Flat Insulation Layer for MRI Gradient Coil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing insulation layers for magnetic resonance gradient coils are complex and require special materials and molds, making them difficult to produce and integrate effectively into the coil structure.
Innovation Solution
A method using thermoplastic materials in the form of plates, strips, or foils that are three-dimensionally shaped through a hot shaping process to create local elevations for insulation, allowing for simpler and quicker production of insulation layers with sufficient insulating and temperature-resistant properties, enabling efficient resin flow and mechanical stability during casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-reinforced laminate plates with nub structure are used as insulation layers, then electrical insulation between coils is improved, but manufacturing complexity increases significantly
Solution Approach 1:
The patent changes the material state from thermosetting glass-reinforced laminate to thermoplastic material, enabling different processing methods. The thermoplastic material can be heated and formed without requiring complex mold structures, thus simplifying manufacturing while maintaining insulation properties through the elevated nub structure that creates spacing between coil layers
Solution Approach 2:
The patent extracts the essential function of the nub structure (creating spacing and insulation) from the complex glass-reinforced laminate system. By using thermoplastic material with integrated nubs formed through simpler processes, the design separates the critical insulation function from the complex manufacturing requirements of the original system
2Reliability
If glass-reinforced laminate plates are manufactured with nub structure using press molds, then insulation and spacing are achieved, but manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent changes the material from thermosetting to thermoplastic, allowing the nub structure to be formed through heating and forming processes rather than complex mold pressing. This enables faster production cycles and simpler manufacturing equipment while maintaining the necessary insulation and spacing functions
Solution Approach 2:
The thermoplastic material with nub structure can be pre-formed and then integrated into the coil assembly, allowing the insulation layers to be prepared in advance through simpler processes. This preliminary formation of the nub structure eliminates the need for complex in-situ molding during coil manufacturing, improving overall production efficiency
3Length of stationary object
If insulation layers are made thin to reduce gap dimension, then radial mounting height is reduced, but resin flow during casting becomes more difficult
Solution Approach 1:
The patent applies local quality by creating elevated nubs at specific locations on the insulation layer. These localized elevations provide the necessary spacing for resin flow paths while keeping the overall insulation layer thin. The nubs create channels and spaces that guide resin flow during vacuum casting, ensuring proper impregnation without requiring increased layer thickness
4Device complexity
If thermoplastic material is used instead of glass-reinforced laminate, then manufacturing is simplified, but temperature resistance must be sufficient for the application
Solution Approach 1:
The patent employs composite materials by combining thermoplastic base material with reinforcing fibers or fillers. This composite structure provides both the manufacturing advantages of thermoplastics (formability, processing speed) and the temperature resistance required for MRI gradient coil applications. The composite nature allows tailoring of thermal properties while maintaining ease of manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the production of insulation layers, ensuring proper spacing and adherence of gradient coils, maintaining mechanical integrity and allowing for efficient resin flow, thus preventing casting faults and ensuring operational stability.
Implementation Method 1
a thermoplastic insulating material in the form of a plate, strip or foil is deformed three-dimensionally in a hot shaping step
Implementation Method 2
thermoplastic insulating material... is deformed three-dimensionally in a hot shaping step
Data Source
AI summary
In a method for manufacturing a flat insulation layer for use in a gradient coil, a thermoplastic insulating material in the form of a plate, strip or foil is three-dimensionally deformed in a hot shaping step to form specified local elevations on at least one side, which are spaced apart from one another.