DESCRIPTION

The present application relates to magnetic resonance magnets, cryomagnets, superconducting magnets, and specifically to the cooling of those types of magnets.

Magnetic resonance (MR) scanners use superconducting magnets, which are cooled to a superconducting temperature, e.g. less than 5.2° Kelvin. Traditionally liquid Helium has been used to cool superconductive magnets because of its thermal properties. However, liquid Helium is expensive. Many areas of the world do not have a ready supply of liquid Helium or replacement liquid Helium.

The electrical and magnetic properties of the magnet are maintained while cooling the magnet to produce a uniform static magnetic field of a magnetic resonance system. Cooling systems uniformly cool the coil without invading the integrity of the magnetic coil.

The bore of the magnet coil used for whole body MR imaging is large enough to accommodate a patient to be imaged as well as the structures which thermally separate the patient from the extreme cold temperature of the cryogenic system. Manufacturing designs accommodate a room temperature in the bore of the coil assembly while maintaining a operating temperature in the surrounding magnet below the critical temperature of the magnet. A room temperature of 70° F is approximately 294°K, while the critical temperature of the magnet is typically below 5.2°K. This extreme temperature difference creates design and manufacturing complexities.

The present application provides a new and improved Helium vapor magnetic resonance magnet which overcomes the above-referenced problems and others.

In accordance with one aspect, a magnetic resonance magnet has a coil form, thermally conductive sheets, thermally conductive tubing sections, at least one layer of thermally conductive electrically insulating material, and a winding of superconductive wire. The coil form is shaped as a hollow cylinder. At least two thermally conductive sheets extend circumferentially on the coil form, separated by non-electrically conductive regions. A thermally conductive tubing section is thermally connected to each thermally conductive sheet. At least one layer of thermally conductive electrically insulating material is disposed around and bonded to the thermally conductive sheets. A winding of superconductive wire is disposed around and bonded together and to the electrically insulating material.

In accordance with another aspect, a magnetic resonance magnet system includes at least one magnet assembly, Helium vapor which as it flows through the thermally conductive tubing around the coil cools the coil below the critical superconducting magnet temperature, and a refrigerator heat exchanger connected to the tubing which cools the Helium vapor. A magnet assembly has a coil form, thermally conductive sheets, thermally conductive tubing sections, at least one layer of thermally conductive electrically insulating material, and a winding of superconductive wire. The coil form is shaped as a hollow cylinder. At least two thermally conductive sheets extend circumferentially on the coil form, separated by non-electrically conductive regions. A thermally conductive tubing section is connected to each thermally conductive sheet. At least one layer of thermally conductive electrically insulating material is disposed around and bonded to the thermally conductive sheets. A winding of superconductive wire is disposed around and bonded together and to the electrically insulating material.

In accordance with another aspect, a magnetic resonance imaging or spectroscopy system includes a magnetic resonance magnet system, a gradient coil, a gradient amplifier, a radio frequency coil, a transmitter, a transmitter, a receiver, and a processor. The magnetic resonance magnet system has at least one magnet assembly, Helium vapor which as it flows through the thermally conductive tubing around the coil cools the coil below the critical superconducting magnet temperature, and a refrigerator heat exchanger connected to the tubing which cools the Helium vapor. A magnet assembly has a coil form, thermally conductive sheets, thermally conductive tubing sections, at least one layer of thermally conductive electrically insulating material, and a winding of superconductive wire. A gradient coil is located within a bore of the magnetic resonance magnet system. A gradient amplifier is connected to the gradient coil. A radio frequency coil is located inside the gradient coil. A transmitter is connected to the radio frequency coil. A receiver is connected to the radio frequency coil which receives the RF signals. A controller connects to the gradient amplifier and to the transmitter and controls the gradient amplifier and transmitter to excite resonance in a subject. A processor is connected to the receiver and to the controller and processes received resonance signals into an image and/or spectroscopic information.

In accordance with another aspect, a method of manufacturing a magnetic resonance magnet includes forming a cylindrical coil form. Thermally conductive tubing section is connected to thermally conductive sheets. At least one layer of electrically insulating material is bonded to the thermally conductive sheets. Superconductive wire is wound around the electrically insulating material and bonds the superconductive wire together and to the electrically insulating material.

In accordance with another aspect, a method of magnetic resonance imaging includes generating a static B ₀ magnetic field in an imaging region using a helium vapor cooled magnet assembly manufactured as discussed above. Gradient magnetic fields are generated in the imaging region. An RF field is transmitted into the imaging region. Magnetic resonance signals are received from the imaging region. An image is reconstructed from the received magnetic resonance signals.

One advantage resides in the reduced volumes of helium.

Another advantage is that helium vapor is used to cool the magnet instead of liquid helium.

Another advantage is the simple and thermally efficient method of attaching heat exchanger plates to the coils without affecting either the coil's fabrication or the electrical performance.

Another advantage is the simplicity of flow of Helium vapor through the system and the ability to uniformly cool the magnet coil.

Still further advantages of the present invention will be appreciated to those of ordinary skill in the art upon reading and understand the following detailed description.

The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.

FIGURE 1 is diagram showing one embodiment of a Helium vapor magnetic resonance magnet system. FIGURE 2 is diagram showing one embodiment of an enlarged view of a magnet.

FIGURE 3 is diagram showing a cross section of one embodiment of a magnetic resonance magnet with an exploded view.

FIGURE 4 is a flowchart illustrating a method of manufacturing a coil assembly.

FIGURE 5 is a diagram illustrating an embodiment of a MR system with a cut-away view of a vacuum dewar showing a magnetic resonance magnet.

With reference to FIGURE 1, an embodiment of a magnetic resonance (MR) magnet in a closed loop system 10 is shown. The closed loop system 10 includes circulating Helium vapor which is heated by an MR magnet assembly 20 and cooled by a refrigerator heat exchanger 30 with an associated cryogenic refrigerator 40, and recirculated to the magnet assembly 20. A suitable refrigerator heat exchanger with associated cryogenic refrigerator is described in US 2008/0209919.

The cooled Helium gas enters the magnet assembly 20 at the bottom and flows up a thermally conductive tubing 50 attached to thermally conductive sheets 60 or plates interior to the magnet. The Helium vapor is cooled in the heat exchanger 30 to approximately 4.2°K, which provides a 1°K margin below the critical temperature of the magnet. The cold gas from the refrigerator heat exchanger 30 is relatively dense but becomes less dense as it is warmed by the magnet assembly 20, producing a downward flow of denser helium gas from the refrigerator heat exchanger 30 to the bottom of the magnet and an upward flow of less dense warmer helium gas through the magnet and back to the refrigerator heat exchanger. The magnet assembly 20 is mounted on a coil form 70.

When manufactured, a coil assembly 25 is created using a winding fixture and then mounted on a coil form 70 or manufactured directly onto the coil form 70. Multiple coils 25 of varying widths are typically used in a MR system. Each coil assembly 25 is mounted on a corresponding coil form 70. The width of a coil 25 affects a number of windings and a strength of the magnetic field generated. The coils manufactured with the process described below vary in size, e.g. up to about 300 mm in width. The coil form 70 is manufactured from a structural metal, such as stainless steel, formed in a hollow cylinder.

As the Helium vapor travels up the tubing 50 heat is absorbed. Heat is generated by the coil assembly 25, and conductively transferred through thermally conductive plates 60 to the thermally conductive tubing 50 and absorbed by the Helium vapor. Good thermal conduction between all components of the magnetic assembly ensures a uniform operating temperature.

With reference to FIGURE 2, an enlarged view of one embodiment of the magnet assembly 20 is shown. Two sections of thermally conductive sheeting 60 are electrically isolated by a non-electrically conductive spacer 90. The region between the sheets 60 prevents circumferential currents in the thermally conductive sheeting 60 which would interfere with the operation of the MR system. The thermally conductive sheets are made, for example, of copper approximately .3 mm in thickness. Aluminum and other thermally conductive materials can also be used for the sheeting 60. The space between the thermally conductive sheets 60 is approximately 6 mm which is filled with the non- electrically conductive spacer 90, e.g. a plastic filler strip. The non-electrically conductive spacer 90 provides a uniform surface on which to wind the coil. The sheets are bent to the circumference of the coil form 70, or if a winding fixture is used during the manufacturing process to the outside diameter of the winding fixture.

Thermally conductive tubing 50 is thermally and mechanically affixed to the thermally conductive sheets 60. An example is 9- 10mm OD refrigerator grade copper tubing. Other materials with good thermal conduction may be used such as aluminum. The size of the tubing 50 is large enough that the pressure drop in the tubing is small. With smaller diameter tubing more friction is created, and a drop in cooling capacity results. With tubing that is too small, there is greater non-uniform cooling of the magnet.

With reference to FIGURES 3 and 4, in a step 400, the coil form 70 is fabricated, e.g. machined from stainless steel.

In a step 402, an insulating material 100 is wrapped around the coil form 70 or a winding fixture (not shown) if used to manufacture the magnet coil. An example of the insulating material 100 is a layer of polytetrafluoroethylene, commonly known as TEFLON™, sandwiched between layers of metalized polyester, commonly found as MYLAR™. The insulation layer 100 allows movement between coil form 70 and sheeting 60 while minimizing friction.

In a step 404, the thermally conductive tubing 50 is soldered or welded to the sheets 60 and the sheets and tubing are bent to the radius of the coil form. The tubing 50 may be attached prior to the bending of the sheets 60 or can be bent first and the thermally conductive sheets and tubing attached in their bent state. In a step 406 the thermally conductive sheet 60 and tubing is position over the insulating layer 100. The thermally conductive sheet 60, preferably, is not affixed to the electrically insulating sheet to accommodate thermal expansion/contraction differences. The electrically insulating spacers 90 are positioned on the electrically insulating material 100 between the thermally conductive sheets and the top and bottom of the coil assembly. The sheeting 60 is cleaned to remove any oxide present to provide for a thermally conductive bond.

In a step 410, over the thermally conductive sheeting 60 is placed a layer of electrical insulation 110 which is thermally conductive. Electrically insulating spacers 120 are disposed on either side of where the coil is to be wound. Flanges may be added to the coil form 70 when formed to limit movement of the sheeting 60 during operation of the magnet 20 and to affix coverings and other structural components. If a flange is present, then the electrically insulating spacer is placed between the flange and the sheeting 60 prior to wrapping in step 402. The layer of electrical insulation 110 is applied after cleaning the sheeting. A thermally conductive, electrically insulating epoxy encapsulant is applied, followed by a layer of material 110 which electrically insulates the coil from the thermally conductive sheets 60, allows good thermal conductivity, and binds with the epoxy. A suitable material 100 is bi-directional fiber glass cloth with a surface treatment to improve bonding with the epoxy. Both sides of the fiber glass material 110 are coated with the epoxy to provide strong bonding and good thermal conduction and the fiber glass material is wrapped around the thermal conductive sheet 60. The process can be repeated with more epoxy coatings and fiber glass material 110 to ensure that any irregularities are taken up and provide structural rigidity. Other thin flexible materials which provide electrical insulation, and permit coating and saturation of the epoxy encapsulant are also contemplated.

In a step 412, the superconducting wire 80 is wound around the layer of encapsulated fiber glass material 110 before the epoxy dries. As each layer of wire is wound, additional thermally conductive epoxy encapsulant is applied to securely bond the wire coil 80 together and to the layer of electrically insulating material 110 which is in turn bonded to the thermally conductive sheets 60. All the interstitial spaces in the wire coil 80 are filled with epoxy encapsulate to ensure a strong and thermally efficient bond with the sheets 60. The epoxy, the sheets 60, and the tubing 50 act as efficient heat exchangers. The thickness of the wire coil 80 is dictated by the magnetic field to be generated and is generally 2.5 - 5 cm. The mechanical bond of the coil assembly 25 or coil should withstand liftoff or hoop forces when current is applied. The thermally conductive sheets 60 bonded to the coil winding with an epoxy have a high peel strength and good thermal conductivity.

With reference to FIGURE 5, operational components of an embodiment of a MR system 500 are shown. A vacuum dewar 515 contains the magnet assembly 20 which generates a static B ₀ field during operation. The covering of vacuum dewar attaches, e.g., using the flange previously described, and encloses the coil form 70, sheets 60, and coil winding 80. A gradient coil 505 and a radio frequency (RF) coil 510 are concentrically located within the bore of the vacuum dewar. The gradient coil 505 generates gradient G _x G _y G _z magnetic fields powered by a gradient amplifier 550 during the imaging process. The gradient magnetic fields are generated under control of a sequence control 520. The illustrated RF coil 510 is a whole body coil which transmits a Bi magnetic field when turned on by an RF transmitter 530. The sequence control 520 determines when the RF coil 510 operates in a transmit mode and when the RF coil 510 operates in a receive mode. When in the receive mode, a receiver 570 demodulates the RF signals. The RF signals are then reconstructed by a processor 580 and may displayed as an image on an output device 590 or stored for other access.

The invention has been described with reference to the preferred embodiments. Modifications and alterations may occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be constructed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.