Flexible MRI Receive Coil Fabrication via Single Screen Printing
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Solution Overview
Problem
Current MRI receiver coils have a rigid structure, leading to suboptimal signal-to-noise ratio (SNR) and poor patient conformity due to their one-size-fits-all design, which limits scan speed and image quality, especially when not properly aligned with the patient.
Innovation Solution
A method for manufacturing flexible MRI receiver coils using a single screen printing mask to create a symmetric multilayer design, where conductive patterns are printed on both sides of a flexible substrate to form capacitors, allowing for adjustable positioning and repeated patterning to form arrays that conform to various patient sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rigid or semi-rigid coil structures are used, then manufacturing is simpler, but patient conformity and signal-to-noise ratio deteriorate
Solution Approach 1:
The patent employs flexible printed circuit board technology to create coil structures that can bend and conform to various patient body shapes. The flexible substrate allows the coil array to adapt to different anatomical configurations while maintaining electrical connectivity, directly resolving the contradiction between manufacturing simplicity and patient conformity.
Solution Approach 2:
The coil array is designed with flexible elements that can dynamically adjust their shape to match different patient geometries. This dynamic adaptability allows the same rigid-manufactured components to achieve soft, conforming behavior during use, improving both SNR through better contact and maintaining ease of manufacture.
2Device complexity
If one-size-fits-all coil design is used, then device complexity is reduced, but signal-to-noise ratio and image quality deteriorate
Solution Approach 1:
The coil array is divided into multiple independent or semi-independent coil elements that can be selectively activated or positioned. This segmentation allows the system to maintain a simple, uniform manufacturing process while achieving optimized SNR for different patient sizes and scan regions by activating only the necessary coil elements.
Solution Approach 2:
The flexible coil array is designed to serve multiple functions and patient types through a single device configuration. By incorporating adjustable positioning mechanisms and flexible geometry, one coil design can universally accommodate various patient anatomies, maintaining design simplicity while improving reliability across different applications.
3Device complexity
If improper distance between coil array and patient is maintained, then device complexity is minimized, but signal-to-noise ratio deteriorates
Solution Approach 1:
The flexible coil array can dynamically adjust its shape and positioning to maintain optimal distance from the patient surface. This dynamic capability allows the coil elements to conform closely to body contours, minimizing the air gap and improving coupling efficiency without requiring complex active positioning mechanisms.
Solution Approach 2:
The flexible substrate enables the coil array to be positioned in close proximity to the patient by conforming to body surfaces. This flexibility eliminates the need for complex positioning mechanisms while improving SNR through reduced distance between the coil elements and the signal source.
4Manufacturing precision
If traditional multi-mask printing process is used, then manufacturing precision is improved, but productivity and production cost deteriorate
Solution Approach 1:
The patent combines multiple printing operations into a single multi-layer printing process using one mask. Conductive layers are deposited on both sides of the flexible substrate in sequence without removing the mask, merging what would traditionally require multiple masks and removal steps into one continuous operation. This increases productivity while maintaining precision through the mask's inherent alignment capabilities.
Solution Approach 2:
The mask is positioned and secured to the substrate before any conductive material deposition begins. This preliminary action establishes the reference frame for all subsequent printing layers, ensuring precise pattern alignment is achieved from the start. The mask remains in place throughout the entire multi-layer printing process, eliminating repeated positioning errors and improving both precision and throughput.
5Manufacturing precision
If traditional multi-mask printing process is used, then manufacturing precision is improved, but production cost deteriorates
Solution Approach 1:
By merging multiple printing operations into a single process using one mask, the patent eliminates the need to manufacture, store, and manage multiple expensive masks. This consolidation significantly reduces production costs while maintaining manufacturing precision through the unified printing approach.
Solution Approach 2:
A single mask serves multiple functions by remaining in place during deposition of multiple conductive layers on both sides of the substrate. This universal mask performs what would traditionally require several specialized masks, reducing tooling costs and simplifying the manufacturing process while maintaining alignment accuracy.
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 approach increases manufacturing throughput, reduces production costs, and enhances SNR by enabling coils to intimately conform to different body types, resulting in higher quality images and faster scan times across various patient anatomies.
Implementation Method 1
printing includes screen printing and the mask includes a screen printing mask
Data Source
AI summary
Methods for forming flexible magnetic resonance imaging (MRI) receive coil devices having at least one receive coil with at least one capacitor are provided and include providing a flexible substrate having a first surface and a second surface opposite the first surface, forming a first conductor pattern on the first surface by printing a first layer of conductive material on the first surface using a printing mask having a pattern, and forming a second conductor pattern on the second surface by printing a second layer of conductive material on the second surface using the same printing mask or identical printing mask, wherein a portion of the first conductor pattern on the first surface overlaps with a portion of the second conductor pattern on the second surface with the flexible substrate therebetween to form the at least one capacitor element.