.01 to 50 ⁇ m, and more preferably 0.1 to 20 ⁇ m. Under the condition of being thinner than 0.01 ⁇ m, it may be difficult to peel the three-dimensional structure from the base material. Moreover, when it becomes thicker than 50 micrometers, it will become easy to peel a non-sintered inorganic powder from a solid structure.
- the thickness of the non-sintered layer is determined by observing the cross section with a scanning electron microscope (hereinafter referred to as “SEM”), distinguishing the non-sintered inorganic powder from other inorganic components by the difference in density of the SEM image. It can be determined by measuring the thickness of the layer containing the bonded inorganic powder as the main component in the inorganic component.
- SEM scanning electron microscope
- the non-sintered layer on the three-dimensional structure side is thick, it can be removed by ultrasonic cleaning or the like to adjust the thickness.
- a first application step in which a non-sintered paste is applied to a surface of a substrate to obtain a peeling auxiliary layer, and the surface of the peeling auxiliary layer is applied.
- a pattern forming step of processing the coating film A to obtain a pattern before baking, a pattern before baking, the coating film B, and the peeling auxiliary layer are baked to form a pattern after baking, a reinforcing layer, and a non-baked layer
- a baking step for obtaining a binder layer and a peeling step for peeling the post-fired pattern, the reinforcing layer, and the non-sintered layer from the substrate to obtain a three-dimensional structure.
- the manufacturing method of the three-dimensional structure of the present invention in this aspect is the same as the manufacturing method of the three-dimensional structure in the third aspect of the present invention, except that the glass powder-containing paste B is applied to the surface of the peeling auxiliary layer.
- a second coating step for obtaining the coating film B is added. Note that the second application step in the third aspect corresponds to the third application step in the fourth aspect.
- the strength of the three-dimensional structure is improved, and defects such as cracks that occur during peeling can be suppressed.
- the substrate is preferably used through the first coating step, the second coating step, the third coating step, the pattern forming step, and the baking step.
- pre-baking may be performed before the third coating step.
- the glass powder-containing paste A is applied to the surface of the coating film B after pre-baking.
- the arithmetic average surface roughness Ra of the surface of the coating film B after pre-baking is preferably 0.01 to 10 ⁇ m, and more preferably 0.5 to 5 ⁇ m.
- Ra is less than 0.01 ⁇ m, for example, in the developing process in the pattern forming process, the adhesion between the coating film B and the pattern is lowered, and pattern peeling tends to occur.
- Ra exceeds 10 ⁇ m, pattern cracks may occur in the firing step.
- the coating film B after pre-baking and the arithmetic average surface roughness Ra of the surface of the reinforcing layer were applied to the glass powder-containing paste B on the substrate and baked.
- VK-9500 manufactured by Keyence Corporation
- a 20 ⁇ lens scanned 5 points vertically from the base material, and the average value of Ra at each point obtained by analyzing the image is calculated. Can be obtained.
- the porosity of the reinforcing layer is preferably 0 to 30% by volume, and more preferably 0 to 20% by volume. When the porosity exceeds 30% by volume, the strength of the reinforcing layer is insufficient, so that the strength improvement effect of the three-dimensional structure may be reduced.
- the resin contained in the phosphor paste may permeate into the non-sintered layer in the step of filling the partition with the phosphor, and the peelability may deteriorate. .
- the porosity of the reinforcing layer is observed by SEM after the cross section of the reinforcing layer is precisely polished, and the inorganic component portion and the void portion are converted into two gradation images, and the area of the void portion occupies the area of the cross section of the reinforcing layer. It can be calculated as a percentage.
- the reinforcing layer contains glass. Since the reinforcing layer containing glass has high strength, the three-dimensional structure can be effectively reinforced.
- the glass powder-containing paste B is composed of an organic component and an inorganic component including glass powder.
- the glass powder content in the glass powder-containing paste B is preferably 10 to 95% by mass.
- the glass powder contained in the glass powder-containing paste B is preferably glass that softens at the firing temperature, and more preferably low-softening point glass having a softening temperature of 700 ° C. or lower. By using the low softening point glass, the firing temperature can be lowered, and the range of selection of the substrate is widened.
- the glass powder-containing paste B is an inorganic component other than the glass powder, as long as it does not impair the properties of the reinforcing layer, such as high softening point glass powder, or silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, or barium titanate.
- White ceramic powder can be appropriately contained.
- the glass powder and other inorganic powders contained in the glass powder-containing paste B can be appropriately selected from inorganic particles having an appropriate softening point, thermal expansion coefficient, chemical stability and refractive index.
- a glass powder-containing paste The same glass powder as A can be used.
- the volume average particle diameter (hereinafter referred to as “D50”) of the inorganic powder sintered at the firing temperature contained in the glass powder-containing paste B is preferably 0.05 to 50 ⁇ m, and preferably 0.1 to 10 ⁇ m. Is more preferable. If D50 is less than 0.05 ⁇ m, Ra of the reinforcing layer becomes small, and the three-dimensional structure pattern easily peels off during development. On the other hand, when D50 exceeds 50 ⁇ m, voids are likely to be included in the reinforcing layer, and the strength improvement effect tends to be small.
- the reinforcing layer can adjust the porosity, thermal expansion coefficient, and visible light reflectance by appropriately adjusting the ratio of the inorganic powder to be sintered and the filler.
- the organic component contained in the glass powder-containing paste B is preferably a binder resin, a curable monomer, a polymerization initiator, a dispersant, or an organic solvent.
- the coating film B is obtained by applying the glass powder-containing paste B, drying by heating and removing the organic solvent in the coating film.
- the organic component is preferably less than 30% by mass.
- the carbon residue concentration contained in the reinforcing layer is increased, so that the reinforcing layer is easily blackened.
- firing shrinkage is increased and cracking of the reinforcing layer is likely to occur.
- binder resin contained in the glass powder-containing paste B examples include those similar to the binder resin contained in the non-sintered paste, but polyvinyl butyral, polyvinyl acetate, polyvinyl alcohol, ethyl cellulose, which has good decomposability in the firing step, Methyl cellulose, a copolymer of ethylene oxide and propylene oxide, polyacrylamide or acrylic resin is preferred. Moreover, the photosensitive oligomer or photosensitive polymer used for the photosensitive glass powder containing paste is also preferable.
- the coating film B is formed on the surface of the peeling auxiliary layer so as to be wider than the coating area of the peeling auxiliary layer, and then pre-baking is performed, so that the substrate and the coating film B are partially It is preferable to bind. Thereby, it can suppress that the coating film B peels from a base material in the 3rd application
- the substrate and the three-dimensional structure can be peeled from the substrate by scratching and cleaving the inside of the peeling auxiliary layer from the surface opposite to the surface on which the three-dimensional structure of the substrate is formed. Can be implemented at any timing.
- the thickness of the coating film B thicker than the thickness of a peeling assistance layer.
- the thickness of the reinforcing layer is preferably 1 to 500 ⁇ m, and more preferably 10 to 100 ⁇ m.
- the thickness of the reinforcing layer is less than 1 ⁇ m, the strength improvement effect of the three-dimensional structure tends to be small.
- the thickness of the reinforcing layer exceeds 500 ⁇ m, the cost of raw materials to be used is increased, which tends to increase the cost.
- radiation is absorbed by the reinforcing layer, and the light emission luminance is likely to be lowered.
- the reinforcing layer may be composed of a plurality of layers.
- a plurality of reinforcing layers can be obtained by repeating the second coating step a plurality of times.
- the composition of each layer may be the same or different from each other.
- the strength of the three-dimensional structure obtained by laminating a reinforcing layer having a low porosity and a reinforcing layer having a large surface roughness in this order on the peeling assist layer, followed by pre-baking and then performing the third coating step and thereafter. Can be sufficiently improved, and the adhesion of the pattern portion during development can be improved.
- the partition wall produced by the production method of the present invention preferably contains 0.1 to 40% by mass of a white pigment as a filler.
- a white pigment is contained in an amount of 0.1% by mass or more, the light emission luminance of the scintillator panel is improved.
- the white pigment exceeds 40% by mass, the strength of the partition walls is lowered.
- a metal oxide selected from the group consisting of aluminum oxide, zirconium oxide and titanium oxide is preferable in order to further increase the emission luminance.
- the white pigment is preferably present as aggregated particles in which ultrafine particles having an average particle diameter of 0.005 to 0.08 ⁇ m are aggregated in the partition walls.
- the average particle diameter of the aggregated particles of the white pigment is preferably 0.3 to 2 ⁇ m, and more preferably 0.5 to 1 ⁇ m, in order to impart high reflectance to the partition walls.
- the average particle diameter of the aggregated particles of the white pigment means a diameter when an observation photograph taken with an electron microscope or the like is image-processed and converted into a circle having the same area as the apparent area. More specifically, a sample processed by the ion etching method is enlarged and photographed using a transmission electron microscope, 50 aggregated particles are selected as samples, and aggregated particles are obtained from image processing of each photograph. The average value of each diameter when approximated to a sphere (circle on the image).
- the scintillator panel manufacturing method of the present invention includes a mounting step of mounting a three-dimensional structure manufactured by the three-dimensional structure manufacturing method of the present invention, preferably a partition wall, on a substrate.
- the substrate in the present invention refers to a flat support that is a target on which the three-dimensional structure is placed after the three-dimensional structure is peeled from the base material in the peeling step.
- the substrate can be freely selected without being restricted by heat resistance or strength. For example, in the production of a scintillator panel, radiation Therefore, it is possible to select a substrate having low absorption and high reflectivity.
- a three-dimensional structure such as a partition placed on a substrate is preferably fixed to the substrate, and more preferably fixed by a resin or an adhesive tape.
- a resin or an adhesive tape for example, a material obtained by mixing a solvent with an organic resin such as an acrylic resin, an epoxy resin, a polyester resin, a butyral resin, a polyamide resin, or an ethyl cellulose resin is preferably used.
- the adhesive tape for example, a tape coated with the above-mentioned adhesive can be used, but it is preferable to use a double-sided tape in which an adhesive is coated on both sides of the tape.
- the three-dimensional structure fixed on the substrate is preferably a partition wall having a non-sintered layer or a reinforcing layer.
- the non-sintered layer and the reinforcing layer are preferably located between the substrate and the partition wall. That is, one aspect of the scintillator panel of the present invention includes a substrate, a partition mainly composed of glass, and a non-sintered layer, and the non-sintered layer is located between the substrate and the partition. It is a scintillator panel.
- a material that is made of a polymer, ceramics, semiconductor, metal, glass, or the like having radiation transparency can be used.
- a substrate include a polymer film such as a polyester film, a cellulose acetate film, a polyamide film, a polyimide film, a polycarbonate film, or a carbon fiber reinforced resin sheet, alumina, aluminum nitride, mullite, steatite, silicon nitride or Ceramic substrates such as silicon carbide, glass ceramic substrates obtained by mixing and sintering ceramic powder and glass powder, semiconductor substrates made of semiconductors such as silicon, germanium, gallium arsenide, gallium phosphide or gallium nitrogen, aluminum sheets, iron sheets Or a metal sheet such as a copper sheet, a glass plate made of glass such as quartz, borosilicate glass or chemically tempered glass, a metal sheet having a metal oxide coating layer, or an amorphous carbon substrate It is but a polymer film made of a polyester film, a
- the thickness of the substrate is preferably 1 mm or less in order to suppress radiation absorption by the substrate.
- the reflectance of the substrate is preferably 90% or more.
- the reflectance refers to the SCI reflectance at a wavelength of 530 nm measured using a spectrocolorimeter (for example, CM-2600d; manufactured by Konica Minolta).
- the substrate on which the adhesive is applied or the double-sided tape is applied is pressed to adhere, or the adhesive is applied to the surface of the post-fired pattern or
- the three-dimensional structure may be peeled off and fixed at the same time, such as attaching a double-sided adhesive tape and pressing and adhering the substrate.
- a reflective film is formed on the surface in order to prevent light leakage from the partition wall.
- the material of the reflective film include substances that transmit radiation and reflect light, which is an electromagnetic wave of 300 to 800 nm emitted from the phosphor, but have a low degree of deterioration, so Ag, Au, Al A metal such as Ni, Ti or a metal oxide such as TiO 2 , ZrO 2 , Al 2 O 3 or ZnO is preferred.
- the opening of the partition wall is not blocked by a reinforcing layer or the like, on each inner surface of the partition wall and on a portion where the partition wall on the substrate does not exist
- the reflective film of the same material can be formed at once.
- the reflective film can be formed only on each inner surface of the partition wall.
- the reflectance of the substrate is higher than the reflectance of the reflective film, in order to effectively utilize the reflectance of the substrate, a reflective film is formed only on each inner surface of the partition, and there is no partition on the substrate It is preferable that no reflective film is formed on the portion.
- Examples of the method for forming the reflective film include a vacuum film forming method, a plating method, a paste coating method, and a spraying method by spraying.
- the space filled with the phosphor is partitioned by the partition placed on the substrate.
- a scintillator panel is completed by filling this space, that is, a cell, with a phosphor to form a scintillator layer.
- Examples of the phosphor include CsI, Gd 2 O 2 S, Lu 2 O 2 S, Y 2 O 2 S, LaCl 3 , LaBr 3 , LaI 3 , CeBr 3 , which have a high conversion rate from radiation to visible light.
- Examples include CeI 3 , LuSiO 5 or Ba (Br, F).
- an activator may be added to the phosphor.
- the activator include sodium (Na), indium (In), thallium (Tl), lithium (Li), potassium (K), rubidium (Rb), sodium (Na), terbium (Tb), and cerium (Ce). ), Europium (Eu), or praseodymium (Pr), but because of its high chemical stability and high luminous efficiency, a phosphor obtained by adding Tb to Gd 2 O 2 S (hereinafter referred to as “GOS: Tb”). ) Is preferred.
- a method of filling the phosphor for example, in addition to a method of vacuum-depositing crystalline CsI and a method of applying a phosphor slurry dispersed in water, phosphor powder, ethyl cellulose, acrylic resin, etc. are used in a solvent such as terpineol.
- coating the mixed fluorescent substance paste by screen printing or dispenser is mentioned.
- FIG. 3 is a cross-sectional view schematically showing the configuration of a scintillator panel manufactured by the method for manufacturing a scintillator panel of the present invention.
- the height L1 of the partition wall 6 is preferably 100 to 3000 ⁇ m, and more preferably 160 to 500 ⁇ m.
- L1 exceeds 3000 ⁇ m, the workability when forming the partition walls is lowered.
- L1 is less than 100 ⁇ m, the amount of phosphor that can be filled is reduced, and the light emission luminance of the obtained scintillator panel is lowered.
- the interval L2 between adjacent partition walls is preferably 30 to 1000 ⁇ m.
- L2 is less than 30 ⁇ m, workability when forming the partition walls is lowered.
- L2 exceeds 1000 ⁇ m, the accuracy of the image of the obtained scintillator panel is lowered.
- the bottom width L3 of the partition wall is preferably 10 to 150 ⁇ m, more preferably 20 to 150 ⁇ m.
- L3 is less than 10 ⁇ m, defects in a lattice pattern tend to occur during firing.
- L3 exceeds 150 ⁇ m, the amount of phosphor that can be filled in the space defined by the partition walls is reduced, and the light emission luminance of the obtained scintillator panel is lowered.
- the top width L4 of the partition wall is preferably 5 to 80 ⁇ m.
- L4 is less than 5 ⁇ m, the strength of the partition walls decreases.
- L4 exceeds 80 ⁇ m, the region from which the emitted light of the scintillator layer can be extracted becomes narrow.
- the aspect ratio (L1 / L3) of the partition wall height L1 to the bottom width L3 is preferably 1.0 to 50.0.
- the aspect ratio (L1 / L2) of the partition wall height L1 to the partition wall spacing L2 is preferably 0.5 to 5.0, and more preferably 1.0 to 3.5.
- the height L1 of the partition walls and the interval L2 between the adjacent partition walls can be measured by exposing a section of the partition perpendicular to the substrate and observing the section with a scanning electron microscope (S2400; manufactured by Hitachi, Ltd.).
- the width of the partition wall at the contact portion between the partition wall and the substrate is L3.
- the width of the partition at the contact portion between the partition and the partition reinforcing layer is L3.
- the width of the topmost part of the partition is L4.
- Photosensitive monomer M-1 Trimethylolpropane triacrylate
- photosensitive monomer M-2 Tetrapropylene glycol dimethacrylate
- Binder resin 100 cP ethylcellulose photopolymerization initiator: 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) butanone-1 (IC369; manufactured by BASF)
- Polymerization inhibitor 1,6-hexanediol-bis [(3,5-di-tert-butyl-4-hydroxyphenyl) propionate])
- Ultraviolet absorber solution Sudan
- the mixture After adding 30 parts by mass of the low softening point glass powder A and 10 parts by mass of the high softening point glass powder A to 60 parts by mass of the organic solution 1, the mixture is kneaded with a three-roller kneader, and the glass powder-containing paste A was made.
- non-sintered paste 2 3 parts by weight of binder resin, 1.5 parts by weight of photosensitive monomer M-1, 0.5 parts by weight of photosensitive monomer M-2, 0.05 parts by weight of thermal polymerization initiator, 55 parts by weight of solvent B was dissolved by heating at a temperature of 60 ° C. After cooling the obtained organic solution 2, 40 parts by mass of silicon oxide powder was added and kneaded with a three-roller kneader to produce a non-sintered paste 2.
- non-sintered paste 3 1 part by weight of binder resin, 0.5 part by weight of photosensitive monomer M-1, 0.5 part by weight of photosensitive monomer M-2, 0.05 part by weight of thermal polymerization initiator, 78 parts by weight of solvent B was dissolved by heating at a temperature of 60 ° C. After the obtained organic solution 3 was cooled, 20 parts by mass of titanium oxide powder A was added and kneaded with a three-roller kneader to produce a non-sintered paste 3.
- non-sintered paste 4 2 parts by weight of binder resin, 0.5 parts by weight of photosensitive monomer M-1, 0.5 parts by weight of photosensitive monomer M-2, 0.05 parts by weight of thermal polymerization initiator, 67 parts by weight of solvent B was dissolved by heating at a temperature of 60 ° C. After the obtained organic solution 4 was cooled, 30 parts by mass of titanium oxide powder B was added and kneaded with a three-roller kneader to produce a non-sintered paste 4.
- non-sintered paste 6 50 parts by mass of the high softening point glass powder B was added to 50 parts by mass of the organic solution 1 and then kneaded by a three-roller kneader to prepare a non-sintered paste 6.
- glass powder-containing paste B1 4 parts by mass of binder resin was dissolved in 50 parts by mass of solvent B by heating at a temperature of 60 ° C. After cooling the obtained organic solution 5, 46 parts by mass of a low softening point glass powder A was added and then kneaded with a three-roller kneader to prepare a glass powder-containing paste B1.
- the roughness Ra was 0.2 ⁇ m and the porosity was 0.5%.
- glass powder-containing paste B2 25 parts by mass of the low softening point glass powder B was added to 75 parts by mass of the organic solution 5, and then kneaded by a three-roller kneader to prepare a glass powder-containing paste B2.
- the solid film produced by the same method as the glass powder-containing paste B1 had a surface roughness Ra of 0.1 ⁇ m and a porosity of 0.2%.
- Example 1 As the substrate, a glass plate of 500 mm ⁇ 500 mm ⁇ 1.8 mm (PD-200; manufactured by Asahi Glass Co., Ltd., linear expansion coefficient 83 ⁇ 10 ⁇ 7 (K ⁇ 1 )) was used. On the surface of the base material, the non-sintered paste 1 was applied with a die coater so as to have a dry thickness of 50 ⁇ m and dried to form a peeling auxiliary layer. The glass powder-containing paste A was applied to the surface of the peeling assist layer with a die coater so that the dry thickness was 500 ⁇ m and dried to obtain a coating film A.
- PD-200 manufactured by Asahi Glass Co., Ltd., linear expansion coefficient 83 ⁇ 10 ⁇ 7 (K ⁇ 1 )
- the coating film A is applied to a coating film A by using an ultrahigh pressure mercury lamp through a photomask having an opening corresponding to a desired pattern (a chromium mask having a grid-like opening having a pitch of 125 ⁇ m and a line width of 20 ⁇ m). It was exposed at an exposure amount of cm 2.
- the exposed coating film A was developed in a 0.5% by mass monoethanolamine aqueous solution, and the unexposed portion was removed to obtain a lattice-shaped pre-baking pattern.
- the obtained lattice-shaped pre-fired pattern was fired in air at 585 ° C. for 15 minutes to obtain a lattice-shaped post-fired pattern.
- An adhesive was applied to the surface of a 500 mm ⁇ 500 mm ⁇ 0.18 mm white PET film (Lumirror (registered trademark) E6SQ; manufactured by Toray; reflectance 97%) to form an adhesive layer.
- the above-mentioned lattice-shaped post-baking pattern was placed on the obtained adhesive layer (without peeling from the substrate) and pressure-bonded, and then the adhesive layer was cured to fix the lattice-shaped post-baking pattern. . Then, the lattice-shaped post-baking pattern was peeled from the base material to obtain a substrate on which partition walls were fixed.
- L2 of the obtained post-baking pattern in the form of a lattice was 125 ⁇ m
- L4 was 30 ⁇ m
- L3 was 30 ⁇ m
- L1 was 340 ⁇ m
- the overall size was 480 mm ⁇ 480 mm.
- a phosphor obtained by mixing GOS: Tb powder having a particle size of 5 ⁇ m with a benzyl alcohol solution of ethyl cellulose was filled in a cell partitioned by a partition so that the volume fraction was 65%, and dried at 120 ° C. was completed.
- the obtained scintillator panel 1 was set in FPD (PaxScan2520; manufactured by Varian) to produce a radiation detection apparatus.
- the radiation detector was irradiated with X-rays having a tube voltage of 60 kVp from the substrate side of the scintillator panel 1, and the amount of light emitted from the scintillator layer was detected by FPD to evaluate the luminance.
- the image clarity was evaluated based on the captured image of the rectangular wave chart. The brightness and image clarity of the scintillator panel 1 were both good.
- Example 2 The examination was performed in the same manner as in Example 1 except that a 500 mm ⁇ 500 mm ⁇ 0.3 mm alumina substrate (reflectance: 70%) was used as the substrate.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 80, which was favorable. Also, the image sharpness was good.
- Example 3 The examination was performed in the same manner as in Example 1 except that PD-200 (reflectance: 15%) having a thickness of 0.7 mm by polishing was used as the substrate.
- PD-200 reflectance: 15%
- the relative value of the luminance was 50, which was relatively good. Also, the image sharpness was good.
- Example 4 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B1 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m, and dried to form a coating film B.
- the application area of the coating film B was larger than that of the peeling assisting layer and was arranged so as to cover the entire peeling assisting layer. This was pre-baked in air at 585 ° C. for 15 minutes.
- the coating film B By forming the coating film B wider than the peeling auxiliary layer as described above, the area where the substrate and the coating film B are in direct contact after pre-baking is fused, and the coating film B is not peeled off. It was.
- the glass powder-containing paste A was applied to the surface of the pre-baked coating film B with a die coater so as to have a dry thickness of 500 ⁇ m, and dried to obtain a coating film A. Thereafter, exposure, development and baking were performed in the same manner as in Example 1 to obtain a lattice pattern, and the lattice pattern was filled with a phosphor and dried.
- the inner four sides of the peeling auxiliary layer were scratched and cleaved from the back side of the base material using a glass cutter. Thereby, the fused part of the reinforcing layer and the base material was removed, and the pattern could be easily peeled from the base material via the peeling auxiliary layer. Since the pattern has a reinforcing layer at the bottom, it has high strength, and damage to the pattern due to handling can be prevented.
- the obtained pattern was attached via a double-sided tape having a thickness of 10 ⁇ m so that the non-sintered layer side of the three-dimensional structure became the white PET film side, and the scintillator panel 4 was completed.
- the luminance in Example 1 was set to 100, the relative value of the luminance was 97, which was favorable. Also, the image sharpness was good.
- Example 5 The non-sintered paste 3 was screen-printed on the surface of the same substrate as in Example 1 so as to have a dry thickness of 0.9 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B2 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 3 ⁇ m, and dried to form a coating film B.
- a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 5.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 98, which was favorable. Also, the image sharpness was good.
- Example 6 The non-sintered paste 4 was applied to the surface of the same substrate as in Example 1 with a die coater so that the dry thickness was 2.2 ⁇ m, and dried to form a peeling assist layer.
- the glass powder-containing paste B3 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 13 ⁇ m and dried to form a coating film B.
- a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 6.
- the luminance in Example 1 was set to 100, the relative value of the luminance was 97, which was favorable. Also, the image sharpness was good.
- Example 7 The non-sintered paste 5 was applied to the surface of the same substrate as in Example 1 with a die coater so as to have a dry thickness of 10 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B1 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m, and dried to form a coating film B. Then, after pre-baking in the same manner as in Example 4, a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 7.
- Example 8 The non-sintered paste 6 was applied to the surface of the same substrate as in Example 1 with a die coater so as to have a dry thickness of 40 ⁇ m, and dried to form a peeling assist layer.
- the glass powder-containing paste B1 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 106 ⁇ m and dried to form a coating film B.
- Example 2 After pre-baking in the same manner as in Example 4, a lattice-like pattern and a phosphor layer were formed, cleaved to peel off the substrate and the pattern, and attached to a white PET film to complete the scintillator panel 8. Since the release layer was thick, the non-sintered inorganic powder that formed the release layer by the impact tended to peel off and scatter easily, but at a level with no problem.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 94, which was favorable. Also, the image sharpness was good.
- Example 9 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B4 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 440 ⁇ m, and dried to form a coating film B.
- a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and affixed to a white PET film to complete the scintillator panel 9.
- the relative luminance value was 78 when the luminance of Example 1 was set to 100. Since the reinforcing layer was thick, X-rays were absorbed and the luminance was low, but it was relatively good. Also, the image sharpness was good.
- Example 10 The non-sintered paste 6 was applied to the surface of the same substrate as in Example 1 with a die coater so as to have a dry thickness of 50 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B5 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 220 ⁇ m and dried to form a coating film B. Then, after pre-baking in the same manner as in Example 4, a lattice-like pattern and a phosphor layer were formed, cleaved to peel off the substrate and the pattern, and attached to a white PET film to complete the scintillator panel 10.
- the non-sintered layer was thick, the inorganic powder forming the non-sintered layer tended to fall off and scatter easily due to impact, but it was at a level with no problem.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 88. Since the reinforcing layer was thick, X-rays were absorbed and the luminance was slightly lowered, but it was good. Also, the image sharpness was good.
- Example 11 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B6 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m, dried, and then pre-baked in air at 585 ° C. for 15 minutes to form a coating film B.
- the glass powder-containing paste A coating film is applied to an ultrahigh pressure mercury lamp via a photomask having an opening corresponding to a desired pattern (a chromium mask having a grid-like opening having a pitch of 125 ⁇ m and a line width of 20 ⁇ m).
- Example 4 Was exposed at an exposure amount of 700 mJ / cm 2 and developed and fired in the same manner as in Example 1 to obtain a post-baking pattern in a lattice form.
- L2 of the obtained grid-like post-baking pattern is 125 ⁇ m
- L4 is 28 ⁇ m
- L3 is 28 ⁇ m
- L1 is 340 ⁇ m
- the overall size is 480 mm ⁇ 480 mm
- a narrower partition is formed than in Example 4.
- no pattern peeling occurred in the development process This is considered to be based on the fact that the surface roughness of the solid film after firing of the glass powder-containing paste B6 is larger than that of the glass powder-containing paste B1, and thus pattern peeling can be suppressed in the development process.
- Example 1 a phosphor layer was formed in the same manner as in Example 4, and the substrate and the pattern were peeled off and attached to a white PET film to complete the scintillator panel 11.
- the luminance in Example 1 was set to 100, the relative value of the luminance was 105, which was favorable. Also, the image sharpness was good.
- Example 12 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B7 was applied to the surface of the peeling assist layer with a die coater so that the dry thickness was 26 ⁇ m, dried, and then pre-baked in air at 585 ° C. for 15 minutes to form a coating film B.
- the glass powder-containing paste A coating film is applied to an ultrahigh pressure mercury lamp via a photomask having an opening corresponding to a desired pattern (a chromium mask having a grid-like opening having a pitch of 125 ⁇ m and a line width of 20 ⁇ m).
- Example 11 was exposed at an exposure amount of 650 mJ / cm 2 and developed and fired in the same manner as in Example 1 to obtain a post-baking pattern in a lattice form.
- L2 of the obtained post-fired pattern in the form of a lattice is 125 ⁇ m
- L4 is 25 ⁇ m
- L3 is 25 ⁇ m
- L1 is 340 ⁇ m
- the overall size is 480 mm ⁇ 480 mm
- a narrower partition is formed than in Example 11.
- a phosphor layer was formed in the same manner as in Example 11, and the substrate and the pattern were peeled off and pasted on a white PET film to complete the scintillator panel 12.
- the luminance in Example 1 was set to 100
- the relative value of the luminance was 111, which was favorable.
- the image sharpness was good.
- Example 13 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B8 was applied to the surface of the peeling assist layer with a die coater so that the dry thickness was 29 ⁇ m and dried, and then pre-baked in air at 585 ° C. for 15 minutes to form a coating film B.
- the glass powder-containing paste A coating film is applied to an ultrahigh pressure mercury lamp via a photomask having an opening corresponding to a desired pattern (a chromium mask having a grid-like opening having a pitch of 125 ⁇ m and a line width of 20 ⁇ m).
- Example 12 was exposed at an exposure amount of 600 mJ / cm 2 and developed and fired in the same manner as in Example 1 to obtain a post-baking pattern in a lattice form.
- L2 of the obtained lattice-like post-baking pattern is 125 ⁇ m
- L4 is 20 ⁇ m
- L3 is 20 ⁇ m
- L1 is 340 ⁇ m
- the overall size is 480 mm ⁇ 480 mm
- a narrower partition is formed than in Example 12.
- a phosphor layer was formed in the same manner as in Example 11, and the substrate and the pattern were peeled off and pasted on a white PET film to complete the scintillator panel 13.
- Example 1 since the voids in the reinforcing layer were large, ethyl cellulose contained in the phosphor paste penetrated the non-sintered layer in the phosphor filling step, and the peelability was slightly deteriorated, but it was peelable.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 122, which was very good. Also, the image sharpness was good.
- Example 14 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- a glass powder-containing paste B9 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m and dried to form a coating film B. Then, after pre-baking in the same manner as in Example 4, a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 14.
- Example 1 When the luminance of Example 1 is set to 100, the relative value of the luminance is 90, and the effect of lead X-ray absorption and the softening temperature are low. Although the tendency to become low was seen, it was favorable. Also, the image sharpness was good.
- Example 15 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B10 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m, and dried to form a coating film B.
- a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 15.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 96, which was favorable. Also, the image sharpness was good.
- Example 16 The non-sintered paste 2 was screen-printed on the surface of the same substrate as in Example 1 so that the dry thickness was 5 ⁇ m and dried to form a peeling assist layer.
- the glass powder-containing paste B1 was applied to the surface of the peeling assist layer with a die coater so as to have a dry thickness of 24 ⁇ m, and dried to form a first coating film B. Thereafter, the glass powder-containing paste B8 was applied and dried on the surface of the first coating film B by screen printing so that the dry thickness was 29 ⁇ m, whereby a second coating film B was formed.
- Example 13 After pre-baking in the same manner as in Example 13, a lattice-like pattern and a phosphor layer were formed, cleaved, the substrate and the pattern were peeled off, and attached to a white PET film to complete the scintillator panel 16.
- the luminance of Example 1 was set to 100, the relative value of the luminance was 119, which was very good.
- the ethyl cellulose contained in the phosphor paste penetrates to the non-sintered layer in the phosphor filling step. The peelability was also good. Furthermore, the image sharpness was also good.
- Example 17 In Example 4, a glass plate (Eagle-XG; manufactured by Corning; linear expansion coefficient 32 ⁇ 10 ⁇ 7 (K ⁇ 1 )) of 500 mm ⁇ 500 mm ⁇ 0.7 mm was used as a base material. In the same manner, the scintillator panel 17 was completed. When the luminance in Example 1 was set to 100, the relative value of the luminance was 97, which was favorable. Also, the image sharpness was good.
- Example 1 Comparative Example 1 Except that PD-200 was used as the substrate and the glass powder-containing paste A was directly applied to the surface thereof, a latticed post-baking pattern was formed in the same manner as in Example 1 to obtain a substrate on which the partition walls were fixed. .
- the phosphor was filled in the cells partitioned by the partition walls so that the volume fraction became 65%, and dried at 120 ° C. to complete the scintillator panel 2.
- a radiation detection apparatus was produced using the obtained scintillator panel 2 and evaluated in the same manner as in Example 1.
- the image sharpness was the same as that of Example 1, the relative value of the luminance when the luminance of Example 1 was set to 100 was as extremely low as 15, which was not practical. This decrease in luminance is considered to be based on the fact that X-rays are absorbed by the substrate, and that the substrate has a low reflectance, and light emitted by scintillation leaks to the substrate side.
- Comparative Example 2 Except that E6SQ was used as the substrate, partition formation was attempted in the same manner as in Comparative Example 1, but the pattern before firing collapsed as the white PET film E6SQ burned out in the firing process, and evaluation was not possible. It was.
- a scintillator panel 3 having no partition walls is formed by applying a phosphor obtained by mixing E6SQ as a substrate and mixing gadolinium oxysulfide powder having a particle diameter of 5 ⁇ m with a benzyl alcohol solution of ethyl cellulose on the surface to form a phosphor layer having a thickness of 340 ⁇ m.
- a radiation detection apparatus was produced using the obtained scintillator panel 3 and evaluated in the same manner as in Example 1.
- the luminance in Example 1 was set to 100, the relative value of the luminance was 145, which was favorable. However, the image sharpness was extremely low and was not practical.
- Comparative Example 4 Investigation was performed in the same manner as in Comparative Example 3 except that the thickness of the phosphor layer was changed to 50 ⁇ m.
- the luminance of Example 1 was set to 100, the relative value of the luminance was as low as 30, the image sharpness was insufficient, and it was not practical.
- the scintillator panel provided with the partition wall manufactured by the manufacturing method of the present invention contributes to the remarkable improvement in luminance and image sharpness in the radiation detection apparatus.
- the present invention can be usefully used as a scintillator panel constituting a radiation detection apparatus used for a medical diagnostic apparatus or a nondestructive inspection instrument.
Abstract
Description
(1)基材上に、ガラスパターンを形成した後、上記ガラスパターンを上記基材から剥離する、立体構造物の製造方法。
(2)基材の表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、塗布工程と、
上記塗布膜Aを加工して、焼成前パターンを得る、パターン形成工程と、
上記焼成前パターンを焼成して、焼成後パターンを得る、焼成工程と、
上記焼成後パターンを上記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。
(3)基材の表面に、非焼結ペーストを塗布して剥離補助層を得る、第1の塗布工程と、
上記剥離補助層の表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、第2の塗布工程と、
上記塗布膜Aを加工して焼成前パターンを得る、パターン形成工程と、
上記焼成前パターン及び上記剥離補助層を焼成して、焼成後パターン及び非焼結層を得る、焼成工程と、
上記焼成後パターン及び上記非焼結層を上記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。
(4)基材の表面に、非焼結ペーストを塗布して剥離補助層を得る、第1の塗布工程と、
上記剥離補助層の表面に、ガラス粉末含有ペーストBを塗布して塗布膜Bを得る、第2の塗布工程と、
上記塗布膜Bの表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、第3の塗布工程と、
上記塗布膜Aを加工して焼成前パターンを得る、パターン形成工程と、
上記焼成前パターン、上記塗布膜B及び上記剥離補助層を焼成して、焼成後パターン、補強層及び非焼結層を得る、焼成工程と、
上記焼成後パターン、上記補強層及び上記非焼結層を上記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。
(5)上記ガラスパターン又は上記焼成後パターンが、ストライプ状、格子状又はハニカム状の隔壁である、上記(1)~(4)のいずれかに記載の立体構造物の製造方法。
(6)上記パターン形成工程は、フォトリソグラフィにより上記塗布膜Aを加工する工程である、上記(2)~(5)のいずれかに記載の立体構造物の製造方法。
(7)上記ガラス粉末含有ペーストAは、ガラス粉末を無機成分中の主成分とする、上記(2)~(6)のいずれかに記載の立体構造物の製造方法。
(8)上記ガラス粉末は、低軟化点ガラスの粉末である、上記(2)~(7)のいずれかに記載の立体構造物の製造方法。
(9)上記(1)~(8)のいずれかに記載の立体構造物の製造方法により製造された、立体構造物を基板に載置する、載置工程を備える、シンチレータパネルの製造方法。
(10)さらに、上記立体構造物を樹脂又は粘着テープにより上記基板に固設する、固設工程を備える、上記(9)に記載のシンチレータパネルの製造方法。
(11)上記基板の反射率が、90%以上である、上記(9)又は(10)に記載のシンチレータパネルの製造方法。
(12)上記基板は、白色PETフィルムである、上記(9)~(11)のいずれかに記載のシンチレータパネルの製造方法。
(13)上記(1)~(8)のいずれかに記載の立体構造物の製造方法により製造された、立体構造物。
(14)上記(9)~(12)のいずれかに記載のシンチレータパネルの製造方法により製造された、シンチレータパネル。
(15)基板、ガラスを主成分とする隔壁、及び、非焼結層を備え、
上記非焼結層が、上記基板と上記隔壁との間に位置している、シンチレータパネル。
アルカリ金属酸化物 : 2~20質量%
酸化亜鉛 : 3~10質量%
酸化ケイ素 : 20~40質量%
酸化ホウ素 : 25~40質量%
酸化アルミニウム : 10~30質量%
アルカリ土類金属酸化物 : 5~15質量%
ガラス粉末を含む無機粉末の粒子径は、粒度分布測定装置(例えば、MT3300;日機装株式会社製)を用いて測定をすることができる。より具体的には、水を満たした粒度分布測定装置の試料室に無機粉末を投入し、300秒間超音波処理を行ってから測定をすることができる。
ペーストの作製に用いた原料は次のとおりである。
感光性モノマーM-1 : トリメチロールプロパントリアクリレート
感光性モノマーM-2 : テトラプロピレングリコールジメタクリレート
感光性ポリマー : メタクリル酸/メタクリル酸メチル/スチレン=40/40/30の質量比からなる共重合体のカルボキシル基に対して0.4当量のグリシジルメタクリレートを付加反応させたもの(重量平均分子量43000;酸価100)
バインダー樹脂 : 100cPエチルセルロース
光重合開始剤 : 2-ベンジル-2-ジメチルアミノ-1-(4-モルフォリノフェニル)ブタノン-1(IC369;BASF社製)
熱重合開始剤 : V-40
重合禁止剤 : 1,6-ヘキサンジオール-ビス[(3,5-ジ-t-ブチル-4-ヒドロキシフェニル)プロピオネート])
紫外線吸収剤溶液 : スダンIV(東京応化工業株式会社製)のγ-ブチロラクトン0.3質量%溶液
粘度調整剤 : フローノンEC121(共栄社化学社製)
溶媒A : γ-ブチロラクトン
溶媒B : テルピネオール
低軟化点ガラス粉末A : SiO2 27質量%、B2O3 31質量%、ZnO 6質量%、Li2O 7質量%、MgO 2質量%、CaO 2質量%、BaO 2質量%、Al2O3 23質量%、屈折率(ng):1.56、ガラス軟化温度588℃、線膨張係数70×10-7(K-1)、平均粒子径2.3μm
低軟化点ガラス粉末B : 低軟化点ガラス粉末Aと同組成、平均粒子径0.5μm
低軟化点ガラス粉末C : 低軟化点ガラス粉末Aと同組成、平均粒子径1.1μm
低軟化点ガラス粉末D : 低軟化点ガラス粉末Aと同組成、平均粒子径40μm
低軟化点ガラス粉末E : PbO 60質量%、B2O3 15質量%、ZnO 9質量%、SiO2 9質量%、Li2O 7質量%、屈折率(ng):1.8、ガラス軟化温度470℃、線膨張係数108×10-7(K-1)、平均粒子径0.9μm
低軟化点ガラス粉末F : Bi2O3 70質量%、B2O3 15質量%、SiO2 9質量%、ZnO 4質量%、MgO 2質量%、屈折率(ng):1.8、ガラス軟化温度520℃、線膨張係数92×10-7(K-1)、平均粒子径1.6μm
高軟化点ガラス粉末A : SiO2 30質量%、B2O3 31質量%、ZnO 6質量%、MgO 2質量%、CaO 2質量%、BaO 2質量%、Al2O3 27質量%、屈折率(ng):1.55、軟化温度790℃、熱膨張係数32×10-7(K-1)、平均粒子径2.3μm
高軟化点ガラス粉末B : 高軟化点ガラス粉末Aと同組成、平均粒子径15μm
酸化ケイ素粉末 : アドマテックス社製SO-E1、平均粒子径0.25μm
酸化チタン粉末A : 石原産業社製ST-21、平均粒子径0.02μm
酸化チタン粉末B : テイカ社製MT-600SA、平均粒子径0.05μm。
4質量部の感光性モノマーM-1、6質量部の感光性モノマーM-2、24質量部の感光性ポリマー、6質量部の光重合開始剤、0.2質量部の重合禁止剤及び12.8質量部の紫外線吸収剤溶液を、38質量部の溶媒Aに、温度80℃で加熱溶解した。得られた溶液を冷却した後、9質量部の粘度調整剤を添加して、有機溶液1を作製した。得られた有機溶液1をガラス板に塗布して乾燥することにより得られた有機塗膜の屈折率(ng)は、1.555であった。
60質量部の有機溶液1に、40質量部の高軟化点ガラス粉末を添加した後、3本ローラー混練機にて混練し、非焼結ペースト1を作製した。
3質量部のバインダー樹脂、1.5質量部の感光性モノマーM-1、0.5質量部の感光性モノマーM-2、0.05質量部の熱重合開始剤を、55質量部の溶媒Bに、温度60℃で加熱溶解した。得られた有機溶液2を冷却した後、40質量部の酸化ケイ素粉末を添加し、3本ローラー混練機にて混練し、非焼結ペースト2を作製した。
1質量部のバインダー樹脂、0.5質量部の感光性モノマーM-1、0.5質量部の感光性モノマーM-2、0.05質量部の熱重合開始剤を、78質量部の溶媒Bに、温度60℃で加熱溶解した。得られた有機溶液3を冷却した後、20質量部の酸化チタン粉末Aを添加し、3本ローラー混練機にて混練し、非焼結ペースト3を作製した。
2質量部のバインダー樹脂、0.5質量部の感光性モノマーM-1、0.5質量部の感光性モノマーM-2、0.05質量部の熱重合開始剤を、67質量部の溶媒Bに、温度60℃で加熱溶解した。得られた有機溶液4を冷却した後、30質量部の酸化チタン粉末Bを添加し、3本ローラー混練機にて混練し、非焼結ペースト4を作製した。
25質量部の有機溶液2に、75質量部の高軟化点ガラス粉末Aを添加した後、3本ローラー混練機にて混練し、非焼結ペースト5を作製した。
50質量部の有機溶液1に、50質量部の高軟化点ガラス粉末Bを添加した後、3本ローラー混練機にて混練し、非焼結ペースト6を作製した。
4質量部のバインダー樹脂を、50質量部の溶媒Bに、温度60℃で加熱溶解した。得られた有機溶液5を冷却した後、46質量部の低軟化点ガラス粉末Aを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB1を作製した。本ペーストを、スリットダイコーターによりガラス板(PD-200;旭硝子社製)に乾燥後厚さ30μmとなるように塗布した後、空気中585℃で15分間焼成して得られたベタ膜の表面粗さRaは0.2μm、空隙率は0.5%であった。
75質量部の有機溶液5に、25質量部の低軟化点ガラス粉末Bを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB2を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.1μm、空隙率は0.2%であった。
65質量部の有機溶液5に、35質量部の低軟化点ガラス粉末Cを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB3を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.2μm、空隙率は0.3%であった。
40質量部の有機溶液1に、60質量部の低軟化点ガラス粉末Aを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB4を作製した。本ペーストを、スリットダイコーターによりガラス板(PD-200;旭硝子社製)に厚さ500μmとなるように塗布した後、空気中585℃で15分間焼成して得られたベタ膜の表面粗さRaは0.2μm、空隙率は0.5%であった。
30質量部の有機溶液1に、70質量部の低軟化点ガラス粉末Dを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB5を作製した。本ペーストを用いて、ガラス粉末含有ペーストB4と同様の方法で作製したベタ膜の表面粗さRaは0.4μm、空隙率は1.3%であった。
54質量部の有機溶液1に、42質量部の低軟化点ガラス粉末A及び4質量部の高軟化点ガラスAを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB6を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.5μm、空隙率は0.8%であった。
54質量部の有機溶液1に、38質量部の低軟化点ガラス粉末A及び8質量部の高軟化点ガラスAを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB7を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.8μm、空隙率は1.2%であった。
54質量部の有機溶液1に、28質量部の低軟化点ガラス粉末A及び18質量部の高軟化点ガラスAを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB8を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは2.6μm、空隙率は17.8%であった。
40質量部の有機溶液1に、60質量部の低軟化点ガラス粉末Eを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB9を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.2μm、空隙率は0.3%であった。
40質量部の有機溶液1に、60質量部の低軟化点ガラス粉末Fを添加した後、3本ローラー混練機にて混練し、ガラス粉末含有ペーストB10を作製した。本ペーストを用いて、ガラス粉末含有ペーストB1と同様の方法で作製したベタ膜の表面粗さRaは0.4μm、空隙率は0.4%であった。
基材として、500mm×500mm×1.8mmのガラス板(PD-200;旭硝子社製、線膨張係数83×10-7(K-1))を用いた。基材の表面に、上記の非焼結ペースト1を乾燥厚さが50μmとなるようにダイコーターで塗布して乾燥し、剥離補助層を形成した。剥離補助層の表面に、ガラス粉末含有ペーストAを乾燥厚さが500μmになるようにダイコーターで塗布して乾燥し、塗布膜Aを得た。次に、所望のパターンに対応する開口部を有するフォトマスク(ピッチ125μm、線幅20μmの、格子状開口部を有するクロムマスク)を介して、塗布膜Aを、超高圧水銀灯を用いて750mJ/cm2の露光量で露光した。露光後の塗布膜Aは、0.5質量%のモノエタノールアミン水溶液中で現像し、未露光部分を除去して、格子状の焼成前パターンを得た。得られた格子状の焼成前パターンを、空気中585℃で15分間焼成して、格子状の焼成後パターンを得た。
基板として500mm×500mm×0.3mmのアルミナ基板(反射率70%)を用いた以外は、実施例1と同様に検討を行った。実施例1の輝度を100とした場合の輝度の相対値は80であり、良好であった。また、画像鮮明性も良好であった。
基板として研磨により厚さ0.7mmとしたPD-200(反射率15%)を用いた以外は、実施例1と同様に検討を行った。実施例1の輝度を100とした場合の輝度の相対値は50であり、比較的良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB1を乾燥厚さが24μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。この際に塗布膜Bの塗布面積を剥離補助層よりも広く、かつ剥離補助層全体を覆うような配置とした。これを空気中585℃で15分間プレ焼成した。上記のように塗布膜Bを剥離補助層よりも広く形成することで、プレ焼成後に基材と塗布膜Bとが直接接触するエリアは融着し、塗布膜Bが剥離してしまうことは無かった。次にプレ焼成後の塗布膜Bの表面に、ガラス粉末含有ペーストAを乾燥厚さが500μmになるようにダイコーターで塗布して乾燥し、塗布膜Aを得た。以降は実施例1と同様に露光、現像、焼成し格子状のパターンを得た後、格子状パターンに蛍光体を充填、乾燥した。次に基材の裏側からガラスカッターを用いて剥離補助層の内側4辺をけがき、割断した。これにより、補強層と基材の融着した部分が除かれ、剥離補助層を介して基材からパターンを容易に剥離できた。パターンは底部に補強層を有するため高い強度を有しており、ハンドリングによるパターンの損傷を防止できた。得られたパターンを、立体構造物の非焼結層側が白PETフィルム側になるように厚さ10μmの両面テープを介して貼り付け、シンチレータパネル4を完成した。実施例1の輝度を100とした場合の輝度の相対値は97であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト3を乾燥厚さが0.9μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB2を乾燥厚さが3μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル5を完成した。実施例1の輝度を100とした場合の輝度の相対値は98であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト4を乾燥厚さが2.2μmとなるようにダイコーターで塗布して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB3を乾燥厚さが13μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル6を完成した。実施例1の輝度を100とした場合の輝度の相対値は97であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト5を乾燥厚さが10μmとなるようにダイコーターで塗布して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB1を乾燥厚さが24μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル7を完成した。実施例1の輝度を100とした場合の輝度の相対値は95であり、良好であった。また、画像鮮明性も良好であった。
(実施例8)
実施例1と同一の基材の表面に、非焼結ペースト6を乾燥厚さが40μmとなるようにダイコーターで塗布して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB1を乾燥厚さが106μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル8を完成した。剥離層が厚いため、衝撃により剥離層を形成する非焼結無機粉末が剥離し、飛散しやすい傾向があったが、問題のないレベルであった。実施例1の輝度を100とした場合の輝度の相対値は94であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB4を乾燥厚さが440μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル9を完成した。実施例1の輝度を100とした場合の輝度の相対値は78であった。補強層の厚さが厚いため、X線が吸収されて輝度が低くなったが、比較的良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト6を乾燥厚さが50μmとなるようにダイコーターで塗布して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB5を乾燥厚さが220μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル10を完成した。非焼結層が厚いため、衝撃により非焼結層を形成する無機粉末が脱落し、飛散しやすい傾向があったが、問題のないレベルであった。実施例1の輝度を100とした場合の輝度の相対値は88であった。補強層の厚さが厚いため、X線が吸収されて輝度が若干低くなったが、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB6を乾燥厚さが24μmとなるようダイコーターで塗布、乾燥した後、空気中585℃で15分間プレ焼成し、塗布膜Bを形成した。次に、所望のパターンに対応する開口部を有するフォトマスク(ピッチ125μm、線幅20μmの、格子状開口部を有するクロムマスク)を介して、ガラス粉末含有ペーストAの塗布膜を、超高圧水銀灯を用いて700mJ/cm2の露光量で露光し、実施例1と同様に現像、焼成し、格子状の焼成後パターンを得た。得られた格子状の焼成後パターンのL2は125μm、L4は28μm、L3は28μm、L1は340μmであり、全体の大きさは480mm×480mmであり、実施例4に比べ細幅の隔壁を形成しても、現像工程においてパターン剥れは発生しなかった。これは、ガラス粉末含有ペーストB6の焼成後ベタ膜の表面粗さが、ガラス粉末含有ペーストB1に比べて大きいために、現像工程においてパターン剥がれが抑制できたことに基づくと考えられる。その後、実施例4と同様に蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル11を完成した。実施例1の輝度を100とした場合の輝度の相対値は105であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB7を乾燥厚さが26μmとなるようダイコーターで塗布、乾燥した後、空気中585℃で15分間プレ焼成し、塗布膜Bを形成した。次に、所望のパターンに対応する開口部を有するフォトマスク(ピッチ125μm、線幅20μmの、格子状開口部を有するクロムマスク)を介して、ガラス粉末含有ペーストAの塗布膜を、超高圧水銀灯を用いて650mJ/cm2の露光量で露光し、実施例1と同様に現像、焼成し、格子状の焼成後パターンを得た。得られた格子状の焼成後パターンのL2は125μm、L4は25μm、L3は25μm、L1は340μmであり、全体の大きさは480mm×480mmであり、実施例11に比べ細幅の隔壁を形成しても、現像工程においてパターン剥れは発生しなかった。その後、実施例11と同様に蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル12を完成した。実施例1の輝度を100とした場合の輝度の相対値は111であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB8を乾燥厚さが29μmとなるようダイコーターで塗布、乾燥した後、空気中585℃で15分間プレ焼成し、塗布膜Bを形成した。次に、所望のパターンに対応する開口部を有するフォトマスク(ピッチ125μm、線幅20μmの、格子状開口部を有するクロムマスク)を介して、ガラス粉末含有ペーストAの塗布膜を、超高圧水銀灯を用いて600mJ/cm2の露光量で露光し、実施例1と同様に現像、焼成し、格子状の焼成後パターンを得た。得られた格子状の焼成後パターンのL2は125μm、L4は20μm、L3は20μm、L1は340μmであり、全体の大きさは480mm×480mmであり、実施例12に比べ細幅の隔壁を形成しても、現像工程においてパターン剥れは発生しなかった。その後、実施例11と同様に蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル13を完成した。ここで、補強層の空隙が大きいため、蛍光体の充填工程において蛍光体ペーストに含まれるエチルセルロースが非焼結層に浸透し、剥離性が若干悪化したが、剥離可能であった。実施例1の輝度を100とした場合の輝度の相対値は122であり、極めて良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB9を乾燥厚さが24μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル14を完成した。実施例1の輝度を100とした場合の輝度の相対値は90であり、鉛のX線吸収の影響及び軟化温度が低いために補強層中に炭素残分が多くなり黒色化したことによって若干低くなる傾向が見られたが、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB10を乾燥厚さが24μmとなるようダイコーターで塗布して乾燥し、塗布膜Bを形成した。その後、実施例4と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル15を完成した。実施例1の輝度を100とした場合の輝度の相対値は96であり、良好であった。また、画像鮮明性も良好であった。
実施例1と同一の基材の表面に、非焼結ペースト2を乾燥厚さが5μmとなるようにスクリーン印刷して乾燥し、剥離補助層を形成した。剥離補助層の表面にガラス粉末含有ペーストB1を乾燥厚さが24μmとなるようダイコーターで塗布して乾燥し、1層目の塗布膜Bを形成した。その後、1層目の塗布膜Bの表面に、ガラス粉末含有ペーストB8を乾燥厚さが29μmとなるようスクリーン印刷により塗布乾燥し、2層目の塗布膜Bを形成した。その後、実施例13と同様にプレ焼成した後、格子状のパターン及び蛍光体層を形成し、割断して基材とパターンを剥離し、白PETフィルムに貼り付け、シンチレータパネル16を完成した。実施例1の輝度を100とした場合の輝度の相対値は119であり、極めて良好であった。また、実施例13と異なり、高空隙率の補強層の下に低空劇率の補強層が形成されているため、蛍光体の充填工程において蛍光体ペーストに含まれるエチルセルロースが非焼結層まで浸透することもなく、剥離性も良好であった。さらに、画像鮮明性も良好であった。
実施例4において、基材として500mm×500mm×0.7mmのガラス板(Eagle-XG;コーニング社製;線膨張係数32×10-7(K-1))を用いた以外は、実施例4と同様にしてシンチレータパネル17を完成した。実施例1の輝度を100とした場合の輝度の相対値は97であり、良好であった。また、画像鮮明性も良好であった。
PD-200を基板とし、その表面に直接ガラス粉末含有ペーストAを塗布したこと以外は、実施例1と同様に格子状の焼成後パターンを形成して、隔壁が固設された基板を得た。実施例1と同様に蛍光体を、隔壁により区画されたセルに体積分率が65%になるように充填して120℃で乾燥し、シンチレータパネル2を完成した。得られたシンチレータパネル2を用いて放射線検出装置を作製し、実施例1と同様の評価をした。画像鮮明性は実施例1と同等であったが、実施例1の輝度を100とした場合の輝度の相対値は15と極めて低く、実用的なものではなかった。この輝度低下は、基板にX線が吸収されてしまうこと、及び、基板の反射率が低く、シンチレーションによる発光光が基板側に漏れ出してしてしまうことに基づくと考えられる。
基板としてE6SQを用いたこと以外は、比較例1と同様にして隔壁形成を試みたが、焼成工程において白色PETフィルムであるE6SQの焼き飛びに伴って焼成前パターンが崩壊し、評価不可であった。
E6SQを基板とし、その表面に粒径5μmの酸硫化ガドリニウム粉末をエチルセルロースのベンジルアルコール溶液と混合した蛍光体を塗布し、厚さ340μmの蛍光体層を形成して、隔壁を有しないシンチレータパネル3を完成した。得られたシンチレータパネル3を用いて放射線検出装置を作製し、実施例1と同様の評価をした。実施例1の輝度を100とした場合の輝度の相対値は145であり良好であった。しかしながら、画像鮮明性は極めて低く、実用的なものではなかった。
蛍光体層の厚さを50μmとした以外は、比較例3と同様に検討を行った。実施例1の輝度を100とした場合の輝度の相対値は30と低く、画像鮮明性も不十分であって、実用的なものではなかった。
2 シンチレータパネル
3 出力基板
4 基板
5 接着層
6 隔壁
7 シンチレータ層
8 隔膜層
9 光電変換層
10 出力層
11 基板
12 電源部
13 反射膜
14 非焼結層
15 補強層
Claims (15)
- 基材上に、ガラスパターンを形成した後、前記ガラスパターンを前記基材から剥離する、立体構造物の製造方法。
- 基材の表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、塗布工程と、
前記塗布膜Aを加工して、焼成前パターンを得る、パターン形成工程と、
前記焼成前パターンを焼成して、焼成後パターンを得る、焼成工程と、
前記焼成後パターンを前記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。 - 基材の表面に、非焼結ペーストを塗布して剥離補助層を得る、第1の塗布工程と、
前記剥離補助層の表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、第2の塗布工程と、
前記塗布膜Aを加工して焼成前パターンを得る、パターン形成工程と、
前記焼成前パターン及び前記剥離補助層を焼成して、焼成後パターン及び非焼結層を得る、焼成工程と、
前記焼成後パターン及び前記非焼結層を前記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。 - 基材の表面に、非焼結ペーストを塗布して剥離補助層を得る、第1の塗布工程と、
前記剥離補助層の表面に、ガラス粉末含有ペーストBを塗布して塗布膜Bを得る、第2の塗布工程と、
前記塗布膜Bの表面に、ガラス粉末含有ペーストAを塗布して塗布膜Aを得る、第3の塗布工程と、
前記塗布膜Aを加工して焼成前パターンを得る、パターン形成工程と、
前記焼成前パターン、塗布膜B及び前記剥離補助層を焼成して、焼成後パターン、補強層及び非焼結層を得る、焼成工程と、
前記焼成後パターン、前記補強層及び前記非焼結層を前記基材から剥離して、立体構造物を得る、剥離工程と、を備える、立体構造物の製造方法。 - 前記ガラスパターン又は前記焼成後パターンが、ストライプ状、格子状又はハニカム状の隔壁である、請求項1~4のいずれか一項記載の立体構造物の製造方法。
- 前記パターン形成工程は、フォトリソグラフィにより前記塗布膜Aを加工する工程である、請求項2~5のいずれか一項記載の立体構造物の製造方法。
- 前記ガラス粉末含有ペーストAは、ガラス粉末を無機成分中の主成分とする、請求項2~6のいずれか一項記載の立体構造物の製造方法。
- 前記ガラス粉末は、低軟化点ガラスの粉末である、請求項2~7のいずれか一項記載の立体構造物の製造方法。
- 請求項1~8のいずれか一項記載の立体構造物の製造方法により製造された、立体構造物を基板に載置する、載置工程を備える、シンチレータパネルの製造方法。
- さらに、前記立体構造物を樹脂又は粘着テープにより前記基板に固設する、固設工程を備える、請求項9記載のシンチレータパネルの製造方法。
- 前記基板の反射率が、90%以上である、請求項9又は10記載のシンチレータパネルの製造方法。
- 前記基板は、白色PETフィルムである、請求項9~11のいずれか一項記載のシンチレータパネルの製造方法。
- 請求項1~8のいずれか一項記載の立体構造物の製造方法により製造された、立体構造物。
- 請求項9~12のいずれか一項記載のシンチレータパネルの製造方法により製造された、シンチレータパネル。
- 基板、ガラスを主成分とする隔壁、及び、非焼結層を備え、前記非焼結層が、前記基板と前記隔壁との間に位置している、シンチレータパネル。
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