Flat insulation layer for a magnetic resonance gradient coil and method for manufacturing such a gradient coil and a flat insulation layer

1. A method for manufacturing an insulation layer for a magnetic resonance gradient coil, said method comprising:

providing a plate, strip or foil of thermoplastic insulating material to a hot press apparatus;

in said hot press apparatus, three-dimensionally deforming said thermoplastic insulating material of said plate, strip or foil in order to form predetermined elevations in said plate, strip or foil on at least one side of said plate, strip or foil, that are spaced apart from each other, and thereby simultaneously forming coinciding recesses at an opposite side of said plate, strip or foil; and

said plate, strip or foil comprising respective peripheral edge regions at opposite edges of said plate, strip or foil, and forming said elevations and recesses at each of said peripheral edge regions so as to proceed in a longitudinal direction of said plate, strip or foil and wherein a number of the elevations and recesses at each of said peripheral edge regions is equal.

2. A method as claimed in claim 1 comprising forming said elevations as nubs each with a round or angled geometry, distributed in a web and proceeding in said web along a straight line or a curved line.

3. A method as claimed in claim 1 comprising forming said elevations in said hot press apparatus on both sides of said plate, strip or foil, and thereby also forming said coinciding recesses on both sides of said plate, strip or foil.

4. A method as claimed in claim 3 comprising forming said elevations on one side of said plate, strip or foil so as to be offset in rows, viewed in a transverse direction of said plate, strip or foil, with respect to the elevations on the other side of said plate, strip or foil.

5. An insulation layer manufactured by the method as claimed in claim 1 .

6. A method for manufacturing a cylindrical magnetic resonance gradient coil assembly comprising:

arranging a plurality of gradient coils respectively in different radial planes;

providing an insulation layer between respective adjacent gradient coils in said plurality of gradient coils said insulation layer comprising a plate, strip or foil of thermoplastic insulating material having a plurality of elevations on at least one side thereof formed by three-dimensionally deforming said plate, strip or foil by hot shaping, said elevations being spaced apart from each other, said plate, strip or foil comprising respective peripheral edge regions at opposite edges of said plate, strip or foil, and forming said elevations and recesses at each of said peripheral edge regions so as to proceed in a longitudinal direction of said plate, strip or foil and wherein a number of the elevations and recesses at each of said peripheral edge regions is equal; and

casting said plurality of gradient coils and said insulation layers with a curable resin that flows around the elevations of each insulation layer.

7. A method as claimed in claim 6 wherein said plurality of gradient coils define a cylinder with a longitudinal axis, and wherein each of said insulation layers comprises more than one plate, strip or foil all proceeding around said longitudinal axis and overlapping each other at said respective peripheral edges regions of each plate, strip or foil.

8. A method as claimed in claim 7 wherein the elevations of one plate, strip or foil in the insulation layer engaging in the depressions or recesses of another plate, strip or foil in the same insulation layer.

9. A gradient coil manufactured by the method as claimed in claim 6 .