Gradient Coil Resin-Free Mechanical Fastening

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Solution Overview

Problem

Conventional gradient coils in magnetic resonance imaging (MRI) devices face issues with resin contraction during hardening, leading to cracks and detachment, especially where large amounts of resin are impregnated, which can cause insulation deterioration and affect imaging quality.

Innovation Solution

The gradient coil design incorporates a saddle coil conductor with a spiral pattern and a second pattern of stripes parallel to the axis, reducing the amount of impregnated resin and using mechanical processing to prevent cracks and detachment, while also employing tape fixation to secure the coils and prevent Lorentz force-induced movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If resin is impregnated to fill gaps between laminated coils and cooling pipes, then the structural integrity is improved, but resin contraction during hardening causes cracks and detachment

Engineering Contradiction:

Improvestructural integrityVSAvoidcrack-free quality

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent extracts the problematic resin impregnation process and replaces it with mechanical fastening using bolts and spacers. The resin is completely removed from the structural bonding function, eliminating the contraction-induced cracking issue while maintaining structural integrity through alternative mechanical means.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (resin hardening) with a mechanical fastening system consisting of bolts, spacers, and pressing members. This substitution eliminates the harmful chemical contraction effect while achieving the same structural consolidation goal through pure mechanical force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional resin impregnation method is used, then manufacturing process is simplified, but manufacturing precision deteriorates due to cracks and detachment

Engineering Contradiction:

Improveprocess simplicityVSAvoidcoil positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent segments the manufacturing process into distinct mechanical assembly steps: positioning coils using spacers, fastening with bolts, and applying controlled pressure with pressing members. This segmentation replaces the single-step resin impregnation process, improving precision through controlled mechanical operations while maintaining ease of manufacture through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary positioning of coils and cooling pipes using spacers and fastening members before final assembly. This preliminary mechanical fixation ensures precise positioning is achieved before the gradient coil is enclosed, preventing positioning errors that would occur with resin contraction.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If gradient coil is enclosed in a bore, then structural stability is improved, but adjustment and repair become difficult

Engineering Contradiction:

Improvegradient coil stabilityVSAvoidadjustability

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The patent creates a dynamically adjustable assembly where the gradient coil can be positioned and secured at different locations along the bore using movable pressing members and fastening mechanisms. This dynamic design allows the coil to be stably enclosed while maintaining adjustability for repair and repositioning, unlike fixed enclosed designs.

Inventive Principle:

Principle #15Dynamics

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 design reduces manufacturing time, stabilizes the gradient coil quality, and minimizes the occurrence of eddy currents and magnetic field components that could interfere with imaging, resulting in a high-quality gradient coil and MRI device.

Implementation Method 1

the occurrence of eddy currents and magnetic field components interfering with imaging is minimized

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

employing tape fixation to secure the coils and prevent Lorentz force-induced movement

Methodology Applied

Scientific EffectLorentz force: Lorentz Force

Data Source

PatentUS10551453B2Gradient coil and magnetic resonance imaging device

Publication Date: 2020.02.04 TOSHIBA MEDICAL SYST CORP

AI summary

A gradient coil according to an embodiment includes a saddle coil conductor part that is formed of a conductive material to have a substantially cylindrical shape. The conductor part includes a first region on which a spiral shaped first pattern is formed and a second region on which a second pattern different from the spiral shaped first pattern is formed.