Gradient Coil Carrier Unit with Encapsulating Pockets
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Solution Overview
Problem
Gradient coil units in magnetic resonance devices suffer from interface damage due to mechanical stresses during the curing of encapsulating materials, leading to vibrations and reduced durability, which impair image quality and increase maintenance costs.
Innovation Solution
Incorporating encapsulating pockets with a delimiting structure and filling material within the carrier unit, allowing for elastic deformation during curing, thereby reducing mechanical stress and preventing interface damage, and using materials like polymers and thermosets to enhance mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If encapsulating material is used to connect primary coil and secondary coil, then mechanical strength and structural integrity are improved, but mechanical stresses during curing cause interface damage such as cracks and delamination
Solution Approach 1:
The patent applies local quality by creating a multi-layer encapsulating material structure with different properties at different locations. The first encapsulating material layer has different characteristics than the second layer, allowing each layer to address specific stress issues at different interfaces, thereby reducing delamination and cracks while maintaining overall structural integrity
Solution Approach 2:
The patent uses composite materials by combining two different encapsulating materials with distinct properties. This composite structure allows the first material to address certain mechanical stress issues while the second material addresses other aspects, reducing interface damage through material diversity and complementary properties
2Volume of moving object
If gradient coil unit is arranged within basic magnet, then space utilization is improved, but Lorentz forces cause vibrations that impair image data quality
Solution Approach 1:
The patent applies beforehand cushioning by incorporating damping elements and vibration isolation structures into the gradient coil unit design before operation. These elements are pre-installed to absorb and reduce Lorentz force-induced vibrations, protecting the system from harmful vibrations that would otherwise impair image data quality
Solution Approach 2:
The patent uses intermediary elements such as damping materials and vibration isolation components that act as mediators between the gradient coil unit and the basic magnet. These intermediaries absorb and dissipate vibrational energy, preventing direct transmission of harmful vibrations to the magnet and maintaining image quality
3Strength
If encapsulating material undergoes thermal and chemical processes during curing, then structural bonding is improved, but mechanical stresses cause material fatigue and reduced durability
Solution Approach 1:
The patent applies parameter changes by carefully controlling and optimizing the curing process parameters such as temperature, pressure, and curing time. By adjusting these parameters, the material achieves adequate bonding strength while minimizing thermal and chemical stresses that would otherwise cause material fatigue and reduce durability over time
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
The solution significantly reduces interface damage, increases the robustness and service life of gradient coil units, and decreases maintenance and spare part costs by allowing controlled mechanical stress relief and efficient integration into the gradient coil unit.
Implementation Method 1
allowing for elastic deformation during curing, thereby reducing mechanical stress and preventing interface damage
Implementation Method 2
A primary coil is typically configured to generate a magnet field gradient in one spatial direction. A secondary coil corresponding thereto screens the magnetic field gradient generated by the primary coil
Implementation Method 3
A gradient coil unit is typically arranged within the basic magnet, as a result of which Lorentz forces act on the gradient coil unit and the connector cables thereof during the operation of the gradient coil unit, thus resulting in vibrations of the gradient coil unit
Data Source
AI summary
A gradient coil unit includes a primary coil, a secondary coil and a carrier unit. The carrier unit stabilizes the primary coil and the secondary coil, and is formed from an encapsulating material. The carrier unit may include at least two encapsulating pockets that each include a delimiting structure and a filling. A thermoset component unit includes an electronic component and a carrier unit surrounding the electronic component, and being formed from an encapsulating material. The carrier unit may include at least one encapsulating pocket that includes a delimiting structure having a first material, and a filling having a second material.