Manufacturing method of electric connection module

Abstract

The invention provides a manufacturing method of an electric connection module. The electric connection module comprises a first connection module and a second connection module. The manufacturing method comprises a punching process, a cutting process and a loading process. In the punching process, a blank of the electric connection module is prepared. And forming a through hole in the blank of the electric connection module along a straight line which is parallel to the axis direction and penetrates through the blank of the electric connection module. In the cutting process, the blank of the electric connection module is cut in the direction perpendicular to the straight line, so that the blank of the electric connection module is divided into a blank of a first connection module and a blank of a second connection module. The through hole is a first through hole in the blank of the first connecting module, and the through hole is a second through hole in the blank of the second connecting module. In the loading process, the first contact pin is placed in the first through hole, and the second contact pin is placed in the second through hole. After the punching procedure and the cutting procedure, it can be guaranteed that the first through hole and the second through hole are mutually aligned in the linear direction, and the position deviation of the through holes can be avoided.

Description

Technical Field

[0001] The present disclosure relates to the field of medical devices, and in particular, to a method for manufacturing an electrical connection module. Background Art

[0002] In the medical field, electrical stimulation systems have been widely studied and applied for analgesia. The system is mainly composed of a pulse stimulator and stimulation electrodes. The connection relies on the corresponding connection between the contacts on the pulse stimulator and the contacts on the stimulation electrodes to achieve signal transmission, thereby achieving an analgesic effect. However, as modern medical technology develops in the direction of miniaturization and refinement, the overall volume of the electrical stimulation system continues to shrink, which leads to the structure that connects the pulse stimulator to the stimulation electrode becoming smaller. In a limited and tiny space, it is extremely challenging to ensure the precise corresponding connection of many contacts. At present, this accuracy problem has become a key technical difficulty in the miniaturization process of the electrical stimulation system, and it needs to be solved urgently to promote the further development of this technology. Summary of the invention

[0003] The present disclosure aims to provide a method for manufacturing an electrical connection module to solve the connection accuracy problem faced by the miniaturization of an electrical stimulation system.

[0004] The present disclosure provides a method for manufacturing an electrical connection module. The electrical connection module is suitable for an electrical stimulation system. The electrical stimulation system includes a pulse generator and a stimulation electrode. The electrical connection module is used to electrically connect the pulse generator to the stimulation electrode. The electrical connection module includes a first connection module and a second connection module. The manufacturing method includes a punching process, a cutting process and a loading process. In the punching process, a blank of an electrical connection module is prepared, and the blank of the electrical connection module is cylindrical. A through hole is formed on the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module. The radial dimension of the blank of the electrical connection module is less than or equal to 3 mm, the number of through holes is greater than or equal to 24, and each through hole is isolated from each other. In the cutting process, the blank of the electrical connection module is cut along a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of the first connection module and a blank of the second connection module. The through hole formed in the punching process is a first through hole on the blank of the first connection module, and the through hole formed in the punching process is a second through hole on the blank of the second connection module. In the loading process, the first pin is at least partially placed in the first through hole, and the second pin is at least partially placed in the second through hole, wherein the first pin is provided with a socket, and the second pin can be inserted into the socket to be electrically connected with the first pin.

[0005] After the punching and cutting processes, the first through hole and the second through hole can be accurately aligned with each other in a straight line direction, which can avoid the probability of position deviation of the through holes caused by the small size of the components during separate processing, creating favorable conditions for subsequent high-precision operations, and providing extremely accurate placement positions for the pins in a small space, greatly improving the positioning accuracy of the connection structure at a small size. In the installation process, the socket provided by the first pin allows the second pin to be accurately inserted to achieve electrical connection. Thanks to the control of the position accuracy of the first through hole and the second through hole in the previous processes, the electrical connection between the pulse generator and the stimulation electrode can be stably and reliably achieved, ensuring accurate signal transmission of the electrical stimulation system, thereby ensuring its efficient analgesic effect.

[0006] In an exemplary embodiment, the punching process includes a first punching step, during which the diameter of the punched hole is set to a predetermined diameter of one of the first through hole and the second through hole, and after the first punching step, the punching process further includes a second punching step, during which the diameter of the punched hole is set to a predetermined diameter of the other of the first through hole and the second through hole, wherein the predetermined diameter of the first through hole is different from the predetermined diameter of the second through hole. Since the second pin needs to be inserted into the plug hole of the first pin to achieve electrical connection, the diameters of the first through hole and the second through hole should be different, and the larger diameter is used to receive the first pin, and the smaller diameter is used to receive the second pin.

[0007] In an exemplary embodiment, in the punching process, a laser is used to punch holes in the blank of the electrical connection module.

[0008] When manufacturing electrical connection modules, the punching process is crucial to achieve precise connection between the pulse generator and the stimulation electrode. Traditional punching often uses molding. However, as electrical connection modules develop towards miniaturization, this traditional method exposes many problems. The electrical connection module is small and contains at least 24 through holes. During molding and pouring, uneven pouring is very likely to occur, and several through holes are easily connected, affecting the independence of the connection of the pin and the stability of the stimulation signal. Moreover, in the process of removing the needle, due to the small space and fragile hole wall, after the perfusion liquid solidifies into a connection module and withdraws from the mold, it is easy to damage the through hole, resulting in several through holes being connected, and even the shape and size of the hole are changed, which cannot meet the high-precision connection requirements, seriously restricting the manufacturing quality and performance improvement of small electrical connection modules.

[0009] With the traditional drill bit method, due to the small size of the electrical connection module and the number of through holes on the blank of the electrical connection module, the drill bit is required to have both a small size and high hardness, which poses a challenge to material selection and increases the cost invisibly. In addition, since there are many through holes on the blank of the electrical connection module, if the drill bit has a slight vibration and deviation during the drilling process, it will cause damage to other through holes.

[0010] By using laser drilling, the first through hole and the second through hole can be accurately formed on the tiny electrical connection module blank, effectively avoiding the problem of holes being connected due to uneven liquid infusion in traditional mold manufacturing, ensuring the independence and integrity of each through hole, and providing a stable and reliable foundation for the connection of the pins. The non-contact processing characteristics of laser drilling avoid the physical damage to the through hole caused by the exit from the mold in the traditional molding process, ensuring the shape and size accuracy of the hole, and ensuring the accuracy requirements of the connection structure of the electrical connection module. The high efficiency of laser drilling can also significantly improve production efficiency and promote the mass production of electrical connection modules.

[0011] In an exemplary embodiment, in a first punching step, a laser having a first beam diameter is used to punch a hole in a blank of an electrical connection module. In a second punching step, a laser having a second beam diameter is used to continue punching holes in the blank of the electrical connection module, and the second beam diameter is smaller than the first beam diameter. When the second punching step is completed, a through hole is formed in the electrical connection module. That is, the generation of the first through hole and the second through hole is continuous.

[0012] In the punching process of the electrical connection module manufacturing, because the second pin needs to be inserted into the socket of the first pin to achieve electrical connection, and the two are required to always maintain an electrically connected state, the outer diameter of the second pin must be greater than or equal to the inner diameter of the first pin socket, which puts extremely high requirements on the concentricity accuracy of the two. Because the first pin must be installed in the first through hole before the second pin is inserted into the first pin socket, in order to ensure that the second pin can be accurately inserted into the socket of the first pin, the position of the socket of the first pin on itself must be guaranteed to be concentric with the first pin, and the first through hole and the second through hole must also be concentric, so that no matter how the first pin is installed in the first through hole, the second pin can be accurately inserted into the socket of the first pin. However, the process of forming the through hole on the blank of the electrical connection component is continuous and uninterrupted, which means that the change in the diameter of the laser beam must also be continuous, so the diameter of the laser beam needs to change from large to small.

[0013] In the present disclosure, in the first drilling step, the first through hole is drilled by a laser with a first beam diameter, and the second through hole is drilled by a laser with a second beam diameter, and the second beam diameter is smaller than the first beam diameter. Although the drilling is divided into two steps, there is a unified center positioning reference. The equipment accurately drills based on this, and the center position of each link is strictly controlled without deviation, which ensures the concentricity of the first through hole and the second through hole, laying the foundation for the subsequent precise docking of the pins and the realization of stable electrical connection.

[0014] During the drilling process, with the help of the laser's high energy density, good directionality and easy focusing control, the larger first beam diameter laser is used to drill holes in the electrical connection module blank, because its energy concentration can act on the material efficiently. Then it is quickly switched to the smaller second beam diameter laser to continue drilling, so that the first through hole and the second through hole are formed continuously. High-precision finishing throughout the process and high laser focusing accuracy can effectively avoid deviations caused by drilling switching or interruptions, ensuring the accuracy and quality of the through holes. At a tiny size, this drilling method gives full play to the advantages of lasers, making the electrical connection module structure stable and the electrical connection reliable, which perfectly meets the stringent requirements of precise connections of the electrical stimulation system, greatly improving the accuracy and efficiency of production.

[0015] In an exemplary embodiment, from the first punching step to the second punching step, the change from the first beam diameter to the second beam diameter is continuous to form a first segment having a first diameter, a second segment having a second diameter, and a transition segment between the first segment and the second segment in the through hole, wherein the first diameter is equal to the first beam diameter, and the second diameter is equal to the second beam diameter.

[0016] The diameter of the laser beam changes continuously from the first beam diameter to the second beam diameter, and a transition section is formed during drilling, and the inner diameter of the transition section is between the predetermined sizes of the first and second through holes. This not only realizes the continuous and uninterrupted drilling process, but also ensures the accuracy of the sizes of the first and second through holes, laying the foundation for the stable electrical connection of the electrical connection module in the electrical stimulation system, and improving the reliability and accuracy of the overall manufacturing process.

[0017] Furthermore, the cutting process includes a first cutting process and a second cutting process. In the first cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the first segment. In the second cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the second segment.

[0018] During cutting, the first section and the second section are cut according to the predetermined length, and the transition section is accurately removed, so that the sizes of the first through hole of the first connecting module blank and the second through hole of the second connecting module blank accurately meet the requirements.

[0019] In an exemplary embodiment, the first pin and the second pin are made of metal. Before the loading process, the manufacturing method further includes a processing process. In the processing process, the inner surfaces of the first through hole and the second through hole are metallized. After the loading process, the manufacturing method further includes a welding process. In the welding process, the first pin is welded to the metallized inner surface of the first through hole, and the second pin is welded to the metallized inner surface of the second through hole.

[0020] Traditional adhesive connections introduce additional resistance and capacitance due to the dielectric properties of the adhesive layer, interfering with the normal transmission of electrical signals. Adhesive connections may also deteriorate when subjected to stress for a long time or when affected by changes in temperature or humidity, increasing the risk of connection failure.

[0021] The metal welding interface provided by the present disclosure has a lower resistance, which can reduce energy loss and signal attenuation during the transmission of electrical signals, ensure that the electrical stimulation signal is transmitted between the pulse generator and the stimulation electrode with higher fidelity, and is conducive to improving the working efficiency and accuracy of the electrical stimulation system. The welding connection has better high temperature resistance. The electrical connection module may generate heat due to the passage of current during operation. The welding structure can maintain the integrity of the connection in a high temperature environment.

[0022] In an exemplary embodiment, during the loading process, the first end of the first pin is extended from the first end surface of the blank of the first connection module, and the second end of the first pin is aligned with the second end surface of the blank of the first connection module.

[0023] The first end of the first pin extends from the first end surface of the first connection module blank to achieve connection with the connection circuit board of the pulse generator. The second end of the first pin is aligned with the second end surface of the first connection module blank, which structurally provides a stable support for the first pin in the first connection module, thereby avoiding the occurrence of poor contact caused by the unexpected displacement that may be caused when the second pin is inserted, and greatly improving the reliability of the overall structure of the electrical connection module.

[0024] In an exemplary embodiment, during the loading process, the first end of the second pin is extended from the first end surface of the blank of the second connection module so that the first end of the second pin can be easily inserted into the second end of the first pin. The second end of the second pin is extended from the second end surface of the blank of the second connection module so that the second end of the second pin can be easily connected to the signal transmission wire of the stimulation electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A schematic structural diagram of an electrical stimulation system is shown.

[0026] Figure 2 A partial perspective structural schematic diagram of the electrical stimulation system shown in FIG.

[0027] Figure 3 for Figure 2 A partial enlarged schematic diagram of .

[0028] Figure 4 A partial structural schematic diagram of a traditional pulse generator is shown.

[0029] Figure 5 A partial structural schematic diagram of a pulse generator of an electrical stimulation system is shown.

[0030] Figure 6 A schematic diagram of the exploded structure of the first connection module in the electrical connection module is shown.

[0031] Figure 7 A schematic diagram of the exploded structure of the second connection module in the electrical connection module is shown.

[0032] Figure 8 A flow chart of a method for processing an electrical connection module according to an embodiment of the present disclosure is shown.

[0033] Fig. 9 Shown according to Figure 8 The processing method flow chart shown is a status diagram of the actual processing process.

[0034] Fig.10 Shown according to Figure 8 A further refined flowchart of the processing method flowchart shown.

[0035] Fig.11 Shown according to Figure 8 Detailed process of one process in the processing method flow chart shown.

[0036] Fig.12 Shown according to Fig.11 The processing method flow chart shown is a schematic diagram of an actual processing structure.

[0037] Fig.13 Shown according to Figure 8 Detailed process of one process in the processing method flow chart shown.

[0038] Fig.14 Shown according to Fig.11 Another actual processing structure schematic diagram performed by the processing method flow chart shown.

[0039] Fig.15 Shown according to Fig.13 The actual processing status diagram of the processing method flow chart shown. DETAILED DESCRIPTION

[0040] Embodiments of the present invention will be described below using the drawings. In the following embodiments, processing of a glass substrate will be described, but the same is true for other brittle material substrates.

[0041] The electrical stimulation system includes a pulse generator 10 and a stimulation electrode 20. The pulse generator 10 is used to generate electrical stimulation pulses, which are delivered to the target tissue via the stimulation electrode 20, thereby achieving electrical stimulation of the target area.

[0042] The pulse generator 10 includes a housing 11 and a main control board 12, a connecting circuit board 14 and a first connecting module 16 located in the housing 11. The main control board 12 is configured to generate electrical stimulation pulses, which are transmitted to the stimulation electrode 20 via the connecting circuit board 14 and the first connecting module 16. The first connecting module 16 includes a plurality of first pins 162, each of which is a long straight structure. The stimulation electrode 20 includes a plurality of second pins 262, each of which is a long straight structure and is connected to a corresponding wire in the stimulation electrode 20. The other end of each wire is connected to the pulse output contact of the stimulation electrode 20 for delivering the stimulation current to the target site. The plurality of first pins 162 correspond to the plurality of second pins 262 respectively. The first end 1621 of each first pin 162 is fixedly connected to the connecting circuit board 14, and the second end 1622 of each first pin 162 is provided with a socket 1623 for receiving the corresponding second pin 262. That is to say, there is no need for indirect connection between the first pin 162 and the connecting circuit board 14 via any form of adapter component (such as an adapter wire). At the same time, the plug-in connection between the first pin 162 and the second pin 262 realizes electrical communication between the first pin 162 and the stimulation electrode 20.

[0043] In conventional neurostimulation systems, such as Figure 3 As shown, after the stimulation electrode 30 is connected to the pulse generator 40, the electrical stimulation pulse generated by the main control board 42 of the pulse generator 40 needs to be transmitted to the stimulation electrode 30 through the connecting circuit board 44, the switching wire 46 and the electrode receiving component 48. Specifically, the electrode receiving component 48 of the pulse generator 40 needs to be welded and connected to the connecting circuit board 44 connected to the main control board 42 that performs the pulse transmission function in the pulse generator 40 through a set of switching wires 46. The switching wire is connected to the connecting circuit board 44 at one end, and connected to the switching contact 482 of the electrode receiving component 48 for contacting the stimulation electrode 30 at the other end. That is, the electrode receiving component 48 is indirectly connected to the connecting circuit board 44 through the switching wire 46. Such an indirect connection not only creates considerable difficulty for the assembly work, but also affects the stability of the connection between the switching wire 46 and the switching contact 482, thereby affecting the stability of the stimulation electrode 30 receiving the electrical stimulation pulse.

[0044] A portion of the first connection module 16 is equivalent to the electrode receiving component 48 of the conventional pulse generator 40. The first pin 162 is fixedly connected to the connection circuit board 14 at the first end 1621 and connected to the stimulation electrode 20 at the second end 1622, thereby realizing the combination of the conventional transfer contact and the transfer wire. This simplifies the structure of the pulse generator, improves the connection reliability between the connection circuit board and the first pin, and improves the production efficiency of the neural stimulation system.

[0045] The connecting circuit board 14 includes a pulse output end 142 for connecting to the first connecting module 16 . The pulse output end 142 has a pulse output end surface 1422 . The pulse output end surface 1422 includes a plurality of pulse output terminals 1424 . Each pulse output terminal 1424 is suitable for connecting to a corresponding first pin 162 .

[0046] The first connection module 16 has a first end surface 164. The first end surface 164 and the pulse output end surface 1422 are both planes. The first end surface 164 is configured to face the pulse output end surface 1422 of the connection circuit board 14.

[0047] The first connection module 16 also has a second end surface 165 , and the second end 1622 of each first pin 162 is exposed to the second end surface 165 . The length of each first pin 162 exposed to the second end surface 165 is the same, and the plug-in mating length of each second pin 262 is the same as that of the first pin 162 .

[0048] The stimulation electrode 20 is adapted to the pulse generator 10 as described above, and comprises an electrode body 22, at least one wire 28, and a second connection module 26. Each wire 28 extends along the length direction of the electrode body 22, and one end of each wire 28 extends outside the electrode body 22, and the other end is connected to the pulse output contact of the stimulation electrode 20 for delivering the stimulation current to the target site.

[0049] The second connection module 26 is suitable for docking with the first connection module 16 of the pulse generator 20. The second connection module 26 includes a plurality of second pins 262. The plurality of second pins 262 respectively correspond to the plurality of first pins 162 in the pulse generator 20. The length of each second pin 262 is the same, and the second pins 262 are separated from the electrode body 22.

[0050] The first end 2621 of each second pin 262 is connected to one end of the wire 28 extending from the electrode body 22, and the second end 2622 of each second pin 262 is used to be inserted into the insertion hole 1623 of the corresponding first pin 162. The second end 2622 of each second pin 262 is flush.

[0051] The first connection module 16 and the second connection module 26 together constitute an electrical connection module. The first connection module 16 is a complete structure with a first plug pin 162 inserted therein. Before forming the complete structure, the first connection module 16 includes a first connection module blank 50 and a first plug pin 162. The second connection module 26 is a complete structure with a second plug pin 262 inserted therein. Before forming the complete structure, the second connection module 26 includes a second connection module blank 60 and a second plug pin 262.

[0052] The electrical connection module is suitable for an electrical stimulation system. The electrical stimulation system includes a pulse generator and a stimulation electrode. The electrical connection module is used to electrically connect the pulse generator to the stimulation electrode. The electrical connection module includes a first connection module and a second connection module.

[0053] like Figure 8 As shown, the present disclosure provides a method for manufacturing the above-mentioned electrical connection module. The method 300 for manufacturing the electrical connection module includes a punching process 310 , a cutting process 330 , and a loading process 350 .

[0054] Punching process 310: forming a through hole on the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module.

[0055] Specifically, in the punching process 310, a blank of an electrical connection module is prepared. The blank of the electrical connection module is cylindrical, and the length of the blank of the electrical connection module in the axial direction is greater than 7 mm, and the diameter is less than or equal to 3 mm. The blank of the electrical connection module is placed on a punching processing platform, which has the function of accurately positioning and stabilizing the blank, and can be accurately docked with the punching equipment. Through fine-tuning, the axis of the blank is completely parallel to the punching straight line preset by the punching equipment, and ensure that the blank is firmly fixed to prevent any displacement during the punching process. A through hole is formed on the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module, and the number of through holes is greater than or equal to 24. Multiple through holes are isolated from each other.

[0056] Cutting process 330: cutting the blank of the electrical connection module along a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of a first connection module and a blank of a second connection module.

[0057] Specifically, in the cutting process 330, the length of the blank of the first connection module group along the axial direction is at least 5 mm, and the length of the blank of the second connection module group along the axial direction is at least 2 mm. The through holes formed in the punching process are first through holes on the blank of the first connection module group, and the number of the first through holes is also greater than or equal to 24; the through holes formed in the punching process are second through holes on the blank of the second connection module group, and the number of the second through holes is also greater than or equal to 24. After the cutting process, the first through holes and the second through holes are aligned along the straight line direction.

[0058] Start the cutting equipment and cut the electrical connection module blank into the first connection module blank (axial length of at least 5 mm) and the second connection module blank (axial length of at least 2 mm) according to the preset cutting parameters. During the cutting process, a high-precision positioning and measurement system is used to monitor the cutting position in real time to ensure that the cutting surface is flat and perpendicular to the punching line, so that the first through hole and the second through hole can be accurately aligned along the straight line after cutting.

[0059] Loading process 350: placing the first pin at least partially in the first through hole, and placing the second pin at least partially in the second through hole, for example, by gluing or welding.

[0060] Specifically, in the loading process 350, the first plug pin has a socket at the second end, and the second end of the second plug pin can be inserted into the socket to be electrically connected to the first plug pin. The first plug pin and the second plug pin are made of metal, such as gold, silver or copper.

[0061] For example, Fig. 9 , which shows the physical processing process of the punching step 310, the cutting step 330 and the loading step 350 in the manufacturing method 300 of the electrical connection module.

[0062] The punching process 310 is performed to punch holes on the blank 1 of the electrical connection module along a straight line parallel to the axis direction. In this example, the total number of holes is 24. The cutting process 330 is performed to divide the blank 1 of the electrical connection module into a blank 40 of the second connection module and a blank 50 of the second connection module along a direction perpendicular to the axis at a preset position. The first through hole 41 and the second through hole 51 are shown. The loading process 350 is performed to insert a plurality of first pins 162 into the corresponding first through holes 41, and a plurality of second pins 262 into the corresponding second through holes 51. The first pin 162 is provided with a socket 1623 on the second end 1622. Each socket 1623 receives the second end 2622 of the corresponding second pin 262.

[0063] After the punching and cutting processes, the first through hole and the second through hole can be accurately aligned with each other in a straight line direction, which can avoid the probability of position deviation of the through holes caused by the small size of the components during separate processing, creating favorable conditions for subsequent high-precision operations, and providing extremely accurate placement positions for the pins in a small space, greatly improving the positioning accuracy of the connection structure at a small size. In the installation process, the socket provided by the first pin allows the second pin to be accurately inserted to achieve electrical connection. Thanks to the control of the position accuracy of the first through hole and the second through hole in the previous processes, the electrical connection between the pulse generator and the stimulation electrode can be stably and reliably achieved, ensuring accurate signal transmission of the electrical stimulation system, thereby ensuring its efficient analgesic effect.

[0064] Preferably, if Fig.10 , the process between the drilling process 310 and the cutting process 330 is shown. Before the cutting process 330, the manufacturing method 300 further includes a processing process 320. Processing process: metalizing the inner surface of the through hole formed in the drilling process 310, for example, by an immersion plating process.

[0065] Specifically, in the treatment process 320, the pretreated blank of the electrical connection component is immersed in a metal salt solution and connected to an electrolytic device. Through electrolysis, zinc or tin metal is evenly deposited on the inner surface of the through hole to form a metallized layer. During the immersion plating process, the metal deposition speed and thickness are continuously monitored to ensure that the thickness of the inner surface metallized layer does not exceed 0.1 mm, which can be precisely controlled by controlling factors such as the current size and the immersion plating time. After the loading process 350, the manufacturing method 300 also includes a welding process 360. In the welding process 360, the first pin is welded to the metallized inner surface of the first through hole, and the second pin is welded to the metallized inner surface of the second through hole.

[0066] Traditional adhesive connections introduce additional resistance and capacitance due to the dielectric properties of the adhesive layer, interfering with the normal transmission of electrical signals. Adhesive connections may also deteriorate when subjected to stress for a long time or when affected by changes in temperature or humidity, increasing the risk of connection failure.

[0067] The metal welding interface provided by the present disclosure has a lower resistance, which can reduce energy loss and signal attenuation during the transmission of electrical signals, ensure that the electrical stimulation signal is transmitted between the pulse generator and the stimulation electrode with higher fidelity, and is conducive to improving the working efficiency and accuracy of the electrical stimulation system. The welding connection has better high temperature resistance. The electrical connection module may generate heat due to the passage of current during operation. The welding structure can maintain the integrity of the connection in a high temperature environment.

[0068] In an exemplary embodiment, the loading process includes: extending the first end of the first pin from the first end surface of the blank of the first connection module. Aligning the second end of the first pin with the second end surface of the blank of the first connection module. The first end of the second pin extends from the first end surface of the blank of the second connection module so that the first end of the second pin is connected to the signal transmission wire of the stimulation electrode; and the second end of the second pin extends from the second end surface of the blank of the second connection module so that the second end of the second pin is conveniently inserted into the second end of the first pin.

[0069] The first end of the first pin extends from the first end surface of the first connection module blank to achieve connection with the connection circuit board of the pulse generator. The second end of the first pin is aligned with the second end surface of the first connection module blank, which structurally provides a stable support for the first pin in the first connection module, thereby avoiding the occurrence of poor contact caused by the unexpected displacement that may be caused when the second pin is inserted, and greatly improving the reliability of the overall structure of the electrical connection module.

[0070] The inner diameter of the jack is greater than or equal to the outer diameter of the corresponding second pin to receive the second pin. The length of the second end of the second pin exposed to the second end surface of the blank of the second connection module is less than or equal to the depth of the jack of the first pin. In this way, the second end surface of the blank of the first connection module and the second end surface of the blank of the second connection module can be connected to improve the connection stability of the first connection module and the second connection module.

[0071] In an exemplary embodiment, if Fig.11 As shown, the punching process 310 includes a first punching step 3110. The first punching step 3110: setting the diameter of the punched hole to a predetermined diameter of the first through hole and the second through hole.

[0072] After the first punching step, the punching process further includes a second punching step 3120. The second punching step 3120: setting the punching diameter to a predetermined diameter of the other of the first through hole and the second through hole, wherein the predetermined diameter of the first through hole is different from the predetermined diameter of the second through hole.

[0073] Since the second pin needs to be inserted into the jack of the first pin to achieve electrical connection, the diameters of the first through hole and the second through hole should be different, with the larger diameter one being used to receive the first pin and the smaller one being used to receive the second pin.

[0074] For example, Fig.12 As shown, the physical processing performed according to the first punching step 3110 and the second punching step 3120 in the manufacturing method 300 of the electrical connection module is a schematic effect.

[0075] The punching parameters are set to determine the larger diameter of the first through hole and the second through hole as the target diameter of this punching (for example, set to D1 = 0.3 mm). During the first punching step, the punching device starts to punch holes on the blank along a predetermined straight line trajectory parallel to the axis of the blank and passing through the blank to form a hole segment with a diameter of D1. The control system of the punching device monitors the punching depth and hole diameter changes in real time to ensure that the diameter of the punched first hole segment is stable at around D1. The punching operation is continued until the predetermined punching depth (for example, set to H1 = 5 mm) is reached.

[0076] After the first punching step is completed, the second punching step is entered. At this time, the punching diameter parameter of the punching equipment is adjusted to the smaller predetermined diameter of the first through hole and the second through hole (for example, set to D2 = 0.2mm). Continue punching the punched part of the through hole along the previous straight punching trajectory again to form a hole segment with a diameter of D2. The control system of the punching equipment monitors the punching depth and hole diameter changes in real time to ensure that the diameter of the punched first hole segment is stable at around D2. Continue the punching operation until the predetermined punching depth is reached (for example, set to H2 = 2mm). The processing of the entire through hole is thus completed, so that each through hole consists of a first segment with a diameter of D1 and a second segment with a diameter of D2, corresponding to the different diameter requirements of the first through hole and the second through hole, respectively.

[0077] During the punching process, the second punching step may be performed after all the first punching steps are completed for all the through holes individually, or one through hole may be used as a punching unit, and the first punching step and the second punching step may be performed continuously for each through hole.

[0078] In an exemplary embodiment, in the punching process, a laser punching device is used to punch holes in the blank of the electrical connection module using a laser, for example, the holes may be punched one by one, or the at least 24 through holes may be punched simultaneously.

[0079] The blank of the electrical connection module is placed on a workbench, which can ensure the stability and position accuracy of the blank during the punching process.

[0080] The punching operation begins, and the laser beam gradually acts on the blank material along a predetermined straight line trajectory that is parallel to the axis of the blank and passes through the blank. Since the electrical connection module needs to form at least 24 isolated through holes, the laser punching equipment uses a precise control system to perform punching operations on the blank in sequence according to the pre-set through hole distribution pattern. During the punching process, the high energy density characteristics of the laser are used to quickly vaporize or melt the material and discharge it to form independent through holes. At the same time, the real-time monitoring system monitors parameters such as the punching depth, hole diameter, and flatness of the hole wall. If any deviation is found, the laser parameters or the workbench position are adjusted in time for correction.

[0081] When manufacturing electrical connection modules, the punching process is crucial to achieve precise connection between the pulse generator and the stimulation electrode. Traditional punching often uses molding. However, as the electrical connection module develops towards miniaturization, this traditional method exposes many problems. The electrical connection module is small and contains at least 24 through holes. During molding and pouring, uneven pouring is very likely to occur, and several through holes are easily connected, affecting the independence of the pin connection and the stability of the stimulation signal. Moreover, after the perfusion liquid solidifies into the blank of the electrical connection module and is withdrawn from the mold, it is easy to damage the through hole, resulting in several through holes being connected, and even the shape and size of the hole are changed, which cannot meet the high-precision connection requirements, seriously restricting the manufacturing quality and performance improvement of small electrical connection modules.

[0082] With the traditional drill bit method, due to the small size of the electrical connection module and the number of through holes on the blank of the electrical connection module, the drill bit is required to have both a small size and high hardness, which poses a challenge to material selection and increases the cost invisibly. In addition, since there are many through holes on the blank of the electrical connection module, if the drill bit has a slight vibration and deviation during the drilling process, it will cause damage to other through holes.

[0083] By using laser drilling, multiple through holes of the desired size can be accurately formed on the tiny electrical connection module blank, and the problem of holes being connected due to uneven liquid infusion in traditional mold manufacturing can be effectively avoided, ensuring the independence and integrity of each through hole, and providing a stable and reliable foundation for the connection of the pins. Laser drilling has the characteristics of non-contact processing, which avoids the physical damage to the through holes caused by the demolding process in the traditional molding process, ensures the shape and size accuracy of the holes, and ensures the accuracy of the connection structure of the electrical connection module. The high efficiency of laser drilling can also significantly improve production efficiency and promote the mass production of electrical connection modules.

[0084] In an exemplary embodiment, in a first punching step, a laser having a first beam diameter is used to punch a hole in a blank of an electrical connection module. In a second punching step, a laser having a second beam diameter is used to continue punching holes in the blank of the electrical connection module, and the second beam diameter is smaller than the first beam diameter. When the second punching step is completed, a through hole is formed in the electrical connection module. That is, the generation of the first through hole and the second through hole is continuous.

[0085] like Fig.13As shown in the figure, in the first drilling step, the laser drilling device 70 is turned on, and the laser L1 with the first beam diameter (set to X mm, for example) is used to start the drilling operation on the blank along a straight line parallel to the axis of the blank of the electrical connection module and passing through the blank. At this time, the laser quickly acts on the blank material with its high energy density characteristic, and gradually forms a blind hole structure with a certain depth H1 and an inner diameter corresponding to the first beam diameter on the blank.

[0086] After the depth H1 is completed in the first drilling step, the second drilling step is immediately entered. The diameter of the laser is switched to the second beam diameter (set to Y mm, and Y < X), that is, the laser L2. Without changing the drilling straight line trajectory and the position of the blank, the laser continues to perform in-depth drilling on the existing blind hole. Due to the smaller second beam diameter, the inner diameter of the hole gradually transitions to the size corresponding to the second beam diameter until the entire through-hole drilling operation is completed, and finally a continuous first through-hole (corresponding to the part drilled with the first beam diameter) and a second through-hole (corresponding to the part drilled with the second beam diameter) are formed on the blank of the electrical connection module. During the entire drilling process, through the control of the high-precision processing platform and the precise parameter adjustment of the laser drilling device, the seamless connection and continuous progress from the first drilling step to the second drilling step are ensured, effectively guaranteeing the concentricity and dimensional accuracy of the first through-hole and the second through-hole, and laying a foundation for the precise docking of the pins and the realization of stable electrical connection in the subsequent process. Among them, X and Y are adjusted according to actual needs.

[0087] During the drilling process, by virtue of the characteristics of the laser with high energy density, good directivity and easy focusing control, first drill holes on the blank of the electrical connection module with a laser of a larger first beam diameter. Because its energy is concentrated, it can act on the material efficiently. Subsequently, quickly switch to a laser with a smaller second beam diameter to continue drilling, realizing the continuous formation of the first through-hole and the second through-hole. In the case of small sizes, such a drilling method gives full play to the advantages of the laser, making the structure of the electrical connection module stable and the electrical connection reliable, perfectly meeting the strict requirements of the precise connection of the electrical stimulation system, and greatly improving the precision and efficiency of production.

[0088] In an exemplary embodiment, the change from the first beam diameter to the second beam diameter is continuous, so as to form a first section with the first diameter, a second section with the second diameter and a transition section between the first section and the second section in the through-hole, where the first diameter is equal to the first beam diameter and the second diameter is equal to the second beam diameter. The cutting process includes selecting a predetermined length to cut the first section from the electrical connection module to form a first blank of the connection module; selecting a predetermined length to cut the second section from the electrical connection module to form a second blank of the connection module.

[0089] As Figure 13-Figure 15, start the laser drilling device 70, set the first beam diameter of the initial laser beam to D1 (for example, 0.3mm), and the laser starts to act on the blank along the predetermined drilling straight line direction. At this time, the laser gradually drills a through hole portion of the first section P1 with a first diameter (i.e., D1) on the blank with a stable power and pulse frequency, and the drilling depth reaches a predetermined depth H1 (such as 5mm). In this process, the control system of the equipment accurately controls the motion trajectory and energy output of the laser to ensure that the straightness and aperture accuracy of the first section of the through hole are within a strict tolerance range.

[0090] Second punching step: After the first punching is completed, the punching process is not stopped. Through the intelligent control system of the equipment, the laser beam diameter is continuously and smoothly reduced from the first beam diameter D1 to the second beam diameter D2 (for example, 0.2 mm). In this transition process, a transition section P3 is formed between the first section P1 and the second section P2. The laser continues to penetrate the blank on the original punching trajectory until the through hole of the second section P2 reaches a predetermined depth H2 (for example, 2 mm). At this time, the entire through hole is completed, including the first section P1 with the first beam diameter D1, the transition section P3, and the second section P2 with the second beam diameter D2.

[0091] like Fig.13 As shown, the cutting process 350 also includes: a first cutting process 3510: selecting a predetermined length from the electrical connection module to cut off at least a portion of the first segment; and a second cutting process 3520: selecting a predetermined length from the electrical connection module to cut off at least a portion of the second segment.

[0092] According to the preset length H1 of the first connection module blank and the preset length H2 of the second connection module blank, the electrical connection module blank with the through hole processed is cut. The cutting tool accurately selects the predetermined length H1 along the direction perpendicular to the punching line to cut off at least part of the first section from the electrical connection module to obtain the first connection module blank; then selects the predetermined length H2 to cut off at least part of the second section from the electrical connection module to obtain the second connection module blank. During the cutting process, the positioning accuracy of the cutting equipment is controlled within ±0.02mm to ensure the dimensional accuracy of the first connection module blank and the second connection module blank, meet the subsequent precision assembly requirements with pins and other components, and thus ensure the high-quality manufacturing of the entire electrical connection module.

[0093] When cutting, the first section and the second section are cut according to the predetermined length, and the transition section is accurately removed, so that the size of the first through hole of the first connection module blank and the second through hole of the second connection module blank accurately meet the requirements. This not only realizes the continuous and uninterrupted punching process, but also ensures the accuracy of the size of the first through hole and the second through hole, laying a solid foundation for the stable electrical connection of the electrical connection module in the electrical stimulation system, and improving the reliability and accuracy of the overall manufacturing process.

[0094] The above description is only an embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of the invention involved in the present application is not limited to the technical solution formed by a specific combination of the above technical features, but should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the inventive concept. For example, the above features are replaced with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A method for manufacturing an electrical connection module, wherein the electrical connection module is applicable to an electrical stimulation system, wherein the electrical stimulation system comprises a pulse generator and a stimulation electrode, wherein the electrical connection module is used to electrically connect the pulse generator to the stimulation electrode, wherein the electrical connection module comprises a first connection module and a second connection module, wherein: The manufacturing method comprises: A punching process, in which a blank of an electrical connection module is prepared, the blank of the electrical connection module is a cylinder with a diameter less than or equal to 3 mm, and through holes are formed on the blank of the electrical connection module along a straight line parallel to the axial direction of the blank of the electrical connection module and passing through the blank of the electrical connection module, wherein the number of the through holes is at least 24, a cutting process, in which the blank of the electrical connection module is cut along a direction perpendicular to the straight line to divide the blank of the electrical connection module into a blank of a first connection module and a blank of a second connection module, the through hole formed by the punching process is a first through hole on the blank of the first connection module, and the through hole formed by the punching process is a second through hole on the blank of the second connection module, and An installation process, in which the first pin is at least partially placed in the first through hole, and the second pin is at least partially placed in the second through hole, wherein the first pin is provided with a socket, and the second pin can be inserted into the socket to be electrically connected to the first pin.

2. The manufacturing method according to claim 1, characterized in that: The punching process includes a first punching step, during which the diameter of the punched hole is set to a predetermined diameter of the first through hole and the second through hole. After the first punching step, the punching process also includes a second punching step, during which the diameter of the punched hole is set to a predetermined diameter of the other of the first through hole and the second through hole, wherein the predetermined diameter of the first through hole is different from the predetermined diameter of the second through hole.

3. The manufacturing method according to claim 2, characterized in that: In the punching step, a laser is used to punch holes in the blank of the electrical connection module.

4. The manufacturing method according to claim 3, characterized in that: In the first punching step, a laser having a first beam diameter is used to punch a hole on the blank of the electrical connection module; In the second punching step, a laser having a second beam diameter is used to continue punching holes in the blank of the electrical connection module, wherein the second beam diameter is smaller than the first beam diameter. After the second punching step is completed, the through hole is formed on the electrical connection module.

5. The manufacturing method according to claim 4, characterized in that: The change from the first beam diameter to the second beam diameter is continuous to form a first segment having a first diameter, a second segment having a second diameter, and a transition segment between the first segment and the second segment in the through hole, wherein the first diameter is equal to the first beam diameter and the second diameter is equal to the second beam diameter.

6. The manufacturing method according to claim 5, characterized in that: The cutting process includes a first cutting process and a second cutting process. In the first cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the first section; in the second cutting process, the electrical connection module selects a predetermined length to cut off at least a portion of the second section.

7. The manufacturing method according to claim 1, characterized in that: The first pin and the second pin are made of metal; before the cutting process, the manufacturing method also includes a processing process, in which the inner surfaces of the first through hole and the second through hole are metallized; after the loading process, the manufacturing method also includes a welding process, in which the first pin is welded to the metallized inner surface of the first through hole, and the second pin is welded to the metallized inner surface of the second through hole.

8. The manufacturing method according to claim 1, characterized in that: A blind hole is provided at the first end of each first pin along the first direction, and the inner diameter of the blind hole is greater than or equal to the outer diameter of the corresponding second pin so as to receive the second pin.

9. The manufacturing method according to claim 1, characterized in that: In the loading process, the first end of the first plug pin is extended from the first end surface of the blank of the first connecting module, and the second end of the first plug pin is aligned with the second end surface of the blank of the first connecting module.

10. The manufacturing method according to claim 1, characterized in that: In the loading process, the first end of the second pin is extended from the first end surface of the blank of the second connecting module, and the second end of the second pin is extended from the second end surface of the blank of the second connecting module.

Images