Solenoidal Magnet Structure with Preformed Support
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Solution Overview
Problem
The high cost and labor-intensive process of producing solenoidal magnet structures for generating strong magnetic fields, particularly in NMR and MRI systems, due to the need for rigid and accurately dimensioned formers, which are expensive and increase the overall diameter of the magnet, affecting patient access and system length.
Innovation Solution
A method involving a preformed mechanical supporting structure, such as a metal or composite cylinder, bonded to the radially outer surface of the coils, which eliminates frictional interfaces and uses a thermal diffusion barrier to prevent quenching, allowing for accurate positioning and reduced internal diameter, thereby reducing production costs and labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid and accurately dimensioned former is used to ensure coil positioning accuracy and prevent quenching, then manufacturing precision and reliability are improved, but production cost and labor intensity increase significantly
Solution Approach 1:
The system is divided into two functional parts: a simple preformed cylindrical support structure that provides mechanical strength and positioning, and a separately applied resin impregnation layer that provides thermal insulation and bonding. This segmentation allows each component to be optimized independently - the cylinder can be made from inexpensive standard materials while the resin provides the precision positioning and thermal protection needed.
Solution Approach 2:
The resin impregnation acts as an intermediary substance between the cylindrical support structure and the coils. It serves multiple functions: thermally insulating the coils from the cylinder, bonding the coils to the cylinder, and providing precise dimensional control for coil positioning. This intermediary allows the use of a simple, inexpensive cylinder while achieving the precision requirements.
2Ease of manufacture
If a preformed cylindrical mechanical support structure is used instead of an accurately dimensioned former, then production cost and labor are reduced, but coil positioning accuracy and structural rigidity may be compromised
Solution Approach 1:
The invention changes the functional parameters of the support structure. Instead of requiring the cylinder itself to provide precise dimensions and thermal insulation, the resin impregnation layer assumes these parameters. The cylinder's role is reduced to providing basic mechanical strength and cylindrical geometry, which can be achieved with standard manufacturing tolerances and inexpensive materials.
3Device complexity
If the coils are directly mounted on a former without a thermal diffusion barrier, then the structure is simpler and shorter, but the risk of quenching due to heat transfer increases
Solution Approach 1:
The resin impregnation merges multiple protective functions into a single layer: thermal insulation to prevent quenching, mechanical bonding to secure coils, and dimensional stability for positioning accuracy. This merged approach provides comprehensive protection while adding minimal structural complexity compared to separate insulation and bonding layers.
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 results in a cost-effective, lightweight, and accurately positioned solenoidal magnet structure capable of withstanding electromagnetic forces, improving patient access and system length while maintaining field quality, by utilizing a preformed mechanical support structure that is not necessarily accurately dimensioned, thus reducing production expenses.
Implementation Method 1
uses a thermal diffusion barrier to prevent quenching
Implementation Method 2
bonded to the radially outer surface of the coils
Data Source
AI summary
A method of manufacturing a solenoidal magnet structure, comprising the steps of providing a collapsible mold in which to wind coils; winding wire into defined positions (88) in the mold to form coils (34); placing a preformed tubular mechanical support structure (102, 120) over the coils (34) so wound; impregnating the coils and bonding them to the mechanical support structure by applying a thermosetting resin and allowing the thermosetting resin to harden; and collapsing the mold and removing the resultant solenoidal magnet structure comprising the resin impregnated coils and the mechanical support structure from the mold as a single solid piece.