Precision self-aligning CT detector sensors

A detector module for receiving x-rays attenuated by an object during a CT scan procedure, the detector module comprising:

• a module frame comprising a top surface and side surfaces;
• and
• a plurality of tileable detector sensors positioned on the module frame to receive the x-rays attenuated by the object, wherein each of the plurality of detector sensors comprises:
• a substrate layer having a first surface and a second surface opposite the first surface;
• an array of detector pixels configured to receive x-rays attenuated through the object and convert the x-rays into electrical signals, wherein the array of detector elements is disposed on the first surface of the substrate layer;
• an alignment plate directly or indirectly coupled to the array of detector elements and positioned on the second surface of the substrate layer opposite the array of detector pixels, the alignment plate including:
• alignment pins forming a datum structure to align the detector sensor on the module frame;
• and
• one or more threaded bosses configured to receive a fastener therein that secures the detector sensor to the module frame;
• and
• a thermal gap pad positioned in a recessed pocket formed in the alignment plate such that the thermal gap pad is compressed between the alignment plate and the module frame when the detector sensor is secured to the module frame, the thermal gap pad comprising a thermal interface material (TIM) that provides a consistent low variation thermal interface with low thermal resistance between the detector sensor and the module frame, wherein the alignment plate is disposed between the substrate layer and the thermal gap pad;
• wherein the module frame includes datum holes formed therein that receive the alignment pins of each respective detector sensor therein when the detector sensors are mounted on the module frame, so as to align the detector sensors on the module frame.

A detector module for receiving x-rays attenuated by an object during a CT scan procedure, the detector module comprising:

• a module frame;
• and
• a plurality of selectively addable detector sensors positioned on the top surface of the module frame so as to receive the x-rays attenuated by the object;
• wherein each of the plurality of detector sensors comprises:
• a substrate layer having a first surface and a second surface opposite the first surface;
• an array of detector elements configured to receive x-rays attenuated through the object and convert the x-rays into electrical signals, wherein the array of detector elements is disposed on the first surface of the substrate layer;
• an alignment plate positioned on the detector sensor on the second surface of the substrate layer opposite the array of detector elements, the alignment plate including alignment pins forming a datum structure to align the detector sensor on the module frame;
• and
• a thermal gap pad positioned in a recessed pocket formed in the alignment plate such that the thermal gap pad is compressed between the alignment plate and the module frame when the detector sensor is secured to the module frame, the thermal gap pad comprising a thermal interface material (TIM) that provides a consistent low variation thermal interface with low thermal resistance between the detector sensor and the module frame, wherein the alignment plate is disposed between the substrate layer and the thermal gap pad;
• wherein the module frame includes datum holes formed therein that receive the alignment pins of each respective detector sensor therein when the detector sensors are mounted on the module frame, so as to align the detector sensors on the module frame.