Overmolded RF Coil Resonators for Precise Wire Spacing
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Solution Overview
Problem
Manufacturing resonators for RF coils in MRI systems is challenging due to the need for precise assembly and integration with electronics units.
Innovation Solution
A method involving overmolding dielectric material over conductive wires held in a fixed spatial arrangement with a former to form overmolded conductive wire assemblies, which are then coupled to electronics units, incorporating features like strain reliefs for a robust interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used for resonators, then manufacturing complexity increases, but manufacturing precision decreases
Solution Approach 1:
The patent combines multiple functions into the overmolded assembly: the former holds wires in precise spacing, the dielectric material provides insulation and structural support, and strain reliefs are integrated into the mold. This merging eliminates separate assembly steps for positioning, insulating, and protecting wires, achieving precise wire spacing while reducing overall manufacturing complexity
Solution Approach 2:
The former is used to pre-position the conductive wires in the exact required spacing before the overmolding process. This preliminary arrangement ensures precise wire spacing is achieved without complex assembly operations later, as the wires are already correctly positioned when the dielectric material is molded around them
2Reliability
If simple assembly processes are used, then manufacturing speed increases, but reliability decreases
Solution Approach 1:
The overmolding process merges multiple protective and functional features into a single integrated component: insulation, mechanical support, strain relief, and electrical isolation are all incorporated into one molded piece. This integration maintains high reliability while simplifying the manufacturing process to a single overmolding operation
Solution Approach 2:
The patent uses composite construction with conductive wires embedded in dielectric material, creating an integrated assembly that combines the electrical conductivity needed for signal transmission with the insulation and mechanical properties of the dielectric. This composite structure enhances reliability while maintaining manufacturing simplicity
Data Source
AI summary
A method for manufacturing overmolded resonators for a radio frequency receiving coil assembly for a magnetic resonance imaging system includes providing a pair of conductive wires, wherein each conductive wire of the pair of conductive wires has a set required length. The method also includes holding the pair of conductive wires in a fixed spatial arrangement relative to each other. The method further includes overmolding dielectric material over the pair of conductive wires to form an overmolded conductive wire assembly. The method even further includes coupling the pair of conductive wires to an electronics unit.