PHOTON COUNTING CONE-BEAM CT APPARATUS WITH MONOLITHIC CMOS INTEGRATED PIXEL DETECTORS
20170055923 · 2017-03-02
Inventors
Cpc classification
A61B6/4241
HUMAN NECESSITIES
International classification
A61B6/00
HUMAN NECESSITIES
Abstract
CBCT including monolithic photon counting FPD for medical applications requiring real-time 3D imaging, like mammography, interventional guided procedures or external beam radiotherapy, includes CMOS processed readout electronics monolithically integrated with a single crystalline X-ray absorber by covalent wafer bonding near room temperature and adapted for single photon counting providing high energy, temporal and spatial resolution.
Claims
1. A cone beam computer tomography (CBCT) system, comprising a. at least one X-ray source, and b. a flat panel detector (FPD) disposed for the direct detection of X-rays, wherein at least one absorber made from single crystal material communicates with at least one CMOS processed readout unit with which it forms a monolithic unit, and wherein the absorber is disposed to transform X-ray photons into electrical signals which are collected by the readout unit, and c. one or more devices providing data collection, computation and/or storage functionality, arranged and connected to receive electrical signals from the FPD and to generate computed tomography images on at least one computer screen.
2. The system of claim 1, wherein the at least one X-ray source and the FPD are mounted on a C-arm permitting interventional radiology.
3. The system of claim 1, wherein the at least one X-ray source and the FPD are mounted on a C-arm permitting 3D imaging for mammography.
4. The system of claim 1, wherein the FPD comprises a. at least one CMOS processed readout unit, and b. at least one X-ray absorber electrically communicating with the at least one readout unit by electrically transparent, oxide-free covalent wafer bonding, and wherein the FPD is configured to provide photon counting capability to permit energy resolved single photon counting.
5. The system of claim 1, wherein the at least one CMOS processed readout unit comprises at least one thinned silicon wafer with a thickness of about 10-100 m.
6. The system of claim 1, wherein the at least one CMOS processed readout unit comprises at least one thinned silicon wafer with a thickness of about 10-20 m.
7. The system of claim 2, wherein the at least one absorber is bonded in an oxide-free covalent wafer bond onto a back surface of the at least one CMOS processed readout unit.
8. The system of claim 1, wherein the FPD comprises buttable tiles and wherein the FPD comprises an area of at least 2020 cm.sup.2.
9. The system of claim 8, wherein the spacing between buttable tiles is in the range of 50-100 m.
10. The system of claim 1, wherein the FPD is adapted to provide a spatial resolution in the range of 100-200 m.
11. The system of claim 1, wherein the FPD is adapted to provide a spatial resolution in the range of 50-100 m.
12. The system of claim 1, wherein the at least one X-ray source, FPD and the one or more devices providing data collection, computation and/or storage functionality are adapted for use in one of a group of applications consisting of projection radiography, mammography and interventional radiology.
13. The system of claim 1, wherein the at least one X-ray source, FPD and the one or more devices providing data collection, computation and/or storage functionality are adapted for use in mammography.
14. The system of claim 1, wherein the absorber comprises at least one element with an atomic number larger than that of Si.
15. The system of claim 1, wherein the absorber is made from at least one of a group of absorber materials consisting of Si, Si.sub.1-xGe.sub.x alloys with Ge fractions 0x1, GaAs, CdTe, and Cd.sub.1-xZn.sub.xTe with x of about 10%.
16. The system of claim 1, wherein the absorber is made from a Si.sub.1-xGe.sub.x alloy with a Ge fraction of 0x1.
17. The system of claim 16, wherein the absorber is a 100-200 m thick epitaxial layer on a Si substrate.
18. The system of claim 1, wherein the absorber is made from a Si.sub.1-xGe.sub.x alloy with a Ge fraction of 0.6x0.8.
19. The system of claim 18, wherein the absorber is a 100-200 m thick epitaxial layer on a Si substrate.
20. The system of claim 1, wherein the at least one CMOS processed readout unit comprises implants configured to receive the analog electrical signals generated by absorbed X-ray photons in the at least one absorber, and wherein further circuitry amplifies, shapes and transforms these electrical signals into digital signals to be further processed in the one or more devices providing data collection, computation and/or storage functionality to be displayed as a computed tomography image on at least one computer screen.
21. A method for performing tomography, the method comprising steps of a. providing at least one X-ray source; b. using a FPD from at least one single crystal absorber covalently bonded to at least one CMOS processed readout unit, the at least one readout unit having single-photon counting capability; c. with the at least one X-ray source and the FPD mounted on a C-arm and a patient positioned in an appropriate operation position, activating the at least one readout unit to communicate with at least one device providing data collection, computation and storage functionality; d. disposing the at least one device to receive electrical signals from the FPD, and e. scanning the patient; and f. generating computed tomography images on at least one computer screen.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0067] It is the aim of this invention to enable a multitude of improved capabilities and new applications for X-ray 3D imaging for example in mammography and in the interventional suite at lower radiation dose by overcoming the limits of actual absorption materials in detectors and manufacturing processes.
[0068] The invention solves in particular the problems of materials incompatibility preventing the fabrication of sensitive, large area monolithic pixel detectors (FPD) employing high-Z materials to enhance absorption especially of X-ray photons with energies typically above 40 keV for use for example in C-arm Cone Beam Computed Tomography (CBCT) units. It is based on low-temperature direct wafer bonding techniques, preferably below 100 C. or even at room temperature, by means of which a CMOS processed readout unit and a single crystal absorber are combined in a monolithic detector structure. The invention is applicable in principle to any absorber material of which large wafers consisting of high quality single crystals are available or may become available in the future, such as for example GaAs, Ge, CdTe, Cd.sub.1-xZn.sub.xTe with x typically around 10% and SiGe. Alternatively, the invention is applicable to absorber materials which can be grown epitaxially on large Si wafers, provided they are substantially defect-free. One preferred class of materials identified to be suitable in particular for mammography applications are Si.sub.1-xGe.sub.x alloys with a Ge content x between about 0.2x0.8 or even more preferably between about 0.6x0.8. The band structure of Si.sub.1-xGe.sub.x alloys is Si-like with band gaps above 0.9 eV for 0x0.8 according to
[0069] Referring now to
[0070] Referring now to generic embodiment 100 of a FPD of
[0071] Depending on the doping sequence and the sign of the voltage 30 applied to the metallized back contact 32 of absorber 18, either holes 42 or electrons 44 may drift along the electric field lines 26 towards the front side 16 of chip 12 to be collected by implants 38 defining the pixels of the detector of size L. The pixel size L may be in the range of about 5-200 m, or preferably in the range of about 10-100 m, or even more preferably in the range of about 20-50 m. The electrical signals induced by the charges 42 or 44 collected by implants 38 may subsequently be processed by circuits 40 of readout unit 14. It is advisable to keep the thickness d of drift region 28 low in order to limit voltage 30 required for its depletion. Preferably the thickness d is in the range of 10-200 m or even more preferably about 10-50 m. The optimum thickness h of absorber 18 depends on the absorber material and the energies of the particles to be detected. It may range from about 20 m to 200 m or from 200 m to 1 mm or even to several mm. For example for mammography applications a 100-200 m thick Ge-rich Si.sub.1-xGe.sub.x absorber may be sufficient. For applications requiring X-ray energies substantially above 30 keV thicker absorbers must be used and/or absorbers from materials with higher Z. Fully CMOS processed chip 12, including all metallization layers, may for example have a size of about 22 cm.sup.2 or larger such as 44 cm.sup.2 or 66 cm.sup.2 or 1010 cm.sup.2 or even 1515 cm.sup.2 or yet more, depending on the available size of absorber 18. In the limiting case, chip 12 may for example cover a substantial part of a complete 200 mm wafer or even a 300 mm wafer.
[0072] Referring now to
[0073] Referring now to
[0074] Referring now to
[0075] When a large voltage 230 is applied to metallized back contact 232 of the absorber, resulting substantially in the depletion of absorber 218 and drift region 228 of CMOS processed wafer 212, e-h pairs generated by absorbed high energy material particles or photons are separated in the associated electric field and collected by implants 238, defining the pixel size, and metal electrode 232, respectively.
[0076] Referring now to
[0077] When a large voltage 230 is applied to metallized back contact 232 of absorber 218, resulting substantially in the depletion of absorber 218 and drift region 228 of CMOS processed wafer 212, e-h pairs generated by absorbed high energy material particles or photons are separated in the associated electric field and collected by implants 238, defining the pixel size L, and metal electrode 232, respectively.
[0078] Referring now to
[0079] In embodiment 200, direct wafer bond 250 is a covalent SiSi bond between back side 220 of CMOS processed wafer 212 and substrate 256 on which absorber 218 is epitaxially grown. In order for an intimate electrical contact to be established, the backside of wafer 212 and the bonding surface of substrate 256 have to be atomically flat and particle-free as well as oxide-free. It may be advisable to subject the backside 220 of wafer 212 and the bonding surface of substrate 256 to a chemical-mechanical polishing step prior to the surface treatment required for oxide-free covalent bonding. The bonding process preferably includes steps of optional pre-bonding annealing to reduce moisture on the as yet oxidized surfaces and post-bonding annealing. Pre- and post-bonding annealing are carried out at low temperature. Annealing temperatures may range between 100 C. and 200 C., or between 200 C. and 300 C., or between 300 C. and 400 C. In any case they must be below about 450 C. in order to avoid disintegration of the metallization of CMOS processed wafer 212.
[0080] When a large voltage 230 is applied to metallized back contact 232 of the absorber, resulting substantially in the depletion of absorber 218 and drift region 228 of CMOS processed wafer 212, c-h pairs generated by absorbed high energy material particles or photons are separated in the associated electric field and collected by implants 238, defining the pixel size L, and metal electrode 232, respectively.
[0081] Referring now to
[0082] Embodiment 200 is the most preferred embodiment for absorber layers which are both lattice and thermally mismatched with the Si substrate 256. The most preferred material of absorber layers 218 may be a Si.sub.1-xGe.sub.x alloy which may preferably have a Ge content above 20%. In a preferred aspect of the embodiment the Si.sub.1-xGe.sub.x alloy may have a high Ge content x of about 0.6x0.8. When having such SiGe alloy absorbers with a thickness of about 100-200 m, embodiment 200 is especially well suited for applications limited to X-ray energies below 40 keV, such as mammography applications. In an even more preferred aspect of the embodiment, the Si.sub.1-xGe.sub.x alloy may be compositionally graded to a high Ge content x of about 0.6x0.8 and optionally have a cap region of constant composition substantially equal to the final composition of the graded part, which may for example be graded linearly. In a most preferred aspect of embodiment 200 interface 258 between Si substrate 256 and pixelated absorber 218 is substantially defect-free. This can be achieved for example by choosing width w.sub.3 of semiconductor patches 252 forming pixelated absorber 218 and the grading rate both sufficiently small to permit elastic relaxation of the misfit stress during the epitaxial growth of absorber 218 (see for example M. Salvalaglio et al. in J. Appl. Phys. 116, 104306 (2014), and F. Isa et al. in Acta Materialia 114, 97 (2016), the entire disclosures of which are hereby incorporated by reference). The grading rate may preferably be chosen below about 3%, or below about 2%, or even below 1%. In other aspects of the embodiment interface areas 258 between substrate 256 and patches 252 of pixelated absorber 218 may not be substantially defect-free, but of sufficiently small size to keep dark currents at acceptable levels, when a large voltage 230 is applied to metallized back contact 232 of absorber 218 and implants 238 of CMOS processed wafer 212. As known to one skilled in the art, such small interface regions are commonly employed for example in techniques of aspect ratio trapping (ART), wherein threading dislocations are trapped at the sidewalls of windows in a dielectric mask into which a semiconductor is selectively grown (see for example I. berg et al., IEDM San Francisco, 2010, the entire disclosure of which is hereby incorporated by reference). With the help of ART, in addition, other absorber materials may be used apart from SiGe, such as GaAs, CdTe or CdZnTe.
[0083] The width w.sub.4 of trenches 254 is preferably smaller (ratio of about 1:2_) than the size w.sub.3 of absorber patches 252 or even more preferably much smaller (ratio of about 1_:10 or even 1:100). The width w.sub.4 of trenches may be below 1 m or below 200 nm or even below 100 nm, when a self-limited epitaxial growth process and deeply patterned substrates are used to define the size w.sub.3 of absorber patches 252 (see for example International Patent Application No. WO 2011/135432 to von Knel, the entire disclosure of which is hereby incorporated by reference). Alternatively, when a method of ART is used to define the size w.sub.3 of absorber patches 252, the width we of trenches 254 may be defined by the spacing of dielectric windows, which may be as narrow as the minimum width achievable by the lithography and deep reactive ion etching techniques used for patterning the dielectric mask. Preferably backside 220 of CMOS processed wafer 212 and substrate 256 are bonded by covalent bonds 250 providing an intimate electrical contact, preferably with few or no interface states or interface states passivated for example by hydrogen to improve interfacial charge transport (i.e. to attain ohmic behavior), between absorber layer 218 and drift region 228 across the entire backside 220 of wafer 212. In order for an intimate electrical contact to be established, backside 220 of wafer 212 and the bonding surface of substrate 256 also have to be atomically flat and particle-free as well as oxide-free. It may be advisable to subject backside 220 of wafer 212 and the bonding surface of absorber layer 256 to a chemical-mechanical polishing step prior to the surface treatment required for oxide-free covalent bonding. The bonding process preferably includes steps of optional pre-bonding annealing to reduced moisture on the as yet oxidized surfaces and optional post-bonding annealing. Pre- and post-bonding annealing steps are carried out at low temperature. Annealing temperatures may range between 100 C. and 200 C., or between 200 C. and 300 C., or between 300 C. and 400 C. In any case they must be below about 450 C. in order to avoid disintegration of the metallization of CMOS processed wafer 212. Distinct absorber patches 252 may be electrically connected by metallized back contact 232 extending substantially across the whole surface of the absorber.
[0084] When a large voltage 230 is applied to metallized back contact 232 of absorber 218, resulting substantially in the depletion of absorber 218 and drift region 228 of CMOS processed wafer 212, e-h pairs generated by absorbed high energy material particles or photons are separated in the associated electric field and collected by implants 238, defining the pixel size L, and metal electrode 232, respectively.
[0085] Referring now to
[0086] If the absorber material is characterized by a large mismatch of the thermal expansion coefficients with respect to those of Si wafer 312, absorber wafer 318 is preferably patterned in the form of distinct patches 352 of width w.sub.1 separated by trenches 354 of width w.sub.2 in a sixth step (
[0087] When a large voltage 330 is applied to metallized back contact 332 of absorber 318, resulting substantially in the depletion of absorber 318 and drift region 328 of thinned CMOS processed wafer 312, e-h pairs generated by absorbed high energy material particles or photons are separated in the associated electric field and collected by implants 338 of pixel detector 310.
[0088] Referring now to
[0089] Referring to
[0090] Fabrication 400 may be the most preferred fabrication method of pixel detector 410 for absorber layers 418 which are both lattice and thermally mismatched with the Si substrate 456. The preferred material of absorber layers 418 may be a Si.sub.1-xGe.sub.x alloy which may preferably have a Ge content above 20%. A Si.sub.1-xGe.sub.x alloy with a high Ge content x of about 0.6x0.8 may be an especially suitable alloy for absorber layer 418. Absorber layers with a thickness of 100-200 m made from Si.sub.1-xGe.sub.x alloys with high Ge content are especially well suited for applications limited to X-ray energies below 40 keV, such as mammography applications. The most preferred Si.sub.1-xGe.sub.x alloy may be compositionally graded to a high Ge content x of about 0.6x0.8 and optionally have a cap region of constant composition substantially equal to the final composition of the graded part, which may for example be graded linearly. In the most preferred fabrication 400 of pixel detector 410, interface 458 between Si substrate 456 and pixelated absorber 418 is substantially defect-free. This may for example be achieved by choosing width w.sub.3 of semiconductor patches 452 forming pixelated absorber 418 and the grading rate both sufficiently small to permit elastic relaxation of the misfit stress during the epitaxial growth of absorber 418 as proven to be effective in the simpler example of step graded SiGe nanostructures (see for example M. Salvalaglio et al., in J. Appl. Phys. 116, 104306 (2014), and F. Isa et al. in Acta Materialia 114, 97 (2016), the entire disclosures of which are hereby incorporated by reference). The grading rate may preferably be chosen below about 3%, or below about 2%, or even below 1%. In other aspects of the embodiment, interface areas 458 between substrate 456 and patches 452 of pixelated absorber 418 may not be substantially defect-free, but of sufficiently small size to keep dark currents at acceptable levels, when a large voltage 430 is applied to metallized back contact 432 of absorber 418 and implants 438 of thinned CMOS processed wafer 412. Such small interface regions are commonly employed for example in techniques of aspect ratio trapping (ART), wherein threading dislocations are trapped at the sidewalls of windows in a dielectric mask into which a semiconductor is selectively grown (see for example I. berg et al., in IEDM 2014, the entire disclosure of which is hereby incorporated by reference). With the help of ART also other absorber materials may be used apart from SiGe, such as GaAs, Ge, CdTe or CdZnTe.
[0091] Referring now to
[0092] Referring now to
[0093] Fabrication 500 of pixel detector 510 has the advantage that only the thickness d.sub.1 of thinned drift region 528 along with the height h.sub.4 of absorber patches 552 need to be depleted during detector operation. It may also be a preferred fabrication method of pixel detector 510 for absorber layers 518 which are both lattice and thermally mismatched with the Si substrate 556. The preferred material of absorber layers 518 may be a Si.sub.1-xGe.sub.x alloy which may preferably have a Ge content above 20%. A Si.sub.1-xGe.sub.x alloy with a high Ge content x of about 0.6x0.8 may be an especially suitable alloy for absorber layer 518. Absorber layers with a thickness of 100-200 m made from Si.sub.1-xGe.sub.x alloys with high Ge content are also especially suited for applications limited to X-ray energies below 40 keV, such as mammography applications. The most preferred Si.sub.1-xGe.sub.x alloy may be compositionally graded to a high Ge content x of about 0.6x0.8 and optionally have a cap region of constant composition substantially equal to the final composition of the graded part, which may for example be graded linearly. In the most preferred fabrication 500 of pixel detector 510 interface 558 between Si substrate 556 and pixelated absorber 518 is substantially defect-free. This may for example be achieved by choosing width w.sub.3 of semiconductor patches 552 forming pixelated absorber 518 and the grading rate both sufficiently small to permit elastic relaxation of the misfit stress during the epitaxial growth of absorber 518 as proven to be effective in the simpler example step graded SiGe nanostructures of (see for example M. Salvalaglio et al., in J. Appl. Phys. 116, 104306 (2014), and F. Isa et al. in Acta Materialia 114, 97 (2016), the entire disclosures of which are hereby incorporated by reference). The grading rate may preferably be chosen below about 3%, or below about 2%, or even below 1%. In other aspects of the embodiment interface areas 558 between substrate 556 and patches 552 of pixelated absorber 518 may not be substantially defect-free, but of sufficiently small size to keep dark currents at acceptable levels, when a large voltage 530 is applied to metallized back contact 532 of absorber 518 and implants 538 of thinned CMOS processed wafer 512. As known to one skilled in the art, such small interface regions are commonly employed for example in techniques of aspect ratio trapping (ART), wherein threading dislocations are trapped at the sidewalls of windows in a dielectric mask into which a semiconductor is selectively grown (see for example I. berg et al., in IEDM San Francisco, 2010, the entire disclosure of which is hereby incorporated by reference). With the help of ART also other absorber materials may be used apart from SiGe, such as GaAs, Ge, CdTe or CdZnTe.
Exemplary Applications of Photon Counting CBCT with Monolithic CMOS Integrated Pixel Detector
[0094] The CBCT of the present invention is integrated into and used in methods of the following medical applications, either human or veterinary, and other applications as described below.
Projection Radiography Example
[0095] The CBCT of the invention is used as a digital radiography system in which the X-rays transmitted through an object are converted into electrical signals in the FPD, generating digital information, which is transmitted and converted into an image displayed on a computer screen either locally or remotely.
[0096] There are many disease states in which classic diagnosis is obtained by plain radiographs, in combination with systems and methods incorporating the CBCT of the present invention. Examples of systems and method include those to diagnose various types of arthritis and pneumonia, bone tumors, fractures, congenital skeletal anomalies, and the like.
Interventional Radiology Example
[0097] The introduction of the monolithic CMOS integrated pixel FPD allows for the replacement of the cesium iodide (CsI) screen in fluoroscope designs. Therefore four dimensional CT (4DCT) is more accurate than fluoroscopy to define the CBCT of the invention even if the field of applications is the same. The photon counting CBCT with monolithic CMOS integrated pixel detectors allows real-time imaging of anatomical structures in motion, and the method is optionally augmented with a radio-contrast agent. Radio-contrast agents are administered by swallowing or injecting into the body of the patient to delineate anatomy, function of the blood vessels and various systems, e.g. the genitor-urinary system or the gastro-intestinal tract. Two radio-contrast agents are presently in common use. Barium sulfate (BaSO4) is administered to the subject orally or rectally for evaluation of the gastro-intestinal tract. Iodine in various formulations is given by oral, rectal, intra-arterial or intravenous pathways. These radio-contrast agents absorb or scatter X-rays, and in conjunction with real-time imaging, permit the imaging of dynamic physiological processes in the digestive tract or blood flow in the vascular system. Iodine contrast agents are also concentrated in abnormal areas in different concentrations than in normal tissues to make abnormalities (e.g. tumors, cysts, inflamed areas) visible.
[0098] More generally, the CBCT is used in interventional radiology systems and methods. Interventional radiology includes minimally invasive procedures that are guided by imaging systems utilizing systems and methods having the FPD described herein. These procedures are diagnostic or involve treatments, such as angiographic intervention and the systems used therewith. Exemplary systems include those procedures to diagnose and/or treat peripheral vascular disease, renal artery stenosis, inferior vena cava filter placement, gastrostomy tube placement, biliary stent intervention, and hepatic intervention. Non-angiographic procedures such as image guided orthopedic, thoracic, abdominal, head and neck, and neuro surgery, biopsies, brachytherapy or external beam radiotherapy, percutaneous drain and stent placement or radiofrequency ablation are also included. Images created with the assistance of the systems utilizing the pixel detector are used for guidance. The images created with the assistance of the photon counting FPD provide maps that permit the interventional radiologist to guide instruments through the body of a subject to the areas containing disease conditions. These systems and methods minimize the physical tissue trauma to the subject, reduce infection rates, recovery times, and hospitalization stays, such as in angiographic interventions, or non-angiographic procedures like image guided orthopedic, thoracic, abdominal, head and neck, and neuro surgery, biopsies, brachytherapy or external beam radiotherapy, percutaneous drain and stent placement or radiofrequency ablation.
Addendum
[0099] The following US patent documents, foreign patent documents, and Additional Publications are incorporated herein by reference thereto and relied upon:
US Patent Documents
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TABLE-US-00001 5,712,484 January 1998 Harada et al. 6,787,885 B2 September 2004 Esser et al. 8,237,126 B2 August 2012 von Knel et al. 8,378,310 B2 February 2009 Bornefalk et al. 8,792,965 B2 July 2014 Ning et al.
Other Patent Documents
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