Stretchable RF Coil Fabrication Using Automated Sewing
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Solution Overview
Problem
Existing methods for fabricating radio-frequency (RF) coil assemblies for magnetic resonance (MR) systems are tedious, prone to errors, and unsuitable for large-scale production due to their manual nature and limitations in flexibility and pattern design, leading to defects and reduced signal-to-noise ratio (SNR) and subject comfort.
Innovation Solution
The use of a sewing machine with specialized accessory assemblies, including a substrate holder and needles with fraying-reducing linings, to automate and customize the fabrication of stretchable RF coil assemblies with nonlinear coil loops and stretchable substrates, enabling precise and efficient assembly of RF coil loops with improved SNR and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual fabrication methods are used for RF coil assemblies, then flexibility in design and customization is achieved, but fabrication time is excessive and productivity is low
Solution Approach 1:
The patent replaces manual mechanical fabrication processes with an automated sewing machine system. The sewing machine uses a programmable needle mechanism to automatically stitch coil loops onto substrates according to digital design patterns, eliminating manual labor while maintaining design flexibility through software control.
Solution Approach 2:
The invention changes the fabrication process parameters by introducing automated control systems, programmable stitching patterns, and adjustable sewing parameters (speed, stitch length, tension). This allows rapid reconfiguration for different coil designs without manual intervention, simultaneously improving productivity and design adaptability.
2Adaptability or versatility
If manual assembly methods are used, then complex patterns can be customized, but fabrication quality is reduced due to human error
Solution Approach 1:
The patent replaces manual assembly with an automated sewing machine system that executes programmable stitching patterns. This eliminates human error in pattern reproduction while maintaining full customization capability through software-controlled needle movements and stitching parameters.
Solution Approach 2:
The invention incorporates feedback mechanisms through programmable control systems that precisely track needle position, stitch count, and stitching pattern execution. This ensures consistent reproduction of complex patterns with high precision, eliminating variability introduced by manual operation.
3Device complexity
If conventional fabrication processes are used, then simplicity of process is maintained, but fabrication time is excessive and errors increase
Solution Approach 1:
The patent replaces complex manual fabrication processes with an automated sewing machine system. While the physical device adds complexity, the process becomes simpler through automation - operators only need to load digital patterns and materials, while the machine handles all stitching operations automatically, dramatically reducing fabrication time.
Solution Approach 2:
The invention implements preliminary action by pre-programming stitching patterns and pre-positioning components before the actual sewing process. Digital designs are prepared in advance, and the sewing machine automatically executes these pre-planned sequences, eliminating time-consuming manual measurements and calculations during fabrication.
4Ease of operation
If stretchable substrates are used to improve subject comfort, then coil loops can conform to body contours, but fraying and sagging issues occur during manual assembly
Solution Approach 1:
The patent replaces manual handling of stretchable substrates with an automated sewing machine system. The machine applies consistent, controlled stitching forces that prevent fraying and sagging while accommodating the elastic properties of the substrate, maintaining both subject comfort and structural integrity.
Solution Approach 2:
The invention uses periodic stitching patterns with regular intervals and consistent tension application. This periodic action distributes mechanical stress evenly across the stretchable substrate, preventing localized fraying and sagging while maintaining the conformal fit needed for subject comfort.
Data Source
AI summary
A method of fabricating a stretchable RF coil assembly of an MR system using a sewing machine is provided. The method includes providing a sewing accessory assembly. The sewing accessory assembly includes a substrate holder including an inner hoop and an outer hoop. The method also includes assembling a former and a stretchable substrate with the substrate holder by coupling sides of the former and sides of the stretchable substrate between the inner hoop and the outer hoop. The method further includes coupling the assembled substrate holder with a sewing machine, and assembling an RF coil assembly by sewing a pattern of a fiber conductor on the stretchable substrate.