Gradient Coil Additive Manufacturing for MRI Systems
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Solution Overview
Problem
Conventional methods for manufacturing hollow gradient coils, such as rolling copper tubing, result in distortion and variability, and fail to meet diverse performance requirements due to uniform insulation materials.
Innovation Solution
A method involving additive manufacturing to create a substrate with a non-conductive material, shaped to match the spiral form of the target gradient coil, which is then coated with a conductive material, allowing for complex geometries and varied material properties to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rolling process is used to form curved surface from wound copper tubing, then hollow gradient coil can be manufactured, but distortion occurs affecting gradient coil performance
Solution Approach 1:
Instead of forming the curved surface first and then winding the conductor, the invention inverts the process by first creating a curved substrate (mold) and then depositing the conductive material directly onto it. This eliminates the distortion problem caused by rolling copper tubing, as the conductor is formed in its final curved shape during deposition rather than being bent afterward.
Solution Approach 2:
The invention replaces the mechanical rolling and winding process with a deposition process. Rather than mechanically forming and assembling components, the conductive material is deposited layer by layer to directly form the curved conductor, eliminating mechanical distortion.
2Ease of manufacture
If conventional rolling process is used to form curved surface from wound copper tubing, then hollow gradient coil can be manufactured, but variations between gradient coils are introduced
Solution Approach 1:
The invention replaces the mechanical rolling and winding process with a deposition process. Rather than mechanically forming and assembling components, the conductive material is deposited layer by layer to directly form the curved conductor, eliminating mechanical distortion.
Solution Approach 2:
The invention changes the manufacturing parameters from mechanical forming to controlled material deposition. By controlling the deposition process parameters (layer thickness, deposition rate, substrate temperature), consistent and reproducible gradient coils can be manufactured with reduced variations between units.
3Ease of manufacture
If single material insulation layer is used, then manufacturing is simplified, but different acoustic properties requirements at different portions cannot be met
Solution Approach 1:
The invention applies local quality by using different insulation materials at different portions of the gradient coil. The substrate can be composed of multiple materials with different acoustic properties, allowing optimization of acoustic performance at specific locations while maintaining overall structural integrity.
Solution Approach 2:
The invention uses composite materials by combining different insulation materials in the substrate structure. This allows the gradient coil to have varied acoustic properties at different portions, meeting diverse performance requirements while maintaining manufacturing feasibility through layered construction.
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 simplifies the manufacturing of hollow gradient coils with complex geometries, reduces distortion, and enables tailored material properties for improved performance in MRI systems, such as tighter structures and efficient heat management.
Implementation Method 1
The curved conductor is formed by a process which comprises depositing at least one non-conductive material layer by layer to form a substrate
Implementation Method 2
coating at least a portion of a surface of the substrate with a conductive material
Data Source
AI summary
A gradient coil comprises a curved conductor, which is tubular and has a general spiral shape. The curved conductor is formed by a process comprising depositing at least one non-conductive material layer by layer to form a substrate, and coating at least a portion of a surface of the substrate with a conductive material. The substrate has a shape matching with the general spiral shape of the curved conductor. Embodiments of the present disclosure further refer to a method for manufacturing the gradient coil.